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IS PLEASED TO WELCOME

HON. MIN. Of Commerce and Industry


SEN. JUBRIL MARTINS-KUYE
And His Entourage

CEMENT DIVISION
IBESE LINE I Commissioning : Jan 2011
IBESE LINE II Commissioning: Feb 2011
TOTAL CAPACITY Line I+II = 6 Million T
OBAJANA LINE 3 Commissioning: Jul-2011
OCP Total Capacity (I+II+III and Debottlenecking)
by July 2011= 10.25 Mi T
BCC Capacity after debottlenecking and
Expansion= 3.75 Mi Tons
GRAND TOTAL OCP: 10.25+IBESE :
6.00+BCC:3.75= 20.0 MiTons
EXPECTED PRODUCTION BY JULY 2011
20 Million Tons
NIGERIA CEMENT CONSUMPTION 2009 MILLION
TONS
6.9 Mil
Tons
7.9
Mil
Tons
IMPORTS
PRODUCTION
DANGOTE
54%
WAPCO
12%
FLOUR MILLS
12%
ASHAKA
5%
IBETO
3%
ATLAS
4%
SOKOTO
1%
OTHERS
9%
2009 CEMENT MARKET SHARE TOTAL CONSUMPTION
1,610
646
397
3,300
1,370
-
500
1,000
1,500
2,000
2,500
3,000
3,500
WAPCO ASHAKA SOKOTO OBAJANA BENUE
0
0
0
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CEMENT SUPPLY BY LOCAL MANUFACTURERS 2009)
WAPCO
ASHAKA
SOKOTO
OBAJANA
BENUE
DANGOTE
42%
FLOUR MILLS
27%
EASTERN BULK
8%
IBETO
7%
DIAMOND
2%
MAGENROI
5%
ATLAS
7%
OTHERS
2%
MARKET SHARE OF CEMENT IMPORTERS (2009)
% of total import
Present Cap,
7.9
Imports, 6.9
Expansion,
14.3
ESTIMATED
CONS, 15
SURPLUS
CAP, 13.2
NIGERIA SUPPLY DEMAND ESTIMATED
FOR 2011 CAPACITY
Present Cap
Imports
Expansion
ESTIMATED CONS
SURPLUS CAP
WAPCO ASHAKA SOKOTO OBAJANA BENUE BUA UNICEM
2006 1,931 727 285 - 208
2007 1,704 669 322 1,621 264
2008 1,677 859 346 2,534 657
2009 1,610 646 397 3,241 1,370 632 695
-
500
1,000
1,500
2,000
2,500
3,000
3,500
0
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CEMENT SUPPLY BY LOCAL PRODUCERS (2006-2009)
LAGOS
22%
OBAJANA
46%
PORTHARCOURT
13%
BENUE
19%
2009 DANGOTE CEMENT SUPPLY
OBAJANA CLINKER & CEMENT PRODUCTION

264969
210835
282002
269516
248446
254340 254340
294673
352779
317338
352779
407273
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
Clinker
Cement
Linear (Cement)
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
Partial Shut down of one Kiln due to high clinker
stock
Clinker
Cement
Cement
projected
Clinker stock
This is the
projected
clinker stock
if we had not
stopped the
kilns in Feb
and March
OBAJANA CLINKER & CEMENT PRODUCTION
Cement projected & Clinker Build up

OBAJANA CLINKER CEMENT
STOCKS
Clinker Stock,
219000
Cement in
Silos, 35000
Cement in Ware
Houses, 52000
LS High Grade,
110000
Cement
Equalent,
536200
Semi finished, finished product stocks
And Cement Equivalent
Clinker Stock
Cement in Silos
Cement in Ware
Houses
LS High Grade
Obajana Plant Market Strength
Location
Distribution network
Volume
Quality of product
Obajana
OCP FACT SHEET
Commissioned with 5 million tons per annum of
installed capacity, largest plant in sub-Saharan
Africa
All raw materials required to produce cement are available at the
facility except Gypsum
US$1.2 Billion investment
135 MW captive gas power plant with 90 km gas pipeline
Limestone quarry with associated 8.5 km conveyor belt and estimated
reserves of 450 million tonnes
13m high dam impounding a reservoir with a total storage capacity of
5.1 million m3
328 units housing complex for staff
Logistic fleet of 1000 trucks
Vast limestone deposits
About 1,200 employees
Airstrip suitable for B 737 aircraft


HISTORY
Plant (line 1) erection work completed end of 2006

OCP line 1 commissioning trial started December 2006

Commissioning trials continued into January 2007

Official commissioning ceremony held may 12, 2007

Commissioning of line 2 was completed in July 2007.

Proposed line 3 of 2.5 million tons at Obajana in progress

Raw material
mining
Mixing bed
Fuller
Roller
Mill
Silo
ILC Pre-calciner Kiln
OK MILL
Auto
Packers
Rotor
Packers
Cement
Silos
Clinker
Silo
2000 T/H
400 T/H
4X10,000 MT
2x75,000 MT
2X5,000 TPD
4X140 T/H
2X450 T/H
15,000 TPD
165,000 MT
2x25,800 MT
OBAJANA CEMENT PLC
LOCATION
Obajana Cement
Factory is
located at
Obajana, Kogi
State, about 400
km north-east of
Lagos, towards
the capital Abuja
in Central
Nigeria
Obajana
LONG
Mixing Bed for storage and material blending,
capacity = 165,000 tons
Fuller Roller Mill
(FRM) Plant for
Rawmeal Grinding
into Fine powder,
capacity = 450 t/h
HOMOGENIZING SILO
FOR STORAGE OF
RAWMEAL AFTER
GRINDING
CAPACITY = 25,800 TONS
The
The
ILC
Precalciner
FLS Kiln with
SF-Cooler
Guaranteed
capacity = 5000
tons per day
CLINKER STORAGE SILO
CAPACITY = 75,000 TONS
CEMENT SILOS
4 NOS, 2 PER LINE
CAPACITY 10,000 TONS EACH
TOTAL CAPACITY
= 40,000 TONS
H & B
ROTO-PACKER
6 NOS.
CAPACITY
15,000 TPD

BAGS
BULK
JUMBO

AUTO-PACKER
15 NOS
COMBINED CAPACITY
15,000 TONS PER DAY
(500 TRUCKS PER DAY)
OBAJANA PLANT
SALIENT FEATURES
Single largest plant in sub-Saharan
Africa having a capacity of 5 million
tones per annum cement.

The plant is centrally located in Nigeria,
just about 220km from the Federal
Capital City, Abuja.

High capacity vertical roller mills with
low power consumption

The plant is equipped with a captive power plant of
135 MW capacity which utilizes natural gas or AGO

The plant is equipped with modern and proven cutting
edge cement technology which include:

Gamma Matrix on-line analyzer for material quality
control right from mines,

Robo Laboratory for automatic sampling, analysis
and correction, Expert Control & Supervision (ECS)
automation with operator console that allows for
operation, control and continuous monitoring of the
kiln, rawmill, and cement mill plants from the central
control room in auto-mode.

photos on
how we built
the plant
OBAJANA PLANT SITE OCTOBER 2002
SHARING OUR OBAJANA EXPERIENCE IN PHOTOS
GRADING WORK IN PROGRESS
APRIL 2003
EXCAVATION IN PROGRESS OCTOBER 2003
RAW MATERIAL MINING
OVERLAND BELT CONVEYOR FOUNDATIONS
OVERLAND BELT CONVEYOR ERECTION
OVERLAND BELT CONVEYOR ERECTION COMPLETED
OBAJANA PLANT SITE
RAW MATERIAL STORAGE
OCT-03 NOV-03
JAN-04 MAR-04
Excavation Depth-7ft.
RAW MATERIAL STORAGE FOUNDATION
RAW MATERIAL STORAGE SHED
OBAJANA PLANT SITE
RAW MATERIAL GRINDING
OCT-03 NOV-03
DEC-03 MAR-04
Excavation Depth-14ft.
OBAJANA PLANT SITE
RAW MEAL SILO
SEP-03 OCT-03
DEC-03
MAR-04
Excavation Depth-14ft.
OBAJANA PLANT SITE
PREHEATER
OCT-03
DEC-03
FEB-04 MAR-04
Excavation Depth-16.5 ft.
KILN COOLER INSTALLATION
OBAJANA PLANT SITE
CLINKER STORAGE
OCT-03 DEC-03
JAN-04 MAR-04
Excavation Depth-26 ft.
OBAJANA PLANT SITE
CEMENT MILL
NOV-03 DEC-03
JAN-04 MAR-04
Excavation Depth-33 ft.
CEMENT MILLS
CEMENT PACKING PLANT
LAYING OF GAS PIPE LINE
GAS PIPE LINE WORK IN
PROGRESS
AJAOKUTA TO OBAJANA

PILING OF PREHEATER TOWER
LINE 02
AUG 04- CLINKER SILO CONSTRUCTION

OBAJANA PLANT SITE
WATER DAM
MAR-03
FEB-04 OCT-03
NOV-04 JAN-05
WATER DAM
WATER DAM COMPLETED
OBAJANA CEMENT HOUSING ESTATE
OVERALL VIEW OF PLANT SITE
CENTRAL CONTROL ROOM
A PANAROMIC VIEW OF THE PLANT
TRUCK PARKING AREA
WELCOME
TO
BENUE CEMENT
COMPANY PLC
GBOKO.
Benue
State

PLANT SITE DATA
RAINFALL :- 1300 MM ANNUAL AVERAGE
WIND VELOCITY :- 41 M/Sec
TEMPERATURE :-
MAXIMUM - 40 DEG. C
MINIMUM - 15 DEG. C
AVERAGE - 32 DEG. C
HUMIDITY :-
MAXIMUM - 85 %
MINIMUM - 65 %
LATITUDE :- 7
0
22
LONGITUDE :- 9
0
3
SITE ELEVATION
ABOVE SEA LEVEL :- 150 MTR.

PLANT CAPACITY BEFORE 2004
TOTAL PLANT CAPACITY :0.9 MILLION TONS ANNUM (MTPA)
NO. OF PRODUCTION LINES :- TWO(0.45 MTPA EACH)
LOCATION :- 72KM,MAKURDI GBOKO
EXPRESSWAY BENUE STATE NIGERIA
NEAREST AIRPORT :- MAKURDI
PLANT DESIGNED BY :- CEMENTIA ENGINEERING
ZURICH
PLANT SUPPLIED BY :- M/S KHD
GERMANY
PHYSICAL POSSESSION OF THE PLANT WAS TAKEN BY
ON

FRIDAY 06.02.2004
NEW PLANT HISTORY
PLANT COMMISSIONING HISTORY
PLANT COMMISIONED IN :- YEAR
1980
Line-II Commissioned after upgrade:-
JANUARY 08
New DGs commissioned:-
DECEMBER 07
Line-I Commissioned after upgrade:-
AUGUST 08.
MINES DATA
LEASE AREA PROSPECTED :- 307 HECTARES
RESERVE UP TO 100 MTRS :- 250 M.M. TONS
RESERVE UP TO 30 MTRS :- 130 M.M. TONS
LEASE TO BE PROSPECTED :-520 HECTARES
MINES EQUIPMENT DATA
LOADING
EQUIPMENT
CAPACITY AVAIL. (NOS.)
EXCAVATORS (5.7& 7.0)M
3
2
CAT HAMMER ROCK
BREAKER (330DL)
1.1 M
3


1

WHEEL LOADERS (5.7 &7.0)M
3
2
DRILLING M/C - 3
BULL DOZER
(D6R,D8R,D8K) - 3
DUMPER
CAT 140 G GRADER
40 TONS
-
9
1
PRODUCTION SUMMARY (2006
2009)
0
200
400
600
800
1000
1200
1400
Yr. 2006 Yr. 2007 Yr. 2008 Nov-09
,
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Year
CLINKER CEMENT DESPATCH
RECLAIMER:- Retrofitting rack of Reclaimer is on Order
from MANTEKRAF

OVERHEAD CRANE:- Crane 2 repair job is in progress.

KILN 1:- Positive Pressures in Gas Circuit at Full Production

CEMENT MILL 3&4:- Chamber modification to be done.

BALL MILLS 1&2:- Raw Meal Transport Conveyors


MAJOR CONSTRAINTS & ACTIONS
IBESE PROJECT
PICTURES
IBESE PROJECT
PICTURES
IBESE PROJECT
PICTURES


THANK YOU
OBAJANA LINE3
PICTURES
OBAJANA LINE3
PICTURES


CINOMA SITE


THANK YOU

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