1999 Cement Projects Report The Americas

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NORTH AMERICA United States Illinois Cement Co.'s contracted Humboldt Wedag, a subsidiary of KHD Humboldt Wedag AG, to provide process/general plant arrangement engineering, equipment supply, erection supervision, and commissioning services for its LaSalle plant. Humboldt Wedag will supply the engineering and deliveries of a 4.2-meter-diam % 11.5-meter-long (shell-supported); a 4,000-hp ball mill equipped with a SKS 2250/120 high-efficiency separator, and two 3.0-meter-diam product cyclones. The company also will supply bucket elevators, airslides, pumps, a compressor, a baghouse, and fans. In addition, new cement finishing milling equipment installation and plant construction will be handled by Watkins Engineers & Constructors. Humboldt Wedag also bought a Peters X-250 pump and a Peters PK-500-A2 compressor for cement conveyance. Start-up is expected by May 1999.

In addition, Humboldt Wedag was awarded a $15 million contract to expand and modernize Southdown's Kosmosdale plant in Louisville, Ky., a joint venture co-owned by Lone Star. The project will increase the plant's capacity by 700,000 tpy to about 1.6 million tpy. The upgrade will include a 4-stage preheater type PR 8254/4 LowNOx calciner with mixing chamber for CO reduction. The kiln will be equipped with a project burner and a new clinker cooler. Humboldt also will supply a complete indirect coal firing system along with other auxiliary equipment and dust collectors. Equipment deliveries begin in July 1999 with plant start-up expected in mid-2000.

Holnam Inc. ordered a ball mill for its Chicago plant. The mill will be used for grinding granulated blast furnace slag in a compound operation with two existing high-pressure grinding rolls. The plant, designed for a throughput of 7o tph and a product fineness of 5,600 sq cm/gram, will start production in April 1999. Krupp Polysius will be the supplier.

Holnam also ordered a cement cooler for its plant in Midlothian, Texas. The cooler was supplied by Christian Pfeiffer. Humboldt Wedag was awarded a $52 million portion of this project. Humboldt will provide process/general plant arrangement engineering, equipment supply, erection supervision, and commissioning services. The systme is comprised of a slewing/luffing stacker of 630-tph capacity and a 120-tph side reclaimer for shale with high moisture content. This purchase also includes a bridge reclaimer with a raised discharge of 680-tph capacity for limestone. The new equipment installation and plant construction will be completed by Watkins Engineers & Constructors. New equipment will include a 4-stage preheater type PR 950 LowNOx calciner with Pyrotop, and a 4.4-meter-diam % 54-meter-long two-station kiln and Pyroject burner. The company will use a 2,250-hp vertical roller mill for raw milling; a 5-meter-diam- % 14.5-meter-long (shell-supported); and an 8,000-hp ball mill with central drive, equipped with a high-efficiency separator for finish grinding. Also, IKN has been contracted to supply a 3,200-tpd pendulum cooler with horizontal aeration for the company's #2 kiln. Start-up is expected come January 2000.

Lone Star Industries spent $33 million on a new production line for its Greencastle, Ind. plant. Details of the purchase were not available but the equipment will be delivered sometime in mid- to late 1999. The new line should be operational in spring 2000. Fuller was the supplier.

Lafarge Corp.'s Alpena plant installed two clinker inlet distribution systems-one a 1,225-tpd unit, the other a 1,825-tpd unit. IKN was the supplier. The company also installed an IKN 1,980-tpd clinker inlet distribution system at its Joppa plant.

Florida Rock Industries ordered a continuous raw material analyzer from Krupp Polysius for chemical on-line analysis of raw materials using an electronically controlled neutron tube as the radiation source.

Arizona Portland Cement, owned by California Portland Cement Co., purchased a roller mill that included an integrated high-efficiency separator and recirculating bucket elevator for its external material circuit. The 360-tph grinding mill, located in Rillito, Ariz., is scheduled to be operating at the end of 1999. Krupp Polysius is the supplier.

In 1998, Lehigh Portland Cement Co.'s Leeds, Ala. operation witnessed the start-up of a CPB 33-85 cement cooler. Christian Pfeiffer was the supplier.

Christian Pfeiffer also supplied a horizontal impact crusher for clinker pre-crushing at Southdown's Knoxville, Tenn. plant.

Signal Mountain Cement Co., a member of the RC Cement Group, awarded a contract in connection with its new 2,200-mtpd production line to be installed at its facility in Chattanooga, Tenn. The contract covers engineering and supply of main processing equipment for the preheater/precalciner, rotary kiln, cross bar cooler, coke grinding and finish grinding. The system is designed for 100% coke firing. Fuller Co. will be the supplier.

Also at Signal Mountain's Chattanooga plant, Loesche will supply a 157-mtph, mill-type LM 38.4 for the communition of cement raw material.

River Cement Co.'s Selma plant is adding a 2,086-tpd clinker inlet distribution system to the cooler on its #2 kiln and a 1,900-tpd clinker inlet distribution system on its #1 kiln. IKN is the supplier.

Essroc's Nazareth plant installed a 3,800-tpd clinker inlet distribution system on its #1 kiln. IKN was the supplier.

Independent Cement's Catskill, N.Y. plant installed a 2,000-tpd clinker inlet distribution system. IKN was the supplier.

Hercules Cement's Stockerton, Pa. plant installed an 1,100-tpd clinker inlet distribution system on its #1 kiln. Again, IKN was the supplier.

Rio Grande Portland Cement Co. of Texas ordered the design and supply of aeration equipment for a Kiln Dust Filter System. BMH Americas will be the supplier.

National Gypsum of Charlotte, N. C., placed an order with BMH Americas for the supply of a Norba crusher.

In 1998, KDH of Holnam, Texas, purchased a stacker/reclaimer, a blending silo, and the products' general pneumatics. BMH Americas was the supplier.

Canada Lafarge Canada's Bath plant installed a 3,100-tpd clinker inlet distribution system on its #1 kiln. IKN was the supplier.

CENTRAL AMERICA Costa Rica Cementos INCSA's Cartago plant installed a 1,350-tpd clinker inlet distribution system on its #1 kiln. IKN was the supplier.

El Salvador Cementos de El Salvador modernized its cement operations in Cessa and Maya using Christian Pfeiffer's QDK 29-N with corresponding auxiliary equipment. Start-up for both is expected for spring 1999.

Guatemala Cementos Progreso, the San Miguel Plant in Guatemala, placed an order for the modification of its 2,500-mt silo. Previously, the comapny modified three storage silos and two mixing silos. BMH Americas will be the supplier.

Mexico Cementos Portland Moctezuma ordered a second 2,400-mtpd kiln line consisting of a rotary kiln with a one-string, 5-stage cyclone preheater with calcining system and reciprocating grate cooler. The order is being jointly processed by Krupp Polysius/Beckum and Krupp Engineering de Mexico.

Cemex's Tamuin plant installed a 1,886-tpd clinker inlet distribution system on its #1 kiln. IKN was the supplier.

Cemex also installed a 2,650-tpd clinker inlet distribution system on the CPN plant's #1 kiln. IKN was the supplier.

In March 1998, Cruz Azul placed an order with Krupp Polysius for the conversion of its grey cement producing kiln line in Hidalgo to a white cement production line. The company also ordered a pozzolana grinding plant consisting of a two-compartment mill, high-efficiency separator, Combiflex drive and hot-gas generator. The throughput capacity of the new system will be 130 mtph.

CARIBBEAN Jamaica Alcan Jamaica Co. purchased a silo withdrawal equipment and a PHB-Someral shiploader for calcined alumina of 1,500 tph capacity. The delivery came to Alcan's Port Esquivel facility in St. Catherine, Jamaica in October 1998. The supplier was BMH Americas.

SOUTH AMERICA Argentina Loma Negra of Argentina is erecting a production line with a 5,150-mtpd capacity in La Pampita. The supplier, Krupp Polysius, will work in conjunction with its subsidiaries in Argentina, Spain, and Mexico to supply and set up a 6-stage, twin-strand Dopol 90 cyclone preheater that will include a calciner, a 4.8-meter-diam % 76-meter-long rotaro kiln, and a reciprocating grate cooler. In addition to this, Loma Negra will purchase a crushing plant for dressing the limestone; conveyors for transporting raw material; a circular blending bed; storage areas for additives; clinker storage and transport equipment; a two-compartment, 170-mtph separator mill; and silos and bulk loading equipment. Krupp also will be supplying the automation system, including a raw meal analyzer, a laboratory automation system, a system for kiln and mill control, and information and management systems. The new line is due to start production in 2001.

Loma Negra also is constructing a greenfield facility in the Olavarria district of Buenos Aires province. The company has ordered a 450-mtph raw meal grinding system from Loesche. The system is part of a new furnace being supplied by Krupp Polysius and is designed for 5,150 mtpd of clinker.

In August 1998, a new 3,100-mtpd kiln line was commissioned at Juan Minetti. The main equipment included two longitudinal blending beds, a 320-mtph roller mill for raw material, two multi-flow silos, and the kiln plant itself consisting of a 5-stage cyclone preheater with calciner, two support kilns and reciprocating grate cooler. The supplier, Krupp Polysius, also installed systems for analyzing the preheater feed meal, hot meal, and clinker, as well as a system for measuring the temperature of the rotary kiln shell.

Brazil In February 1998, a ball mill that included Combiflex drive and Sepol high-efficiency separator started production with a throughput of 125 mtph at Cia. de Cimento Portland Rio Branco. Krupp Polysius was the supplier.

A two-compartment, 110-mtph mill including Combiflex drive and Sepol high-efficiency separator was commissioned at Cimento Tocantins. Again, Krupp Polysius supplied the equipment.

In June 1998, Polysius also supplied a two-compartment, 120-mtph mill with Combiflex drive and Sepol high-efficiency separator at Cemento Planalto's Ciplan plant. In addition, the facility is adding a 2,000-tpd pendulum cooler with horizontal aeration on its Polysius #1 kiln. IKN is the supplier.

Votorantim Cimentos' Salto de Pirapora plant is adding a 6,000-tpd pendulum cooler with horizontal aeration to its new Polysius #5 kiln. IKN is the supplier.

Another Votorantim operation, the Sta. Helena plant, installed a 2,800-tpd clinker inlet distribution system onto its #1 kiln. IKN was the supplier.

Cia. de Cimento Itambe's plant installed a 2,400-tpd clinker inlet distribution system on its #2 kiln. IKN was the supplier.

Cimento Poty da Paraiba's Cipasa plant installed a 4,000-tpd clinker inlet distribution system. IKN was the supplier.

Cimento Portland de Sergipe commissioned a 3,000-tpd production line from F.L. Smidth. The production line will include the ROTAX two-support kiln with direct hydraulic drive via the supporting rollers.

Chile In October 1998, Cementos Melsn had a new grinding plant installed consisting of a two-compartment mill, high-efficiency separator, and conveying equipment for clinker, pozzolana, gypsum, and cement production. Depending on the cement type, the plant has a capacity of as much as 130 mtph. Krupp Polysius was the supplier.

Colombia Cementos Paz Del Rio, a member of the Argos Group, has purchased a complete packing plant, which will include a palletizer, from BMH Americas.

Ecuador With the aim of increasing the production capacity of its kiln line from 2,000 to 3,000 mtpd of clinker, La Cemento Nacional placed an order with Krupp Polysius for an extensive modernization program in its Cerro Blance works. In addition, Krupp will integrate a new 5-stage, one-string cyclone preheater (including a calcining system) into the present preheater construction and install a new tertiary air duct. Also, a 3,500-tpd clinker inlet distribution system was installed on the #1 kiln. IKN was the supplier.

Peru In April 1998, a finish grinding plant was commissioned by Cementos Lima's Atogongo works. The finish grinding plant with high-pressure grinding roll and high-efficiency separator produces about 320-mtph of raw meal with a total specific power requirement of 10 kW hours/ton. Krupp Polysius was the supplier.

In addition to the Atogongo project, Cementos Lima ordered a pneumatic conveying system from BMH Americas for the new extension at its Lima plant.

Venezuela Corporation de Cementos Andino's Trujillo plant is adding a 2,500-tpd clinker inlet distribution system to its kiln #1 cooler. IKN is the supplier.

Lafarge Cementos of La Vega placed an order with BMH Americas for the modification of its existing silos.

EUROPE Iberian Peninsula Portugal Pataias Cement's facility installed a 1,000-tpd clinker inlet distribution system on its #4 kiln. IKN was the supplier.

Spain In September 1998, Cementos Especiales de las Islas commissioned a 110-mtph cement grinding plant consisting of a ball mill with Combiflex drive. Krupp Polysius will be the supplier.

Cementos Alfa placed an order for modernizing its Mataporquera works. The first phase of the plant optimization will include the conversion of its raw mill conveying system, blending silo, and preheater. Later, the coke grinding plant and measuring and control equipment will be modernized. Krupp Polysius will be the supplier. In addition, the Mataporquera facility is adding a 1,700-tpd replacement pendulum cooler with horizontal aeration. IKN will be the supplier.

In order to increase its capacity and minimize heat requirements, S.A. Tudela Veguin Abono placed an order with Krupp Polysius for the integration of two new cyclones into its cement production line in Abono.

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