PRODUCTS

Maihar Cement is pioneer in producing Blended Cement i.e. Portland Pozzolana

Cement. The motivation for the production of blended ccement has been primarily
with the aim of preserving limestone reserves and environment.

Advantages
 Low Heat of hydration resulting in resistance to cracking.
 Resistance to corrosive water and chemical attacks and thereby longer life to
steel/iron structure underneath.
 High degree of impermeability and workability for the concrete mix.
 Higher ultimate strength at longer duration
 Higher degree of fineness, resulting in -
- Complete chemical reaction
- Easy workability
- Increased plasticity
 Reduced Alkali aggregate reaction as also free lime expansion and thereby
resistance to cracking.
 Lower drying shrinkage and low leaching value.
 PPC can be used for any type of construction which earlier had been the forte
of OPC. However due to it's special attributes, it's use is rather imperative for
the following construction works.
Uses
 Hydraulic Structures
 Mass Concreting Works
 Marine Structures
 Masonry Mortars and Plastering
 Under aggressive Conditions

PROCESS OF MANUFACTURING
The basic raw material in the production of cement is Limestone. The Limestone ore
as obtained from the Mines is fed to the Raw Mills after first crushing it to acceptable
size. Certain additives such as Laterite, Bauxite, High Grade Limestone(Sweetener)
etc. are also introduced alongwith Limestone into the Raw Mills as applicable. In the
Raw Mills, the above inputs are reduced to a particular fineness. The output of the
Raw Mills, called 'Raw Meal' is then burnt in the Kiln and then cooled to produce
Clinker.

The fuel used for burning of limestone is powdered coal produced from the coal Mill.
The Clinker is thereupon fed into Cement Mill & pulverized alongwith Gypsum to
yield the basic cement. A certain proportion of Clinker in the production of cement is
replaced by Flyash to produce PPC.

Scenic View of Our Uniqueness

 1. Limestone excavated from Mines is transported through Dumpers and fed to
crushers wherein it is reduced from above 850 mm to 80 mm size.
2. Environmental friendly Conveyor belts transport the limestone from the
Crusher to the Plant Site over a distance of 7 kms.
3. Scientifically designed Stackers provide for stacking of the limestones received
from the mines in circular / longitudinal stock piles. Use of Reclaimers ensure
consistency in quality.
4. State of the Art Vertical Roller Mill grinds Limestone feed to powdered form
called Raw Meal.
5. Most advanced Coal Mill pulverizes the coal to be injected into Kiln for
burning of Raw Meal.
6. Rotary Kiln provides for Clinkerisation where in Raw Meal fed from VRM is
first burnt to melting (1400 C) & then cooled to 100 - 120 C by means of
coolers immediately outside the Kiln to produce Clinker.
7. Close Circuit Cement Mill ensures high quality grinding of clinker, gypsum
and pozzolana to yield best possible uniformity of the cement particles.
8. Centralised Control Room monitoring the manufacturing process through
computers.

Packing & Despatch

Consistency and accuracy in the packing of bags by electronic packing machines.
Packing Plant is equipped with computer controlled electronic packers, which ensure
that cement bags are packed and sealed to 50 kg of cement each accurately. Manual
check is also carried out at random to monitor computer accuracy and introduce
correction as applicable.
Loading of bags in the wagon/trucks is carried out automatically by means of wagon /
truck loading machines, equipped with Electronic Loading Counters which accurately
keep count of the Number of bags being loaded.

Efficient logistic & transportation network ensures prompt delivery of materials to the
customers.
 ENVIRONMENTAL SAFETY

Right from inception, great emphasis has been laid at Maihar Cement on maintaining
ecological balance and environmental preservation so as to provide green, healthy
and pollution free environment. Continuous monitoring of various Pollution Control
equipments are done round the clock to maintain emission levels much below the
norms specified by State Pollution Control Board.

View of Greenaries in Plant AreaTotally Dust-free Chimneys

Measures Taken Towards a Cleaner Environment
 Installation of highly efficient Pollution Control Equipments viz., ESPs, Bag
Houses and Pulse Jet Dust Collectors at every dust generating point in the
Plant.
 Regular monitoring of all stacks and ambient air quality.
 Proper treatment of domestic affluent generated from residential colony in
Oxidation Ponds and use of treated water for plantation purposes.
 Massive efforts for plantation of various species of trees for ecological up-
gradation.
  To control fugitive emission, following additional steps have been taken:
 Covering of Conveyor belts transporting various process materials
 All raw materials are stored in covered gantry.
 Water sprinklers have been provided on the roads to check fugitive emission
generated due to movement of vehicles
 Concretisation of roads and floors inside the Plant
 The Fly Ash generated from Thermal Power Plant is used as an additive for
manufacture of PPC.
 The Plant maintains perfect harmony with environment through effective
pollution control measures in respect of air, water, land and noise level. All
efforts are made to curb pollution at grass root level.

Environment Policy
We at Maihar Cement are fully conscious of the envionmental impacts of our
activities. We also realise the need for minimising the impacts, towards preservation
of environment in keeping with the image of BK Birla Group of companies as a
socially responsibile organisation.

We, therefore, commit ourselves to:

 Prevention of pollution incidental to Plant operations
 Adopting clean technology and eco-friendly processes in the Plant
 Compliance with all applicable legal and statutory requirements
 Conservation of natural resources
 Reduction in waste generation.
 Awareness amongst employees and business associates.
 Continual improvement in environmental performance by effective
implementation

The plant has been accredited with IS / ISO 14001 Environmental Management
System Certification.
 TREES ARE TREATED OUR BEST FRIEND

Every year tree plantation is undertaken in a planned manner on a massive scale. As a

result the barren land acquired by the Company looks like green land today with
different varieties of trees, gardens, lawns, fountains, flora and fauna. The plant
presents a wonderful balance between concrete and ecology with smokeless chimneys
and lush greenery all around. Number of Trees surviving as on date is 1058840.View
of Greenaries in Plant AreaClean Development Mechanism

Cement Industry is highly energy intensive and leads to generation of CO2 during
clinkerisation process due to calcination of limestone and combustion of fossil fuel
inside the Kiln. CO2 is a Green House Gas (GHG) which leads to depletion of ozone
layer above earth's atomosphere causing health hazard for all living beings. Maihar
Cement is actively engaged in reduction of GHG emissions and has undertaken CDM
projects. The project activities consist of an increase in % addition of flyash in
Portland Pozzolana Cement (PPC) as well as an increase in the proportion of PPC in
the over all product mix. This leads to reduction in usage of clinker in cement
production which in turn contributes to reduction in GHG emissions.
At Maihar Cement, proportion of Blended Cement has been gradually enhanced over
the last few years and today total cement production comprises of Blended Cement
only. The project activity contributes to sustainable development at Regional, National
and Global levels in the following ways.
Reduction of GHG emissions - by way of reduction in clinker usage in cement
production as explained above;
Industrial Waste Utilisation - Fly Ash Handling and disposal not only involves extra
cost for Thermal Power Plant (TPP) but also leads to land and air pollution as well as
water contamination at fly ash ponds / land fills. Hence the project indirectly helps
TPP in cost reduction and pollution abatement. It also leads to reduction in specific
energy consumption for cement manufacture and positively contributes to
conservation of coal which is a valuable renewable natural resource.
Reduced usage of clinker in cement manufacture also means reduction in mining /
extraction of limestone and its associated fugitive dust emission, loss of bio-diversity
etc.Therefore the CDM project related activity has excellent environmental benefits in
terms of reduction of carbon emissions, conservation of natural resources like
limestone and coal, decreased environmental degradation and enhanced waste
utilisation.

Energy Conservation
All out efforts are made at every level to achieve the highest level of efficiency in
managing and conserving energy resources. This includes involvement of both
financial and human resources coupled with technological upgradation.Following
measures have been taken at Maihar Cement for conservation of electrical and thermal
energy:
 Upgradation of Kilns by installation of LP cyclones and upgradation of
preheater section and CIS MFR system on Clinker Grate Cooler;
 Close circuiting of Raw Mills and Cement Mills by installation of High
efficiency Classifiers;
 Installation of pregrinder in conjunction with close circuit Cement Mills for
capacity upgradation and reduction of specific power consumption;
 Replacement of pneumatic conveying system of Raw meal and cement by
Mechanical handling system
 Incorporation of VVVF drives;
 Replacement of low efficiency fan impellers by high efficiency Impellers;
 Optimisation of Raw Mills and Cement Mills by upgradation of internals and
grinding media charge;
 Dry Fly Ash storage and handling system has been installed at Cement Mill.
 Installation of high efficiency dyamic seperators for Coal Mills in place of
static Grit seperators for power saving and better residue control
 Process automation with DCS and Fuzzy logic control
 MARKETING OF CEMENT

Marketing Policy
 Product Quality exceeding Customer's expectations
 Timely Despatches
 Attractive and functional packaging
 Quick Business Response
 Prompt After-Sales service
 Adhering to fair and ethical business practices

Customer Service
Customer service cells have been established at various marketing centres which are
manned by qualified and experienced technical personnel. They provide advice to
customers on getting the best value from cement and offer assistance on civil
construction related issues.

Influencing the influencers is a plank of our marketing strategy by disseminating

information about our products through one-to-one interaction with
masons/architects/engineers.