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International Cement Conference - Cemtech -Dubai - March 2011
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POLYSIUS in the Middle East &
Africa
Case Studies
International Cement Conference - Cemtech -Dubai - March 2011
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MARKET
Middle East and Africa cement industry is undergoing a fast
growth fuelled by
Urbanisation: expanding populations in the need of improvement
of living conditions leading to housing, infrastructure, etc.
Industrialisation: developing industries also need building
materials
Boom on commodities: despite the recent financial crisis, a
sustained boom on commodities and subsequent Mining Capital
Expenditure providing funds for GDP growth and requirement for
building materials
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TRENDSOther significant trends in the cement industry :
Reduction of CAPEX of the cement plant projects. Cement
industry being highly capitalistic, access to funds is a challenge,
particularly after the recent financial crisis leading to debt
reduction policies for the companies
Reduction of OPEX: many customers are focusing on more
efficient and innovative solutions to reduce the operating costs
(power and calorific savings, use secondary fuels, increase in
plant availability)
Sustainable and environmentally friendly solutions
Challenges to POLYSIUS Keep High Quality Standards
with Optimized Costs
Equipment Reliability
Innovative Solutions
International Cement Conference - Cemtech -Dubai - March 2011
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DIVERSITY
Remarkable is the variety of our customers, ranging f rom :
major international historical companies (LAFARGE, HOLCIM ,
ITALCEMENTI, etc.)
middle-size historical cement companies (VICAT, CIMENTS
MOLINS or SCHWENK ZEMENT, etc.)
local players + significant number of new players
state owned companies
Corresponding organization, skills, technical and financial resources
vary a lot from a company to another, and accordingly the
requirements and expectations
Challenges to POLYSIUS Flexibility and Adaptability
Suitable Projects Schemes &
Contractual Set up
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POLYSIUS IN THE
MIDDLE EAST & AFRICA
CASE STUDIES
International Cement Conference - Cemtech -Dubai - March 2011
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EGYPTIAN CEMENT Co - LINE 5 5 300 tpd
ECC Line 5 - Overview of achieved quantities
Mechanical Equipment 11 200 tons
Electrical Equipment 750 tons
Reinforced Concrete 45 000 m3
Structural Steel 5 500 tons
GA & Detailed Drawings 410
Civil & Structural Drawings 1 750
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EGYPTIAN CEMENT Co - LINE 5 5 300 tpd
Main Factors of Success:
Fast and controlled project execution thanks to copy plant
concept: reduced CAPEX & time for completion, rapid
production ramp up > improved financial return
Largely sized equipment allowing capacity increase of each
line from 4300 to 5300 tpd clinker and no additional raw mill for
line 5 thanks to reserves on first 4 raw mills
Civil & Structural Design by POLYSIUS SAS with same
suppliers through long lasting collaboration in France. Policy of
Best Cost
Large manufacturing & construction capabilities and efficiency
of OCI
Excellent complementarity with OCI, shared values
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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd
MBCC Line 2 - Overview of achieved quantiti es
Mechanical Equipment 10 400 tons
Electrical Equipment 750 tons
Reinforced Concrete 33 000 m3
Structural Steel 5 500 tons
GA & Detailed Drawings 325
Civil & Structural Drawings 1 150
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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd
MBCC main requirements for Line 2:
High quality standards for the supplied equipment
Project management of the full scope of supply & works by
one Contractor
Reduced investment and controlled overall budget
Reduced time for completion
International Cement Conference - Cemtech -Dubai - March 2011
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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd
Advantages to MBCC & key criteria of successful project:
Secured overall budget thanks to copy plant concept fixed
price for supply contract + guaranteed quantities for concrete
and structural steel
Full project management by POLYSIUS as for a turnkey-type
contract of the supply chain (inquiry, procurement, quality
control, coordination, planning, supervision, commissioning
and training)
Use of suitable industrial resources in Egypt from civil &
structural design to civil works, steel manufacturing and
erection works
Fast plant execution, rapid production ramp up to 5300 tpd of
clinker > profit maximisation
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AL SAFWA CEMENT Co - GREENFIELD PLANT 5 000 tpdAl Safw a Cement - Overvi ew of achi eved
quantities
Mechanical Equipment 13 600 tons
Electrical Equipment 700 tons
Reinforced Concrete 70 000 m3
Structural Steel 6 700 tons
GA & Detailed Drawings 445
Civil & Structural Drawings 1 800
International Cement Conference - Cemtech -Dubai - March 2011
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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE
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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE
The main targets of the project were:
Installation of additional 10.000 tpd clinker production capacity
as well as 630 tph cement grinding capacity
Implementation of most modern technologies to achieve
highest reliability and energy efficiency
Meeting most advanced environmental standards and legal
regulations
Execution of the construction works without major influences
on the existing 6 production lines
Meeting the challenging time schedule with early cement in
one grinding unit after 16 months
International Cement Conference - Cemtech -Dubai - March 2011
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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE
YAMAMA SAUDI CEMENT 10 000 tpd - Overview of achieved
quantities
Mechanical Equipment 31 000 tons
Electrical Equipment 4 000 tons
Reinforced Concrete 72 000 m3
Structural Steel 25 000 tons
GA & Detailed Drawings 262
Civil & Structural Drawings 11 000
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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd
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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd
The main requirements of CIMAT were:
Efficient raw material preparation thanks to on line analyser, circular
mixing bed and POLAB quality control
A balance between energy efficient modern technology, such as raw
grinding vertical roller mill, CC calciner for petcoke firing,
POLYTRACK clinker cooler with intermediate roll crusher, and well
proven solutions such as a cement grinding plant
Efficient and environmental friendly solutions such as a single high
temperature integrated bagfilter for both kiln and cooler dedusting
without any use of water and cooling air; pyro processing design to
allow use of secondary fuels
Optimized design of multi-compartments cement silos to ensure
flexibility of cement types production and reduced investment costs
High quality level of the equipment manufacturing
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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd
Some of our challenges were to:
Manage 2 big contracts, with significant constructions
volumes to be achieved in a short period
Deal with lengthened delivery times for main machinery at
a period of time (2007 and 2008) where industry was
booming with suppliers backlog at a record high level
Deal with corresponding rising prices of metals and
materials
Properly select the capabilities of suppliers and contractorsto ensure a proper quality and planning
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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd
CIMAT cement plants - Overview of achieved quantities
Ben Ahmed plant Beni Mel lal plant
Mechanical Equipment 11 900 tons 12 100 tons
Electrical Equipment 900 tons 900 tons
Reinforced Concrete 66 000 m3 68 000 m3
Structural Steel 9 500 tons 9 500 tons
GA & Detailed Drawings 830 450
Civil & Structural Drawings 3 350 3 000
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SOTACIB FERIANA WHITE CEMENT LINE 2 1 000 tpd
SOTACIB White cement line 2 - Overview of achieved
quantities
Mechanical Equipment 4 600 tons
Electrical Equipment 200 tons
Reinforced Concrete 12 000 m3
Structural Steel 2 100 tons
GA & Detailed Drawings 440
Civil & Structural Drawings 885
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SOTACIB FERIANA WHITE CEMENT LINE 2 1 000 tpd
Specific competitive advantages to drive SOTACIB decision to
award POLYSIUS SAS were:
Innovative POLYSIUS design for white cement pyro processing
with a drum cooler + POLYTRACK grate to ensure high level of
whiteness and reduced heat consumption when comparing to
existing technologies on the market Skills and experience of POLYSIUS SAS in turnkey projects
particularly in Tunisia, where all last major turnkey plant
expansion were achieved by POLYSIUS SAS (upgrading in
Ciments de Djebel Oust, new line n2 for Socit des Ciments
dEndifha and subsequent conversion to petcoke of the same
plants)
Strong cultural links that ease communication and mutual
understanding
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SOTACIB KAIROUAN GREENFIELD PLANT 3 600 tpd
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SOCOCIM INDUSTRIES LINE 5 3 600 tpd
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SOCOCIM INDUSTRIES LINE 5 3 600 tpd
SOCOCIM main requirements:
Low Operating Cost solutions (low energy consumption
power & heat design to use secondary fuels)
Low Capital Expenditure
Environmental friendly solutions
Turnkey execution
Short time for completion
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SOCOCIM INDUSTRIES LINE 5 3 600 tpd
SOCOCIM line 5 - Overview of achieved
quantities
Mechanical Equipment 7 600 tons
Electrical Equipment 500 tons
Reinforced Concrete 41 500 m3
Structural Steel 4 100 tons
GA & Detailed Drawings 520
Civil & Structural
Drawings
1 400
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CIMENTS DU SAHEL LINE 5 3 600 tpd
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OHORONGO CEMENT GREENFIELD PLANT 2 100 tpd
OHORONGO CEMENT plant - Overview of
achieved quantities
Mechanical Equipment 7 600 tons
Electrical Equipment 500 tons
Reinforced Concrete 41 500 m3
Structural Steel 4 100 tons
GA & Detailed Drawings 520
Civil & Structural
Drawings
1 400
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CONCLUSION
Variety of our Customers Requirements, Resources, Experience
& Culture > Each Industrial Project is Specific
Our Aim: to Fit Customers Requirements & Resources by
providing a Comprehensive Range of Project Solutions &
Contractual Set up
Best Cost strategy > Outstanding quality of POLYSIUS
products and services + optimise the CAPital EXpenditure
Efficiency & reliability of our Products + Flexibility & Proximity of
our Services & our Experience in Middle East and Africa > quick
financial return to our customers.
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THANK YOU