Vinh Son Cement visit & Cemtech International...

Vinh Son Cement visit &

Cemtech International Experience

Presented by : Dr. Surapich Phuvoravan

Date: 2 March 2016 Rev 1

Vietnam

CTI's experience in Plant UPGRADE for Vinh Son Cement visit 1© Copyright : 2 Mar. 2016

Cemtech International Co. Ltd.

83/33, Soi Shinaket 2, Ngamwongwan Road,

Tungsonghong, Lak Si,Bangkok, 10210 Thailand

[email protected]

+66 954 7232

mailto:[email protected]

CTI's experience in Plant UPGRADE for Vinh Son Cement visit

Agenda

1. Cemtech International Introduction

2. Selected Experience of Cemtech in UPGRADING Clinker production

3. Selected Experience of Cemtech in UPGRADING Cement Production

4. Selected Experience of Cemtech in Waste Heat Power Generation (WHG) system – Generate Elect. Power

5. Next Steps and Potential Co-operation

6. Site Visit

2© Copyright : 2 Mar. 2016


Agenda






6. Site Visit



Cemtech International Co., Ltd.

• Cemtech International was founded by experts in the cement and related fields.

• Main activities: Engineering, Consulting, Project Management, Local

representation of Owners.

• Main fields: Cement, Paper, Power, Waste to Power (with Wehrle Umwelt GmbH),

Alternative Fuel and Raw Materials for various industries (AFR), Waste Heat

Recovery system in various industries, Fuel storage and feeding systems for

various industries.


Value Customers in South East Asia Region

PT Semen Bosawa Corporation

Phonesack Group

United Pulp and Paper Co.,Inc.Electricity Generating

Authority of Thailand

Siam City Cement Plc.

Siam Kraft Industry Co., Ltd.

TPI Polene Plc.

Holcim (Lanka) Ltd.Conwood Co., Ltd. Holcim (Vietnam) Ltd.

PT Bintang Cement

Mandiri

Indonesia Cement and

Concrete Institute

PT Semen TonasaThai Pride Cement

CEMEX (Thailand) Ltd.

PT Holcim Indonesia Tbk.

Ferro (Thailand) Co., Ltd.

Siam Cement Group

Geocycle Co., Ltd.

IRPC Plc.

BANPU Plc.

Double A (1991) Plc.

PT Indocement Tunggal Prakarsa Tbk.

Asia Cement Plc. Jalaprathan Cement Plc.

© Copyright : 2 Mar. 2016 5CTI's experience in Plant UPGRADE for Vinh Son Cement visit

Kampot Cement

Metso Plc.

LPC

http://www.conwood.co.th/index.asp

http://www.conwood.co.th/index.asp

What do we do?

Complete Cement Plant: EPC & Consulting

Plant Operation Optimization & Improvement

Kiln Upgrade

Mill Design and Mill upgrade

Terminal and Packing Plant

Innovative projects – Kiln Shell Replacement

Spare Parts, Supply and Logistic


Complete Cement Plant : EPC & Consulting


KCC 2 – Clinker Production 2,500 TPD in Cambodia



MCL 1 – Clinker Production 5,000 TPD in Myanmar – Preheater Engineering



Laos Pattana– Clinker Production 5,000 TPD in Laos

Phonesak Group– Clinker Production 5,000 TPD in Laos

1. Raw material pre blending

area

2. Raw material feed bin

3. Raw material grinding

4. Blending silo and kiln feed

system

5. Clinker Manufacture

6. Clinker storage

7. Cement grinding

8. Cement storage

9 Packing and dispatch

10 Coal Grinding

11 Control room (CCR)

12 Workshop and

warehouse

13 Weight bridge

14 Canteen

15 Customer service

16 Parking area

1

2

34

1

05

6

8

9

7

1

1

1

2

1

4

1

3

1

51

6

Owner Consultants and Feasibility Study

Phonesack Group

LPC

Kiln Upgrade


Upgrade compare with build new line

Suitable for heavy AFR usage

Capacity increase up to 40%For example : Upgrade capacity

from 5000 to 7000 TPD.Mixing Chamberallow good mix between

Fuel and raw meal

Fast Return of Investment

Faster Execution

Build New production line

Cost: ≈ 5X-7X

Upgrade

Cost: ≈ X

Build New production line

Time: ≈ 2-3 years

Upgrade

Time: ≈ 1 year

CTI Precalciner

Kiln Upgrade


June 2011 – Sept 2012 ( Completed)

Client: PT SEMEN BOSOWA MAROS / SOUTH SULAWESI - Indonesia

Project: Bosowa Upgrade Project from 5,000 to 7,000 TPD Clinker Production

CTI’s scope of works : Process, Mechanical and Civil Engineering

Project Management consultancy and Commissioning

BOSOWA Upgrade 5,000 to 7,000 tpd in Indonesia

12

1 Sept 11

5000 tpd

EXECUTION PHASES BEFORE AND AFTER

© Copyright : 2 Mar. 2016

1 May 12

7365 tpd


Value Proposition & Investment Justification


Return of Investment within 1 year.

Faster Execution


Build New2000 tpd production line

Cost: > 100 mil USD

This upgrade (50007000 tpd)

Cost: 8-15 mil USD

Build New2000 tpd production line

Time: 2-3 years

This upgrade (50007000 tpd)

Time: < 1 year


The upgrade also enable the system to be

Suitable for AFR usagewith special design caliner and related systems

Feasibility Study:

Upgrade 2000 tpd toward 4000 tpd with Mininum Investment

L/S Hammer Crusher

500 t/h (exist.)

Clay Roller Crusher

200 t/h (replace)

Raw Mill

150 t/h (exist.)

180 t/h (new)

Homogenizing Silo

2x1,668 m3

2x3,365 m3

Rotary Kiln

4,000 t/h

(replace gear)

Clinker Silo

1 x 15,000 t. (exist.)

1 x 30,000 t. (new)

New Cement Ball Mill

2 x 125 t/h

Coal Mill

15 t/h (exist.)

20 t/h (new)Quarry

(outsourcing)

Joint work with Indonesian Cement Institution

FOR

Preheater

1 2 string, 4th stage

New precalciner

New Cement Silo

3 x 12,000 t

New Packing Plant

3 x 120 t/h

© Copyright : 2 Mar. 2016 CTI's experience in Plant UPGRADE for Vinh Son Cement visit 14


Assessment: Go in Detail Equipment to inspect – Semen Tonasa


Plant Operation Optimization & Improvement:

For example, Previous quality issues in Semen Kupang

Source: Kupang Quality Monthly report – Oct 2010

Raw Mix Kiln feed Clinker%Oxide %Oxide %Oxide %Oxide

SD. LSF. 12.5 11.25 9.1% F.Cao 0.93

C3S 44.02C2S 28.29C3A 9.98C4AF 12.72


Standard Assessment Approach

(for Operation Improvement)


Project

Definition

& Planning

Data

analysisReporting

30 days

Summary

meeting

Plan for

Next phase

Next plan

Performance

assessment

ConclusionSite

visit

Project

Kick-off

3 days 30 days 1 day

Improvement

potential


Activities during Site visit in Assessment


Operation Investigation of every sections

Inside inspection of main equipments

Detail assessment by gas Measurement in Raw Mill,

Preheater and Cooler sections

Mutual agreement between plant and Cemtech team

about improvement potential (technical) and

measures

During 3 day assessment, Cemtech and

Owner team members conducted:


Example of result from Analysis from Assessment

: Find Process Bottlenecks (in current operating condition)

5,000 t/d 7,000 t/d

© Copyright : 2 Mar. 2016 19CTI's experience in Plant UPGRADE for Vinh Son Cement visit

Example of Assessment result:Operational Recommendation from inside inspection


3.) Enlarging the reject cone of

classifier

As-is: Worn hole of reject cone + too narrow

Impact: reduced grinding efficiency , high

recirculation inside mill

To do: Install additional cone, which extend all the

way to the grinding table + design to

accelerating velocity inside mill to avoid pre-

separation of particle inside mill body

Reject cone too small

Example of Assessment Result:Operational Recommendation from inside inspection


2.) Reduce gap between inner sealing ring

and rotor <10mm

As-is: Gap is too wide at 15-20mm

Impact: Coarse particle bypass through rotor then give

high % residue of 200 µm and high speed of rotor

lead fine particle return to reject material

To do: Gap Adjustment

following Operational

criteria and Fine tune.

Mill Design


Cemtech Dynamic

SeparatorRoller Press

Tube Mill

V-Separator

KCC Cement mill in Cambodia

Mill upgrade


Install part of CT Separator for coal mill

BOSOWA Coal mill upgrade 35 tph to 50 tph

in Indonesia

Cement mill upgrade

Increase Capacity from 120tph to 210 tph

Value Proposition of Mill upgrade v.s. New Mill


Faster Execution


Build New Mill (210 tph)

Cost: > 30 mil USD

Mill upgrade (120->210 tph)

Cost: 6-9 mil USD


Time: 12-18 months

Mill upgrade (120-> 210 tph)

Time: ≈ 6-9 month


The upgrade also has

No Production Losswith tie-in only 5-10 days during yearly maintenance shutdown


CTI's experience in Plant UPGRADE for Vinh Son Cement visit 25

© Copyright : 2 Mar. 2016Cement SiloIs a structure for storing materials

for transport

Inverted coneGive more space under silo

Hence , We can put machine

to reduce footprint

Aeration systemThe aeration system is

designed using concept of

material discharge prevent

dead stock inside silo.

Section of Cement silo

Small footprint

less space for expensive

area near seaport.

© Copyright : 2014

CTI Design

Small footprint

HOLCIM - Indonesia

BOSOWA - Indonesia

Innovative Project - Kiln Shell Replacement


Cemtech - Kiln Shell ReplacementThe project of Tarjun the factory of Indonesia

in 2010 , Under our design.

Kiln Shell Replacement- Reduce time from 60 to 25 days

Normal kiln high : 50 m.

- Convention technic: Crane 500 ton can lift up kiln shell 62 ton. (at boom 14 m.)- Our technic : we concept use the lift jack , so can

be up to 600 ton



Support roller

Transmission gear

Truss roller

Kiln tyreSpare Parts

Spare part for

Roller Press

Spare Pasts, Supply and Logistic


Gypsum Akali or Alumina – Raw Material

CementClinker

Spare Pasts, Supply and Logistic


Fluorine - Additive

Alternative Fuel

Any material for adjust cement quality

Logistic

What do we do?

Complete Cement Plant: EPC & Consulting


Kiln Upgrade

Mill Design and Mill upgrade


Innovative projects – Kiln Shell Replacement




Agenda





5. Site Visit



2. Experience of Cemtech in UPGRADING

Clinker Production

See separate slides for

Bosowa upgrade 50007400 tpd Project



Agenda






6. Site Visit



3. Experience of Cemtech in UPGRADING

Cement Production

See separate slides for

Cement Mill upgrade 90175 tph Project


Value Proposition of Mill upgrade v.s. New Mill


Faster Execution



Cost: > 30 mil USD

Mill upgrade (120->210 tph)

Cost: 6-9 mil USD


Time: 12-18 months

Mill upgrade (120-> 210 tph)

Time: ≈ 6-9 month


The upgrade also has

No Production Losswith tie-in only 5-10 days during yearly maintenance shutdown


Agenda






6. Site Visit



4. Experience of Cemtech in Waste Heat Elect.

Power Generation (WHG) for Cement plant

Not yet presented



Agenda






6. Site Visit



5. Next Steps & Potential Co-operation

Protential Projects from discussion

►Clinker upgrade project - Cemtech has prelim site visit today

- Cemtech will send Questionnaire/checklist to request plant

information to Mr. Duong

- After getting information, Cemtech will come to discuss upgrade idea.

►Cement mill upgrade project - Cemtech has prelim site visit today

- Cemtech will send Questionnaire/checklist to request plant

information to Mr. Duong

- After getting information, Cemtech will come to discuss upgrade idea.



Agenda






6. Site Visit


Vinh Son Cement visit &

Cemtech International Experience

Presented by : Dr. Surapich Phuvoravan

Date: 2 March 2016 Rev 1

Vietnam


Cemtech International Co. Ltd.

83/33, Soi Shinaket 2, Ngamwongwan Road,

Tungsonghong, Lak Si,Bangkok, 10210 Thailand

[email protected]

+66 954 7232

mailto:[email protected]

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