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Green Products, Materials and TechnologiesGreen Building Congress- October 2016, Mumbai
JSW Cement - Overview
� Part of US $11 billion OP Jindal group.
� First cement manufacturer in India with GreenPro Certification for Portland Slag Cement (PSC)
� State-of-the-art integrated cement plants with environment-friendly production
Nandyal(4.8 mtpa)Vijaynagar
(0.60 mtpa)
Dolvi(0.60 mtpa)
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Environment-friendly Production
� 100% eco-friendly product (PSC & GGBS)
� Lower GHG emission intensity
� Lower sp. energy and sp. water consumption
� Conservation of natural resources through extensive utilization of industrial waste
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Nandyal, Vijaynagar & Dolvi 6 MTPA
Existing plants
Expansion Plan
Dolvi MH
0.3 MTPA 2016
1X1.2 MTPA 2018
West Bengal
2X1.2 MTPA
2017
Orissa
1X1.2 MTPA
2017
Tamilnadu
1X1.2 MTPA
2018
Mangalore
1X1.2 MTPA
2018
Vijaynagar KA
2X1.2 MTPA
2016
Upcoming project
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Reduced Environmental Impacts Due to Quarrying
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Utilization of Alternate Raw Materials
45%45% Chemical gypsum used in cement manufacturing
45%45% Pet coke used in pyro processing
100%100% Replacement of iron ore with flue dust (industrial waste from steel plants) in raw mix
100%100% Petro Polymer Fuel (PPF) used as a substitute for HSD/ LDO for kiln light up
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(-) 55%(-) 49%
Extraction of Raw Material & Use of Alternate Raw Material
(-) 34%
Laterite Flue Dust
(-) 35%
Note: Cementitious material includes GGBS9
Overall Slag Addition in PSC
10
(-) 45%
CO2 Emissions
Note: Cementitious material includes GGBS
Material Kg CO2 per ton
Clinker 920
OPC 870
PPC 640
PSC 490
GGBS 65
CO2 emission in PSC is lower by 44% and 24% in comparison to OPC and PPC respectively. 11
(-) 24%
Energy Efficiency
(-) 65%
(-) 3.7%
Note: Cementitious material includes GGBS
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(-) 22%
Water Efficiency
(-) 13.4% JSW Cement is a water JSW Cement is a water
positive unit.positive unit.
Our GW recharge Our GW recharge
exceeds GW extractionexceeds GW extraction
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Product Stewardship
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Post GreenPro Initiatives
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JSW Cement – First cement manufacturer in India to have achieved GreenPro Certification
for Portland Slag Cement (PSC)
JSW Cement – First cement manufacturer in India to have achieved GreenPro Certification
for Portland Slag Cement (PSC)
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Post GreenPro Initiatives – Apr’16 to Sept’16
AprApr ’’1616
SeptSept ’’1616
Reduced electrical energy consumption from 67.37 to 62.35 kWh/t PSC
Reduced thermal energy consumption from 709 to703 Kcal/Kg Clinker
Increased slag addition in PSC from 56% to 58%
Reduced Sp. CO2emission from 441 to 392 kg CO2/ cementitious material.
Reduced Sp. water consumption for process cooling from 0.44 to 0.42M3/t cementitious material
Redudced Total sp. water consumption from 0.16 to 0.14 M3/t cementitious material
Increased GGBSproduction consistently
Initiated GreenCo rating of Nandyal facility and Product Life Cycle Assessment (under progress)
Planned utilizing waste heat from clinker cooler in slag mill HAG for slag drying (project under implementation)
Conducted comprehensive Energy Audit of Nandyal facility by 3rd party
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Energy Conservation Projects Planned for 2016-17Sl. No. Title of Project
Estimated Annual Electrical Savings
(kWh/year)
Estimated Annual Thermal Savings (Coal Ton/year)
1. Coal firing line modification 1,60,512 458
2. Reducing clinker factor for PSC from 0.44 to 0.42 3,888
3. Minimize pressure drop across Static Separator of R aw Mill circuit 10,75,000
4. Reduce air infiltration in Raw Mill Circuit 5,28,900
5. Reduce air infiltration across Coal Mill 1,93,500
6. Reduce air infiltration in Kiln Bag House Circuit 3,48,300
7. Reduce air infiltration in Cooler Bag House Circuit 4,17,100
8. Minimize pressure drop in Duct Collector fan circui t 521FN3 & 521FN3A in Slag Mill 1
2,16,000
9. Minimize pressure drop across Bag house of Slag Mil l 2 Circuit 9,12,000
10. Minimize pressure drop in Dust collector fan Circui t (522FN3) in Slag Mill 2 84,800
11. Minimize pressure drop in Dust Collector fans Circu it (520FN3A) in Cement Mill
2,43,200
12. Minimize pressure drop in Packing House Circuit 2,27,200
13. Minimize pressure drop in crusher Dust Collector fa n Circuit 55,900
14. Reduce output voltage in selected lighting transfor mers 82,152
15. Installation of Variable Frequency Drive(VFD) for 211FN1
119103.00
16. Installation of VFD for 481BL5 112532.00
17. Installation of VFD for 552FN5 66165.00
48,42,364 4,346
4.84 million kWh electricity and 4346 tonnes of imported coal
savings
4.84 million kWh electricity and 4346 tonnes of imported coal
savings
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Green Product Certification for Market Development
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GreenPro Certification - Publicity� JSW Cement is using “GreenPro” renowned accolade by CII, on many platforms
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