Contents - TECHNO Group · Contents Forward from the ... process design, ... Cantilever Scraper, Combined Stacker Reclaimer, Bridge-type Scraper, and multi purpose Portal Bridge ...

ContentsForward from the President 3

Company Profile 4

Our Vision 5

Our Mission 5

Strategy 6

Our Business Partners 7

Activities 8

A- Construction Materials Industries: 9

I. Cement Industry 12

II. Insulation Material Production Lines 20

III. Concrete Batching Units 23

B-Electrical & Process Automation: 24

I. Electrical System Design 25

II. Electrical Panels Manufacturing 26

III. Process Control System Design 29

IV. Engineering & Application Design 29

V. FAT test 32

C- Agro-Industries: 33

I. Grain Receiving, Storage & Port Facilities 35

II. Feed Mills 37

III. Fertilizers Plants 43

Markets 44

Forward from theTechno Group President:

Dear valued client,

It gives me a great pleasure to introduce the Techno Group of Companies as a leading engineering group in the fields of design, manufacturing, supply and installation of machines and complete industrial production plants.

Since Techno Group was established in 1990, we have evolved as a reliable partner for the establishment of different industrial activities in the region; that is because we avail ourselves to our client’s insights, merging those with our diversified capabilities and strong industrial experience to achieve the best Industrial solutions.

In order to be closer to its clients, Techno Group companies and representatives offices are present in nearly every country of this region. Furthermore, Techno Group has formed alliances and cooperation relations with a number of international companies in Europe and the US to better serve clients. These efforts lead to the spread of Techno Group market in the region.

To realize our slogan “Dedication to excellence”, we have concentrated our energies on high-tech design and fine craftsmanship. The satisfaction of our clients and our commitment to adopt the latest technologies are the primary forces driving the Techno Group.

We hope that this catalog conveys our philosophy, approach, capabilities, skills and achievements.

We are proud of our accomplishments, and we look confidently for a promising future for ourselves and for our clients.

Cordially

Eng. Yousef I. Kamal Techno Group President

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The “Techno Group” is an association of leading engineering firms in the fields of process design, machine design and fabrication, and industrial automation. The Techno Group is specialized in providing industrial solutions and Turn-key projects at the highest International Standards.

Our presence around the MENA region and Europe, gives us the unique position of being close to our clients. Our network of companies includes the following independent entities:

PERTECH-UAE Dubai – United Arab EmiratesCEMATECH-JO Amman – JordanPERTECH-GER Munich – Germany

Techno Group-JO Amman – JordanTechno Group-SA Riyadh – Saudi ArabiaTechno Group-EG Cairo – Egypt

The Techno Group considers its people as its biggest asset. Its highly energetic and knowledgeable staff of Engineers (Mechanical, Electrical, Control, Automation, Civil), Process Designers, Computer Programmers, Agricultural specialists, and Technicians are passionate about maintaining the Techno Group at the cutting edge of technology.

Techno Group

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Our Vision: To be a globally recognized leader in the fields of design, supply, manufacturing and erection of complete automated turn-key industrial projects.

Our Mission:• Providing clients with high quality products and services at reasonable

prices and excellent after-sale services,

• Becoming one of the regional economic pillars contributing to the economic and cultural development, with the best utilization of technical knowledge and expertise, and

• Maintaining workers satisfaction and self esteem, while achieving reasonable return on Investment that would facilitate the continuing growth of business.

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Strategy• Investing in our Engineers and Technical staff to stay on the cutting edge of

industrial design and fabrication accuracy. • Pursuing strong cooperation links with most renowned international

companies in their fields.• Expanding of activity into industries related to areas where the Techno Group

has accumulated experience and knowledge.• Providing best client service through:- Providing pre-contract assistance and preliminary studies to clients- Developing proposals for new projects for investors and financing

establishments- Providing reliable after sales service under all conditions.

Techno Group has formed strong and long term cooperation relations with the most renowned international industrial firms specialized in supplying machines for the Construction and Agro Industries* , and parts for Industrial Automation.

The list of companies that the Techno Group cooperate with reflects the strong commitment Techno Group has for excellence, as each of these companies is considered to be a global leader in its field. Our technical ability and long experience allows us to have strong interaction with these companies leading to the best industrial solutions for our Clients.

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Our Business Partners

Behlen Manufacturing

USA * Logos are registered trade marks of the respective companies.* Techno Group maintains excellent relations with all major sub-suppliers in its field, accordingly Techno Group reserves the right

to source and procure its equipment from the a/m sub-suppliers or other prominent ones.

ActivitiesThe Techno Group took a strategic decision of establishing its activities in the Construction Industries, Electrical and Process Automation, and Agro-Industries being the three industries most active in the MENA region. By assembling the right teams of engineers & experts, and cooperating with the most renowned International Companies in their fields, the Techno Group was able to build a proven track record in building Turn-Key fully-automated projects and production lines in each of Construction Material Industry, the Electrical and Process Automation, and the Agro-Industries. Our main emphasis in these sectors has been on the following fields:

A- Construction Materials Industries:• Clinker-Cement Production Lines.• Insulation Materials Production Lines (Rock Wool, Glass Wool, and Ceramic fiber) • Concrete Batching Plants ( 20 - 150 m3/hr ).

B- Electrical & Process Automation :• Electrical System Design• Electrical Panels Manufacturing• Process Control System Design• Engineering & Application Design• FAT test

C- Agro-Industries:• Grain Receiving, Storage & Port Facilities• Feed Mills• Fertilizers Plants

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I. Cement Industry

II. Insulation Materials Production Plants

III. Concrete Batching Plants

A Construction Industry

The construction industry has been the main target of the Techno Group at the time of its establishment. Techno Group took the strategic decision of diversifying its activities in this sector to cope with constant changes of focus in this industry. The Construction Industry in the MENA area has experienced a great expansion in the last decades inspite of the volatile nature of the area. This expansion is expressed in both size and diversity of activities.

The Techno Group activity in this sector started by building Insulation Material production plants, mainly Rock Wool production plants; proceeded into producing concrete batching units of different capacities; fabricating and suppling spare parts for the Cement and Potash Industries; and culminating in developing a strong presence in the cement, and cement-related Industry. A great effort is currently spent into expanding the Techno Group activities into other mineralogical industries, like Calcium Carbonate plants, and Gypsum industries.

With the Techno Group strong technical background, its long experience in undertaking turn-key projects, and the addition of highly

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qualified and specialized engineers and experts, the Techno Group was able to forge strong relationships and alliances with the most internationally renowned companies in the different fields of the Construction Industry.

The Techno Group commitment to excellence and cooperation with major international partners has helped it become one of the main regional Turn-key project providers in the MENA region. We are proud of successfully undertaking of many projects in the region and gaining the trust of major companies throughout the region, and as always we look forward to proving our abilities in all our future projects.

Portland cement is made of a combination of calcium, silicon, aluminium, and iron. Production of cement that meets specific chemical

I. CementIndustryand physical specifications requires careful control of the manufacturing process. Cement manufacturing starts with quarrying the needed raw materials. The raw materials for the cement industry consist of combinations of limestone (for calcium) coupled with much smaller quantities of clay, sand and iron ore. Clay, sand and iron ore mined from a quarry near the plant.

The First step in the Cement Manufacturing Process is initial minimizing of the size of the raw materials entering the production process by running the raw materials through the Crushing Department; the second step is formulating the raw mix at the right content, size , and blend; the third step is burning the formulated raw mix to undergo chemical reaction ending with the production of Clinker; the fourth step is Grinding the Clinker into Cement; and the final step is loading the produced Cement in bulk or bags.

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1. Cement : Crushing Department This department consists of two crushing areas, the first area is for quarried Limestone and Clay, and The second area is for other Additive Materials.

- Quarried Limestone and Clay are received through two receiving stations. The material is then transferred to an Impact Crusher to crush the Limestone-Clay mix. Impact Crushers can handle individual lumps of materials as large as 1,500mm x 1,200mm x 1000 mm in size; effectively crushing raw materials into a product size of 0-80mm. Crushers could be stationary, mobile, or semi-mobile depending on the project particulars.

- Cross belt analyzer performs online analysis of the Limestone and clay material thus adjusting inclusion rates of those materials at this early stage to command a stringent quality assurance on the process.

- Other additive materials (Gypsum, sand, Iron Ore, Correction Limestone, etc) are received through separate receiving station. The Gypsum and Correction Limestone are crushed by a Gypsum crusher before storing these additives into a multi compartment Storage.

- Longitudinal or a circular Storage with a stacking system provides a covered storage for the crushed limestone-clay. The stacking system places the materials in layers effectively pre-blending the raw materials.

- Additives longitudinal hanger with a stacking system provides a covered storage for additive materials: Gypsum, Sand, Iron Ore, and other correctional materials. The stacking system places the materials in different compartments of the two sided facility. This system could be expanded if required.

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2. Cement : Raw Mix Department2.1 Raw Mix ReclaimingA Scraper Reclaimer is used to reclaim Limestone-Clay mix from the storage facility by going through profiles of the material at the time thus achieving reclamation and blending of files of the material at the same time. The scraper inclination can be adjusted to match the slope of the Limestone-Clay stack. An inclined drag trough is integrated into the scraper bridge located at the scraper chain’s discharge end, loads the reclaimed material onto the belt conveyor while traveling with the machine.

A Scraper Reclaimer reclaims through profiles of the raw materials from the slope side while operating automatically along the whole length of the stockpiled materials, thus ensuring an optimum reclaim of raw material layers. The Scraper can also travel between different working locations. A semi portal scraper is used to handle multi compartment storage hanger. Scraper chains has a proven track record of low maintenance and operating Costs. Other types of Scrapers can be used depending on the configuration of the storage space, and the type of stored material. (e.g. Portal Scraper, Cantilever Scraper, Combined Stacker Reclaimer, Bridge-type Scraper, and multi purpose Portal Bridge Reclaimer).

2.2 Raw Mill ProportioningA number of Weigh feeders dose the Raw Meal (Limestone-Clay) and the different additives, to produce the required chemical composition of the cement. The Weigh Feeders feed the various materials to the Raw Mill accurately and reliably. Apron feeders could be used for poorly flowing materials.1�

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2.3 Raw MillThe Proportioned Raw Mix is fed into the Vertical Roller Mill where the Raw Mix is drawn in between three stationary grinding rollers and grinding track, resulting in the grinding of the raw mix by pressure and shear. The compression force is generated by hydro-pneumatic tensioning system. Ground material is moved by the centrifugal force toward a stationary nozzle ring. Air flowing through the nozzle carries the ground material up to a classifier where the fine finished product is separated from the grits. The finished product is carried through the classifier with the air stream and into cyclones where the ground material is separated. The grits fall back into the center of the grinding zone to be re-ground. The vertical raw mill utilizes the thermal energy of process gases while operating dust fee and have low noise level.

2.� Raw Meal HomogenizationThe finely ground Raw Meal is conveyed to a Homogenization Silo. The Homogenization silo bottom is divided into sectors. Each of the sectors is further subdivided into triangular segments. Each of the segments is equipped with aeration boxes to allow for air to be blown into the material in a controlled sequential manner. Separate rotary blowers can be aerated simultaneously.

The fluidization air is blown through pipe when a pre-set pressure is reached. The discharge openings are equipped with slide gates and pneumatically operated shut-off valves. Fluidized material drops onto air slides to the centrally placed mixing tank below. Effective aeration fluidizes the raw meal in the mixing tank, which performs as an ideal mixer.

The mixing tank is placed on load cells, the weighing signal from these cells regulates the total extraction process from the silo bottom, keeping the material level in the tanks within set limits. The minimum amount of material in the tank will typically correspond to 12 minutes consumption of kiln feed.

The Homogenization silo acts as insurance against upset conditions at the raw mill, ensuring that final clinker quality remains unaffected.

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3 Cement : Burning Department

3.1 Kiln FeedThe Burning Department starts from the point where ground Raw Meal is discharged from the Homogenization Silo and conveyed into the Pre-Heater tower and dosed by combination of kiln feed bin and solid flow meters.

3.2 Pre-heater and Pre-CalcinerThe Pre-heater is designed to save energy and increase kiln capacity by preheating the Raw Meal using hot exit gases from the kiln before the Raw Meal enters the kiln. The Pre-Heater Tower supports a series of cyclone chambers through which the Raw Meal is exposed to the hot exit gases as it passes on its way to the kiln.

3.3 KilnThe Pre-heated Raw Meal is directed to a rotary cement kiln for a process commonly called the pyro-processing phase. A rotary kiln is a slightly inclined cylindrical furnace lined internally with refractories. Upon entering the Kiln from its upper end, the Raw Meal slides and tumbles down the kiln through progressively hotter zones toward the flame. The intense heat triggers chemical and physical changes (evaporation of water, dehydration of minerals, and calcinations of the Raw Meal) ending with Oxidation reaction at 14500C were the calcium and silicon oxides are converted into calcium silicates, cement’s primary constituent. At the lower end of the kiln, the raw materials emerge as red hot particles called clinker, often the size of marbles. The kiln is the world’s largest piece of moving industrial equipment.

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A cooling process follows the pyro-processing phase to lock in the mineral structure of the clinker and to reduce the temperature of the Clinker so that it can be handled with conventional conveyors. Cooling is done by directing ambient air through the clinker so that it cools to 650C above ambient temperature. The heat that is transferred to the air from the clinker is then recovered and reused in the furnace as combustion air.

3.� Clinker StackingThe Cooled Clinker is conveyed by inclined pan Conveyors to Clinker Stacking Silos where Clinker is stored for further processing. These are flat type Concrete Silos. A separate silo is set for off-spec Clinker to be returned to the process in small amounts or to be sold out. All the Clinker stacking Silos are equipped with filter systems to prevent dust emission. Sector gates at the bottom of the silos allow for the discharge of the Clinker from the stacking Silos.

Techno Group was able to secure a good number of major projects in the Cement Industry in a record time

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�. Cement Grinding

�.1 Clinker ReclaimingClinker is discharged from the Clinker Stacking silos through sector gates situated at the bottom of the silos onto reclaiming belts reaching into the Cement Ball Mill.

�.2 Cement GrindingThe Clinker is fed into a Ball Mill . The Clinker enters the Ball Mill through transport lifters in the diaphragm inside the mill cylinder. The Clinker is conveyed beneath the air flow into the grinding chamber that contains the steel balls behind the diaphragm. As the mill Cylinder rotates, the steel balls tumble and crush the Clinker into a superfine powder, which is the Portland Cement. A small amount of correctional Gypsum is added during final grinding.

�.3 Cement Silo FeedThe cement is transported mechanically from the Ball Mill grinder into the Cement Bulk Loading Silos by a Bucket Elevator. A net of Conveyors allows transporting the cement into any of the Cement Silos, thus allowing for higher flexibility in managing the Cement Storage and Loading, especially in the case of producing different types of Cement.

�. Cement Loading

�.1 Bulk LoadingThe standard raised Central Cone silos is used to store Cement in Bulk in preparation to loading Bulkers, or transferring the Cement to Packaging Station. The raised cone is divided into sectors incorporating porous aeration boxes to allow for the fluidization of the Cement within the Silo. The silo has one extraction hole through which the Cement enters a feed box with several outlets. Above the extraction hole is a large cone-shaped steel structure that releases the pressure above the outlet and creates a flow inside the silo helping to maximize Cement discharge from the Silo. This design allows for complete discharge of the cement in the silo while minimizing the specific power consumption for aeration needed.

From the silo outlet, the material passes via air slides to the feed tank, which is aerated by a single rotary blower. The feed tank has one or more outlets with pneumatically regulated flow gates that can open and close quickly to assist in bulk loading operations or releasing materials to the Packing Plant.

The Cement silos are raised over ground thus allowing for direct truck loading and increasing the efficiency of the selling station.

�.2 Packing PlantAlthough new market trend is evolving towards receiving Cement in bulk rather than in a bagged form, still a large percentage of Cement is sold in its bagged form. Thus it is imperative that a Cement plant plans on setting packing Plant that can handle 80% of the Cement production. To allow for greater flexibility, small storage bins (45 m3 each) are included in the Packing station. Each short-term storage bin feeds two Packing Machines specially designed for the Cement Industry with a reliable dosing efficiency and dust control. A Packing Plant is also equipped with Palletizing Line to insure effective storage and loading of bagged cement into truck.

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II. Insulation Materials Production PlantsAs Global awareness of Energy conservation is increasing, the importance of utilizing insulation materials as means of energy conservation and efficient utilization of energy is taking center stage. As a major part of Energy consumption is used for industrial processing, heating and cooling of living and working spaces It is an indisputable fact that large amount of this consumed thermal energy can be saved by more efficient insulation practices.

Consequently, the world is presently experiencing an increased demand for Insulation materials including the use of different types of Mineral Wool. Mineral wool includes the different fibers made from minerals or metal oxides, including:

1- Rock Wool 2- Ceramic Fiber 3- Glass Fiber 4- Slag Wool

Mineral Wool fibers package air so well, that when pressed into rolls and sheets, they make excellent and reliable thermal and sound insulator. Mineral Wool products possess further characteristics and properties advancing them to all other thermo-acoustical insulation materials.

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Rock Wool

The Techno Group has vast experience in this industry, and has accumulated over fifteen years of technical know-how in this field resulting in designing, manufacturing and commissioning a number of Rock Wool production plants in the MENA area. Rock wool possess excellent thermal and acoustical insulation for residential and industrial uses (furnaces, steam lines, stack chimneys, etc...). Rock Wool has other industrial uses, as filler in compounds for gaskets, brake pads, false ceiling, in plastics in the automotive industry and as a filtering medium. Furthermore, Rock Wool is used in agricultural hydroponics activities.

As all mineral Fibers, Rock Wool has the following Characteristics:

- Very efficient in thermal insulation applications, with a low thermal conductivity factor, which complies with the international standards.

- An inorganic, non-aging and dimensionally stable material.

- A water-repellent material.

- A noncombustible and non-flammable material, highly resistance to fire spread without any development of gases.

- Chemically and electrically inert.

- A non-hazardous and medically safe material.

- Durability and resistance to aging, chemical, weathering.

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Rock Wool Production Process:1- Melting: Rock Wool production starts by melting crushed basaltic igneous volcanic rocks at a considerably high temperature (1500˚C) to form a free flowing Lava. Two types of melting furnaces are used for this industry worldwide, the tank furnaces and the copula furnaces. The first type has to be operated non-stop, and will not allow adding other rocks to the basaltic rocks, however the copula furnaces are considered to be the high-tech systems and are operated on a batch-by-batch bases and will easily accommodate a vast range of mixes of different rocks producing Rock Wool products with superior quality.

2- Spinning: The Lava is then spun at high speed spinning wheels forming a a mass of fine intertwined fibers with a typical diameter of 6 to 10 micrometers. A misting of the mass of fibers with a binder and oil reduces dusting, makes the fibers water repellent, and enable forming the mass of fibers into different shapes. The mass of fibers is spread with a pendulum to maintain a constant density of fibers along the width of the produced mass of fibers.

3- Forming: The Rock Wool fibers are then processed by different chemical and mechanical operations (compaction, stitching, facing, edge trimming, shearing, transverse cutting, coil forming, etc), to end up with the final desired product of the specified physical and chemical properties and specifications.

Rock Wool products are made in different types with different sizes and forms to suit the different application needs. Rock Wool basic types are:

- Loose Wool - Stitched Mattresses - Felted blankets - Panels (Rigid and Semi-Rigid) - Pipe sections

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III. Concrete Batching Plants

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B Electrical & Process Automation

I. Electrical System Design

II. Electric Panels

III. Process Control System Design

IV. Engineering & Application Design

V. FAT test

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B Electrical & Process Automation

I. Electrical System DesignExperienced professionals specialized in electrical design for heavy industries.

• Design power distribution systems for heavy industries.• Perform load flow studies, short circuit calculations and cable selection for medium voltage, low voltage and variable speed drives consumers.• Work with electrical brand name such as ABB, Siemens, and Schneider.

Techno Group engineering team designs and builds electrical low voltage panels in house.

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II. Electric PanelsQuality workmanship, timely delivery, competitive pricing, and friendly service are the cornerstones of our Electric Panel building business. Panels can be fabricated and wired to any size or configuration based on client requirement.

1. LVDP (low voltage distribution panel):- Low voltage distribution panels (Fixed and withdrawable). - Feeding panels and motor control center (M.C.C) (Fixed and withdrawable).

The low-voltage electrical distribution panel is designed according to the criteria of “safe, economical, reasonable and reliable” by the requirements of energy departments.

2. Lighting panels: They are produced to distribute power to all non-process consumers, such as Lighting, HVAC, and Sockets…etc.

- Transfer switch and automatic starter panels. - Process control panels. - Power factor correction panels.

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�. ATS (Automatic Transfer Switch):ATS panels transfers load from the main power supply to the emergency power, and will auto start the emergency generator in case of power failure.

3. MCC (motor control center) – Fixed and Withdrawable: The motor control center forms the brain part governing the process of motor coordination and protection.

- Motor Starter Combination.- AC Drives.- Motor Feeder.

�. MP (marshalling panels): These Panels insures the interconnections between the field devices and the control room, through the exchange of data and signals between them.

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�. Sub-control units: The sub control local panels parts of the plants that operate as stand alone system, but communicate with the central system, and exchange data through communication protocols such as Ethernet and Profibus.

�. Power factor correction panels:They are produced to increase the power efficiency for plant with high inductive loads, such as inductive motor; AC\DC drives; arc furnaces; electronic controls. By using a power factor correction panel, we avoid drawbacks of poor power factor.

�. Junction boxes: The part collects signals of field devices and sends them to the electrical rooms through multi-core or field bus cables.

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III- Process control system Design The architecture of the targeted automation system is defined at an early stage of a project.

The architecture of the automation system mainly depends on the nature of industry, and the type of process. These factors determine the quantity and type of control units definition, and the quantity and type of operation system.

IV- Engineering and Application Design Engineering work starts by creating flow sheets. The flow sheets are divided into layers according to the process requirements in the plant.

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Configuring the system includes the following: -Creating an address for each station and PLC, -Configuring the PLC memory, -Configuring the IO system,

Designing an interface between the operator and the plant equipment.The interface must fully simulate the equipment conditions (E.g. motor running, motor stopped, motor fault or motor local stop…etc). It is animated for ease of use. This interface must enable the operator to fully control his equipment such as: - Start/Stop groups.- Write process set point.- Giving local permission for the field equipment. All of that will be done through special software dedicated for HMI design, the designed HMI and the PLC must be connected to a database in which they will exchange the information (set point, motor fault, analog signals…etc).

General function specification describes the plant production shops, sequences, the motors of each sequence and the concerned loops.

Detailed function specification (logic diagram), specifies a group of motors corresponding to the same function that should start together.

A program consists of special function blocks, each function block presents equipment (motor, valve…etc) or a special task (PID, PWM…etc).

A program is organized with respect to the production shops, in such way that a group of equipment presents a separate operation group.

A software tool is used for recording the analog values (trends) and the operation history, which are configured according tothe process people.

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Techno Group has its own experts in the field and has a certified PROFIBUS engineers.

Techno Group personnel are capable of designing and installing such communication system and have special equipment for that.

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n V- FAT TestThe aim of this test is to check with the system suppliers the complete System compatibility, both the hardware and the software, then testing developed application.

Testing the applications includes:• Testing all the sequences.• Interlocks.• Safe start up and shutdown of equipments.• Alarms. • The color of the sequence.

During the application testing, the software runs a simulation that generates test signals between them to check the reaction of the application.

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I. Grain Receiving, Storage & Port Facilities

II. Feed Mills

III. Fertilizers Plants

C Agro Industry

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The Techno Group has recognized the importance of the Agro-Industry sector since its early beginning, were the Techno Group has constructed the first fully automated chemical fertilizer plant in Jordan for the benefit of the Modern Company for Fertilizers in 1990. However, it wasn’t until 1997 that the Agro business became a major focus of the Techno Group

To set a clear positioning of the Techno Group in the Agro-Industry market, the Techno Group management decided to form strong relationship with the major international suppliers of machines in the Feed, Fertilizers, Grain processing, and Grain storage industries. With a clear cooperation and commitment from Van Aarsen International of the Netherlands, Stella Co. of Germany, Behlen Mfg. of Nebraska-USA, and many other sub-suppliers. The Techno Group approaches the market with a clear positioning, strategy, and commitment to excellence.

The Techno Group takes bride in its role in increasing the regional awareness in the Agro-Industry sector of the importance of efficiency and adopting modern production techniques as the main source of increasing revenues. Through diligent marketing, technical competency maintained relations with International renowned supplier, and efficient after sales services, the Techno Group has succeeded in building a good number of projects for the major companies in the region. These projects include the first fully automated fertilizer processing plant in Jordan for the benefit of the Modern Company for Fertilizers, the largest feed mill in Palestine for the benefit of Palestine for industrial Investment Co., the largest feed mill and Grain Storage Facility in Jordan for the benefit of National Poultry Co. a company of the DELMONTE Co., the largest Ostrich feed mill (non traditional feed) in the region for the benefit of AlWatania Agriculture-one of the companies of A-Rajhi Group, and many other projects. These accomplishments elevated the Techno Group to the status of the largest turn-key project provider for the Agro industry in the Middle East area.

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I. Grain Receiving, Storage & Port Facilities

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Receiving PitGrains and meals are mainly received through receiving pit equipped with dust Control system to reduce emissions. Grains are released to the receiving pit either through in-truck release mechanism or by the aid of Truck Dumper. Received material is passed through a magnet trap and a De-stoner to remove metals and non-magnetic debris, in order to prevent damages of the different moving mechanical parts of conveyors.

Grain StorageGrain are conveyed into different storage structures through a net of conveyors to allow for flexibility and maintained reliability: Different types of grain storage systems could be employed depending on the nature of stored material, Amount of received materials, storage duration, and local environmental conditions.

Grain Storage Systems include: Steel Silos, used mainly for grains Concrete Silos, employed for certain applications in the flour milling industry; or Flat Hangers, commonly used in moderate environment for meal storage; Soymeal flat silos equipped with meal cutter. All types of storages have to be equipped with adequate aeration system, temperate sensing system, a mechanism for turning grains over and/or prevent caking, and a reliable discharge system. Other equipment could be used, like fumigators, Air Coolers, Thermal insulation, etc.

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II. Feed MillsFeed Formulation and Consistency is the main element for successful animal production activities, as it determines the health, and growth rate of reared animals. Feed cost accounts for about 70% of the total cost of animal production activity, therefore the cost-effective formulation and high quality of feed is aggressively sought.

Industrial Feed Milling produces standardized and controlled feed quality with high standards of hygiene and uniform compounding of all the nutritional requirements of the different animals. Heat treatment and compression of well balanced compound feed into pellets, crumbs, flakes, or expandates ensures the hygiene and higher conversion factor of the feed.

Feedmill Industry is linked to other highly specialized activities like, Vitamin/Mineral Premix production lines and Feed Concentrates production lines. New trend in establishing Non-traditional feedmills based on utilizing byproducts and fibrous farm materials.

The Feed Mill contains the following main processes:Dosing Process: to ensure the strict formulation of the compound feed. Grinding: to reduce the particle size of raw materials.Mixing: to ensure the optimum distribution of different raw materials within the meal.Pelleting: to change the physical character, hygiene, and nutrient availability of feed ingredients.

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DosingRaw materials are transported to the feed mill from storage facilities or directly from bag emptying stations. The raw materials are weighed on line while being transported into their specially designated bins at the feed mill. The on-line weight of each incoming raw material is recorded in the facility’s main computer system.

Groups of six to eight raw materials bins are connected to a separate dosing Unit to speed up the dosing process. Each raw material is designed to allow for good flowability of materials, and is equipped with level sensors connected to the feed mill control system to allow for automatic filling of the bins with raw materials. Special knockers or vibrators are installed on bins with a low-flowability materials Each bin ends with a pneumatic gate that is under the control of a frequency converter. The length of the dosing slide’s stroke and the speed of the opening/closing process in combination with a feed-back from the sensitive dosing apparatus assures the precision of the dosing process. Once all the raw materials are dosed, the batch is released to a buffer bin to be transported to the next stage of processing.

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Grinding and MixingThe feed batch is transported into a milling machine (Hammer mill, or a Roller mill) to reduce the size of different particles thus ensuring a larger surface area for enzymatic digestion and higher availability of nutrients to animals. Furthermore, size reduction ensures the success of pelleting process. Fine materials can be sieved ahead of the grinding station to conserve power usage. Another known system named Pre-Grinding implies grinding materials before the dosing step. However, certain measures have to be takes to prevent molding.

Ground batch (including premixes and additives) is dumped into the mixer station where liquids and oils are sprayed while all the ingredients are mixed to a highly uniform mix.

Different types of Mixers could be used (ribbon, double ribbon, and paddle). The mixing time of every type of mixer should be followed strictly according to the equipment supplier recommendation to avoid any under mixing, or segregation of the feed meal components. The mixed meal of ruminant feed could be further mixed with molasses in a specially designed molasses mixer equipped with molasses dosing system.

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PelletingThe feed meal is fed into the pelletmill by a feeder with varying speeds that changes depending on the temperature of the meal in the following conditioning process. The meal is then fed into a conditioner where it gets heated and mixed with steam at high temperatures. Feed Conditioning is a crucial step that determines the feed quality , as the steam cooking of the meal increases its digestibility resulting in a higher feed conversion factor; sterilizes the feed ensuring the elimination of potential diseases; and lead to the gelatinization of starches in the meal which is reflected into a better pellet quality. A new type of conditioner (Long Term Conditioner) ensures that the meal is heated up to 120˚C for 4 minutes to kill Salmonella bacteria.

The Cooked meal is then transported to the Pelletmill where the feed is forced through pellet dye pores of standard dimensions through the high force of rollers moving against the dye. This force and the gelatinizing of starches in the feed meal, forms the shape of the feed compact pellets of uniformly mixed feed. The diameter of pellets is determined by the dye pores, and the length is determined by adjusting the distance of a special knife from the dye.

The final step in the pelleting process involves cooling the pellets to around ambient temperature to prevent any cracking or caking of the produced pellets. Cooling is achieved by passing pellets through a counter flow cooler.

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Post Pelleting

Crumbling:Pelleted feed could be run through a crumbler machine consisting of two moving rollers with adjustable distance, which cause the crumbling of feed into smaller sizes called crumbs that are used to feed chicks.

Post Pelleting Applicator:

Temperature sensitive amino acids, enzymes, and vitamins could be sprayed onto cooled pellets to prevent degredation by heat in the pelleting process. Oils and other liquids could also be sprayed onto cooled feed to increase the nutritional value of pellets.

Selling StationProduced Feed is finally transferred into selling station where it could be bagged in 50Kg bags or in jumbo bags, or feed can be sold in bulk. A Bulk feed terminal consists of a number of large bins with slides that are controlled from the control system and are connected to the truck weigher to determine the amounts of feed loaded into feed trucks. The truck weigher signals an indicator connected to the invoicing system.

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III. Fertilizers Plants

MarketsThe Techno Group has been active since its establishment in expanding its activities to the regional and international markets. Thus a large number of Techno Group projects could be found mainly throughout the MENA region.

Egypt

Iraq

Jordan

Lebanon

Libya

Palestine

Qatar

Saudi Arabia

The Netherlands

Turkey

United Arab Emirats

USA��

Mar

kets