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Benefits of

Performing Equipment & Contract Execution


Example in Qatar and Egypt

Cemtech Middle East & Africa / Dubai / March 2011

Fives
Fives FCB - 06th March 2011

Driving Progress
Cemtech Middle-East & Africa - Duba

CASE 1 : QATAR NATIONAL CEMENT Co.


Umm Bab Line n4 5000 tpd

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

QATAR
UMM BAB LINE N 4 5,000 TPD QNCC

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New extension line for QNCC on the UMM BAB site


Fives FCB scope : full turnkey contract
Fuel : natural gas
Contract into force :
November 2006

Fives FCB - 06th March 2011

QATAR
UMM BAB LINE N 4 5,000 TPD QNCC

Cemtech Middle-East & Africa - Duba

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RAW MATERIALS PREPARATION :


9 IMPACT DOUBLE ROTOR CRUSHER 900 tph FOR LIMESTONE AND SHALE
9 LONGITUDINAL PREBLENDING STORAGE
2 x 30,000 tons for limestone and 2 x 10,000 tons for clay/shale

RAW MILL GRINDING WITH


TWO 220 tph SHOE-BEARING
BALL MILLS

BLENDING SILO 15,000 t

BURNING LINE 5,000 tpd

9 5 STAGES PREHEATER
SINGLE STRING ( 9m cyclones)
WITH LOW-NOx PRECALCINER

9 A 3 PIERS ROTARY KILN


4.8 m x 76 m
Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

QATAR
UMM BAB LINE N 4 5,000 TPD QNCC

BY-PASS SYSTEM 15%


(DESIGN 25%)

CONCRETE CLINKER SILO 40,000 t


OUTSIDE STORAGE 35,000 t

CEMENT GRINDING WITH


TWO 115 tph SHOE-BEARING
BALL MILLS

TWO 15,000 tons CEMENT


STORAGE SILOS

PACKING AND DISPATCH


93 BULK LOADERS 200 tph each
92 PACKING LINES
93 TRUCKS LOADERS FOR BAGS

Fives FCB - 06th March 2011

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Cemtech Middle-East & Africa - Duba

CASE 2 : BENI SUEF CEMENT Co. (Egypt)


Beni Suef Line n2 4000 tpd (TITAN Group)

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

EGYPT
BENI SUEF LINE N 2 4,000 TPD (TITAN Group)

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2nd production line for BENI SUEF


CEMENT Co.
Fives FCB scope :
turnkey contract for the complete line
(modifications on existing for
preparation of raw materials,
new line from raw grinding)
Fuel : gas or fuel oil
Contract in force : August 2007
Scheduling :
IPT Cement at 26 months
IPT Clinker at 28 months

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

EGYPT
BENI SUEF LINE N 2 4,000 TPD - LAFARGE/TITAN

EQUIPMENT

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CAPACITY

SUPPLIER

Raw meal grinding with vertical


roller mill

310 tph

Loesche

Blending silo

5,000 t

IBAU

Preheater with low pressure drop


cyclones and low NOx precalciner

5 stages one string

Fives FCB

By Pass system

Design : 50 %

Fives FCB

Kiln 3 piers 4.5 m x L 70 m

4,000 tpd

Fives FCB

Clinker cooler

IKN

Nodulizer

20 tph

Grelbex

Clinker storage silo

50,000 t

Fives FCB

Cement ball mill with TSV

170 tph (OPC)

Fives FCB

Packing & Truck loading plant

2 x 2,400 bags/h

Haver & Boecker

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

EFFECT of DELAY
EFFECT of
UNDERPERFORMANCE
Time

Cash flow principle of a project

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

Achievement
Case 1- Umm Bab Line n4 5000 tpd (Qatar)

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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UMM BAB LINE N 4 5,000 TPD QNCC


Cement Grinding section

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Contract commitment, from effectiveness of the contract :


Cement Mill #4 IPT : 17 months
Cement Mill #5 IPT : 22 months

Realized :
CEMENT MILL #4

CEMENT MILL #5

First cement on 20/04/2008


IPT achieved on 01/05/2008 (i.e. M+17)
Performance test completed 07/05/2008

Fives FCB - 06th March 2011

First cement on 23/06/2008


IPT achieved on 04/07/2008 (i.e. M+20)
Performance test completed 08/07/2008

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Cemtech Middle-East & Africa - Duba

UMM BAB LINE N 4 5,000 TPD QNCC


Cement Grinding section

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Guarantied production (OPC 3200 Bl.) : 115 tph


Realized :
CEMENT MILL #4

CEMENT MILL #5

Performance test result : 121.5 tph

Fives FCB - 06th March 2011

Performance test result : 121.7 tph

Cemtech Middle-East & Africa - Duba

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UMM BAB LINE N 4 5,000 TPD QNCC


Kiln section

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Realized schedule :

First Clinker 26/04/2009


I P T : 18/05/2009
Performance test : 16/06/2009
P A C : 09/07/2009

Only 2 months for kiln line acceptance

Realized kiln capacity :


5260 tpd clinker (performance test)

Fives FCB - 06th March 2011

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Cemtech Middle-East & Africa - Duba

UMM BAB LINE N 4 5,000 TPD QNCC


Kiln section

2/2

Production time over 90% after only 2 weeks

QATAR 5000 tpd LINE - CUMULATED PRODUCTION TIME (%)


excluding cold stoppages
1.000

0.900

0.800

0.700

0.600

0.500

0.400

25/4/09

25/5/09

Fives FCB - 06th March 2011

24/6/09

24/7/09

23/8/09

22/9/09

Cemtech Middle-East & Africa - Duba

22/10/09

21/11/09

21/12/09

20/1/10

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Achievement
Case 2- Beni Suef Line n2 4000 tpd (Egypt)

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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BENI SUEF LINE N 2 4,000 TPD TITAN Group


Above all priorities

Safety First :
6.5 millions hours performed on site

ZERO Lost Time Injury

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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BENI SUEF LINE N 2 4,000 TPD TITAN Group


Cement Package

First cement on 22/09/2009


IPT completed on 08/10/2009
i.e. 26 months from effectiveness

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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BENI SUEF LINE N 2 4,000 TPD TITAN Group


Clinker Package

First clinker on 10/11/2009


IPT completed on 07/12/2009
i.e. 28 months from effectiveness

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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BENI SUEF LINE N 2 4,000 TPD TITAN Group


Innovation

Due to chlorine content of the raw material, by-pass design at 50% of kiln gases
By-pass dust treatment system designed for 30t/h
Design of a specific fluidized dust cooling system for efficient pelletization.

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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The Fives FCB Solution

Innovative technologies to highest standards


Full turnkey engineering and construction with single
responsibility
Reliable long-term partnership with the Client
Dedicated team of skilled engineers for the projects

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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THANK YOU FOR YOUR ATTENTION

Fives FCB - 06th March 2011

Cemtech Middle-East & Africa - Duba

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