Cement

Manufacturing Facilities

Jaypee Rewa Plant (JRP) is located at 14 km from Rewa city of Madhya Pradesh at Jaypee Nagar; and Jaypee Bela Plant (JBP) is situated at Jaypee Puram within vicinity of 5 km. The first line of production having capacity of 1 MTPA, Jaypee Rewa Plant was commissioned on 02.12.1986 and 2nd line of production having a capacity of 1.5 MTPA was commissioned on 10.01.1992 at JRP. The Jaypee Bela Plant, the 2nd unit of JAL-Cement Division, which is having a production capacity of 1.5 MTPA was commissioned on 21.10.1996. The 1st line of production i.e. Unit-I has been upgraded for better energy efficiency and enhanced production of 4500 TPD clinker, and was started on 05.09.2004 after upgradation. For better economy and to encash market opportunities, Jaypee Cement Blending unit (JCBU) of 0.6 MTPA capacity was commissioned in December, 2002 at the Vill: Sadwa-Khurd, Dist. Allahabad, (UP). This is situated on Allahabad – Rewa road at a distance of 28 KM from Allahabad. The latest addition in cement manufacturing capacity came through Jaypee Ayodhya Grinding Operation (JAAGO) having 1.0 MTPA capacity. With a view to use locally procured Fly Ash from NTPC-Tanda so as to save on logistics cost and support environmental causes, this plant was commissioned in August, 2004 at Tanda in U.P. As a result of commitment of management, team support and expertise in project management, all these projects were executed and commissioned in record time.

Power is one major input, and its uninterrupted availability at economical cost is a critical success factor for a cement manufacturing plant. Strategically, thus, we have set up our own captive power plants (CPP) to support our cement production process. The 1st CPP - 22.5 MW Thermal Plant was commissioned at JRP in November, 2003. Another, 22.5 MW Thermal Plant (CPP-II) was commissioned at JBP in November, 2004. With the addition of two thermal power plants, the energy cost per tonne of cement has reduced considerably. With 38.5 MW capacity of third CPP, having been commenced entire energy requirement of cement complex can be completely met by captive thermal power plant. Another major input for cement manufacturing and success in the market place is availability of good quality limestone in high volumes. We have total mining lease of 14.67 Sq. KM. with the three captive limestone mines in the name and style of Naubasta limestone mine, Jaypee limestone mine and Bankuiyan limestone mine situated at a distance of 4 to 5 km. apart from each other. The Naubasta limestone mines cater to requirements of two plants at Jaypee Rewa Plant where as the Jaypee limestone mine mainly cater to Jaypee Bela Plant. The mining operations are carried at JAL-Cement Division using advanced technology and with utmost care to the environment.

Our cement manufacturing process is fully automated. Field Instruments installed at different locations provide data to control room operator through DCS for the purpose of monitoring of the process. Each of the equipments, right from limestone crushing to cement grinding is operated from Central Control Room (CCR). The operating parameters of each equipment are defined in the computer and the operators at CCR run the plant based on these parameters for optimal production.

The status of the health of the equipments is also monitored by CCR. In addition to the operation of the plant, the CCR helps in carrying out various tests pertaining to process parameters, analyzing the power consumption, gas flow analysis and leakages for the purpose of optimal production at low cost. The units at JRP and JBP are most modern plants in the country with IT-enabled systems like Computer Aided Deposit Evaluation, State-of-the-art computer based Online Bulk material Analyzers, Computerized process control systems, Computer aided maintenance management system, etc. Selection of machinery from the manufacturers of world repute, association of the best consultants, and extent of sophistication and modernity incorporated in the plants, reflect the concern of the management towards customer requirements. As far as quality is concerned, while everything possible is being done to ensure adherence to relevant standards in the overall interest of the ultimate consumers of cement, the Company has also focused its attention in the areas of energy conservation and pollution control. Adequate and advanced measures have been adopted by choosing energy efficient and less polluting equipments and appropriate equipments and machineries.

Jaypee Ayodhya Grinding Operations

• Fly ash is brought from ash pond/ESP hoppers of NTPC, Tanda U.P. through Pipeline / Tankers and stored in a designated storage yard.
• Clinker is transported from our Jaypee Rewa Plant and Jaypee Bela Plant located at Rewa (M.P.) and unloaded into hoppers by a hydraulic tippler and transported to the Storage yard by Belt Conveyors.
• For drying out the moisture in the cement mill feed viz in gypsum and fly ash hot air generated in a Hot Air Generator (HAG) is used in the cement VRM. Pulverised coal ground in a Ball mill after crushing is stored in a fine coal bin from where it is extracted and fired in the HAG. The hot air thus generated is also used in the coal mill for drying of coal.
• Material is collected in a Bag House and is stored in a Cement Silo comprising of 3 compartments having 10000 Tons of capacity.
• From the Cement Silo, the cement is extracted and packed in 50 kg. bags by two electronic packers.
• The plant is fully computerized and operated through centralized Control Room which is equipped with latest and most modern FLS Automation Equipment.
• There is no fugitive or any other emission, since the most effective Pollution Control Equipment and bag House are installed. The plant is totally environment friendly.
• There are three 5 MW Diesel Generating sets to meet the requirement of plant operation in addition to the supply from UPPCL.
• The Diesel Generating set are operated with Furnace Oil.

Jaypee Cement Blending Unit, Sadva, Allahabad (JCBU)

Dry mixed fly ash from the various sources are transported by the tankers to the JCBU plant from where it is dumped into the truck tippler hopper with the help of truck tippler. From truck tippler hopper mixed fly ash is transported with the help of variable rotary feeder mass conveyor and elevator to the mixed fly ash silo.
Ordinary Portland Cement (OPC) is transported from Jaypee Rewa Plant by tanker and dumped into the OPC hopper with the help of truck tippler, from where it is transported to OPC silo with the help of mass conveyor and elevator.
Mixed fly ash is separated into fine fly ash (Blaine 360 m2/Kg. approx.) and coarse fly ash by LNV separator. Fine fly ash is transported with the help of air slide and elevator to the fine fly ash silo and in the same way coarse fly ash is transported to the coarse fly ash silo.

Required quantity of OPC and fine fly ash are extracted from OPC silo and fine fly ash silo with the help of Dozing Valve and it is fed into a common air slide from where the material goes to the Blender(make- WAM, Italy .) Blender blends the material with the help of chopper blades. After blending it is transported to the PPC silo with the help of air slide and elevator.

Portland Pozzolana Cement is extracted from PPC silo by a rotary feeder and fed to an electronic packer where it is packed in 50 Kg HDPE bags and transported to trucks with the help of truck loaders.