Cement for Life IRD Swiss

Cement for 

Life 

Greenfield Plant Project 

4000 TPD – HFO Fired 

IRD Swiss 

Cement Plants

Plot Size 

900 x 450 m 

Cement for 

Life 



Limestone will be transported into the plant by a 

covered belt from the quarry site into a circular preblending 

storage yard of a diameter of 90m which 

can contain 8-day storage. The pile will be 

permanent layered by the new incoming raw 

material to provide low chemical differences. 



The most needed additives, Clay and Gypsum will 

be stocked in open yards to be crushed and moved 

by hydraulic windlasses into a huge roofed yard. 

Accordingly the prevailing local weather conditions 

all walls of the yard can be closed. 



The roofed yard will be fed with other additives like 

Ore, Sand and special process amendments which 

can be stocked directly by dump trucks also from 

back side; 

...and comes out automatically by belts to be fed 

into the clinker and cement process. 



Cement Plants 


The pre-mill section contains a vertical mill with a 

capacity of 460 to/h of the latest generation 

inclusive an effective dedusting and a 

homogenisation silo for 3-day storage. 

All devices and aggregates are in-housed. 



Lifted by feeder the pre-blended raw mix will be 

moved in the pre-heater tower and pass a 5-stage 

cyclone heater to be warmed up in a high graded 

calciner at the end of the pre-heating process on 

650°C. 



A state of the art rotary kiln with a length of 56m 

plus tertiary air duct guarantees an optimized 

energy and fuel need. The clinker will be cooled 

down after passing kiln by a high efficiency grate 

cooler. 



If NG or Oil available we offer a sufficient Oil / Gas 

firing unit as part of turn-key price, includes either 

HFO oil dust blower or Gas nozzle system; 

inclusive entirely auxiliary equipment. For coal 

firing need please call for an optionally and suitable 

coal treatment and milling plant. 



A central situated process control building contains 

all control options and a fully equipped cement Lab. 

A water treatment system including a re-circulation 

sewerage dispose unit let drop the daily fresh 

water need to a minimum amount. 



After clinker cooling the crushed clinker will be 

lifted up by belt into the top of the clinker silo, 

Ø50x45m with 8-day storage capacity before 

entering the grinding department where two lines 

of roller presses plus 13m long ball mills grind the 

clinker material with Gypsum to Portland-Cement. 

. 



4 cement silos can store for 8 days cement, 

Ø18x40m each with separate dedusting filter and 

automatic belt conveyor feeding the loading 

department to fill bags, big-bags and bulk truck 

cement. The silos are connected to each other due 

to level the cement amount similarly. 

Execution of the cement silos as well as all other silos can be done 

in steel or concrete. Between the two possibilities there are 

considerable pricing differences, so we will advise the right solution 

for your circumstances. All silos belong except from the inside 

technical equipment like lifts, in and outlets, to the civil work (CW). 

We hand over at start of construction all necessary drawings and 

statement of works therefore, so the CW-company must not do any 

design work. Executing the silos in concrete and steel re-inforceded 

construction needs to have an experienced team of concrete 

workers to setup a sufficient slipform by a well known shuttering 

formwork manufacturer. Use our lots of experiences in this field! 



The loading department provides a bag loading 

zone, a big-bag zone and a bulk loading zone. 

4 bag trucks, 2 big-bag trucks and 2 bulk trucks 

can be loaded simultaneously. In addition are 3 

hand-loading truck places available, 2 at outer wall 

and 1 in the rear loading department yard. 



Bulk loading zone provide 2 self-filling stations with 

easy connecting flanges to load up the silo trucks 

through the truck drivers themselves. Bags and big 

bags will be loaded up by forklifters which requires 

piling the bags on pallets according the European 

pallet system EURO-PALLET. 

All vehicles, trucks, dump loaders and forklifters don’t belong to 

our equipment delivery but are in responsibility of each client 

himself. If wished we will assist to buy a sufficient motor pool. 



The pallet system needs to hand back all used 

pallets before loading new. Therefore the plant 

provide a pallet revoking place where all unused 

pallets will be returned to the filling department 

above the loading zones in order to be reused. 



Well structured plant traffic guarantees a clean and 

safe vehicle management within the factory. 

Arriving trucks have to be parked on a separate 

truck waiting zone before entering the loading 

department. All ways are obviously denoted on the 

ground as well as by special traffic signs. 



Incoming and leaving pick-up trucks are complete 

controlled by SAP® management software system 

SAP-ALL which guarantees a secure sale of 

cement amounts and customer clearness while 

staying in the plant area to every point in time. 

After passing the loading 

department all trucks have to be 

weighed on a truck weigh bridge to 

specify the loaded data which will 

be instant submit to the sales 

department, where a SAP software 

system recognize the difference 

between the tare weight and the 

loaded weight to compute the 

cement amount which leaves the 

plant by each truck. Every incoming 

truck gets a special transponder 

sticker on each vehicle for 

determining of customer’s purchase 

record, readable in the sale, so each 

client becomes invoiced 

instantaneously. Cash payers have 

to pay before loading, but can just 

leave the plant if the amount hasn’t 

overstepped the payment in 

advance. On the same weigh bridge 

will be weighed the incoming traffic 

after a truck will be prompted to 

enter the loading department by an 

electronic pager on the opposite site 

of weigh bridge. In addition to the 

electronic bill of loading paper will 

be submitted all vehicle data on the 

mentioned transponder as well. 

Hence are thefts impossible 

because mismatching data between 

the weights or driving past at the 

weigh bridge keep the exit gate 

closed because the transponder 

transmits a wrong rapport. This 

system is new and very efficient to 

manage a cement plant under 

avoiding losses. 



The plant has 2 Gates which can be entered. First 

is the main gate, controls the incoming and leaving 

traffic. All vehicles get stick a flexible one-way 

transponder to submit the position, customer data, 

plate number and times while staying in the plant. 

Finally the transponder gives way out if all is done. 

Second gate let only supplier 

traffic in. All deliveries for 

additives come by dump 

trucks from outside and will 

be controlled by plate 

numbers and materials 

delivered. It is independent if 

the incoming trucks belong 

to the plant owner or are 

sent from sub contractors 

from other companies 

….each vehicle has to pass a 

registration while entering 

and leaving. The traffic ways 

for such deliverers do not 

disturb the customer truck 

ways inside the plant. 

Anyway, truck accidents 

happen a lot within cement 

companies worldwide a year. 



In some regions of the world customers have either 

Natural Gas or Oil available, so we can offer several 

solutions for nearly all energy problems, either 

using different Oils or other waste gas; that is also 

valid for creating own electrical energy within the 

plant area. 

Optionally we offer a wide range of 

additional equipment to run a cement 

plant. Either you have a special need of 

pyro-sourcing, neither oil nor gas available, 

or you face a lack of internal electricity, we 

find the right way out. You can choose 

between several facilities to produce a 

needed electrical power supply by a 

sufficient own power plant or you have 

Brown Coal availably only and need a coal 

firing system for the kiln. Anyway we find 

and install the right solution for you. 

Therefore please get a separate quotation 

under filling a questionnaire. Please 

consider a sizable additional more price we 

have perhaps to setup. Fueling the plant by 

Gas or Oil is included in our standard offer. 



An integrated social area imply a main office for 

managing personnel, worker homes, a dining hall 

inclusive a drinking water plant, a relaxing green 

zone, prayer facilities and a medical care point. 

All buildings belong to the responsibilities of the 

CW contractor, but can be chosen by drawings. 

We provide a 

various range of 

sufficient building 

design drawings for 

customer’s choice 

according his 

requirements. 

Because of lots of 

experiences from 

different parts of 

worldwide cement 

plant configurations 

we like to introduce 

our client suitable 

offers regarding the 

local need of his 

region and there 

people behaviours. 



We are permanent endeavoured to reach the 

figures in quality and quantity promised to our 

clients when closing the contract. Our highest aim 

is to satisfy our customers completely for their 

confidence in our work and the high investment the 

clients have to transact during a long period of time 

Trust us! 

IRD IRD Swiss 

Swiss 

Cement Plants

Cement for Life IRD Swiss

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