Unique Design Concrete Preheater Tower

Transcription

1 Unique Design Concrete Preheater Tower Preheater tower constructed of concrete with steel floors Concrete section 105m high (35 storey building) Additional 10m cyclone structure Footprint 25.3m by 20.4m tons steel reinforcing & m³ concrete tons structural steel for floors Important to have vertical aspect of preheater constructed when preheater parts started arriving at site Time saving Only achieved by utilising concrete & sliding to a special design Cost effective (+7% saving compared to steel) Aesthetically pleasing Used our product 1

2 In-Line Calciner Plus Six-Stage Preheater Cyclones 1-2: 6.9m diameter Cyclones 3-6: 7.2m diameter 3 Air 2.5m diameter 268 o C Kiln 4.55m diameter x 54m Calciner 6.6m diameter x 27m 2

3 Pre-Heater H2 3

4 Pre-Heater H2 4

5 Pre-Heater H3 5

6 Pre-Heater H4 6

7 Pre-Heater H5 7

8 Pre-Heater H6 8

9 Pre-Heater H7 9

10 Pre-Heater H8 10

11 Pre-Heater H9 11

12 Pre-Heater H9 12

13 1200 Metres of Piling Installed 1.2metre diameter piles March

14 Constructed Using 80 ton Slide Platform 14

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16 Around the Clock Construction 16

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20 Preheater Topped-Out After 58 Days May

21 Preheater Structure Dominates the Skyline 21

22 Mechanical Installation Began Immediately June

23 Structural Steel Floor H3 Kiln Drive Installation Kiln Pier 2 Preheater Steelwork: Level H3 23

24 Steel Fixing in Preheater: Level H3 24

25 MMC Clinker Cooler Frame 25

26 Kiln Shell Arriving on Site 26

27 Kiln 2 LT Substation Kiln 2 Cooler ESP New Clinker Return System Burners Platform Kiln Pier 1 Clinker Cooler Coal Mill Building New Kiln Shell Sections August

28 Riding Ring Hoisted into Position 28

29 August

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36 Raw Mill Building: Sept

37 Kopanelang Contractors Village Feb

38 Contractors Camp Catering Facilities 38

39 28 New Staff Houses Built Existing Village New Houses Nov

40 2 Lost Time Injuries Recorded to Date More More than than 2 million million man man hours hours worked worked to to date date 40

41 Focus on Local Community Involvement 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 community Recruitment centre built Daily transport to & from home provided One good meal per day at site for every worker Excellent labour relations between contractors & local community employees Excellent labour relations between contractors & local community employees 41

42 Batsweledi in the Community Opening of Holfontein Pension Payout & Recruitment Centre (June 2006)

43 Jupiter Clinker Milling Facility Upgraded Jupiter plant commissioned 1970 Mothballed in 1998 (eight years) Used as bag/bulk cement depot 43

44 Upgrade Programme at Jupiter Environmental Issues Addressed Enclosed & de-dusted clinker store Enclosed all dust-generating belts Overhaul/addition of dust collectors Automatic doors to tippler enclosure Improvements Affected New Haver & Boecker packer & Beumer palletiser All spillage eliminated Upgrade of extender-blending facility Major Refurbishments All electric motors/gearboxes overhauled Overhauled overhead crane, tippler, cement transport system etc. Plant clean up & extensive painting 44

45 Clinker Storage Facility Enclosed 45

46 Dust Collectors Upgraded Clinker Store Raw Mill Tippler Kiln ESP 46

47 Other Projects in the Pipeline Batsweledi project first phase of 20 year modernisation programme Based on combination of capacity replacement & expansion New cement milling complex under construction at Hercules plant 1Mt/yr capacity Loesche vertical roller mill (3150kW) 35kt clinker silo, 10kt cement silo, tippler upgrade Cost~ 61m Commissioning planned for July 2009 Replace 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 project In feasibility stage (in middle of EIA approval process) Capital cost estimated at ~ 340m Commissioning planned for 2010/2011 Studies underway for next Inland Region expansion 47

48 Summary Batsweledi PPC s first new factory in over 20 years Part of PPC s 20 year modernisation programme Most modern South African cement factory Utilises latest technology Lowest cost producing factory Environmentally friendly & energy efficient Project within budget & on time Safety is not negotiable Community involvement key Other projects planned to meet country s future cement demand Only 6 months to commissioning date & counting! For ongoing project update refer PPC website: For ongoing project update refer PPC website: 48

49 Port Elizabeth Cement Silo Thank You