Chettinad Cement, a key player in South India’s infrastructure sector, operates a high-capacity production facility in Suryapet, Telangana, with a capacity of 1.2 MTPA. To sustain this output, the plant relies on the seamless operation of a critical 16MW Captive Power Plant (CPP). Hofincons serves as the complete implementation partner, ensuring that power generation remains consistent, efficient, and environmentally responsible.
The Challenge: Integrating Technology with Resource Conservation
Commissioned in 2016, the 16MW thermal power plant utilizes advanced technology provided by Siemens & Thermax. Maintaining this facility required overcoming two distinct hurdles:
- Technical Complexity: The plant relies on the precise operation of an AFDC Boiler (Atmospheric Fluidized Discharge Combustion) and complex turbine systems. This equipment demands a workforce possessing niche technical skills to adhere to strict OEM standards.
- Sustainability Mandates: Supporting a 3000 TPD (Tonnes Per Day) cement unit requires massive energy inputs. The challenge was to deliver 24/7 availability while simultaneously reducing resource consumption, specifically water, which is a critical constraint in the region.
The Hofincons Solution: Integrated Lifecycle Management
Hofincons stepped in not just as a maintenance contractor, but as a total Implementation Partner. We assumed end-to-end responsibility for the power plant’s O&M, embedding a culture of “Kaizen” (continuous improvement) from day one.
- 50+ Specialist Personnel Deployed: We mobilized a resident team of over 50 experts to handle 24/7 operations, ensuring immediate response capabilities and routine preventive care.
- Safety & Infrastructure: We went beyond operations to physically upgrade the plant environment, installing robust safety and maintenance structures to ensure a “Zero-Harm” workplace.
- Process Optimization: Our team focused on the specialized upkeep of the AFDC boiler while running parallel efficiency programs to optimize fuel and water usage patterns.
Manpower Deployed
Resident experts inclusive of operations and maintenance personnel handling 24/7 uptime for the 16MW Captive Power Plant we mobilized.
The Outcome: Sustainable Efficiency and Productivity
The partnership transformed the power plant into a benchmark for sustainable industrial operations.
- Resource Conservation: Through rigorous process optimization, we reduced raw water consumption from 0.60 ltrs/KWh to 0.35 ltrs/KWh, significantly lowering the plant’s environmental footprint.
- Operational Gains: Our integrated management approach drove productivity improvements exceeding 40%, ensuring the cement plant never faced a power deficit.
- Financial Value: The implementation of Kaizen efficiency initiatives generated direct cost savings of approximately INR 25 Lakhs per annum.