,16(5(5 3$*( - cesa eng the geological structure was done in close collaboration with ... cesa acts...

AROUND AROUND AROUND

THE THE THE

WORLDWORLDWORLD

CEMENT ENGINEERING (CESA) S.A.

Consulting Engineers 16, rue Alexandre Gavard

CH– 1227-GENEVE (Suisse)

Web site: www.cesaeng.com Tel . +41(0) 22 304 14 50

Fax +41(0) 22 304 14 51

E-mail: [email protected]

GREENFIELD CEMENT PLANT Sheet no 176 - 1

Client: Société des Ciments de Sigus, Groupe GICA, Algeria

Project: Greenfield cement plant 6’000 tpd

Date: 2016

Service provided: Technical assistance and construction management

CESA has been appointed to review and to validation all studies in the fol-lowing domains:

Geology and geotechnics Process and mechanical Civil work and structures Electricity, automation and process control systems Start-up procedures and commissioning

For more information, please contact:Cement Engineering (CESA) S.A.

Consulting Engineers, 16, R. Alexandre Gavard, CH-1227 Carouge-Genève www.cesaeng.com Tél: +41 (0) 22 304 14 50 Fax: +41 (0)22 304 14 51 E-Mail: [email protected]

EPC contractor: Thyssen-Krupp Industrial Systems (Polysius France) Project description :

The team of CESA is involved in the control of all studies and plans of the Contractor. All con-tracts were also examined in order to preserve the interest of the Employer. CESA will also assist the Employer in:

The supervision of the construction site and smooth progress of the project Assuring the efficient transfer of all technical and commercial documents Actively participate in all meeting and pointing out potential problems Propose mitigation measures and remediation Supervise and assist the supplier in the commissioning of all the production line Training of the operation personnel of the plant and redaction of the operation and mainte-nance manuals


Client: Société Saoura Ciment - Béchar, Groupe GICA, Algeria


Date: 2016

Service provided: Technical assistance and managerment of the realisation

CESA has been mandated to control and to validate all studies in the fol-lowing domains:

Geology and geotechnics Process and mechanical Civil work and structures Electricity, automation and process control system Performance tests and commissioning



EPC contractor: CBMI Project description :

The team of CESA is involved in the control of all studies and plans of the Contractor. All con-tracts were also examined in order to preserve the interest of the Employer. CESA will also assist the Employer in:

The supervision of the construction site and smooth progress of the project Assuring the efficient transfer of all technical and commercial documents and manuals Actively participate in all meeting and pointing out potential problems Propose mitigation measures and remediation Supervise and assist the supplier in all the start-up tests and clinker and cement production of the plant



Project description : The cement plant project of CEVITAL Minerals situated at El Khroub is close to the city of Constantine. It is a Greenfield project with a foreseen clinker production capac-ity of 12’000 tons per day. The region is quite industrialized and populated, and very well con-nected; airport, highway, railroad, electrical grid and natural gas. The realization of this project is estimated to take 3 years.

LARGEST ALGERIAN CEMENT PLANT Sheet no 171 - 1

Client: CEVITAL Minerals, Algeria


Start of the project: January 2015

Service provided: CESA has been awarded for the project management for the full project

Due diligence for contracts and execution engineering.

CESA was selected by CEVITAL Minerals for the complete realization of this multi-package project.

In a first step, several plant capacities and layouts have been evaluated. Then, tender documents ac-cording to the selected scenarios were written and sent to the relevant suppliers. Their offers were evaluated and negotiated to allow elaborate the contact documents.





Service provided: CESA has been awarded for reviewing the exploration work for the raw ma-terials and geological modeling

Cevital Minerals is producing several mineral commodities and is therefore well experienced in field exploration, including geological mapping and management of drilling campaigns. Nevertheless, CESA was asked to supervise the exploration works in order to assure that the cement production specific requirements were met. Further, CESA did all the geological evaluation, from chemical da-tabase construction to 3D geological modeling of the limestone and clay deposits



Project description :

CESA supplied Cevital Minerals with exploration specifications regarding drilling techniques and chemical and environmental analyses. Field visits were carried out to verify these specification were respected so that the field results are representative of the deposit. Then, the 3D modeling of the geological structure was done in close collaboration with the geologist of Cevital Minerals. Finally, statistical tests and geostatistical procedures were implemented in order to estimate are reliable bloc model of both the limestone and clay deposit.

Geological mapping resulting in 3D-modeling and bloc modeling

CaO concentration





Service provided: CESA has been awarded the modeling of the raw material extraction

Geological modeling and bloc model estimation are important steps in the path to archive optimal raw material utilization. But the last step is to model the extraction of the raw materials of the vari-ous deposits in order to .




The modeling of the extraction of the raw materials, also known as scheduling, allows confirming that a suitable raw mix can be produced in each pre-homogenisation bed. The scheduling opti-mize the extraction by:

reducing the need of correctives Increasing the lifetime of the deposits

Further, several extraction scenarios can be evaluated

LSF

SR

AR

Process fed by limestone and clay pits, as well as by

corrective stockpiles

Output from the limestone and clay pits

Management of the stockpiles

Visualisation of the blocs taken at each extraction period

Yearly maintenance

stop

TURNKEY CEMENT PLANT MONGOLIA Sheet no 167 - 1

Client: Monpolymet, Mongolia

Projet: Senj Sant cement factory

Date: 2012 - 2015

Service provided: Lenders Technical Advisor Services as independent Engineer for EBRD co-financing the project.

CESA has been awarded to control and validate: The compliance with technical requirements. Realistic implementation scheme Realistic time schedule Monthly progress of realization Technical completion report



EPC contractor: Huxin China Project description :

Moncement Urgun-Soum, situated in the Southeast of the country, is a Greenfield project whose capacity is 1750 tpd clinker. The project consisted of levelling the area, construction of 12 km ac-cess road, construction of one railway connection with the Russia-China trans Mongolia railway, construction of an employee village, opening the quarries and construction of the plant with all process and non-process facilities. The total construction time was 32 months.

NEW GRINDING PLANT - ULAAN BAATOR Sheet no 167– 2

Client: Monpolymet, Mongolia

Project: New grinding unit of 120 tph in the Songino-Khairklian District

Date: 2014—2016

Service provided: CESA acts as the LTA for the EBRD and provides the following services: Review of the technical and financial EPC contract documents Compliance with the technical requirements and the erection sched-ule Monthly supervision of work progress Control of the performance tests documents and technical comple-tion report



EPC contractor: Jidong China Project description :

Moncement builds close to Ulaan Baator, the capital of Mongolia, the largest cement grinding unit of the country in the Songino-Khairklian District. The plant has a cement capacity of 120 tph. Clinker and gypsum arrive by train from the new Urgun Soum plant where the grinding capacity is of only 60 tph.

The project includes the utilisation of fly ash of the coal power plants located close by.


Client: GIANT CEMENT WORKS LTD, Nigeria

Projet: Feasability study for a Greenfield plant between 3000 and 6000 tpd ca-pacity

Date: 2014-2015

Service provided: Raw material exploration.




A complete geological exploration campaign was conducted including over 100 drill holes. The terrain proved to be especially difficult requiring close monitoring of the progress. Geological mapping was done by a local geologist under the supervision of CESA. The cores were geologi-cally described and chemically analysed. A complete database was constructed to register all data and forms the basis of the next step: the 3D geological and bloc modeling.




Statistical analyses are conducted in order to verify that the chemical samples were assigned to the correct domains (basically to geological formations). Then, variography is conducted is order to delineate the intrinsic anisotropy of the deposits and define the correlation ellipsoid. Finally the chemical composition of each bloc is estimated. At this stage, a detailed description of the deposit is available that can be considered as an inventory of the available qualities.




Date: 2015-2016

Service provided: Raw material deposit modeling.

Statistical analyses

Geostatistics: variogramme of CaO

Correlation ellispoïd

Major axis: 615 m




Date: 2014-2015

Service provided: Technical studies, market studies, financial studies and profitability studies .




Honywell Group of Nigeria was desirous to establish a new factory in Cross River State and awarded the consultancy services to Cement Engineering S.A. (CESA) to elaborate a bankable feasibility study that aims at determining whether the project is technically feasible, commercially viable and financially protitable.

YAMAMA CEMENT COMPANY Sheet no 161 - 1

Client: Yamama Cement Company, Kingdom of Saudi Arabia

Projet: New cement factory outside Riyad

Date: 2013 - 2014

Service provided: Planning and management of an exploration campaign and modeling of the deposit.




Yamama Cement Company is actually located in the outskirt of Riyad. The company will move its activities in a new location, some 80km of Riyad. CESA was invited to define and supervise the exploration campaign. Drilling, sampling and analyses specifications were defined. A database of the chemical analyses was constructed and, together with the 3D geological model a bloc model was estimated.

CEMENT PLANTS AUDIT IN ETHIOPIA Sheet no 157-1

Client: Pégase International S.A., Switzerland

Project: Audit of two cement plants in the vicinity of Adis Abeba in view of their pur-chase

Date: 2013

Service provided: CESA has been mandated to visit the sites and validate: The occurrence of raw material in terms of quality and quantity The production data and estimated economical viability The value of the assets and evaluate the necessary investments to allow production at the nominal capacity




Pégase International S.A. is a cement trading company with among other an import terminal in Djibouti. Much of the imported cement is transported further to Ethiopia and in particular to the economically booming region of Addis Abeba. The purpose of the audit was to evaluate the feasi-bility for Pégase to buy two existing cement plants in order to produce cement within the market region and save the important transport costs. The particularity of these plants is that they are equipped with vertical kilns. The goal of the study was to evaluate the actual production costs, the necessary investments to rehabilitate some of the kilns and estimate the payback period.

MARBLE EXPLORATION IN UGANDA Sheet no 153 - 1

Client: Kiboko Cement Industries Ltd

Projet: Geological mapping and preliminary drilling in north of Moroto, Uganda

Date: 2013 - 2014

Service provided: CESA has been awarded to: Review available data Selection of the drilling contractor Organisation and management of the drilling campaign Estimated raw material ressources Evaluate raw mixes Reporting and recommendations




Kiboko Cement Industries had launched a project to build up a small cement plant 30 km north of Moroto, Karamoja region, for the local needs to avoid expensive imports of cement. CESA pro-posed a feasibility study which first part was to recognise the limestone / marble potential of a 42.8 km2 Exploration Licence

Project Scheduling_ _ _ Part 1: Ap

ril 2

013

May

201

3Ju

ne 2

013

July

201

3Au

gust

201

3 S

ept.

2013

Visit of the geologist of CESAField visit and surface sample collectionSample dispatch and analysesFirst geological report

Part 2:Definition of exploration campaign Drilling campaignSample preparation, dispatch, and analysesFinal reporting

CLINKER COOLER UPGRADE Sheet no 150 - 1

Client: HOLCIM, Philippines

Projet: Upgrading and replacement of Clinker Cooler

Date: 2013

Service provided: Engineering, Mechanical Design and Civil Design.




Kiln burner replacement. Kiln shell replacement. Clinker cooler replacement. Drag chain conveyor modification. Air Tertiary modification. New hydraulic room New MCC Room

FLY ASH BLENDING Sheet no 149 - 1

Client: HOLCIM, Philippines

Projet: Fly Ash Blending Addition to Existing Cement Terminal

Date: 2012

Service provided: Engineering, Mechanical Design and Civil Design.




This cement / fly ash blending plant can reach up to 375’000 t/year blended fly ash cement. The blending operation shall be sufficient for one rotary packing machine. The new 500 m3 metallic storage silo feeds a mixing screen through the intermediary of screw and airslides. The finished product is transported to the rotary packer.

CEMENT PLANT EXPANSION Sheet no 147 - 1

Client: TANGA CEMENT, Tanzania

Projet: New Production Line of 2500 tpd of clinker

Date: 2011 - 2015

Service provided: Lenders Technical Advisor Services as independent Engineer for Public Investment corporation mandated to arrange the financial loan facilities.

CESA carried out the due diligence report for the lenders.

CESA followed and validated the construction progress and reported ac-cordingly




The Project Works comprise the complete design, supply and setting to work of a new clinker pro-duction line at Tanga, Tanzania, comprising the plant departments:

Raw Material preparation Raw Meal Preparation Clinker Production Traditional Fuels Preparation and Handling Alternative Fuels Preparation and Handling Coal grinding plant

CEMENT GRINDING AND DISPATCH Sheet no 146 - 1

Client: CMS for Mambong Sarawak, Malaysia

Project: Cement mill 150 t/h Cement dispatch 1 million tpy

Date: 2013

Service provided: CESA has been awarded to:Basic engineering Call for tender establishment Tender evaluation Negociation assistance Management of project execution and site supervision in partnership with CME Philippines



Equipment Supplier: CPB


Due to the demand of the market, CMS has decided to install a cement producing section in the existing clinker production line at Mambong, Sarawak.

The production rate is 1’000’000 t/y. The cement production section includes:

Cement grinding plant Cement storage silo Cement packing plant and dispatch


Client: INTERNATIONAL CEMENT COMPANY LTD, Nigeria

Projet: Feasability study for a Greenfield plant with 3600 tpd capacity

Date: 2012

Service provided: Raw material exploration.




CESA was entrusted a complete feasibility study for a new 3600 tpd clinker line. A preliminary exploration campaign was conducted including 17 drill holes. The cores were geologically de-scribed and chemically analysed. A 3D geological model was constructed in order to estimate the resources.



Projet: Construction of a new cement plant with 3600 tpd capacity

Date: 2012

Service provided: Technical studies, market studies, financial studies and profitability studies for the construction of a second line of 3’600 tpd capacity.




International Cement Company Limited was desirous to establish a new factory in Ogun State of Nigeria and awarded the consultancy services to Cement Engineering S.A. (CESA) to elaborate the best profitable solution for capacity, process, technology and costs, based on a turnkey pro-ject. In the scope of its mandate, CESA prepared a bankable feasibility study that aims at deter-mining whether the project is technically feasible, commercially viable and financially profitable.

CALL FOR TENDER Sheet no 145 - 3


Projet: Call for tender for a Greenfield plant with 3600 tpd capacity

Date: 2013 - 2014

Service provided: Establishment of the tender and contract documents. Technical and com-mercial negotiations with suppliers.




CESA provided exhaustive tender documents with full description of the equipment, the buildings and all necessary installations. The level of quality desired by the client was defined and suppliers and sub-suppliers selected accordingly. CESA conducted all technical discussions and negotia-tions up to the final contract. Finally, CESA supported the client in the commercial negotiation with the selected supplier and the financial institutes.

RAW MATERIAL AUDIT IN KSA Sheet no 144 - 1

Client: Petro-Hunt Middle East, Kingdom of Saudi Arabia

Projet: Preliminary Prospection and Surface Sampling of the Harrat Hadan licences, KSA

Date: 2011

Service provided: CESA has been awarded to: Review available data Visit the site and collect surface and trench samples Supervise chemical analyses Estimated raw material ressources Evaluate raw mixes Reporting and recommendations




Petro-Hunt Middle East (PHME) was invited to participate in the bid for two licences covering ce-ment raw material deposits situated about 120 km northeast of Taif, Kingdom of Saudi Arabia.

CEMENT MILL Sheet no 010 - 064

Client: HOLCIM, Guinea

Projet: 80 t/h Cement Mill Addition to Existing Plant

Date: 2011

Service provided: Design estimation of a turn Key Grinding Terminal Expansion Project.



Services performed:

Clinker & additive material handling design Cement mill 80 t/h G.A. design for estimates Equipment inquiries for project cost estimation Complete project budget estimate Preparation of turn key proposal

FEASIBILITY STUDY Sheet no 141 - 1

Client: HOLCIM, Spain

Projet: Feasibility study for the replacement of the calciner and clinker cooler (3300 tpd)

Date: 2011

Service provided: Market survey, feasibility study, project management and basic engineering.




The objective of this study commissioned by Holcim Spain was to investigate the feasibility of modifying the pyro processing system at their Carboneras facility, in order to increase the system efficiency and the steadiness of the quality of the clinker production. The increased use of alter-native fuels was also taken into account. The capability to burn higher percentages of these fuels allows reducing the production costs. In order to attain these goals it has been shown that exten-sive modifications and equipment replacement must be made to both the existing preheater and the clinker cooling systems.

FIRST CEMENT FACTORY IN NAMIBIA Sheet no 132 - 1

Client: DEG – SCHWENK Group, Namibia

Projet: Ohorongo Cement (Schwenk group)

Date: 2008 - 2011

Service provided: Lenders Technical Advisor Services as independent Engineer for DEGmbH mandated by Schwenk Group to finance the project.

CESA has been awarded to control and validate: The compliance with technical requirements. Realistic implementation scheme Realistic time schedule Monthly progress of realization Eligible cost certificate with farecast and real cost review Technical completion report




OHORONGO Cement, situated in the North of the country, is a Greenfield project whose capacity is 2000 tpd. The project consisted of debushing the area, construction of 11 km access road, opening the quarries and construction of the plant with all process and non-process facilities, con-struction of a biomass plant for bush wood firing, total construction time was 32 months.

PULVERIZED COAL TRANSPORT Sheet no 130 - 1

Client: Les Ciments du Sahel, Senegal

Projet: Pulverized coal transport and storage

Date: 2009 - 2010




Full turnkey project for a pulverized coal conveying system and storage, engineering, civil design, materiel supply, erection, supervision and commissioning.

Transport capacity: 2 x 19 t/h

Storage capacity: 2 x 400 m3

Inertisation: CO2 high pressure 60 bars

GRINDABILITY STUDY Sheet no 129 - 1

Client: Obajana Cement, Nigeria

Projet: Study of grinding optimization

Date: 2009

Service provided: Evaluation of test results and recommendation for grinding optimization.



Laboratory: Loesche GmbH

Project description:

In order to optimize the production of cement CEM II-B, Class 32.5-N, a set of grindability tests were conducted to determine the optimal conditions of profitability. In particular, the content of limestone additive was determined. The tests showed that it was adding up to 35% of limestone was possible while still respecting the European and Nigerian standards.


Client: NOCIBE, Benin

Project: Greenfield cement plant 3600 tpd

Date: 2011 – 2014

Service provided: Full engineering responsibility, i.e. feasibility study, engineering, call for tender, management of all contracts, management of project execution, supervision and commissioning.




Benin has only one cement plant whicht does not satisfy the needs of the country. Taking advan-tage of its good relationship with the state of Benin, the Company of "Les Ciments du Sahel" has decided to build a new cement plant in the south of Benin. This project represents the largest pri-vate investment ever made in Benin.

GEOLOGICAL SURVEY Sheet no 128 - 2

Client: NOCIBE, Benin

Project: Raw material evaluation

Date: 2009-2011

Service provided: Planning and management of the exploration campaign, sample prepara-tion and chemical analysis. Construction of a 3D model of the deposit and resource assessment. Calculation of raw mixes.



Survey Company: Foratec

Chemical Analysis Laboratory: Les Ciments du Sahel

Modeling software: Gemcom Surpac

Project description: See sheet 128-1 for the main project description

The only exploitable limestone formation to cover the needs of such a project is the limestone of the middle Paleocene. This is a layer of about ten meters thickness that has undergone different levels of karstification. These karsts are filled with clay creating a natural blend of the desired raw mix. It is therefore essential to know the deposit in detail to plan its extraction.

MODELING RAW MATERIAL Sheet no 128 - 3

OPERATION Client: NOCIBE, Benin

Project: Modeling of the extraction of the raw materials

Date: 2011-2013

Service provided: Following the exploration program, the chemical analysis and the con-struction of the 3D model of the deposit, a block model was calculated. On this basis, the detailed extraction of the deposit was modeled.




Knowing that all of a deposit can be exploited to produce clinker is one thing, but assure that the desired raw mix in terms of quality and quantity can be produced at all times is another. To this end, detailed modeling of the exploitation of the deposit is required. It also allows calculating sev-eral scenarios to minimize waste and the use of correctives.

EXPLORATION OF CEMENT Sheet no 127 - 1

RAW MATERIALS

Client: Société Générale des Travaux du Maroc (SGTM), Morocco

Project: Exploration of limestone and clay deposits in order to find suitable raw ma-terials for clinker manufacturing

Date: 2010

Service provided: Desk study, field visits, planning and management of the exploration cam-paigns, sample preparation and chemical analysis. Construction of a pre-liminary 3D model of the deposit and resource assessment. Calculation of



Survey Company: Laboratoire Public d'Études et Essai (LPEE)

Chemical Analysis Laboratory: SGS Analabs

Modeling software: Gemcom Surpac


The limestone deposit is as such very large. Unfortunately, some layers show a level of phos-phate that would reduce the reactivity of the clinker. Detailed geological mapping and correlation between drill holes allowed to find enough resource of good quality for the project in mind.

CHARACTERISATION OF PHOSPHATE Sheet no 127 - 2

IN CEMENT RAW MATERIALS

Client: Société Générale des Travaux du Maroc (SGTM), Morocco

Project: Characterisation of naturally occurring phosphate behaviors during clinker manufacturing

Date: 2011 - 2012

Service provided: Following the Bovine spongiform encephalopathy (mad cow desease),large quantities of animal meal had to be destroyed. The Verein Deutscher Zementwerke (VDZ) started a study to define an upper limit for burning animal meals in cement kilns and therefore of phosphate content in clinker. VDZ was contacted by CESA for further clarifications. It was pointed out that the phosphate minerals in limestone might be in less deleterious then in animal meal. CESA undertook then a detailed study to understand the issue and assert the suitability of the deposit for clinker manufacturing.



Project description: Phosphor occurs naturally in limestone mainly in the form of apatite minerals. This mineral has three end-members: a hydroxyl, a fluorine and a chlorine form. In animal meal, 95% of the apa-tite is in the form of hydroxyl apatite. The study made by VDZ showed that the limit of tolerable phosphate was then by 1%.

But in the limestone deposit of this project, mineral analyses showed that more then half of the apatite is in the fluorine form. As fluorine is know to have mineralizing effects during clinkerisa-tion, the deleterious effect of the phosphate is in great part compensated. The cement samples done from the limestone deposit proved to perfectly fit the cement norms, this without finer grind-ing.

CEMENT PLANT EXPANSION Sheet no 119 - 1


Project: Second clinker production line of 3600 tpd

Date: 2007 – 2010

Service provided: Full engineering responsibility, i.e. feasibility study, engineering, call for tender, management of all contracts, management of project execution, supervision and commissioning.



Construction: Multiple Package

Equipment supplier: Polysius

Electricity and automation: RMT (Group Clemessy), FLSA

Project Description:

The Company "Les Ciments du Sahel (CDS)" was founded in 2000. A first line was built between 2001 and 2004 with a capacity of 1750 tpd supplied by FLS. As the the market situation was fa-vorable, CDS decided to build a second line to upgrade the plant capacity to 3600 tpd clinker pro-duction.

CEMENT PLANT FEASIBILITY STUDY Sheet no 117 - 1


Project: Feasibility study for project extension

Date: 2006 - 2007




Technical studies, market studies, financial studies and profitability studies for the construction of a second line of 3’600 tpd capacity. Call for tender and contract negociation

COAL GRINDING PLANT Sheet no 116 - 1


Project: Coal mill 28 tph

Date: 2004 – 2006

Service provided: Full engineering responsibility, i.e. feasibility study, engineering, call for ten-der, management of all contracts, management of project execution, super-vision and commissioning.

Equipment supplier: CEMAG

Electricity and automation: FLSA


The client built this equipment in connection with the transformation of its cement factory from heavy fuel to coal firing. The project include the coal storage, trans-port and raw coal dosing as well as the mill with a capacity of 14 t/h extensible to 30 t/h in a second step.Coal dust storage and burner feeding.



CEMENT ENGINEERING (CESA) S.A.

Consulting Engineers 16, rue Alexandre Gavard

1227 GENEVA, Switzerland

Web site: www.cesaeng.com Tel. +41(0) 22 304 14 50

Fax +41(0) 22 304 14 51

E-mail: [email protected]

,16(5(5 3$*( - cesa eng the geological structure was done in close collaboration with ... cesa acts...

Documents