KCP’s Cement Business is over 60+ years old with manufacturing plants in Macherla & Muktyala in the state Andhra Pradesh with captive supply of high grade limestone and producing a combined annual capacity of 4.3 million tons of the finest quality premium grade cement in India.

Why KCP Cement ?

Proven record for 60+ years as one of India’s oldest producers of High Grade Cement.
Used at various landmark projects in India like Nagarjuna Sagar Dam, SriSailam Dam, Prakasam Barrage and Godavari Railroad Bridge in Andhra Pradesh.
Manufactured at ISO 9000 quality certified plants to Global Quality standards.

Primarily used in building foundations structures like Columns, Beams, Slab and other concrete structures and hence popularly called Concrete Cement.

Products

Grade 53 Ordinary Portland Cement (OPC)
Ordinary Portland Cement (OPC):

Grade OPC 53

  • Produced by grinding clinker with gypsum as per BIS specification IS: 269-2015.
  • Also known by the name 'grey cement'.
  • Used to produce pre-stressed & precast concrete with high strength.
  • Meets BIS requirements of minimum 28 days compressive strength which should not be less than 53 MPa (IS : 269 - 2015).

Grade OPC 43

  • Produced by grinding clinker with gypsum as per BIS specification IS: 269-2015.
  • Used to produce pre-cast blocks, pipes, tiles and non-structural works like flooring & plastering.
  • Meets BIS requirements of minimum 28 days compressive strength which should not be less than 43 MPa (IS : 269 - 2015).
Portland Pozzolana Cement (PPC)
Portland Pozzolana Cement (PPC)
  • Produced by blending OPC with gypsum and high quality fly ash as per BIS specification IS: 1489 - 2015.
  • Characterised by high compressive strength, workability & durability.
  • Recommended in projects where heat of hydration is required to be low.
  • Produces a 28 day strength higher than OPC 53
Rapid Hardening Portland Cement (RHPC)
Rapid Hardening Portland Cement (RHPC)
  • Produced as per BIS specification IS: 8041 - 1990
  • Special construction projects where high early strength is required.
  • Used in construction and repair of roads and bridges.

Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) & Rapid Hardening Portland Cement (RHPC).

KCP Cement is sold in India in Telangana, Andhra Pradesh, Karnataka, Tamil Nadu, Kerala, Maharashtra, Madhya Pradesh, Chhattisgarh and Orissa. We also export cement to Sri Lanka, Bangladesh & Myanmar.

We have been delivering high-quality cement to prestigious and large infrastructural projects including leading infrastructure developers, private companies and major cement manufacturers who source our products as they stand out in strength & efficiency.

Plants

Muktyala Cement Plant

Muktyala Cement Plant:

A Greenfield plant setup in 2011 is one of India’s most modern, highly automated, cost efficient and Eco Friendly plant with an annual capacity 1.86 m tons expandable to 3.52 million tons. Built with world class Pyroprocessing technology from KHD Humboldt, Germany, Grinding technology from GEBR Pfeifer, Germany and Plant Automation & Automated Packing technology from FLSmidth, Denmark, world leaders in Cement plant technologies.

Further in 2019, the plant capacity was expanded to 3.52 million tonnes per annum by addition of a new line of operation by replicating the Pyroprocessing of the 1st line and adding grinding technology from Loesche, Germany.

The plant is also enhanced with Captive Power Generation of about 20 MW (Thermal & Solar) with turbines from Siemens, Germany.

The plant was designed with aim to minimize material transportation and commence complete operational automation from the central control room (CCR) without manpower and feeding equipment in the field.

Macherla Cement Plant

Macherla Cement Plant

Commissioned in 1958, it is one of India’s oldest cement plants and South India’s Ist dry process Kiln with technology from KHD Humboldt, Germany. Starting with an annual capacity of 200 tons, it has been gradually expanded and modernized to a current annual capacity of 0.8 million tons with additional technology from Fives Lille, France and later FLSmidth, Denmark (Fuller, USA).

In 1999 an 8.25 MW Hydel Power Plant was set up on the Nagarjuna Sagar Dam right canal generating clean & sustainable power. A 2.3 MW Waste Heat Recovery Power plant was set up by utilizing waste fuel gases exhausted from the pre-heater and cooler chimneys.

This plant was India’s first dry process kiln of 400 TPD setup in 1958 with technology from Humboldt, Germany. In 1962 a 600 TPD wet process kiln in collaboration with Fives Lille Cail France was later installed.

In the 1980’s the plant was further modernized with assistance of The World Bank incorporating the latest advancements in technology, such as an energy-efficient dry process with two support kilns, and a five-stage preheater with a flash calciner and vertical grinding mills from Fuller International Inc (now FL Smidth). Later a state of art centralized process system was installed using hardware and software from FLSmidth Automation, Denmark to help enhance productivity.

Major Equipment Installed

  • Limestone Crusher from Hazemag : Capacity 1100 TPH
  • Stacker & Reclaimer from Takraf: Capacity 850 TPH
  • Raw Mill: MPS 4500B Gebr Pfeiffer, Germany - Capacity 350 TPH
  • CF Blending Silo 20m Diameter x 45m High: Capacity 15,000 MT
  • Coal Mill: MPS 2800BK Gebr Pfeiffer, Germany - Capacity 60 TPH
  • ILC 6-stage preheater with pre-calciner
  • Rotary Kiln - 63-support, 4.20m dia x 64m long: Capacity: 4,700 TPD
  • KHD Humboldt, Germany
  • PSC Cooler with cooling area of 91 Sq Mts
  • Cement Mills 2 x 1,850 KW each main motor: Capacity 2 × 120 TPH
  • Packing Plants: FLSmidth 2x16 Spots 240 TPH with double discharge packers

Reduced Noise Level

There has been a strong focus on reducing the noise level on the plant, and hence silencers and noise enclosures have been provided for all noisy equipment. Along with traditional noise-abating solutions, many new and unique ones have been implemented in the project. One of them is for the kiln shell cooling fans, which are among the noisiest pieces of equipment. For the first time in India a stack of centrifugal fans with noise enclosures have been used for kiln shell cooling.

Low Emission

Taking future pollution control standards into account, the main process bag filters and nuisance bag filters were designed for an extremely low emission level of < 30 mg/Nm3, the lowest level of emissions in any Indian cement plant.

Automation using Fuzzy Logic Operation

A state-of-the-art process control instrumentation and Fuzzy Logic Operations for the smooth functioning of the plant to maintain consistent quality.

State of Art Testing Lab

The plant is one of the most modern of its kind in India, featuring FLSmidth, Denmark supplied automation and plant instrumentation and a fully automated robotic lab facility capable of sampling and sample transportation, preparation and analysis. As a result of this focus on quality, KCP cement specifications exceed those set by BIS, SLS, ASTM by a wide margin. Strict supervision and quality control at every stage in production and packing.

Special Features

  • Availability of large reserves of high grade limestone
  • Minimum waste rock generation(< 5%) in mines
  • Limestone mine is within 1km from the plant
  • Automated Limestone stacker and reclaimer
  • High efficiency pre-heater (97 %)
  • Lowest power (43 KWh/MT Clinker) & coal consumption (690 KCal/Kg Clinker)
  • High level of plant operational, packing and dispatch automation.
  • Lowest maintenance cost

One of the Most Energy-Efficient, Cost Effective & Reliable Cement Plants in India

Quality

KCP ROBO, Unit 2, Muktyala
Robotic Testing Lab

The testing lab is one of the most modern of its kind in India, featuring FL Smidth, Denmark supplied automation and plant instrumentation and a fully automated robotic lab facility capable of sampling and sample transportation, preparation and analysis. As a result of this focus on quality, KCP cement specifications exceed those set by BIS, SLS, ASTM by a wide margin. Strict supervision and quality control at every stage in production and packing.

Mobile Concrete Lab

The mobile concrete testing lab at KCP is to make better and durable concrete at the construction site. It acts as a guide in adopting better construction practices. While the concrete care team checks parameters such as the grain size distribution of (jelly), coarse aggregate or (sand) fine aggregate, the concrete care engineer checks for harmful impurities in sand – clay or silt, for example. In addition to the above, samples of concrete made at the site can be tested after 7 days or 28 days as per BIS standards. The cement care van also has the capability to test the suitability of water.

The mobile concrete lab is equipped to test the following parameters:

  • Coarse & fine aggregates
  • Fresh concrete workability via the slump tes
  • Fresh & hardened concrete through cube testing
  • Quality of water

All the above tests confirm to BIS specifications.

Mobile Concrete Testing Lab