15.00 paolo bossi, md, sinai white cement
DESCRIPTION
15.00 Paolo Bossi, MD, Sinai White CementTRANSCRIPT
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1CEMTECH - Dubai, March 6th 2011
www.sinaiwhitecement.com
Stateoftheart White Cement production:two production lines of 1500 tpd clinker eachat Sinai White Cement.
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INDEX OF THE PRESENTATION
1.Cementir Holding & Sinai White Cement2.Sinai White Cement Social Responsibility3.White Cement Applications4.White Cement Market Overview5.Sinai White Cement Total Quality System 6.Plant Technical Overview7.Second Production Line Project: Capacity doubling
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INDEX
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23Cementir Holding
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Cementir Holding Organization Structure
4Cementir Holding
CEMENTIR HOLDINGManufactures and distributes white and grey cement, aggregates, ready-mix
concrete and concrete products in many countries worldwide.
Has operations in 13 countries;
20 cement production and concrete production plants of which 4 in Italy, 4
in Turkey, 1 in Denmark, 5 in Portugal (JV CRH), 1 in Egypt, 3 in the USA (2 JV
Heidelberg and Cemex), 1 in China and 1 in Malaysia
110 ready-mix concrete plants of which 6 in Italy, 90 in Scandinavia and 14
in Turkey
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Cementir Holding operates production plants in 13 countries ~ 15 mt of cement capacity; 3.1 m of Rmc and 4.1 m of aggregates
DENMARK - SCANDINAVIAGrey cement capacity: 2,100,000 tWhite cement capacity: 850,000 tRMC sales: 1,800,000 m3Aggregates sales: 4,100,000 m3Terminals: 9
TURKEYGrey cement capacity: 5,400,000 t RMC sales: 12400,000 m3
ITALYGrey cement capacity: 4,300,000 tRMC sales: 120,000 m3Terminals: 3
EGYPT White cement capacity: 1,100,000 t
USAWhite cement capacity: 260,000 t *Cement products plants: 1Terminals: 1
MALAYSIAWhite cement capacity: 200,000 t
CHINAWhite cement capacity: 500,000 t **
PORTUGALCement products plants: 5 ***
ICELANDTerminals: 1
POLANDTerminals: 1
THE NETHERLANDSTerminals: 1
*In JV with Heidelberg and Cemex (Cementir Holding holds a 24,5% stake)** Incremental 500,000 tons from Q1 2010 *** In JV at 50% with Secil P. Bossi
Group Overview
6Cementir Holding
Cementir Holding, through its subsidiary Aalborg Portland, is:- world leader in white cement (1 producer in Denmark, Egypt,Malaysia and China)-1st cement producer in Denmark-1st ready mix concrete producer in Scandinavia-2nd cement producer in ScandinaviaCementir Holding has also the following competitive positions :- 3rd cement and ready-mix producer in Turkey (Cimentas)- 4th cement and ready-mix producer in Italy (Cementir)The Product portfoglio breakdown is: cement 64%, ready-mix andaggregates 32%, other 4%.
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47Cementir Holding
6550
398650
40256760
Cementir Holding, through Aalborg Portland Group, has the global leadership with more than 3 m tons of production capacity.
* Source: Cementir Holding estimates** The white cement produced in Oceania contains so much iron that the whiteness does not exceed 90%
(called off-white), so that it is not included
- White cement is a niche product sold globally- Global white demand has grown around 5-6% in the last 10 years- White cement capacity tends to be inland, less subject to imports and raw materials scarcity limits new capacity additions - White cement is used mainly for decoration and repairs and maintenance work
19951595
Global capacity * : 19,515,000 tGlobal consumption * : 15,287,000 t
North America
Carribean
Latin America
0
Europe
Africa
Middle East
South / North Asia(excl. China)
China
East Asia
Oceania**
14111610
12881285
18612160
37504450
457955
370
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8Cementir Holding
R & D2 state-of-the-art research and development centers
in Italy and in Denmark
SWC like all the other companies of the group enjoy the
technical and quality support, with more than 50 years
experience, of Cementir in Italy (Rome ) and of Aalborg in
Denmark
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59SWC Corporate
SINAI WHITE CEMENT CO.
SWC was incorporated in 1999
The Plant was established in the Sinai Peninsulaapprox. 50km from the city of Al Arish
SWC entered in the market with its first bag ofwhite cement in November 2001 when the plantstarted production with a capacity of 410,000 MTof clinker per year.
In 2004 Cementir Holding, became owner ofAalborg Portland Group and took over themanagement of SWC purchasing 57% ofcompany shares.
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10SWC Corporate
SWC Shareholder Composition: Aalborg Portland : 57%
Sinai Grey : 24%
IFU : 14%
Sama Group : 4%
Dr. Hassan Kamel Rateb : 1%
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611Social ResponsibilityEnvironmental
SWC complies with European energy and environmental
requirements: in the plant all equipments in both kilns meets the
international environmental and safety standards.
The plant has converted from the use of oil to gas as primary fuel
The company has implemented an environmental reporting system and
participates in the online environmental monitoring system that allows
the central authorities to supervise plant operation and emissions
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12Social Responsibility
Social & Economic Through creation of jobs and support for local initiatives the company has a
significant positive social and economic impact in this area.
To support the local economy, SWC uses local contractors and companies to
transport all type of materials
SWC contributed in the creation of a police station, a mosque and a new village
in the desert improving the quality of the life in the area
SWC is committed in the increase of the level of the education in the area by
supporting construction of schools and by providing scholarships in the local
university
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713Product - Applications
Tiles & Terrazzo Precast Concrete
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Dry Mix Artificial Stones
14Product - Applications
Interlock BlocksP. Bossi
Ready Mix
Concrete StructuresBricks & Blocks
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815Product - Applications
GRC
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Outdoor Art Mortar
Finishing works
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Type
EN 197-1-CEM I 52.5 N
EN 197-1-CEM II/B-LL 42.5 N
EN 197-1- CEM II/A-LL 52.5 N
EN 197-1-CEM I- 42,5 Dark White
SWC Cement Production Types
Products
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917Products - BrandsDomestic Market Brands:
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White Portland Cement
Sinai Super White
New Sinai
18Products - BrandsExport Market Brands:
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Sinai White Portland Cement CEMII
Aalborg White Cement -CEMI Aalborg White Cement -CEMII
Aalborg Jumbo White
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19Sales Overview
Export SWC is exporting white cement of premium quality to 28 countries and hasexisting markets located in the Middle East, Africa, Asia and Europe.
SWC always adapts to meet the ongoing changing needs of its customersand provide individually customized solutions.
SWC created a successful relationship in the international businessenvironment.
SWC offers client care services through Commercial support (paymentterms/short lead time of production), Logistical support (shipping/just-in-time delivery) and Technical support (use of products/ quality of products)
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20Sales Overview
SWC exportsto 28 countriesaroundthe world
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21Sales OverviewEgypt Domestic Market
The Egyptian market has been growing over the last 5 years, on theback of the high activity experienced in the construction and realestate sectors. Egypts cement consumption has been growing ata CAGR of 6% over the past 40 years although most of the worldmarkets were in crisis and this is seen to continue for the future.
It is expected that the Egyptian market will consume 450.000 tonsduring the year 2011.
Sinai White Cement is covering all the governorates of Egypt forits high quality and its economic value.
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22Sales Overview
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0
50000
100000
150000
200000
250000
300000
350000
400000
450000
500000
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Market Capacity
Sinai White Cement stabilized at 60% domestic market sharein the last two years.
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23Products - LogisticsPacking: SWC provides several choices of packing for its customers that include:
25 / 50 Kg bags Sling bags Jumbo bags Shrink Wrap Containers Bulk
SWC takes pride in its packing quality and as such can offer 'Shrink Wrapping' as an outstanding method protecting its products from various harsh weather conditions.
Delivery (for export market):Main Ports:
1. El Arish: Bulk and all type of bags2. Port Said: Containers and all type of bags3. El Sokhna: Containers and all type of bags4. Adabey: General Cargo and all type of bags5. Alexandria: Containers and all type of bags
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24Quality
Situated near some of the purest raw material sources in the world,SWC plant was designed to deliver products with highest strengths andmaximum performance.
The high product quality of SWC is monitored by a comprehensive andwell-proven quality control system that covers every facet startingfrom raw materials and process phases to finished products.
Modern technology and computerized controlling are vital elementsin the quality control system, in accordance with EN 197.
The unique raw materials and advanced production technology that wasdeveloped over many decades made the foundation on which SWC haswon worldwide acclaim for its superior quality
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25Quality
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Production Technology
Aalborg Technical Centre have developed several methods formodelling clinker burning and cement grinding.Equipment includes several laboratory furnaces for small scaleburning of cement clinker for burnability testing, clinker reactivity,the distribution of minor components and their impact onperformance and colour.Laboratory grinding of the clinker to test the cementperformance is also performed where full scale production trialsare deemed too costly.
26Quality
SWC Products Main Certification
EGYPTIAN STANDARDSES : 4756 1 / 2009
EUROPEAN STANDARDSEN 197 1 : 2000
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27Quality
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The following properties are tested:
Compressive strength Water demand Setting time Fineness (Blaine) Mortar expansion Chemical composition Particle size distribution Cement colour Water soluble Chromium
Chemical analysis:
In addition to the standardizedtesting of cement, water, fuels, rawmaterials and intermediateproducts in production areanalysed on a regular basis.
These analyses include particle sizedistributions, chemical analyses,heat values of alternative fuels andraw materials, etc.
Cement testing is routinely performed according to the relevant EN standards
28Quality
Domestic Certification Body:
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Egyptian Organization for Standardization and Quality
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29Quality
Foreign Certification Bodies
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MATERILPRTIFUNGSANASTALTBERLIN GERMANY
LGAI TECHNOLOGICAL CENTERBARCELONA SPAIN
30Quality
Foreign Certification Bodies
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Russian Certification: Sanitary-Epidemiological Conclusion Certificate for the AAlborg White Portland white cement issued by Department of Federal Service for Supervision in the Sphere of Protection of Consumer Rights and Human Welfare.
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31Plant Overview
Plant Design Specifications Units Line I Line II
Designer FLS FLS
Annual capacity design / actual t/y
440,000 /500,000
440,000 /500,000
Clinker capacity design / actual t/d
1300 / 1500
1300 / 1500
Heat consumption kcal/kg ck 1,270 1250
Type of fuels H. Oil / Natural Gas H. Oil / Natural Gas
Fuel oil LCV kcal/kg fuel 9,600 9,600
Natural gas LCV kcal/Nm3 8,700 8,700
Plant Data
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Raw Material Conveyor
Plant Overview
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Raw Mix design
Raw Materials Percentages Units Value
High Grade Limestone % 81.00White Sand % 12.00Kaolin % 6.00CaF2 % 1
Raw Materials Sources Supplier
High Grade Limestone SWC quarry ASCOMKaolin South Sinai Kaolin ASCOM
Sand South Sinai White Sand ASCOM
CaF2 Imported from Iran Golden triangle
Raw Materials
Plant Overview
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Limestone Storage
Limestone storage Units Sinai
One Silo for Each Line 2 SiloCapacity ton 7,000Total Capacity ton 14,000
Plant Overview
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Raw Mill feeding
Raw Mill Hoppers for Each Line UnitsHoppers
Capacity, ton
Limestone Silo Ton 7000Kaolin Hopper Ton 140
Additive Hopper Ton 170
Sand Slurry Turbo Mixer m3 20
Plant Overview
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Sand Mill4 Sand Mills Two per Line Units Value
Type Slurry MillOpen Circuit
No. of Compartment # 1Type of Discharge EndType of lining RubberThe Mill Drive KW 700Type of Grinding Media Flint PebblesS. P. Consumption KWh/t 63Charge Diameters mm 32 to 16No. of Mills # 2Capacity / Mill t/h 5 of the Mill m 2.9Length of the Mill m 16Fineness on 45 % 3 Wet SieveWater Added % 45-55Ground Sand Tank Capacity ton 30 ton
Plant Overview
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2 Raw Mills (ATOX)
Raw Mill Units Value
Type ATOX 25 Vertical MillNo. of Rollers # 3 rollersProduction rate t/h 90Mill Drive Power KW 600
Wear Rate gm/t 3Fineness on 90 % 5Grind-ability Power KWh/t 5The Classifier RAR 30, SEPAX TypeThe Mill Exhaust Gas Fan KW 1000Moisture in Raw Materials % 6Kiln Exhaust Gases For
Drying % 58 to 60
Dust emission from the Stack mg/Nm
3 50 (Wet)
Plant Overview
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2 Pre-heater Towers
Pre-heater Units Value
No. of Stages # 4No. of Strings # 1Type of Cyclones FLS Low PressureDiameter of CyclonesC1 m 4.60C2 m 4.60C3 m 4.60C4 m 4.60
Plant Overview
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2 Kilns
Kiln Units Value
Diameter m 3.75Length m 57No. of supports # 3Kiln Drive KW 132Kiln Inclination % 4Kiln Speed rpm 3.6Kiln Volume m3 515Kiln Load t ck/24 h/m2 1.9Cross section thermal Load G.cal/m2.h 3.9L/D ratio inside Lining 17Capacity : Design / Actual TPD 1300/1500Heat Consumption kcal/kg ck 1270
Plant Overview
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Clinker Coolers
Line 1 Cooler
Type Grate Cooler Folax
# of Grates 2
# of cooling Fans 5
Area m2 39.9
Grate Load t/m2.24h 25.06
Speed 3 to 30 stroke/min
Crusher Hammer crusher at cooler exit
Cooler De-dusting Hot EP , 50 mg/Nm3
Line 2 CoolerType FLS Rotary Cooler
Diameter 3.95
Speed 6 rpm
Length 10
Crusher Crusher at cooler exit
De-dusting Hot EP 50mg/Nm3
Plant Overview
Clinker Quenching is in the Kiln on Line 1 Clinker Quenching is in the Cooler on Line 2
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Clinker Storage Silos
Ck Storage Units Value
Type Concrete Silo
Line 1 1 Silo
Line 2 2 Silos
Diameter m 20
Height m 35
Capacity ton 20000 ea.
Withdrawal 2 conveyors per silo
Total Capacity ton 60000 tons
Plant Overview
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Cement Mill Feed Hoppers
Mill Hoppers Units Hoppers Capacity, ton
Clinker m3 100
Gypsum m3 50
Additive m3 50
Plant Overview
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Cement Mill
Cement Mill Units Value
Type FLS UMS 42x 14.5No. of Mills # 2Capacity Des./Actual t/h 80 / 90Mill Diameter m 4.1Mill Length m 14.50No. of compartment # 2Power KW 3579Mill Charge mm 80 to 15Dynamic Separator
Type SEPAX 335M-222
UMS 2 compartment mill
Plant Overview
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Cement silos Units Value
Supplier FLS
Number of silos # 2Internal diameter m 17Internal height m 39.5 / 35 Effective
Capacity ton 10,000ea.
Total capacity ton 20,000
Steel Silo Units Value
Capacity ton 2,500
Total Capacity 22,500
Cement Storage
Plant Overview
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Packing and Dispatch Area
Packing Units ValuePaper Bags bags
Type VENTOMATIC
Number of packing machine # 2
Number of spouts/machine # 8
To Truck or Palletizer (sling Bags)
Capacity of each machine t/day 2400
Jumbo Bags t/day 500
Type FLS
Number of Packing Machine # 1
Bag Mass ton 1.5
Sent to Truck or Storage
Capacity t/day 800
Ventomatic Palletless
Shrink Wrapped Cubes t/day 2400
Plant Overview
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Final Product
Dispatch Overview
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47Line II Project
2006Decision to build the second line
The production of the plant was fully utilized in 2006 and the
future growth in the demand of the high quality products locally
and on the export markets required further capacity.
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48Line II Project
The Quarry & Raw Material
SWC is situated near some of the purestraw material sources in the world.
The viable raw material sources exist in thequarry owned by SWC for more than 100Years production (with double capacity: 1,2million tpy).
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49Line II ProjectAvailable Operation & Maintenance Experience
The experience of operating line no. 1 has been successfully
achieved with ASEC as Maintenance & Operations Contractor
and ASCOM as quarry-contractor.
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Several auxiliary building were already available as workshop,
control room, laboratory, main substation, canteen, dressing room,
and the packing plant were already extended.
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Line II Project
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51Line II Project
Based on:
1. Growth in the demand
2. Availability of appropriate raw materials of sufficient
quantity and quality owned by company.
The Board of Directors of SWC decided to complete a feasibility
study for an expansion of the SWC Plant with the aim of doubling
plant capacity from 600,000 tones to 1,200,000 tons white
cement.
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52Line II Project
Type Of Contract For Line II - Alternatives
Line 1 was built in 1999 with a Turnkey Contract (TC) with FLS/ASEC and the
preferred solution for the second line was again a TC-solution.
3 TC bids were obtained, but all of them were over the expected budget and
this was considered to be the contractors contingencies for their risk in a TC.
Based on this it was decided to pursue a self managed execution of the project
The first step was to select a project management company and RHI was
selected due to their cement experience and knowledge of the Egyptian
contractors.
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53Line II Project
Risk Of A Self Managed ContractThe risk with a self managed contract compared to a TC is the
management of the different contractors who will be involved
in the project, and who only will be responsible for their own
contract.
To minimize this problem it was agreed with RHI to try to split the
project up into different packages, where the contractor would be
responsible for erection and local manufactories of equipment
for their defined scope of the project.
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54Line II Project
Self Managed VS Turnkey Contract DISADVANTAGES
Contract negotiation with many (main) contractors (RHI,FLS, ASAESACO and Shotmet) instead of one.
Elaborate BID-documents to be sent to min. 3 suppliers for directpurchase. Evaluate the received offers and placing purchase orders.
Coordination at site between the different contractors to avoid that aeventual delay of one contractor would result in claim from another.
Monthly report of progress and budget follow-up.
ADVANTAGES Savings of approximately 10 % compared to a Turnkey Contract.
RESULTS All production guaranties has been achieved.
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55Line II ProjectConclusion On Self Managed Contract
1. With a strong Project Management team is it possible todo a Self Manage project and obtain the savings comparedto a Turnkey Contract.
2. It is important to be very critical in setting upprequalification demand, for involved contractors andsuppliers.
3. Application of delay penalties are difficult and small, asthey are related to the contract value of a contractor and notthe whole project cost as it would have been the case in aTurnkey Contract.
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56Line II Project
Project Timeline Goals
Contract in Force 29th November 2006
Raw Mill Production 11th October 2008 (22 months)
Kiln Production 28th November 2008 (24 months)
85 % of guaranteed kiln production 28th December 2008
(25 months)
SCHEDULE
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57Line II Project
In November 2006 contracts for the 2nd ProductionLine were signedF.L.Smidth-Design and process equipment supplies, manufactory drawings,and inspection of local manufactures and supervision of erection and commission
(40% cost)
RHI-Project management and civil design (5% cost)ASEC-Automation for electrical deliveries, erection and commission (11% cost)ESACO-Civil work, local fabrication and mechanical erection (21% cost)Shotmet- Local fabrication and mechanical erection (6% cost)Direct purchase (by RHI) BID documents sent to min. 3 suppliers: 17% cost
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58Line II Project
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59Line II Project
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60Line II ProjectEnvironmental compliance
To achieve our high request of environmental compliance the plant is equipped
with:
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1) Separate grinding mills
for sand
Wet mills for sand grinding to
avoid possible silicosis.
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61Line II Project
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2) Electrostatic Precipitators
Emission Guarantee of < 50 mg
62Line II Project
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3) Baghouse Dust Collectors
Jet Pulse baghouses at transfer points
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63Line II Project
Equipment Description Capacity2 Sand Mills Pebble media 6 tph
Vertical Raw Mill Atox 25 with RAR Sepax 30 90 tph
Preheater Four Stage FLS Low pressure Four 4.6 m cyclones
Kiln Design / actual FLS 3 tire, 3.75 x 57 1300 / 1500 tpd
Cooler FLS Rotary 3.95 x 10, 6 rpm
Clinker Silos (2) Concrete 20,000 tons
Equipment and Capacity
Cement Mill FLS UMS 42 x 14.5 80 tph
Cement Silo Concrete with Truck Loading 10,000 tons
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64Line II Project
Capacity of 90 tph, with 600 kw motor.
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ATOX Raw Mill
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65Line II Project
Capacity of 1500 tpd,
4-Preheater cyclones 4.6 m diameter
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Preheated with Calciner
66Line II Project
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Rotary Kiln
3 Support, 57m x 3.75m
Girth Gear Electric Drive
Design Capacity: 1300 tpd
Actual Capacity: 1500 tpd
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67Line II Project
10m x 3.95m
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Rotary Cooler
68Line II Project
Two Concrete Silos 20,000 ton
capacity per Silo
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Clinker Silos
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69Line II Project
FLS UMS 42 x 14.5
3579 kw drive
Side mounted Flender Gear
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Cement Mill
70Line II Project
Capacity of 10,000 tons, Truck
Loading and Withdrawal for
Packaged Products
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Cement Silo
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71Line II ProjectCompleted Line
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72Line II Project
Production Capacity Increase The new line started production in October 2008
SWC became the main producer of white cement in Egypt
By the end of 2009 SWC has reached a production capacity of
1.2 Million MT of high quality white cement
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73Financial Overview
The project was completed within the approved budget of 90 M USD
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74SWC Plant
1,000,000 TPY Clincker capacity
1,200,000 TPY Cement capacity
2 x 3800 kw cement mills
2 x Ventomatic 8 spout packing machines
1 Ventomatic jumbo bag packing machine
Ability to ship bulk white clinker
FULL PLANT
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75Both Production Lines
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76Cemtech Dubai, March 2011
THANK YOU
www.sinaiwhitecement.com
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