USA – Consultec

Cement Kiln Line, 3000 t/d

Challenge

A fast-track project was commissioned by the owner to take advantage of a robust local cement market. The onus fell upon the engineering integrator, Consultec, to bring together diverse equipment suppliers and construct a new facility, adjacent to an existing kiln line that remained in operation throughout the project.

Process

For a new 3000 t/d kiln line, a carefully planned phased design was scheduled to facilitate equipment tie-ins during planned plant shutdowns.

Delivery

Consultec was the overall engineering integrator for this $250M project, and was responsible for balance of plant equipment procurement, mechanical, civil, structural and electrical design as well as construction supervision.

Waste Fuels

Challenge

Waste fuels such as tire chips, agricultural waste are an excellent and economic source of replacement fuel to coal and natural gas. This cement producer had a long term contract for waste fuel supply that needed to be integrated into an existing kiln system.

Process

As recycled, waste fuels come from multiple sources, they can be highly variable in material properties largely dependent on the process of the source. As a result, the equipment and facility needed to be designed with considerable flexibility.

Delivery

Consultec was the overall engineering integrator for this project. Responsible for balance of plant equipment, mechanical, civil, structural and electrical design, construction supervision.

Rail Terminal – Coal

Challenge

To meet the growing demand for energy, coal from this western US coal mine is loaded on rail cars at the astonishing rate of 70 tons in 10 seconds. A reliable discharge system needed to be designed that could deal with the difficult flow properties of coal.

Process

After a detailed flowablility analysis, design of the unique withdrawal hopper and concrete silo was done with particular geometric properties and lined with materials to promote mass flow.

Delivery

As a fast track project, detail design was done in four months to enable a 12 month overall construction schedule. Consultec provided detailed civil, structural design.