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Lebanon: Intercem is building a hot gas system for a coal mill at the LafargeHolcim Chekka plant. The engineering company won the contract for the job in 2015. It is the second such contract for Intercem to build a hot gas system following a previous project at a plant in Jordan in 2013.
The new hot gas system in the coal mill plant in Chekka connects the preheater with the coal mill and comprises a hot gas duct with a length of 360m and a diameter of 900mm. The process data of the hot gas outlet of the heat exchanger are of 18,500Nm3/hour at 400°C.
The turnkey scope of supply and services for the project includes:
- Project management
- As-built-survey of the existing plant using 3D-Laser scanning
- Review of the statics of the existing steel structure and concrete construction
- Process- and detail engineering
- Supply of the mechanical equipment including steel structure
- Coordination of the locally produced components
- Supply of the electrical equipment including clarification of connections and integration into the existing control systems
- Execution of the complete foundation works
- Transport management
- Electrical and mechanical assembly of the plant
- Commissioning of the hot gas system
- Training of the operating team
In addition ducts, a cyclone, a process fan and several control dampers, compensators, the complete instrumentation and automation as well as a new recirculation duct with two control dampers at the existing vertical coal mill have been supplied.
Handover to the customer is planned for fourth quarter of 2016.
KHD to install 3-string preheater at Shree Cement 08 September 2016
India: Shree Cement has awarded KHD with new projects for three more kiln lines, each with a capacity of 6000t/day.
The first project is for line two at Shree’s Raipur plant. The second new line will be built in Karnataka using a three-string preheater with the following equipment from KHD: three-string, six-stage preheater, PRZ 9575; three-pier rotary kiln Ø 5.4/5.0m x 75m long; and a Pyrojet burner; Pyrostep clinker cooler, PSC 3-154.16T. The project commencement date was 2 September 2016. The third project, at a location to be announced, will also be built using the equipment mentioned above.
Shree Cement has implemented 11 KHD high-efficiency kiln lines and many grinding stations, including 10 KHD roller presses.
McInnis Cement starts building Sainte-Catherine Terminal 08 September 2016
Canada: McInnis Cement has started construction work at its Sainte-Catherine Terminal. The unit will be built along the Boulevard Hébert over an area of two acres and will host two silos erected near the existing wharf. Approximately 25 ships per year should make stops at the terminal. Construction will continue until early 2017 at the site and the Sainte-Catherine Terminal is scheduled to be fully operational by spring 2017.
“While the cement plant is a few months away from being fully operational, we are taking the final steps for this important project to take shape and become the expected commercial success,” said the Director of Canadian Sales at McInnis Cement, Francis Forlini.
The cement transiting in Sainte-Catherine is intended to serve markets in New England, in addition to replacing imports in Quebec and Ontario. To feed its other markets, McInnis plans to build other terminals on the east coast of North America, including recent construction work in Providence, Rhode Island.
Update on cement industry of Oman
Written by Global Cement staff
07 September 2016
Update on Oman
It’s been an interesting month for the cement industry in Oman with the announcement of various producer projects and a recent market report predicting steady growth in the country.
A late August 2016 sector report from Al Maha Financial Services concluded that government-backed infrastructure projects in the country have pushed cement demand over the production capacity of the two leading local cement producers, Oman Cement and Raysut Cement. The report tempered the good news though with fears that excess production capacity from neighbouring producers in nearby countries would continue to lower prices in Oman. This matches the situation Global Cement found when it visited Oman Cement’s plant in early 2015. Such was the demand-production gap that this producer sometimes imported clinker to keep its supply constant when it shutdown its kiln for maintenance.
Cement production capacity in Oman currently stands at 8.81Mt/yr according to Global Cement Directory 2016 data. The major cement producers hold most of the local market with Oman Cement’s 4.2Mt/yr plant at Rusayl and Raysut Cement’s 3Mt/yr plant at Salalah.
Raysut Cement has announced progress on a number of local projects throughout 2016 including launching a new 20,000t silo at Salalah in May 2016, building a new terminal at the Port of Duqm due to open by the end of the third quarter of 2016, installing a new 150t/hr rotary packing plant with auto truck loader for expected commissioning by the end of October 2016 and it is currently upgrading its gas supply station at Salalah, also to give cement production a boost.
This last project is of particular interest because when Global Cement visited Oman Cement the staff at the Rusayl plant were concerned about the rapidly rising price of natural gas. The plant used gas as its primary fuel and at the time of the interview in January 2015 they were considering diversifying into alternative fuels such as a tyres or using local coal instead. The issue also received a mention in the company’s first quarter report, where it attributed the rise in gas prices to a 26.8% hit in its operational profit taking it down to US$15.6m in the first quarter of 2015.
Meanwhile, both Raysut Cement and Oman Cement are in the process of building a cement plant together at Al Duqm. The latest news on this joint venture emerged in mid-August 2016 when the companies announced that they had registered Al Wusta Cement as the company designated to carry out the project. So far the plant is at the feasibility study stage with further progress to be released at a later date.
Operating in a full-capacity environment will be a dream to many cement producers around the world. However, it is not without its pitfalls from input issues such as gas supply or fighting off external competition who may want a piece of the pie. Oman's construction industry is expected to see growth of 3.4% to US$5.74bn in 2016 backed by government spending. It is there for the taking for the local producers.
Vietnam/Germany: Loesche GmbH has won an order for a new cement grinding plant in Ha Nam. The customer is Xuan Thanh Cement Joint Stock Company, a private company group (est. 1976) in Vietnam with more than 30,000 employees. In December 2015, Xuan Thanh Cement decided to invest in a new cement line from FLSmidth. Germany's Loesche GmbH, however, was chosen for the delivery of the cement mills.
After Loesche had already supplied a vertical roller mill for the first cement line in the same plant, Xuan Thanh JSC placed the order for the construction of the new grinding plants with two cement mills with Loesche once again.
During the signing ceremony, Mr Nguyen Xuan Thuy, General Director of Xuan Thanh Cement JSC, thanked Dr Thomas Loesche on behalf of the Xuanh Thanh Group. The contracting partners discussed future developments and confirmed their interest in continuing to work together on a long term basis.
The challenge of this project for Loesche lies in the integration of the new grinding plants into a cement line which is presently under construction.
The key elements of the scope of supply are two cement mills type LM 56.3+3 CS. In addition to the two cement mills, Loesche is also supplying further plant components, from the fresh material supply, the product filter and the mill fan to the finished material transport to the product silos. Loesche Automatisierungstechnik GmbH will be the supplier for the electric part and the automation of the grinding plants. Two hot gas generators type LF 20 L are designed to provide the product moisture guaranteed in case of kiln standstill. An extensive engineering package provided by Loesche will conclude the scope of supply.
Xuan Thanh cement plant will thus be fitted with state-of-the-art equipment for low energy consumption and for reduction of emission values to European standards. The lead time for the entire package is eleven months. Commissioning is forecasted for the second quarter of 2017.