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How a cement plant gets off the ground

Peter Krger, Vice President, FLSmidth


FLS Industries Capital Market Day, 18 January 2005

Thailand
Thailand

Filter

Crusher

Filter
Analyzer

Limestone

Sand

Clay
1

Iron
3

Raw meal
silo

4
Storage

Coal mill

4 3

1
Raw mill

Clinker
Silo

Separator
2

Packers

3
Cement
silo

Cement
silo

Cement
silo

Cement mill

Gear unit

Ship unloading

Roller press

Ship loading

Limestone quarry

Limestone loading

Limestone Crusher

EV Hammer Impact Crusher

Filter

Crusher

Filter
Analyzer

Limestone

Sand

Clay
1

Iron
3

Raw meal
silo

4
Storage

Coal mill

4 3

1
Raw mill

Clinker
Silo

Separator
2

Packers

3
Cement
silo

Cement
silo

Cement
silo

Cement mill

Gear unit

Ship unloading

Roller press

Ship loading

CHO Circular Homogenising storages

Longitudinal raw material store

Raw material handling & storage

Filter

Crusher

Filter
Analyzer

Limestone

Sand

Clay
1

Iron
3

Raw meal
silo

4
Storage

Coal mill

4 3

1
Raw mill

Clinker
Silo

Separator
2

Packers

3
Cement
silo

Cement
silo

Cement
silo

Cement mill

Gear unit

Ship unloading

Roller press

Ship loading

ATOX Raw Mill

Robo laboratory

Blending and storage silo, CF

Filter

Crusher

Filter
Analyzer

Limestone

Sand

Clay
1

Iron
3

Raw meal
silo

4
Storage

Coal mill

4 3

1
Raw mill

Clinker
Silo

Separator
2

Packers

3
Cement
silo

Cement
silo

Cement
silo

Cement mill

Gear unit

Ship unloading

Roller press

Ship loading

ATOX coal mill

DRW Rotor Weigh Feeder

Anti pollution equipment

SLC
-D
SLC-D

Cimsa
CimsaMersin
Mersin,, Turkey
Turkey

The Rotax-2 rotary kiln

Kiln hood

Control room

SF - CROSS BAR COOLER

SF - CROSS BAR COOLER

Filter

Crusher

Filter
Analyzer

Limestone

Sand

Clay
1

Iron
3

Raw meal
silo

4
Storage

Coal mill

4 3

1
Raw mill

Clinker
Silo

Separator
2

Packers

3
Cement
silo

Cement
silo

Cement
silo

Cement mill

Gear unit

Ship unloading

Roller press

Ship loading

UMS Ball Mill

OK vertical roller mill

Filter

Crusher

Filter
Analyzer

Limestone

Sand

Clay
1

Iron
3

Raw meal
silo

4
Storage

Coal mill

4 3

1
Raw mill

Clinker
Silo

Separator
2

Packers

3
Cement
silo

Cement
silo

Cement
silo

Cement mill

Gear unit

Ship unloading

Roller press

Ship loading

Packing equipment

Lifting table

Rotary packer

Cement packing

Pneumatic ship unloader

Approximately 3 months

3 - 9 months
Quotation
Contract draft

Financial, legal and commercial conditions


Performance warranties and conditions
Logistic information
Technical specifications
Sales pricing
Cost price estimates
Equipment list
Flow sheet
Plot plan, Proposal drawings
Enquiry/ Process design
Mass flow.
Tender
documents

Negotiations and Contract


modifications
award

Project management
Planning / Logistics
Accounting / Invoicing
Commissioning
Supervision of erection
Shipping docs. and despatch
Inspection and expediting
Purchasing
Manufacturing
documentation
General Arrangement
drawings and specifications
Contract

Process design
Order list
1st year

2nd year

3rd year

2 x 5,000 tpd Plant


Mechanical Equipment
Electrical Equipment
Turnkey Activities
- Site levelling
- internal roads and squares
-

excavation
concrete
formwork
reinforcement

Structural steel
buildings
storages
conveyor bridges
other

- Cladding steel
- Masonry walls

27.510
2.830

ton
ton

25.000
127.000

m3
m2

150.000
140.000
310.000
17.000

m3
m3
m2
ton

9.000
1.500
2.400
3.800

ton
ton
ton
ton

72.000
13.000

m2
m2

Cost-distribution for a Cement


Plant
Typical
1 Machinery & Equipment

UK

Egypt

Algeria

Indonesia

40

36

49

26

42

3 Civil Works incl. Steel Structures

35

38

30

47

29

4 M+E Erection Works

15

20

10

11

12

5 Supervision/Site Expenses

10

6 Miscellaneous

100

100

100

100

100

2 Shipping

Total

Total Installed Cost


(Country specific)

280
260
240

RECENT JOBS

US$/MTPY

220
200
180

NORMAL COST

160
140

LOW COST

120
100
80
60
1000

2000

3000

4000

5000

6000

Capacity (MTPD)

7000

8000

9000

10000