Greenfield Plant Project
4000 TPD – HFO Fired
900 x 450 m
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
...and comes out automatically by belts to be fed
into the clinker and cement process.
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
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
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
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
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
design drawings for
Because of lots of
different parts of
we like to introduce
our client suitable
offers regarding the
local need of his
region and there
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
IRD IRD Swiss