Professional Documents
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A
fter competing with some of
the worlds largest engineering
companies, Cemengal was
awarded the engineering, procurement
and construction (EPC) contract to build
the state-of-the-art grinding plant. The
companys scope of supply for the 140tph
unit included:
150,000t raw material storage
raw material transport and handling
Cemengal 4350kW ball mill (4.8m x
18m) with drying chamber
two Redecam process filters (mill and
separator)
type SD Magotteaux separator The turnkey contract for Espabels new
grinding unit was awarded to Cemengal
six cement silos with individual capacities
of 3000t
bulk loading facilities
palletising, bag loading and storage hall supervised the civil works, commissioning contributing to the clients confidence in
control building and electric room. and training of personnel. The project the solution.
As the projects EPC contractor, deadline was 20 months to the first The silos were built in a workshop less
Cemengal supplied all mechanical, approved cement, in February 2012. than 70km away from the erection site
electrical, structural and civil engineering and transported by vessel to a harbour
as well as supply and erect all electrical Project overview 2km away from the Espabel plant.
and mechanical equipment and the Cemengals Technical Department decided Cemengal transported the silos in two
plants steel structure. The company also to install six 3000t steel silos rather pieces cone and cylinder. Start-to-finish
than one 18,000t concrete silo on the the process took only one working day.
basis of cost advantages and a shorter The transport of the 4350kW ball
turnaround time. Moreover, having six mill followed a similar process. It was
silos allows greater flexibility to produce transported by vessel to the jetty close to
different cement types a configuration the plant and later transferred by a special
also offered to other clients in Europe and truck.
The 150,000t storage unit for clinker Internal end flanges units, which are fitted with an alignment
and other raw materials was engineered Two inside end rings, manufactured from system and have a white antifriction steel
in-house according to the latest S275J0 EN 10025 steel, are welded on coating. Two thrust bearing units are
engineering practices, based on years of the shell. One is needed to fix the head incorporated on the mill discharge end.
experience. Cemengal used the X-light internal lining and the other to apply the The shoe-bearings are located in
system, similar to that used to build discharge diaphragm. supports anchored in foundations and
Europes gothic cathedrals. High ceilings protected with a cover and manholes.
and light structures offer plenty of space Shoe-bearings and supports In addition, units are further provided
and are less concrete intensive. The system The mill is supported by two shoe-bearing with pumps suited to high and low
means that only parts of the building
would need repair and the entire structure
would not be affected. Table 1: cement mill specifications
Internal diameter (m) 4.4
Cement mill
Total internal length (m) 18
Cemengal delivered a horizontal three-
chamber ball mill with shoe-pad bearings Mill output 140tph OPC or 90tph CEM III/A
42.5R at 4200Blaine
with the main characteristics as shown in
Estimated output after raw material
Table 1.
analysis is 85-90tph CEM III/A 42.5R
at 4200Blaine 140tph OPC
Mill shell
Power consumption in mill shaft (kWh/t) 51 (value to be confirmed with
The 50mm-thick mill shell is made of
raw material analysis)
S275J2G3 EN10025-standard steel plates,
Transmission system pinion/crown
which after welding are subjected to
distention thermal treatment. Speed 15.2 (75.38% of critical speed)
The crown end flange is welded onto Motor (kW) 4200
the shell and the shell area leaning on the Gear box included
shoe-bearing units consists of 85mm-thick Lubrication system included
steel.
First- and second chamber filling level (%) 30
Two manholes with related locking
Auxiliary drive included
covers one for each chamber are
also included. The holes for liners are Intermediate and end walls included
manufactured in accordance with the
appropriate DIN standard.
As part of the companys quality control
process, welds are checked before heat
treatment (100 per cent ultrasounds on
all welds) and after heat treatment (MT at
100 per cent on all welds and UT at 100
per cent on welds around the manholes).
lubricating system with a double pump Health and safety The team
and oil/air heat exchanger (3x). The oil Cemengal had to prove its knowhow in The success of the project and one of
flows at 430l/min. The cooling power is health and safety issues and the trust Cemengals key strengths are its staff,
130kW at maximum ambient temperature put in the company by not only big particularly its site managers. They
of 35C and the oil temperature at inlet players but also by independent cement are crucial in reaching the companys
is 60C. The drives auxiliary reduce is companies. objectives and solving the day-to-day
equipped with a stop brake, manual Bearing in mind that prevention is better issues that inevitably arise. Thanks go
coupling and a 30W motor. A motor than the cure, Cemengal and its partners to the team led by project manager Eng
coupling joint is also included with plates applied preventive safety principles Alfredo Camporro and assistant Eng
and screws for foundations. during the design stage, implementing Valentina Parra.
improvements to equipment to avoid any Meanwhile, the combination of
Load and discharge systems possible risk. Potential risks were evaluated Cemengals technology and the
The mill inlet device is manufactured and action to eliminate or at least minimise strategiclocation of the facilities will
in welded S275JR steel with a support them was taken at source. In addition enable the Espabel plant to become
saddle, complete with wearproof plates. to ergonomic principles in building, a cement production reference in
The mill outlet is made from welded passage and maintenance design, all northernEurope. ______________I
S275JR steel.
Anchorage plates
Anchorage plates are included for the
mill support, control unit and load and
discharge unit. They are electro-welded
with MT heat treatment and mechanised.