16.00 luc rudowski, polysius

7/21/2019 16.00 Luc Rudowski, Polysius

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International Cement Conference - Cemtech -Dubai - March 2011

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POLYSIUS in the Middle East &

Africa

Case Studies


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MARKET

Middle East and Africa cement industry is undergoing a fast

growth fuelled by

Urbanisation: expanding populations in the need of improvement

of living conditions leading to housing, infrastructure, etc.

Industrialisation: developing industries also need building

materials

Boom on commodities: despite the recent financial crisis, a

sustained boom on commodities and subsequent Mining Capital

Expenditure providing funds for GDP growth and requirement for

building materials


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TRENDSOther significant trends in the cement industry :

Reduction of CAPEX of the cement plant projects. Cement

industry being highly capitalistic, access to funds is a challenge,

particularly after the recent financial crisis leading to debt

reduction policies for the companies

Reduction of OPEX: many customers are focusing on more

efficient and innovative solutions to reduce the operating costs

(power and calorific savings, use secondary fuels, increase in

plant availability)

Sustainable and environmentally friendly solutions

Challenges to POLYSIUS Keep High Quality Standards

with Optimized Costs

Equipment Reliability

Innovative Solutions


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DIVERSITY

Remarkable is the variety of our customers, ranging f rom :

major international historical companies (LAFARGE, HOLCIM ,

ITALCEMENTI, etc.)

middle-size historical cement companies (VICAT, CIMENTS

MOLINS or SCHWENK ZEMENT, etc.)

local players + significant number of new players

state owned companies

Corresponding organization, skills, technical and financial resources

vary a lot from a company to another, and accordingly the

requirements and expectations

Challenges to POLYSIUS Flexibility and Adaptability

Suitable Projects Schemes &

Contractual Set up


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POLYSIUS IN THE

MIDDLE EAST & AFRICA

CASE STUDIES


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EGYPTIAN CEMENT Co - LINE 5 5 300 tpd

ECC Line 5 - Overview of achieved quantities

Mechanical Equipment 11 200 tons

Electrical Equipment 750 tons

Reinforced Concrete 45 000 m3

Structural Steel 5 500 tons

GA & Detailed Drawings 410

Civil & Structural Drawings 1 750


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EGYPTIAN CEMENT Co - LINE 5 5 300 tpd

Main Factors of Success:

Fast and controlled project execution thanks to copy plant

concept: reduced CAPEX & time for completion, rapid

production ramp up > improved financial return

Largely sized equipment allowing capacity increase of each

line from 4300 to 5300 tpd clinker and no additional raw mill for

line 5 thanks to reserves on first 4 raw mills

Civil & Structural Design by POLYSIUS SAS with same

suppliers through long lasting collaboration in France. Policy of

Best Cost

Large manufacturing & construction capabilities and efficiency

of OCI

Excellent complementarity with OCI, shared values


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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd

MBCC Line 2 - Overview of achieved quantiti es








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MBCC main requirements for Line 2:

High quality standards for the supplied equipment

Project management of the full scope of supply & works by

one Contractor

Reduced investment and controlled overall budget

Reduced time for completion


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Advantages to MBCC & key criteria of successful project:

Secured overall budget thanks to copy plant concept fixed

price for supply contract + guaranteed quantities for concrete

and structural steel

Full project management by POLYSIUS as for a turnkey-type

contract of the supply chain (inquiry, procurement, quality

control, coordination, planning, supervision, commissioning

and training)

Use of suitable industrial resources in Egypt from civil &

structural design to civil works, steel manufacturing and

erection works

Fast plant execution, rapid production ramp up to 5300 tpd of

clinker > profit maximisation


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AL SAFWA CEMENT Co - GREENFIELD PLANT 5 000 tpdAl Safw a Cement - Overvi ew of achi eved

quantities








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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE


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The main targets of the project were:

Installation of additional 10.000 tpd clinker production capacity

as well as 630 tph cement grinding capacity

Implementation of most modern technologies to achieve

highest reliability and energy efficiency

Meeting most advanced environmental standards and legal

regulations

Execution of the construction works without major influences

on the existing 6 production lines

Meeting the challenging time schedule with early cement in

one grinding unit after 16 months


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YAMAMA SAUDI CEMENT 10 000 tpd - Overview of achieved

quantities


Electrical Equipment 4 000 tons






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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd


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The main requirements of CIMAT were:

Efficient raw material preparation thanks to on line analyser, circular

mixing bed and POLAB quality control

A balance between energy efficient modern technology, such as raw

grinding vertical roller mill, CC calciner for petcoke firing,

POLYTRACK clinker cooler with intermediate roll crusher, and well

proven solutions such as a cement grinding plant

Efficient and environmental friendly solutions such as a single high

temperature integrated bagfilter for both kiln and cooler dedusting

without any use of water and cooling air; pyro processing design to

allow use of secondary fuels

Optimized design of multi-compartments cement silos to ensure

flexibility of cement types production and reduced investment costs

High quality level of the equipment manufacturing


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Some of our challenges were to:

Manage 2 big contracts, with significant constructions

volumes to be achieved in a short period

Deal with lengthened delivery times for main machinery at

a period of time (2007 and 2008) where industry was

booming with suppliers backlog at a record high level

Deal with corresponding rising prices of metals and

materials

Properly select the capabilities of suppliers and contractorsto ensure a proper quality and planning


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CIMAT cement plants - Overview of achieved quantities

Ben Ahmed plant Beni Mel lal plant

Mechanical Equipment 11 900 tons 12 100 tons

Electrical Equipment 900 tons 900 tons

Reinforced Concrete 66 000 m3 68 000 m3

Structural Steel 9 500 tons 9 500 tons

GA & Detailed Drawings 830 450

Civil & Structural Drawings 3 350 3 000


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SOTACIB FERIANA WHITE CEMENT LINE 2 1 000 tpd

SOTACIB White cement line 2 - Overview of achieved

quantities






Civil & Structural Drawings 885


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SOTACIB FERIANA WHITE CEMENT LINE 2 1 000 tpd

Specific competitive advantages to drive SOTACIB decision to

award POLYSIUS SAS were:

Innovative POLYSIUS design for white cement pyro processing

with a drum cooler + POLYTRACK grate to ensure high level of

whiteness and reduced heat consumption when comparing to

existing technologies on the market Skills and experience of POLYSIUS SAS in turnkey projects

particularly in Tunisia, where all last major turnkey plant

expansion were achieved by POLYSIUS SAS (upgrading in

Ciments de Djebel Oust, new line n2 for Socit des Ciments

dEndifha and subsequent conversion to petcoke of the same

plants)

Strong cultural links that ease communication and mutual

understanding


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SOTACIB KAIROUAN GREENFIELD PLANT 3 600 tpd


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SOCOCIM INDUSTRIES LINE 5 3 600 tpd


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SOCOCIM main requirements:

Low Operating Cost solutions (low energy consumption

power & heat design to use secondary fuels)

Low Capital Expenditure

Environmental friendly solutions

Turnkey execution

Short time for completion


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SOCOCIM line 5 - Overview of achieved

quantities






Civil & Structural

Drawings

1 400


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CIMENTS DU SAHEL LINE 5 3 600 tpd


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OHORONGO CEMENT GREENFIELD PLANT 2 100 tpd

OHORONGO CEMENT plant - Overview of

achieved quantities






Civil & Structural

Drawings

1 400


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CONCLUSION

Variety of our Customers Requirements, Resources, Experience

& Culture > Each Industrial Project is Specific

Our Aim: to Fit Customers Requirements & Resources by

providing a Comprehensive Range of Project Solutions &

Contractual Set up

Best Cost strategy > Outstanding quality of POLYSIUS

products and services + optimise the CAPital EXpenditure

Efficiency & reliability of our Products + Flexibility & Proximity of

our Services & our Experience in Middle East and Africa > quick

financial return to our customers.


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THANK YOU

16.00 luc rudowski, polysius

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