Cement, Energy and Environment

48 cement production unit located at Bilakalaguduru village near Kurnool District, Andhra Pradesh. The plant is recognized for its environmental friendliness and is one of themost energy-efficient cement plants in India. The plant has an annual production capacity of approximately 2.2 million tons of clinker and 4.8 million tons of cement. Key features of the plant include: • The use of Blast Furnace Slag as a rawmaterial, which reduces the consumption of limestone and consequently lowers emission intensity. • Combi-Comflex technology, making Nandyal the first cement plant in India to adopt this technology for enhanced efficiency and reduced emissions. • Multiple systems designed to control air and dust pollution. • An automatic packing and truck loading system that minimizes air pollution. • The consumption of half the amount of limestone required by conventional cement plants. • Utilization of slag as a raw material, thereby reducing pollution and wastage. LOWCARBON PRODUCT PORTFOLIO Since Nandyal uses significant amount of BF slag in its process, it produces a variety of low-carbon cement products, including: • Portland Slag Cement (PSC), a mix of Blast Furnace Slag and Ordinary Portland Cement (OPC). • Ground Granulated Blast Furnace Slag (GGBS). • Ordinary Portland Cement (OPC) in 43 and 53 grades. RENEWABLE AND CLEAN ENERGY INITIATIVES JSW Cement is committed to decarbonizing its operations by investing in renewable energy sources. At the Nandyal plant, solar power contributes significantly to reducing the plant’s carbon footprint. The plant has secured power from a 15.5 MW solar plant, which, along with the Waste Heat Recovery System (WHRS), meets approximately 42% of the plant’s power requirements. The Waste Heat Recovery Plant was installed and commissioned in June 2023, generating approximately 78 GWh of electricity without any breakdowns or stoppages. What makes its WHRS noteworthy is an in-house water harvesting system has also been along with WHRS. This system captures condensate water from air conditioners and stores it in a common reservoir. The system currently collects approximately 200 litres of water per day, which is used for non-potable purposes like washing hands and faces. Since its installation in June 2024, the system has harvested around 60,000 litres of water. ALTERNATIVE FUEL RESOURCES (AFR) Nandyal Cement Works has been actively involved in co-processing waste for the past six years. The plant gradually upgraded its Alternative Fuel and Raw Materials (AFR) feeding system, which resulted in a significant increase in the Thermal Substitution Rate (TSR) from approximately 4% to 18% over five years. This initiative contributes to the reduction of fossil fuel consumption and further lowers the plant’s carbon footprint.