Intro
M HEAVY TECHNOLOGY carries out design and provides engineering services for construction, overhaul and modernization of cement industry facilities of various capacities and technologies, including cement terminals and ready-mixed concrete plants.
The deep knowledge and extensive experience of our professional team make it possible to perform a full-scale design of cement plants from choosing a concept to a production start of the enterprise.
We assess the needs of each Customer and in close cooperation with equipment suppliers provide high-tech solutions for each individual situation.
Cement Plant Engineering & Design Process
Construction and modernization of cement plants is a capital-intensive process that requires high-quality planning as well as highly competent specialists.
M HEAVY TECHNOLOGY offers a full range of services to support the project throughout its entire lifecycle, including:
☑️ laser scanning of the existing enterprise,
☑️ conceptual engineering, preliminary design,
☑️ capex estimate,
☑️ detailed design,
☑️ development of design documentation and construction support.
The company’s team of specialists carries out development and offers solutions for all parts of the project:
- Technology,
- Civil Construction,
- Water supply and sewerage,
- Heating, Ventilation, and Air Conditioning,
- Electrical,
We also provide services in designing automation systems for production processes and development of design documentation for machine parts, process units and non-standard equipment.
Laser scanning and modeling of existing conditions.
Laser scanning of the existing facility greatly improves project predictability. Laser beam scanning creates a 3D “point cloud” of the situation, giving designers a real-life view of the site that may not be fully reflected in available documentation.
Integration of the resulting point cloud with the designed 3D model makes possible adaptation to the present conditions, avoiding collisions with pipelines, air ducts, buildings and other existing structures.
It significantly speeds up the design process, further construction and functional accuracy of production operations.
Using scan data and a 3D model you can quickly analyze the status of work at any design stage.
M HEAVY TECHNOLOGY has its own equipment and performs scanning by its means, thereby guaranteeing design quality and accuracy.
BIM modeling in designing cement plants
Our company has historically been performing 3-dimensional design.
3D design makes it much easier to view and understand the project layout and details. Combining our laser scanning capabilities with BIM modeling allows us to:
- carry out design and effectively configurate the cement plant equipment,
- determine a proper construction sequence,
- eliminate collisions during design and construction.
This improves the quality of work, leaves fewer questions to contractors, minimizes change demands and a ensures a stable project schedule.
The benefits of laser scanning and 3D modeling extend beyond the design phase. These technologies can be used throughout the entire lifecycle of a project, from construction to maintenance. The 3D model can be used to create accurate bills of materials and help identify potential maintenance issues before they become problems. This level of precision and detailing can save time and money, increase project efficiency and reduce the risk of unexpected delays or costs. Ultimately, using these technologies can help ensure project success and improve overall efficiency.
The layout of a cement plant must ensure optimal interaction between individual components of the enterprise, facilitating efficient production, transportation, inventory management, etc.
Estimation of mineral resources and ore stocks.
Our specialists, responsible for mineral resources, and mining engineers carry out management of core drilling, sampling, geological mapping, mine planning, reserve calculations and recommend optimal feed mix compositions to extend the mine life.
Survey works.
We carry out geodetic and geological survey, which is necessary for further design of the facility.
Feasibility study of cement plant projects.
Estimation of capital and operating costs for new construction, modernization or reconstruction, calculations of technical and economic production indicators, assessment of technological processes and analysis of operations.
Audit and assessment of the plant and company.
A comprehensive assessment that takes into account business assets, historical earnings, market, mining reserves, production methods and technologies, reliability, plant personnel, financial performance.
Technology and equipment for cement production and services of M HEAVY TECHNOLOGY
Due to advanced technologies and close cooperation with leading European institutes and equipment manufacturers we can offer highly efficient solutions for various projects and engineering of cement plants. The plant design is carried out with consideration of the future modernizations.
Our engineers will help you select the most appropriate process schemes and equipment for each stage to ensure high product quality, productivity, safety and energy efficiency of production.
Using coal fuel.
Design of processing stages, facilities for preparation, handling and using solid fuel for cement plants: receiving vessels with car dumpers, coal warehouses, transportation and crushing of raw coal, drying and grinding of coal, transportation of pulverized coal fuel to storage silos and the silos themselves, systems for feeding pulverized coal to the kiln burners.
Crushing and grinding of raw materials and product.
Design of optimal drying and grinding systems in ball and roller mills, roller-, cone-, hammer-type crushers, high-performance separators, cyclones and screens. To achieve optimal process efficiency our engineers take an individual approach to this stage. Equipment for crushing and grinding clinker, cement and solid fuel consumes about 2/3 of all energy in cement production. Therefore, any technical improvement or optimization at this stage is very important.
Kiln roasting and clinker cooling.
Development of kiln systems;
Cyclones-heaters;
Preroasting furnaces and klinker coolers;
Emissions management;
Cooling, transportation and storage of clinker.
The rotary cement kiln is the most important device of a cement plant, it is the place where the raw material mixture is roasted and converted into cement clinker.
Transportation and storage of materials.
Belt, screw and pneumatic conveyors, bucket, tray and scraper conveyors; bucket elevators; handling systems for road and rail transport; storage silos.
Gas dedusting and aspiration systems.
Gas dedusting plants and aspiration systems for all areas of material handling that require dust removal with subsequent purification.
Packing and storage of products.
The packing station is an important part of the production process, which provides a certain added value to the finished product. The production of multi-layer paper bags can also be started directly at the plant. It is possible to pack cement in big bags.
A part of cement is loaded from cement silos in bulk and transported in hopper cars on the railroad, while the rest is usually packed into standard bags on site.
Before shipment or packing finished cement is stored in cement silos.
Utility lines and systems.
M HEAVY TECHNOLOGY carries out fulldesign of process pipeline systems.
Cement terminal.
Design of automobile and railway terminals of various capacities.
Cement Plant Modernization
Instrumentation and process control of a cement plant.
Design of state-of-the-art instrumentation and process control loops.
Many functions, previously performed by operators, are today carried out by complicated electronic equipment.
The automation degree in cement production is constantly increasing and improving labour efficiency, product quality, environmental indexes and reducing operation costs.
Nowadays cement plant design is based on cutting-edge developments in the field of remote monitoring, computer software, big databases and even artificial intelligence. Reducing human intervention in technological processes has become a trend that determines the competitiveness of the industry.
Local automation of individual processes of drying, clinker roasting and crushing is gradually being replaced by modern operating systems, which take control of all production processes and become responsible for the final result.
Computer technologies improve environmental performance of cement plants as they help control emissions and keep the most dangerous stages of production within acceptable limits. All this contributes to the image of enterprises and protects against imposition of penal sanctions.
Get a Free Consultation of Our Experts on the Most Efficient Methods and Technologies
M HEAVY TECHNOLOGY Experience and Expertise in Cement Plant Engineering
An example of successful activities of M HEAVY TECHNOLOGY in designing cement industry facilities is reconstruction of cement silo blocks at «YUG Cement plant», an affiliated enterprise of PJSC “Dickergoff Cement Ukraine”.
Within this project modernization of cement railway loading systems, discharge into cement trucks and supply of cement from the block of silos Nos. 1-4 to the old packing station and from silos No. 5-8 to a new packing station was provided. This project also included installation of new “Lühr” filters for cement silos dedusting. For cleaning dusty air from the vehicle loading unit a “Lühr” bag filter with a capacity of 3600 m3/hour was installed. Residual dust content in the air at the bag filters’ outlet is less than 20 mg/nm3.
Instrumentation and process control systems of the silo blocks have been also replaced.
According to the project and «Claudius Peters» proposal, modernization of cement silos No. 1-8 included the following works:
– reconstruction of silo bottoms with installation of new aeration systems, operating on the air from the low-pressure blowers;
– installation of a system with a capacity of 450 t/h for loading cement into the railway transport;
– installation of a loading system with a capacity of 150 t/h for feeding cement into vehicles;
– installation of the “FLUIDCON” electropneumatic system;
– changing over mechanical scales under silos No. 1-4 to electronic weighing;
– installation of electronic scales, “Schenk” manufacture, under silos No. 5,7;
– installation of pneumatic screw pumps for feeding cement from silos No. 1-8 to packing departments.
Thus, an increase in the following main indicators of the enterprise was achieved:
✔️ increase of efficiency;
✔️ reduction atmospheric emissions;
✔️ improvement of process automation.
✔️ product quality increase.