The company was formed in year 2004 with small group of highly experienced people who had worked for big companies like FLSmidth, KHD and Polysius.small group SAIPHIA TECHNOLOGY deals in Cement, Minerals, Power Plants and Aerospace industries. The company became private limited in year 2009. Saiphia Technology has also got ISO 9001-2008 certification in Jan 2010.
Quick and Honest service to our clients Give most sensible and economically viable solution to our clients. Study and analyze the operation & design of existing plants to remove the bottlenecks for higher production at low cost. Suggest improvement in plants for reduction in power and fuel consumption to get more benefit at lower cost. Make tailor made solution as per client’ s needs. Last but not the least, Helping all of us to grow together
Project Consultancy Layout Engineering Process Engineering Raw Mix Design Detailed Engineering Erection and Commissioning Services Plant Optimization Plant Technical Audit Tailor-made Engineering New Equipment Design
Plant Consultancy We take consultancy for both new and up-gradation projects. We provide layout engineering, process engineering, raw mix design, detailed engineering, erection & commissioning supervision services.
Layout Engineering We have highly experienced professionals to provide plant layout engineering services. Our plant layouts have only essential equipments with lower operational cost for whole plant life. All the layout designs are done in Inventor, which enables client to see the 3-dimensional view of plant.
Process Engineering Process Engineering of our organization is very strong and capable of designing the best process for complete cement plant. Process Engineering is done with the help of Simulation Programs which enables us to see the actual operation in plant and allow us to adjust the operating parameters without changing the actual operation.
Raw Mix Design We provide raw mix design based on available raw materials to reap maximum benefit and to produce a good quality product. We have designed raw mix to use up to 20% of blast furnace slag which directly increases the clinkerization capacity without changing any equipments.
We provide the design of bypass system for Alkalis, Chlorides etc. to overcome raw mix or fuel deficiencies for easy operation. We provide designs of raw mix to suit alternate fuel firing like, rice husk, bagass, pet coke, plastic waste, tire chips, wood chips, municipal waste, Bio and medical waste, animal waste, solvents etc. We have worked extensively on use of AFR and have achieved up to 90% fuel substitution rate. We have modified the system to use any kind of alternate fuels (as mentioned above).
Detailed Engineering We provide detailed engineering services for the complete cement plant equipments, Electrical systems, Instrumentation and Control systems. We provide detailed fabrication drawings for equipments which are to be fabricated on the project site. We also provide 3-D views of equipments along with detailed engineering, on request.
Erection & Commissioning services We provide supervision services for erection of equipments and machinery during project implementation phase for better site co-ordination and correct installation of equipments. We undertake commissioning activities for better co- ordination, smooth and speedy startup of the plant.
Plant Optimization We undertake complete plant technical audit for cement plants. This audit gives complete picture of plant operation, identifies bottlenecks and opportunities for improvements. We provide optimization solutions for different sections like raw material grinding, pyro-processing and cement grinding etc. based on technical audit of that section.
Plant Technical Audit We do the complete plant technical audit and provide detailed report highlighting the deficient areas. We provide short term suggestions which will give improvements without any significant investment and long term suggestions to increase plant capacity to its maximum level.
Tailor-Made Engineering Generally, all cement plants have some problems due to raw materials, equipments either new or old, fuel etc. which are identified during technical audit. We in Saiphia believe “Better Solutions are Possible” and have provided tailor made solutions for these typical problems successfully and achieved desired results.Better Solutions are Possible
New Equipment Design We are fully capable of designing new equipments for specific needs like waste fuel firing, material drying, Lime chips calcinations and drying of very highly moist material (up to 50-70% moisture). We have developed a static preheater system for OLIMAG SANDS in Quebec, Canada for calcination of Serpentine ore. DPS system.DPS system
Technical Strength Proficient in using modeling softwares like Autodesk Inventor & Autodesk Mechanical. Analysis of Equipment under different load conditions using ANSYS. Design of equipments using latest codes and standards to achieve optimum safety and economy.
Technical Strength of Civil Department Analysis and design of Steel and RCC structures subjected to heavy equipment loads Seismic and wind analysis of structures Good knowledge of Indian as well as International codes & Standards (e.g. IS 800, IS 875, IS 456, IS 1893, IS 13920, ACI codes, UBC standards, AISC standards, BS standards etc.) Proficient in using structural design and drafting software like STAAD.pro 2007, AUTOCAD Design of structures using latest codes and standards to achieve optimum safety and economy.
Product Range Coal Firing System Coal Firing System Cyclones Cyclones Immersion tube Immersion tube Chloride Bypass System Chloride Bypass System Alkali Bypass System Alkali Bypass System Rotary Air Lock Rotary Air Lock Flap Gate for Hot and Cold applications Flap Gate for Hot and Cold applications Preheater Dispersion box Preheater Dispersion box High Efficiency Dynamic Separator High Efficiency Dynamic Separator Inspection Doors Inspection Doors Kiln Inlet Seal Kiln Inlet Seal Calciners Calciners Slide Gate Slide Gate Expansion joint Expansion joint
Our first and foremost strength is our colleagues who are hard working, honest, committed and knowledgeable. We develop our own methods for reducing the overall plant cost with our own innovative ideas. The Design (Mechanical & Civil) and Process Departments are well equipped with Simulation programmes, 3-D design software and all the required gadgets. We can proudly say that our design team is one of the best not only in India but, also in the world.
HOLCIM CEMENT, VIETNAM Optimization of Cement Mill and the Roller Press Circuit for 2 units. Results : Production increase by 14% and equivalent reduction in power. Plant availability increased from 70 to 89. Later on some minor modification was done as suggested by us, further improvement was achieved. CEMENT PLANT, HONGCHONG (Order Received and Executed) GRINDING UNIT,HANOI Optimization of Pyro system for higher AFR utilization. Result achieved were 30% TSR.
HOLCIM LANKA LTD. ( RHUNU GRINDING UNIT) SRILANKA Plant Audit of 2 Cement Mills. Optimization of Cement Mills. Results (Order Received and Executed) GRINDING UNIT, Increase in production by almost 10%, with a reduction of power by 13%. The consistency of 28 days strength increased ( strength remained between 1.5% which was the main target of audit and optimization) The product residue consistency was added achievement.
HOLCIM LANKA LTD. ( PALAVI UNIT) SRILANKA Plant Audit of 2 Raw Mills ( Line 1 & 2) Optimization of Raw Mills. Modification of Raw Grinding section ( Line 1 &2) Results (Order Received and Executed) RAW GRINDING UNIT, Increase in production by almost 5 % with Optimization and additional 15% by modification. Specific power consumption reduced by almost same proportion.
HOLCIM LANKA LTD. ( PALAVI UNIT) SRILANKA Plant Audit of 2 Cement Mills ( Line 1 & 2) along with Roller Press Optimization of Cement Mills and Roller Press. Modification in Roller Press Section. Results (Order Received and Executed) CEMENT GRINDING UNIT, Increase in production by almost 8 % with Optimization and additional 28% by modification. Specific power consumption reduced by almost same proportion.
HOLCIM LANKA LTD. ( PALAVI UNIT) SRILANKA Plant Audit of Line 1& 2. Optimization of Line 1& 2 Modification in Pyro-Processing, Line 1 &2 Results (Order Received and Executed) PYRO-PROCESSING,LINE 1&2 Increase in production by almost 5 % with Optimization and additional 26% by modification. The production increase in modification was from 950 TPD to 1170 TPD, however the final achieved production was 1205 TPD Specific power consumption reduced by almost 1.5 Kwh/ton. Specific Fuel consumption reduced from 3900 Kj to 3450 KJ/ton. AFR feeding increased from 15% to 35 % Cooler efficiency increased from 70% to 76% even though the loading increased from 45 to 57.5.
HOLCIM SDN BHD. ( JOHAR BAHRU GRINDING UNIT) MALAYSIA Plant Audit of Cement Mill. Optimization of Cement Mills. Results (Order Received and Executed) GRINDING UNIT, Increase in production by almost 8%, with a equivalent reduction of power till date. An improvement of 25 % or more is anticipated after implementation of all improvement measures and minor modifications in cyclone, separator, grinding media pattern and control logics, the work is going on and may take some time for final results.
HOLCIM LANKA LTD. (PALAVI UNIT) SRILANKA Complete plant Hot Mapping Results (Order Received and Under Execution) Reduction in sudden breakdowns. Proactive and Predictive maintenance. Identification of bottlenecks and improvements, either by maintenance, optimization or by modification. Capax projects for sustainability and improvements.
HOLCIM LANKA LTD. (PALAVI UNIT) SRILANKA Chloride bypass system for Line 1 & 2 Results (Order Received and Under Execution) Reduction in Power consumption by 1.2 Kwh/ton Increase in Alternate Fuel Firing in Kiln Inlet from 18% to 40%. Increase in firing of Chloride based AFR.
TASEK CEMENT, MALAYSIA Study of the Pyro-processing Section and its optimization was done. (Order Received and Executed)
YTL CEMENT, MALAYSIA Study of the Pyro-processing Section and its optimization was done. (Order Received and Executed)
QESHM CEMENT, DUBAI Phase 1 (Already Executed) : Plant up-gradation from 900 TPD to 1200 TPD completed successfully. Modifications in Preheater and Cooler were done for capacity enhancement. Phase 2 (Under Execution) : Plant up-gradation upto 2500 TPD by installing : New Preheater tower New cooler. Roller Press in Raw grinding section.
SANGESAR CEMENT, IRAN (Under Execution) Complete engineering ( Process, Layout, Mechanical, Detailing, Civil, Electrical, Erection Supervision, Commissioning & Supervision ) for 1 million ton capacity plant is being done.
PARSIAN CEMENT, IRAN (Under Execution) Presently on Hold due to Economic sanctions Complete engineering ( Process, Layout, Mechanical, Detailing, Civil, Electrical, Erection Supervision, Commissioning & Supervision ) for 1 million ton capacity plant is being done.
KORDESTAN CEMENT, IRAN (Order Executed) Energy Audit for the plant is completed. Modification of Pyro-processing system is completed and Cement mill section is under execution. (Order Under Execution)
ZARIN RAFSANJAN CEMENT, IRAN (Order Executed) Energy Audit for the plant is completed. Modification of Pyro-processing system and Cement mill section is under execution. Modification of two cement mill lines is under execution. (Order Under Execution)
ABADEH CEMENT, IRAN Undertaken contract for Energy Audit of the plant and is completed. (Order Executed)
SPARTA CEMENT-I, INDIA Capacity enhancement of the plant up to 1800 TPD is being done by Saiphia Technology with the modification in cyclones, ducting's, Calciner. Complete Plant Optimization is also being done. (Completed) (Under Execution as Technical Consultant ) Capacity enhancement of the plant up to 2800 TPD is being envisaged with following major changes. New Kiln and Preheater cyclone. New VRM for Raw Grinding. Additional New VRM for coal. New cooler Installation of Roller press in cement grinding.
BOJNOURD CEMENT, IRAN Plant Optimization of the complete plant. Give consultancy for the Pyro Modification, design checks for old line. (Order Received & Executed)
SHARG CEMENT, IRAN Plant Optimization of the complete plant is under execution. Audit of the plant has been completed and implementation of recommendations is still under execution. (Order Received & in line for Execution)
YASUJ CEMENT, IRAN Plant Optimization of the complete plant is under execution. (Order Received & in line for Execution)
Bridge Gap Engineering is a highly responsive engineering company lead by a team of cement and mineral industry experts. Bridge Gap Engineering specializes in plant design, process, commissioning, optimization, retrofits, modifications etc. Bridge Gap Engineering formed an agreement with Saiphia Technology Pvt. Ltd. for doing projects in U.S. with our support. We have worked with them and delivered some very outstanding results. Bridge Gap Engineering will be marketing for us in the U.S. market.
Hitech Bulk Handling Systems Pvt. Ltd. An ISO 9001:2008 certified company and is pioneer in manufacturing and specializes in material handling, crushing, screening equipments etc for all types of industries. HBHS Pvt. Ltd. is already serving industries from Bangkok, Middle East, Indonesia, Kenya and Canada. Saiphia Technology Pvt. Ltd. is relying on its timely supplies for the equipments designed by STPL since March 2008. Besides that, HBHS Pvt. Ltd. is supporting STPL for its development works.
Saiphia Technology entered into an agreement with one of the largest Roller Press supplier in the world Sahut Conreur, France in Oct 2009. They provide all capacity Roller Presses ranging from 50 kg/hr to 500 tonne/hr applicable in various industries like Chemical, Pharmaceutical, Cement, Fertilizers etc. Saiphia Technology will act as their partner for the Indian markets and at the same time Sahut Conreur will help us in European market.
Our team has 34 members(in total) comprising of 6 Process men, 24 Engineering personnel and 4 people for HR & Administration. Our Team Strength
Our Confidence Level “Our Confidence Level is high enough. STPL is ready to accept any kind of challenge in Cement Industry where others have failed & guarantee 100% solution. In case of any failures, STPL will refund all the amount received from client without any discussion.”