Riddhi Siddhi Crusher & Land Transport LLC is a large supplier of aggregates based in Fujairah, United Arab Emirates. The company operates its own quarry producing limestone rocks for the Middle East construction industry and the Indian steel industry. Fujairah is an emirate on the east coast of the United Arab Emirates, lying along the Gulf of Oman. It is almost completely mountainous and has seasonal weather, although it is warm most of the year.
The Indian steel industry is registering exponential growth thanks to increasing urbanization, infrastructure developments, automobile supply, etc. Consequently, the demand for related raw materials such as limestone has increased. Steelmaking limestone deposits in India are however limited which requires manufacturers to import these aggregates from other countries like the United Arab Emirates.
To keep up with the growing demand for high quality limestone from Indian steel manufacturing customers, Riddhi Siddhi recently decided to invest in a larger crushing and screening plant. The objective was to increase the production capacity and improve the quality of end product thus increasing the company's profitability.
Metso was the partner of choice in this project since it has proven to be a trusted single-source supplier with knowledgeable experts and leading technologies. In addition to engineering, automation, manufacturing and delivery of the complete three-stage crushing and screening plant, Metso supervised the mechanical and electrical erection, oversaw the cold and hot commissioning of the plant, and personalized a service contract. Metso's ability to provide a full solution gave peace of mind and synergy savings to Riddhi Siddhi.
"We decided to partner with Metso because it is the best in the crushing industry" – Raj Kumar Bohra, Chairman and CEO, Riddhi Siddhi.
Minimizing costs and optimizing end-product quality
Metso's experts analyzed the plant's setting and chose the best possible locations for each of the three crushing stations to minimize haulage and transportation, thus production cost. For instance, the primary crushing stage which is performed using a Nordberg® C Series™ jaw crusher (C160) fed by an HRBM Series push feeder (HRBM7019) and a VG Series grizzly scalper (VG860-4V), was positioned close to the point of extraction.
To maximize the production of the most valuable coarse material (55/85 for export market) while generating less fines, Metso's process experts chose an upgraded BCD roller crusher (48x60) for the secondary stage. The machine has been customized for this purpose by Metso's engineering team in France, helping Riddhi Siddhi to ultimately increase its profitability.
The tertiary crushing stage is processed by a Nordberg® NP Series™ impact crusher (NP1520). The material is then classified using four PREMIER CVB™ inclined screens and a PREMIER TS™ multi-slope screen (TS5.3). These screens offer maximum operational flexibility and allow Riddhi Siddhi to execute safe and simple maintenance through easy access and walkways.
Automation and service bring further benefits
Metso has also implemented an automation system as an integral part of the entire process design to ensure the highest efficiency of Riddhi Siddhi's plant. Two control rooms allow operators to monitor and steer the system limiting downtime thanks to optimized utilization rate, reducing energy consumption and cutting operating costs, as well as improving work conditions.
Another key component of the long-term partnership between Riddhi Siddhi and Metso is a service contract. It allows Riddhi Siddhi to benefit from Metso's knowledge and experience to increase uptime, reduce maintenance and wear parts inventory, thus remaining competitive and reaching sustainable growth.
"The service contract guarantees that we get a smooth and continuous flow of technical input and spare parts." – Anil P Singh, General Manager, Riddhi Siddhi.
The plant is now capable of an annual throughput of 5 million tons of limestone with multiple end product sizes. The solution implemented by Metso helps Riddhi Siddhi minimize production costs, optimize the value of the end product and execute safe and simple maintenance.
"At Metso, we work in close partnership with our customers to develop win-win solutions that make their operations more profitable." – Luis Santos, Senior Vice President, Africa, Middle East and Turkey, Metso.
*Metso Outotec was formed July 1, 2020 when Metso and Outotec merged into one company. This case study has been written prior to the merger under the old company name.