An important consideration for an owner is the

break down of the investment which will very

widely with the particular circumstances of the
proyect. However,typical guide-line figures are
offered for reference.
These are relative cost breakdowns for multi
package,green field plants of various sizes
using Western equipment .Captive power plants
whichs are frequently required for remote locations
sare omitted.
 1Mta 2Mta 3Mta
Mech Equipt : 37 % 40 % 42 %
Elect Equipmt : 9% 10 % 12 %
Civil works incl : 24 % 21 % 18 %
struct steel
Erection & local : 11% 13 % 15 %
fabrication
Access road, : 7% 5% 3%
services,auxiliaries.
Engineering : 12 % 11 % 10 %

Total construct ( US $ ) $ 150 $ 260 $ 350

COST
 To which should be
added :

1Mta 2Mta 3Mta

Feasibility Study : $1.5m $1.5m $ 1.5m
Quarry plan, drilling : $1.4m $1.4m $1.4m
,analysis.
Total feasibility study cost : $$2.9m $$2.9m $2.9m

Quarry development : $14m $16m $18m

& equipment.
Land : ? ? ?
Financial expences : $7.5m $13m $17.5m
( 5% of construction ).
Offices workshops, $5m $5m $5m
Laboratory,etc. :
TOTAL Investment 180m $297m $394m

Cost per Installed tonne : $180 $149 $131m

 Phase I : feasibility study which formulated the project and de-
termines its return on Investment.
Phase II: Basic engineering which develop the design &
economic analysis and leads to the major decision
point beyond which significant investment begins.
Phase III : PROJECT execution covers contract negotiations,
detailed engineering site supervision of civil work and
plant erection.Essential function are time and cost
control,guarantees and warranties.
Phase IV : Start-Up covers the commissioning of plant and its transfer to
plant operations.
Phase V : Management of the plant for commercial operation,maitenance
and administration. This is not necessary for existing plants.
 PROJECT SCHEDULE
Typical FOR GREENFIELD PLANT CONSTRUCTION ASSUMING
NO DELAY FOR LAND ACQUISITION OR PERMITTING IS A FOUR
YEARS SCHEDULE.THERE IS CERTAINLY SCOPE TO ACCELERATE
SUCH A SCHEDULE BUT,FREQUENTLY,this involves
additional cost of risks.

Months
Inception : 0-1
Feasibility study : 1- 3
Tendering & Contracting : 5 - 14
specification 5-7
tender doc preparation 6-8
call for tender & evaluation 9 12
negotiation & award 12 - 14
 Months

Detailed design : 15 26
basic engineering 15 - 21
detail equipment eng 18 - 25
detail civil design 18 - 26
Execution : 19 39
equipment delivery 23 -34
equipment fabrication 19 -34
steel structure fabric 21 - 34
civil work ( site ) 21 - 36
erection 24 - 39
 Months

Commissioning : 43 48
no - load testing 43 - 45
commissioning 44 - 46
acceptance 47 48
 Disbursement Schedule
typical payment schedule incorporated in
the contract ( s ) is :

Down payment: Import parts and services:

10% of total contract
value against performance
bond.
Local and site work :
90% of total local price as
Irrevocable,trasferable,
and divisible LC to be paid
pro rata against certified
invoices.
90% of total C&F price as
Irrevocable,transferable,
and divisible Letter of
Credit ( LC ) to be paid :
80% pro-rata against pre-
sentation of shipping doc
and inspection certificate.
10% on taking over.
 Typical payment schedule incorporated
in the contract( s ) is :
Local and site work: Potential of project Failure:
90% of total local price as irre Many projects are completed
vocable ,transferable,and on budget and schedule
divisible LC to be paid pro-rata though one tends to hear
against certified infoices. more about those that over
run particularly grandiose
Public projects.
 Specific Power Consumption
Power consumpt which may
be broken down :
Power consumpt signifi Kwh/tc %
cantly with introduct of
dry process kiln and Quarry & preblend 6 5
has continued to rise Raw Mill 28 24
with conversion to Coal, Blending 7 6
increased fineness of cement, and
with the Burning & cooling 25 32
demands of enfironment Finish Mill 44 38
protection.Typically,power
Conveying ,Packing, 6 5
consumption is presently
100 120 Kwh / t cement loading
which may be broken down. TOTAL 116
 Cost Accounting
Cost by process area
Quarry & Crushing.
On site raw mat to Raw Mill.
Raw Mill & Additives.
Blending.
Burning & Cololing.
Finish Mill & Additive.
Bulk handling & load out.
Manufacturing Overhead.
Bag premium.
Cost by natural Expence
Operating Salaries.
Operating & service labour.
Supplies,rental services.
Griding media.
Refractories.
Purchased raw materials.
Fuel.
Power.
Maintenance,including
repair parts and Labour.s
 KILN Burning
Kiln operation is monitored Kiln operating is monitored
By: by:
Production ,rate ton/hour CLINKER. Kiln feed-end O2 , %.
Operating hours ( feed-on ). Downcomer O2 , %
Total fuel rate ( tons/hour).
Kiln feed end material
Proporsioning of fuel to
precalciner/riser,%. LoI , %
Spec HEAT Consumption SO3, %
kcal/kg. Cl , %
Secondary air temp,0C
K2 , %
Kiln feed & temp 0C.
Preheter & exhaust gas temp,0C
Na2O,%
ID fan draft , min H2O. Kiln drive,power Kw.