ENGINEERING & DESIGN SERVICES

CEMENT & MINERALS

ProU General Information

PROCESSES UNLIMITED
I N T E R N AT I O N A L

rocesses Unlimited (ProU) is a multidiscipline engineering, project management, and

design/drafting firm. ProU provides services to a diversified market including oil,
gas, cement, chemical, alternative energies, building products, power, utilities,
food, beverage, packaging, plastics, minerals, mining, power, and utilities.
The company structure is built on a foundation of quality engineering practices and
management procedures, as well as a belief in strong customer service. The services
offered by Processes Unlimited range from engineering and design to process and construction management. Initially providing mechanical engineering services to the oil
and gas industry and other industrial clients, the areas of discipline now incorporate
civil, structural, instrumentation, electrical, controls, panel fabrication, process, and
chemical engineering.
Because we work in multi-disciplinary, client-centered teams, we offer our clients a
single point of responsibility. With this focus on teams, accountability and service, our
clients benefit from more efficient project execution and coordination. Our hallmark is
our ability to clearly understand our clients needs and customize our services to meet
their individual requirements.

Processes Unlimited International

Processes Unlimited International has the breadth and depth of experience to offer your
project the expertise needed to ensure confidence in its successful completion. ProU
provides expertise in the following:

Beverage
Building Products
Cement/Lime
Chemical
Energy/Alternative Energy
Engineered Wood Products
Fiber Cement Board
Food
Forest Products
Gas
Green Power/Biofuel

Kaolin
Manufacturing
Metals
Minerals
Oil
Petrochem
Power
Refining
Roofing
Textile
Utilities

Capabilities

Cement & Minerals Experience

Conceptual

Engineering Specialties

Block Flow
Mass Balance
Equipment General Arrangements
Order of Magnitude Cost Estimate
Site Selection Criteria
Permit/Code Review
Control Philosophy

On-site Project Services

Construction Management
Training
Checkout, Commissioning & Start-up

Preliminary
Permitting
Air Emission/BACT/MACT
Storm Water
Waste Water
Equipment Plans
Motor/Equipment Lists
Class 10 Cost Estimate
Site Development
Utilities

Procurement
Equipment/Material/Construction
Specifications
Procure Equipment
Procure Construction Contracts
Expediting

Engineering/Design
Mechanical
Building/Foundation/Structures
Civil/Site Permitting
Materials Handling
Piping, Plumbing, HVAC
Power Distribution
Instrumentation & Electrical
Control Systems/Programming
Lighting/Grounding

Processes Unlimited International

Greenfield Plant Design

Geotechnical & Topographical Investigation
Environmental Permitting
Grant/Funding/Permitting Assistance
On-site Project Support
Due Diligence
Site Selection & Preparation
In-Plant Projects
Maintenance Modifications
Process Improvements
Equipment Retrofits

Construction Management
Commissioning Plans
Startup Services
Training
Construction Oversight

Safety Services
Facilitate HAZOPs & PHAs
Process Safety Management
Contractor & Construction Safety
Behavioral Based Safety
Safety Training
Program Development & Implementation

Material Handling and Storage

Thermal Operations

Bagging, Palletizing, Super Sacks, Warehousing

Mechanical Conveying
Belt, Screw, Drag, Bucket
Pneumatic Conveying
Dilute & Dense Phase
Slurry Transport
Pipeline & Bulk Container
Bulk Storage
Silos, Bunkers, Hoppers, Live Bottoms
Bulk Loading & Unloading
Truck, Rail Car, Barge, Ship
Containers

Drying
Rotary, Conveyor, Fluid Bed
Flash/Pneumatic, Spray
Calcining
Rotary, Multiple Hearth, Flash
Solids Cooling
Heat Recovery
Fluid Heating
Evaporation
Single & Multiple Effect

Agglomerization
Briquetting
Extrusion
Disk Pelletizing
Rotary Drums
Fluidized Beds
Mixers

Comminuting and Classification

Raw Mineral Shredding & Crushing
Dried & Calcined Mineral Milling
Roller Mill
Cage Mill
Wet Grinding
Screening
Centrifugation
Air Classification
Jaw
Cone
Gyratory
Tube Mill
Autogenous Mill
Impact Crusher
Vertical Roller Mills
Roll Presses

Solid/Liquid Mixing
High Shear Blunging
Blending
Powder/Slurry Makedown
High Viscosity Paste Mixing

Solid/Liquid Separation
Settling, Clarifying
Flotation
Centrifugation
Filtration (Pressure & Vacuum)
Belt, Drum, Plate & Frame
Cartridge, Automatic
Hydrocyclones

Mining
Crude Ore Evaluation & Testing
Mine Planning
Reserves Validation

Dust Collection
System Design
Equipment Selection
Plan & Evaluation

Partial Client List

PROCESSES UNLIMITED
INTERNATIONAL

CEMENT & MINERALS

INDUSTRY

Cement
Bessemer Cement

Screening and conveying system

Box Crow Cement

Blending systems for aggregate

Cemex (Formerly
Southdown)

KHD/Eagle Materials/
Mountain Cement

roU and its staff of engineers and managers list more than fifty projects for the cement
and minerals industry. These projects range from process studies and cost estimating
to design and engineering projects and in-plant commissioning and start-up services for
multi-million dollar projects. Our expertise and talents include process and material handling
system design, electrical and control systems design, and detailed plant engineering services.
Some of our customers include:
Bessemer Cement

Lehigh Southwest Cement Co.

Box Crow Cement

Medusa/Citadel Cement

CalPortland Cement

Mountain Cement Co.

Carmeuse

National Cement Co.

Cemex/Southdown

Nevada Cement Co.

Chemical Lime Co.

Polysius

Dravo Lime

Quikrete

Eagle Materials

South Dakota Cement

Engelhard

Suez Cement

Florida Rock Co.

Tarmac

Giant Cement

Texas Lehigh Cement

Illinois Cement Co.

Thiele Kaolin

Imerys

US Lime

KHD

Zemex

Lafarge

Processes Unlimited International

Tire handling truck dumper system

Centralized air compressor system
Tire conveying system
Plant-wide electrical system study
Construction management (Quarry to Clinker
Cooler)
Drainage and paving project
Clinker storage feasibility study
2,400 STPDexpansion
Six stage pre-heater with kiln feed system
Kiln
Clinker transport
Coal transport and grinding

Partial Client List

Partial Client List

Florida Rock Cement

Gainesville plant design

Illinois Cement Co.

400,000 t/yr dry process plant

High efficiency OSEPA air separator to finish mill
Limestone and shale quarry plan, relocated primary
crusher and extended plant belt conveyor
Clinker storage building
Preheater modification
Modified existing kiln feed system

KHD

Design and structural review of tertiary air ducting

and pyrotop

Lafarge

Lehigh Cement

Medusa/Citadel Cement

Processes Unlimited International

Cement air conveying system

Water reclaim system
Color plant expansion
Kiln discharge hood modification
Aggregate handling system with crusher, screens,
transfer towers and conveying
Preheater system
Rail car dumper
Power distribution system
Precipitator rebuild
Plant-wide control systems
Tire handling truck dumper system

Engineer and design finish mill transport line purge

air system
Equipment Plot Plans, selection and line routing
Engineer, design and manage install of a Clinker Silo
truck unloading system
B3 FK pump relocation
Clinker transfer tower dust control
Kiln feed de-aeration system
Replacement ID fan

Mountain Cement Co.

Wet to dry conversion of plant to 500,000 t/yr

utilizing a two stage preheater addition to the
kiln, new raw feed system, new roller mill for
raw grinding
6,000-ton rail/truck terminal in Denver, Colorado

National Cement

Engineering feasibility study for a Limestone and

Gypsum material handling system.

Nevada Cement Co.

10,000 ton truck load-out silos, clinker storage

building
One stage preheater to kiln #2 blend silo, kiln
feed system

Quikrete Companies

Process tower design

South Dakota Cement Plant

600,000 t/yr dry process expansion including a

coal handling system and conversion of three
existing kilns from gas/oil firing to coal firing
Added two 2,000 hp finish mills,150,000 t/yr
clinker storage building

Sun Belt Cement/Cemex

Rail unloading modification, storage and truck

load-out in Fort Worth, Texas

Partial Client List

Partial Client List

Lime

Holcim Cement

Aqueous ammonia injection system

Conveyor structural analysis

Texas Lehigh Cement

500,000 t/yr greenfield dry process plant

Expansion of plant to 1,000,000 t/yr with
addition of flash calciner, new raw mill, and
finish mill
High efficiency OSEPA air separator to 3,500 hp
finish mill
Alkali, and sulfur bypass system to preheater
calciner
Roanoke rail/truck transfer terminal 4,800 tons
of storage
Waco rail/truck transfer terminal 3,000 tons of
storage
Houston rail/truck transfer terminal 5,000 tons
of storage
Kiln dust conveying system and mill feed system
Clinker conveyor structural modification
Cooler vent relocation and redesign
Cooler vent duct redesign
Proposed combined stack design
Flash calciner, and structural modifications
Corpus Christi rail unloading

Processes Unlimited International

Chemical Lime Co.

(over 30 projects)

Hydrator feed bin

Transload terminals
Facility platforms and structure design
Rail pit structure
Rotating Grizzley
Kilns
Limestone dryer
Limestone handling systems
Dust collection system
Coal mills
Plant optimization studies
Kiln baghouse replacement
Electrical studies

Dravo/Carmeuse Lime

Conveying systems
Baton Rouge terminal
Stone storage
Stockpiling
Screening
Pre-Heater
Lime kiln
Lime handling
Loadout
Lime grinding

Partial Client List

Partial Client List

Kaolin
AKI Berhad

Preliminary design, flow sheet development and capital

costing for kaolin plant in China

BHP Minerals

Due diligence services for an Australian kaolin project

Included crude clay reserves through final product
shipment

Burgess Pigment Co.

Chemical treatment, VOC emissions, thermal oxidizer, and

steam generator

Caulim Da Amazonia, S.A.

Plant layout and assistance for plant expansion from 360k8,00K t/yr
Design of a super sack bulk bagging and shipping
Redesign of blunging operation and addition of second
system
Detailed design and start-up assistance of a single-effect
evaporator system

Para Pigmentos, S. A.

Conceptual design and plant layout for a greenfield

kaolin plant in Brazil for the production of 250,000
t/yr of kaolin
Design assistance for a 180-kilometer slurry pipeline
from mine and plant area across an undeveloped
area of Amazonia to the drying facility and port
Plant start-up assistance

Rio Capim Caulim

Design of a product slurry makedown facility

Design of a mine blunging, degritting, storage and
shipping facility
Layout and strategic planning for expansion of an
existing 240,000t/yr plant to 1,000,000 t/yr

Southeastern Clay Co.

Rotary dryer and roller mill efficiency testing and

analysis
Rotary dryer capacity upgrade design
Mine-to-shipping thermal and electrical energy
reduction analysis
Electrical rate analysis
Wood fired heating and cogeneration analyses

Dry Branch Kaolin Co.

(formerly Georgia Kaolin
Co.)

Design of ship terminal facilities for the import, storage,

and reshipment of kaolin slurries

Thiele Kaolin Co.

Engelhard Corp.

Spray dryer process and control evaluation

Processing Plant layout; civil estimate and design

Fullers Earth/Attapulgite

Evans Clay Co.

J.M. Huber Co.

Bennett Mineral Co.

Wood firing of rotary dryer (sizing), control P&ID,

furnace and baghouse assistance

Georgia-Tennessee Mining
and Chemical Co.

Rotary dryer efficiency and control upgrade

Packaging fugitive dust reduction

Oil Dri Corp. of America

(Three facilities)

Rotary dryer and roller mill capacity and efficiency

Baghouse troubleshooting/blinding elimination
Airfloat rotary dryer, roller mill, and cage mill combustion
system tests

Kaolin International, B.V.

Design of import terminal for the receipt of dry kaolin

from Brazil, storage, slurry production, and shipment by
truck, rail, or barge in Europe and Scandinavia

Kentucky-Tennessee
Mining Co.

Rotary dryer efficiency testing and analysis

Design of a slurry makedown facility for finished slurry
from crude kaolin

Processes Unlimited International

Rotary dryer capacity and efficiency improvement

Particulate/SO2 scrubber design and upgrade
Scrubber water treatment
Discharge pond design

Partial Client List

Partial Client List

Zemex

30 t/hr plant expansion

Hear sources controls
CM for plant expansions

Other Minerals
Feldspar Corp.

Rotary dryer capacity and efficiency study

H.C. Spinks Co. (Ball Clay)

Detailed design for installation of a used Italian spray

dryer with all auxiliary equipment
Bulk loading and bagging operation

Manufactured Products
Crossville Ceramics
(Ceramic Tile)

Designed a large particle system including material

handling and agglomerization
Kiln modification
Revision of recycle water system
Expansion of facility

Engelhard Corp.
(Zeolite Catalyst)

Mechanical and control upgrade projects

Illinois Mineral Co. (Silica)

Replacement of existing bag house

Design of a wet ground silica slurry plant, including
design of pilot and production grinding equipment

Kohler Co.
(Porcelain Ware)

Tunnel kiln heat recovery

Plant thermal study

Mid-western location
(Synthetic Gypsum)

Design and startup of a greenfield calcium sulfite plant,

including offices and storage/shipment facilities

Lapp Insulator Co.

(High Voltage Insulators)

Environmental permitting

Design of a minerals pilot plant, including purchase of

equipment
Preliminary design and flow sheet design for several
greenfield industrial minerals plants in the U.S. and
abroad

Santerios Azteca
(Bricks)

Kiln thermal efficiency study

U.S. Borax, Inc.

Waverly Mineral Products

Burner efficiency tests; recommendations for thermal

efficiency improvement

Monarch Mountain Marble

Addition to plant in Salido, CO

Huber

Processes Unlimited International

Addition to plant in Marble Hill, GA

Pigments
Kemira Pigments Inc.
(Titanium Dioxide)

36 electrical, control, and mechanical projects

PSM activities on chloride and sulfate processes
Chlorine/titanium tetrachloride vent scrubber
Slurry process preliminary engineering

Pacific Smelting Co.

(Zinc Oxide)

Process engineering for a secondary zinc smelting/

French process zinc oxide facility

www.prou.com

Corporate Headquarters
Processes Unlimited International Inc.
5500 Ming Avenue, Suite 400
Bakersfield, CA 93309
1-661-396-3770

Additional Office Locations

Atlanta, GA
Dallas, TX
Fresno, CA
Pasadena, CA
Walnut Creek, CA
Kingdom of Bahrain