Ambuja Cement Limited – Maratha
60 TPH AFR Plant – Complete Electrical Turnkey Solution
The Challenge:
Ambuja Cements undertook a brownfield expansion project at its Maratha Cement Plant to expand its AFR facility. As part of the expansion, the existing AFR plant was relocated, and a new AFR facility was developed with a combined handling capacity of 60 TPH. The aim was to increase the use of alternative fuels, reduce reliance on traditional coal, and support the company's sustainability goals.
The project required a complete electrical turnkey implementation for both existing and new AFR facilities, while ensuring seamless integration with existing plant infrastructure and minimal disruption to ongoing operations. Reliable power distribution, extensive conveyor protection, and maintaining the highest standards of safety, quality, and operational reliability added to the complexity of the project.
The Solution:
Velox Automation delivered a complete SITC (Supply, Installation, Testing and Commissioning) electrical turnkey solution for the entire AFR facility. This scope of work includes engineering, supply, installation, testing and commissioning of 6.6 kV HT switchgear panels, 1600 kVA transformers, 3200 A bus ducts, PMCC panels, APFC panels, LT distribution panels (MLDB, SLDB, SPDB and MPDB), cable trays, power and control cable laying with terminations, electrical panels, transformers, field instruments, junction boxes, earthing and lightning protection systems, plant lighting, CCTV for substations, conveyor protection devices, flameproof junction boxes and VCS systems for conveyors.
The complete electrical infrastructure was successfully integrated with the existing cement plant, ensuring reliable power distribution, safe operation and easy commissioning of the combined 60 TPH AFR facility.
Why Velox Solutions Makes Sense
For the Client:
The project was successfully completed with zero safety incidents while maintaining 100% HSE compliance and strict adherence to site SOPs. The integrated electrical infrastructure provided reliable power distribution, enhanced operational safety, and reliable conveyor protection, enabling smooth commissioning of the combined 60 TPH AFR facility with minimal disruption to ongoing plant operations.
The new electrical system provides a scalable and reliable infrastructure that supports greater use of alternative fuels, reduces reliance on traditional coal, and provides a strong foundation for future plant expansion.
For the Environment:
By making greater use of alternative fuels, this project supports clean cement production by reducing reliance on traditional coal and reducing carbon emissions. Energy-efficient electrical infrastructure ensures reliable plant operations while contributing to Ambuja Cement's long-term sustainability and environmental objectives.