Manufacturing Process
Selected
Low Ash coking coals from Australia, China, Russia
and other sources are brought in large cap size
vessels to well equipped ports next to both the
plants. The coal is stocked in the port area and
then is transported in batches to the Plant.
The coal is stored in concreted storage yards at the
plant site. Provision exists for the storage and
accurate proportioning of different types of coals
and carbonaceous material required for blending. The
coal blend is then conveyed to crusher machines
where they are crushed to the desired finesse (x
3mm).
After it is crushed it is then mixed with water in a
moisture machine to desired moisture level. It is
then stored in an
overhead storage bunker of a capacity of 1400 tonnes
to serve two batteries which consist of 40 ovens.
Each oven capacity has a charging capacity 55 tonnes.
The coal mix is drawn through a series of discharge
pockets below to a moisturised charging car for top
charging of an oven.
The coke ovens are fully mechanised and are equipped
with a pusher cum levelling machine, oven door
lifting devices etc. After approximately 48 hours
the coal is converted into coke. The burning coke is
pushed out on to a concrete landing platform. The
coke is quenched with water to extinguish the fire.
The coke is then lifted with dumpers and then
transported by trucks to the different screening
plants.
Here the coke is separated into different sizes
ranging from 0-3 mm to 100+ mm for different
customer needs. After screening the coke is left for
drying in open stock yards for more than 24 hours.
The coke is then either transported by trucks, rakes
or barges to buyers all over the country. This a the
whole manufacturing process in a nutshell.
Maha Shakti Coke Plant at Mundra
The
promoters of the company were always looking to
expand their business and increase the capacity.
Therefore after touching a capacity of nearly
150,000 in Porbandar, the directors thought of
setting up a second factory. After much research
they narrowed their choice to Mundra, a small town
in the Kutch region.
The plant was named as Maha Shakti Coke Plant.
Construction of the plant started in end of 2002.
The construction of battery number 1 and 2 started
in 2003. Battery number 1 and 2 was commissioned in
November 2003. The oven size was double the size of
Porbandar, having a charging capacity of 42 tonnes.
Each battery has a capacity to produce 100,000
tonnes per annum.
Battery number 3 and 4 were commissioned in July
2004. Therefore at present the plant has an
installed capacity of 400,000 tonnes per annum.
Due to intense research and development work,
Battery number 5 and 6 have an increase in capacity
of 25%.
The plant is spread across 240 acres of land.
Digging has already been completed for battery
number 7 and 8 which have the same capacity as 5 and
6.
After completion of 7 and 8 the plant will boast of
a capacity of 900.000 tonnes per annum making it the
largest merchant coke plant in India.
The coke plant is totally environment friendly and
has been certified by the Environment department.
Maha Shakti coke plant is a state of the art coke
plant having the most modern technology and
machinery. The plant has 7 screening plants which
facilitates 30 different sizes.
Maha Shakti plant is very well located. It is very
close to the Adani port which has 4 berths and has a
draft of 18 metres. There is a huge opportunity for
the company to export from this plant due to the
advantages stated above. There are many options of
transport from this plant which includes trucks,
rakes and Mini Bulk Carriers.
The quality of Maha Shakti Coke is outstanding and
has set a benchmark for other manufacturers in the
market.
The Plant has been appreciated by the Environment
Department and visitors for its outstanding house
keeping. It is the cleanest and well maintained coke
plant in India. Considering its size it is a big
achievement for the company’s promoters for who the
protection and conservation of the environment is
top most priority.
Environment Friendly
Preservation of the environment is one of the most
important aspects for both the directors. The
directors have taken many measures to ensure that
both the factories are non- polluting units. The
company has spent huge amounts to cover specific
areas where 0-20mm coke and coal dust is stored to
control the flying of dust. The company has
concreted both their factories to control polluting
the land. The factories draw power from self-owned
windmill which is one of the cleanest forms of
generating power. All the conveyer belts are covered
from all side to reduce pollution.
The company has 2 recycling plants to save on water
consumption as Kutch is a drought area. The company
is going to start Rain water harvesting to save on
water consumption.
Due to the supreme technology used in its oven, all
the poisonous gasses are burnt and no gasses are
taken out from the chimney. A person will never see
smoke coming out of any Saurashtra Fuels chimney.
They factory has one of the best house keeping, and
has been acknowledged for that from all its
visitors.
The Environment department of India appreciated the
measures of preservation so much that they have kept
SFPL has a benchmark for other coke producers to
reach. The company was never given a shut down order
by the department when practically every other coke
producer was given one.
