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    Cement Process

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    Srinivas N Gowda
    The document discusses the process of establishing a cement plant from start to finish. It begins with obtaining necessary approvals, developing tender documents, negotiating contracts and awarding the contract. Engineering design is then carried out followed by manufacturing, shipping and installation of equipment. Commissioning involves testing all processes before commercial operation. Cost distribution shows machinery typically accounts for 40% of costs but can vary significantly between countries and projects. Total installed cost depends on location and capacity, with recent plants ranging from $80-260 per annual ton.

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    Cement Process

    Uploaded by

    Srinivas N Gowda
    1K views38 pages
    The document discusses the process of establishing a cement plant from start to finish. It begins with obtaining necessary approvals, developing tender documents, negotiating contracts and awarding the contract. Engineering design is then carried out followed by manufacturing, shipping and installation of equipment. Commissioning involves testing all processes before commercial operation. Cost distribution shows machinery typically accounts for 40% of costs but can vary significantly between countries and projects. Total installed cost depends on location and capacity, with recent plants ranging from $80-260 per annual ton.

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    The document discusses the process of establishing a cement plant from start to finish. It begins with obtaining necessary approvals, developing tender documents, negotiating contracts and awarding the contract. Engineering design is then carried out followed by manufacturing, shipping and installation of equipment. Commissioning involves testing all processes before commercial operation. Cost distribution shows machinery typically accounts for 40% of costs but can vary significantly between countries and projects. Total installed cost depends on location and capacity, with recent plants ranging from $80-260 per annual ton.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views38 pages

    Cement Process

    Uploaded by

    Srinivas N Gowda
    The document discusses the process of establishing a cement plant from start to finish. It begins with obtaining necessary approvals, developing tender documents, negotiating contracts and awarding the contract. Engineering design is then carried out followed by manufacturing, shipping and installation of equipment. Commissioning involves testing all processes before commercial operation. Cost distribution shows machinery typically accounts for 40% of costs but can vary significantly between countries and projects. Total installed cost depends on location and capacity, with recent plants ranging from $80-260 per annual ton.

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    How a cement plant gets off the ground

    Peter Krger, Vice President, FLSmidth


    FLS Industries Capital Market Day, 18 January 2005

    Thailand
    Thailand

    Filter

    Crusher

    Filter
    Analyzer

    Limestone

    Sand

    Clay
    1

    Iron
    3

    Raw meal
    silo

    4
    Storage

    Coal mill

    4 3

    1
    Raw mill

    Clinker
    Silo

    Separator
    2

    Packers

    3
    Cement
    silo

    Cement
    silo

    Cement
    silo

    Cement mill

    Gear unit

    Ship unloading

    Roller press

    Ship loading

    Limestone quarry

    Limestone loading

    Limestone Crusher

    EV Hammer Impact Crusher

    Filter

    Crusher

    Filter
    Analyzer

    Limestone

    Sand

    Clay
    1

    Iron
    3

    Raw meal
    silo

    4
    Storage

    Coal mill

    4 3

    1
    Raw mill

    Clinker
    Silo

    Separator
    2

    Packers

    3
    Cement
    silo

    Cement
    silo

    Cement
    silo

    Cement mill

    Gear unit

    Ship unloading

    Roller press

    Ship loading

    CHO Circular Homogenising storages

    Longitudinal raw material store

    Raw material handling & storage

    Filter

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    Limestone

    Sand

    Clay
    1

    Iron
    3

    Raw meal
    silo

    4
    Storage

    Coal mill

    4 3

    1
    Raw mill

    Clinker
    Silo

    Separator
    2

    Packers

    3
    Cement
    silo

    Cement
    silo

    Cement
    silo

    Cement mill

    Gear unit

    Ship unloading

    Roller press

    Ship loading

    ATOX Raw Mill

    Robo laboratory

    Blending and storage silo, CF

    Filter

    Crusher

    Filter
    Analyzer

    Limestone

    Sand

    Clay
    1

    Iron
    3

    Raw meal
    silo

    4
    Storage

    Coal mill

    4 3

    1
    Raw mill

    Clinker
    Silo

    Separator
    2

    Packers

    3
    Cement
    silo

    Cement
    silo

    Cement
    silo

    Cement mill

    Gear unit

    Ship unloading

    Roller press

    Ship loading

    ATOX coal mill

    DRW Rotor Weigh Feeder

    Anti pollution equipment

    SLC
    -D
    SLC-D

    Cimsa
    CimsaMersin
    Mersin,, Turkey
    Turkey

    The Rotax-2 rotary kiln

    Kiln hood

    Control room

    SF - CROSS BAR COOLER

    SF - CROSS BAR COOLER

    Filter

    Crusher

    Filter
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    Limestone

    Sand

    Clay
    1

    Iron
    3

    Raw meal
    silo

    4
    Storage

    Coal mill

    4 3

    1
    Raw mill

    Clinker
    Silo

    Separator
    2

    Packers

    3
    Cement
    silo

    Cement
    silo

    Cement
    silo

    Cement mill

    Gear unit

    Ship unloading

    Roller press

    Ship loading

    UMS Ball Mill

    OK vertical roller mill

    Filter

    Crusher

    Filter
    Analyzer

    Limestone

    Sand

    Clay
    1

    Iron
    3

    Raw meal
    silo

    4
    Storage

    Coal mill

    4 3

    1
    Raw mill

    Clinker
    Silo

    Separator
    2

    Packers

    3
    Cement
    silo

    Cement
    silo

    Cement
    silo

    Cement mill

    Gear unit

    Ship unloading

    Roller press

    Ship loading

    Packing equipment

    Lifting table

    Rotary packer

    Cement packing

    Pneumatic ship unloader

    Approximately 3 months

    3 - 9 months
    Quotation
    Contract draft

    Financial, legal and commercial conditions


    Performance warranties and conditions
    Logistic information
    Technical specifications
    Sales pricing
    Cost price estimates
    Equipment list
    Flow sheet
    Plot plan, Proposal drawings
    Enquiry/ Process design
    Mass flow.
    Tender
    documents

    Negotiations and Contract


    modifications
    award

    Project management
    Planning / Logistics
    Accounting / Invoicing
    Commissioning
    Supervision of erection
    Shipping docs. and despatch
    Inspection and expediting
    Purchasing
    Manufacturing
    documentation
    General Arrangement
    drawings and specifications
    Contract

    Process design
    Order list
    1st year

    2nd year

    3rd year

    2 x 5,000 tpd Plant


    Mechanical Equipment
    Electrical Equipment
    Turnkey Activities
    - Site levelling
    - internal roads and squares
    -

    excavation
    concrete
    formwork
    reinforcement

    Structural steel
    buildings
    storages
    conveyor bridges
    other

    - Cladding steel
    - Masonry walls

    27.510
    2.830

    ton
    ton

    25.000
    127.000

    m3
    m2

    150.000
    140.000
    310.000
    17.000

    m3
    m3
    m2
    ton

    9.000
    1.500
    2.400
    3.800

    ton
    ton
    ton
    ton

    72.000
    13.000

    m2
    m2

    Cost-distribution for a Cement


    Plant
    Typical
    1 Machinery & Equipment

    UK

    Egypt

    Algeria

    Indonesia

    40

    36

    49

    26

    42

    3 Civil Works incl. Steel Structures

    35

    38

    30

    47

    29

    4 M+E Erection Works

    15

    20

    10

    11

    12

    5 Supervision/Site Expenses

    10

    6 Miscellaneous

    100

    100

    100

    100

    100

    2 Shipping

    Total

    Total Installed Cost


    (Country specific)

    280
    260
    240

    RECENT JOBS

    US$/MTPY

    220
    200
    180

    NORMAL COST

    160
    140

    LOW COST

    120
    100
    80
    60
    1000

    2000

    3000

    4000

    5000

    6000

    Capacity (MTPD)

    7000

    8000

    9000

    10000

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