Civil Design – 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.

Silo – Ecuador

Challenge

An exceptionally large, 70,000 t capacity clinker storage was required for this cement producer in a remote, high seismic part of Ecuador. The silo was located in close quarters to the existing plant structures and had to be built in a timely manner.

Process

Extra large capacity storage silos run the risk of encountering eccentric flow on withdrawal. Advanced methods of calculating the impact of eccentric flow on material pressure was employed. Also, in order to speed up construction, the large roof and penthouse was designed such that it was integrated into the slipform deck.

Delivery

Consultec was responsible for mechanical and civil/structural design.

New Kiln Line

Challenge

Design and construction supervision of a 5600 mtpd clinker kiln line from raw material storage and handling, raw grinding, pyro-processing through clinker storage.

Process

5600 t/d Clinker production line (increased to 6300 t/d with process improvements)

Delivery

St. Marys Cement replaced 2 existing wet klins with one 5 stage, double string new kiln line with a capacity of 5,600 tpd. In 1999 Consultec engineered modifications to increase clinker production capacity to 6,400 mtpd. Projects included a new downcomer, ID Fan, indirect kiln coal firing system, dust collection, upgrades, cooler enlargement and new tertiary air duct.