1 Unique Design Concrete Preheater Tower z Preheater tower constructed of concrete with steel floors z Concrete section 105m high (35 storey building) z Additional 10m cyclone structure z Footprint 25.3m by 20.4m z 1 720 tons steel reinforcing & 9 540 m³ concrete z 1 270 tons structural steel for floors z Important to have ‘vertical’ aspect of preheater constructed when preheater parts started arriving at site z Time saving z Only achieved by utilising concrete & sliding to a special design z Cost effective (+7% saving compared to steel) z Aesthetically pleasing z Used our product
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Unique Design Concrete Preheater Tower
Preheater tower constructed of concrete with steel floorsConcrete section 105m high (35 storey building)
Additional 10m cyclone structureFootprint 25.3m by 20.4m
1 720 tons steel reinforcing & 9 540 m³ concrete
1 270 tons structural steel for floorsImportant to have ‘vertical’ aspect of preheater constructed when preheater parts started arriving at site
Time savingOnly achieved by utilising concrete & sliding to a special design
Cost effective (+7% saving compared to steel) Aesthetically pleasing Used our product
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In-Line Calciner Plus Six-Stage Preheater
Kiln 4.55m diameter x 54m Calciner 6.6m diameter x 27m
268oC
Cyclones 1-2: 6.9m diameter
Cyclones 3-6: 7.2m diameter
3 Air 2.5m diameter
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Pre-Heater H2
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Pre-Heater H2
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Pre-Heater H3
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Pre-Heater H4
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Pre-Heater H5
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Pre-Heater H6
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Pre-Heater H7
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Pre-Heater H8
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Pre-Heater H9
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Pre-Heater H9
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1200 Metres of Piling Installed
March 2007
1.2metre diameter piles
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Constructed Using 80 ton Slide Platform
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Around the Clock Construction
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Preheater Topped-Out After 58 Days
May 2007
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Preheater Structure Dominates the Skyline
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Mechanical Installation Began Immediately
June 2007
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Kiln Drive Installation Kiln Pier 2
Preheater Steelwork: Level H3
Structural Steel Floor H3
24Steel Fixing in Preheater: Level H3
25MMC Clinker Cooler Frame
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Kiln Shell Arriving on Site
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Kiln 2 LT Substation
New Clinker Return System
Kiln 2 Cooler ESP
Burners Platform
Coal Mill Building
Clinker CoolerKiln Pier 1
New Kiln Shell Sections
August 2007
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Riding Ring Hoisted into Position
29August 2007
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36Raw Mill Building: Sept 2007
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‘Kopanelang’ Contractors Village
Feb 2006
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Contractors Camp Catering Facilities
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28 New Staff Houses Built
Nov 2006
Existing Village
New Houses
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2 Lost Time Injuries Recorded to Date
More than 2 million man
hours worked to dateMore than 2 million man
hours worked to date
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One of PPC’s core values: ‘We assist with up-liftment in communities in which we operate’
Dwaalboom situated near three (very rural) communities Rate of unemployment in area >50%
Important to ensure maximum economic spin-off from the project into the disadvantaged Dwaalboom communities‘Labour’ component comes from these areas only
>40% of staff at site from local communityRecruitment centre built
Daily transport to & from home provided
One good meal per day at site for every worker
Focus on Local Community Involvement
Excellent labour relations between contractors & local community employeesExcellent labour relations between contractors & local community employees
Opening of Holfontein Pension Payout & Recruitment Centre (June 2006)
Batsweledi in the Community
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Jupiter Clinker Milling Facility Upgraded
Jupiter plant commissioned 1970
Mothballed in 1998 (eight years)
Used as bag/bulk cement depot
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Upgrade Programme at Jupiter
Environmental Issues AddressedEnclosed & de-dusted clinker storeEnclosed all dust-generating beltsOverhaul/addition of dust collectorsAutomatic doors to tippler enclosure
Improvements AffectedNew Haver & Boecker packer & Beumer palletiser All spillage eliminated Upgrade of extender-blending facility
Major RefurbishmentsAll electric motors/gearboxes overhauledOverhauled overhead crane, tippler, cement transport system etc.Plant clean up & extensive painting
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Clinker Storage Facility Enclosed
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Raw MillClinker Store
Kiln ESPTippler
Dust Collectors Upgraded
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Other Projects in the Pipeline
Batsweledi project first phase of 20 year modernisation programmeBased on combination of capacity replacement & expansion
New cement milling complex under construction at Hercules plant1Mt/yr capacity Loesche vertical roller mill (3150kW)35kt clinker silo, 10kt cement silo, tippler upgrade Cost~€61mCommissioning planned for July 2009Replace two old mills, maximise product extension (~0.3Mt/yr) &balance clinker/milling capacity in Inland Region
Planned new 1.25Mt/yr factory at Riebeeck (Western Cape) Greenfields projectIn feasibility stage (in middle of EIA approval process)Capital cost estimated at ~€340mCommissioning planned for 2010/2011
Studies underway for next Inland Region expansion
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Summary
Batsweledi PPC’s first new factory in over 20 yearsPart of PPC’s 20 year modernisation programmeMost modern South African cement factory Utilises latest technology Lowest cost producing factoryEnvironmentally friendly & energy efficientProject within budget & on timeSafety is not negotiableCommunity involvement keyOther projects planned to meet country’s future cement demandOnly 6 months to commissioning date & counting!
For ongoing project update refer PPC website: www.ppccement.co.zaFor ongoing project update refer PPC website: www.ppccement.co.za
Thank You
Port Elizabeth Cement Silo
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