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1.2 million tons/year cement plant

Code : 120929
raw milling
(2) ball mills, 9 ft. 6 in. diameter x 18’8” long, f.l. smidth, 19.1 rpm, 74.5% critical, 800 hp
synchronous 2400v, capacity 52 tons per hour each at 90% -200 mesh, ball load 40 50 tons
31%, (1948) - raw mills #1 & #2
each ball mill includes:
- 16 ft. diameter sturtevant separators with 150 hp
motor
- elevators – 50 hp, 300 tons per hour
- f-k pump, 150 tons per hour, 125 hp
- clean up elevator 5 hp
- dust collectors for each mill and separator
(2) ball mills, 9 ft. 6 in. diameter x 18 ft. 8 in. long, f.l. smidth 19.1 rpm, 74.5% critical, 800 hp
synchronous 2400v, capacity 52 each (1948 , 1950) - raw mills #3 & #4
each ball mill includes:
- 16 ft. diameter sturtevant separators with 150 hp motor
- elevators - 50 hp, 300 tons per hour
- f-k pump, 225 tons per hour, 100 hp
- clean up elevator 3 hp
- dust collectors for each mill and separator
(1) ball mill, 9 ft. 6 in. diameter x 18 ft. 8 in. long, f.l. smidth, 19 rpm, 74.5% critical, 800 hp
synchronous 2400v, capacity 52 tons per hour at 90% - 200 (1952) - raw mills #5
ball mill includes:
- 16 ft. diameter sturtevant separator with 150 hp
motor
- elevator 50 hp 300 tons per hour
- f-k pump
- dust collectors for each mill and separator
(1) ball mill, 9 ft. 6 in. diameter x 18 ft. 8 in. long, f.l. smidth,
19 rpm, 74.5% critical, 800 hp synchronous 2400v, capacity 30 tons per hour at 90% -200 - raw
mill # 6
ball mill includes:
- fan 300 hp synchronous 2400v
- 42,000 cfm exc 8.8a dc 250v.
- buell classifier
- bucket elevator
- fan
- dust collectors for each mill and separator
kiln area
(5) rotary kilns, 10 ft. diameter x 350 ft. long, f.l. smidth, (2) 100 hp d.c. drive motors, 60 to
80 rpm, capacity of 20 tons per hour each. 59.9 therm/ton. - rotary kilns #1 - #5each kiln system includes:
- i.d. fan with 400 hp
- clinker cooler, 5 x 21 grate type
- 47,000 cfm, baghouse dust collector
- bucket elevators
- raymond coal mill, model 573, 250 hp
o rated at 13 tons per hour
- alternative fuel oil and natural gas burners
- deltech waste heat recovery boilers, 24,760 pounds of steam per hour at 900ºf
kilns #1, #2, #3, new in 1948; #4, #5 new in 1952
(2) rotary kilns, 10 ft. diameter x 12ft. diameter x 310 ft. long, allis chalmers, pre-heater
design, 500 hp gyrol drive, 500 hp i.d. fan, capacity of 20 tons per hour. - rotary kilns #6 & #7
each kiln system includes:
- clinker cooler, 7 ft. diameter x 41
grate type, 67,000 cfm
- baghouse dust collector, 95,000
cfm
- raymond coal mill, m/n 573, 250
hp, 130 tons per hour
- deltech waste heat boilers
- alternative fuel oil and natural gas
burners
- kilns #6 & 7 new in 1959
finish milling
(1) ball mill, 10 ft. diameter x 10 ft. long,
marcy mill, 17.6 rpm, 72.5% of critical, 800 hp
synchronous 2400v, capacity 42 tons per hour
- finish mill #1
ball mill includes:
- elevator #1-30 hp 100 rpm
- elevator #4 (clean up), 7 ½ hp 84 rpm
- 16 ft. diameter sturtevant air separator
- bucket elevators
- norblo dust collector
- f-k cement pump
(1) ball mill, 9 ft. 6 in. diameter x 18 ft. 8 in. long, f.l. schmidt, 19.1 rpm, 74.5% of critical, 800
hp synchronous 2400v, capacity 35 tons per hour (1948) - finish mill #2
ball mill includes:
- elevator #1-30 hp 100 rpm
- elevator #5 (clean up), 7 ½ hp 84 rpm
- 16 ft. diameter sturtevant air separator
- bucket elevators
- f-k cement pump
- norblo dust collector
(1) ball mill, 9 ft. 6 in. diameter x 18 ft. 8 in. long, f.l. schmidt, 19.1 rpm, 74.5% of critical, 800
hp synchronous 2400v, capacity 14.7 tons per hour at 3600 blaine (1952) - finish mill #3
ball mill includes:
- elevator #6-25 hp 92 rpm
- 16 ft. diameter sturtevant air separator
- bucket elevators
- f-k cement pump
- norblo dust collector
(4) ball mills, 7 ft. diameter x 30 ft. long, allis chalmers, 21.2 rpm, 70.5% of critical, 600 hp
synchronous 2400v, capacity 17.4 tons per hour at 3600 blaine (1944) - finish mill # 4, # 5, #6 &
#7
each ball mill includes:
- 16 ft. diameter sturtevant air separator
- claudius peters cement pump
- norblo dust collector
(2) ball mills, 12 ft. diameter x 17 ft. long, f.l.
smidth, slide shoe mills, with symmetro drive, 17.6
rpm, 78% of critical, 1400 hp synchronous 2400v,
capacity 27 tons per hour each at 3600 blaine
(1957) - finish mill #8 & #9
each ball mill includes:
- symmetro gearbox with 720/17.6 gear ratio
- elevators #7 & #8 30 hp
- o-sepa classifier
- claudius peters cement pump
- dust collector for mill and air classifier
power house
(7) waste heat boilers each 23,000# steam per hour
(2) fuel-fired boilers each 40,000# steam per hour
(2) turbines-rated 7500 kwwith steam at 600 psig and 850ºf, exhausting at 1.5 inches high,
back pressure 3600 rpm
(2) generators-rated 7500 kw, 2400v, 60 hz, .8 p.f. approximately 10# steam/kwh
1977 plan – based on generating own electricity
total kwh 118,000,000
# steam/kwh 10.22
# steam/hr waste 118,000
# steam/hr aux. 7,700
# steam/hr fuel 28,000
therms/mo. 316,114
miscellaneous equipment
(1) traveling stacker system, rail mounted, (2) stockpiles 500 ft. long.
(7) raymond coal pulverizers, bowl mill model 573, 200 hp motor, complete system with fan
ductwork feed hoppers etc., rated at 13.5 tons per hour.
(1) bag packer, st. regis, 4-spout, complete system
(96) baghouse dust collectors, to 90,000 cfm capacity
(20) belt conveyors, 24”, 36” and 48” widths, to 1,100 length
(4) air compressors,

used dry process clinker plant, capacity 1,100,000 tons per year

Code : 120930
- originally commissioned in 1978, plant was upgraded in 1988 and 1992
- electrics for 50hz power supply

1. raw material preparation department:

1.0 steel structure for crushing department building (1 unit)
- steel frame, metal siding

1.1 limestone receiving hoppers (3 units)
- size 12' wide x 18' long
- capacity 4000 mt

1.2 wobble feeders (2 units)
- 60" wide x 16 bar, 12.5" pitch
- capacity 600 mtph
- 50hp drive motor
- weight 48,000 lbs.

1.3 limestone crushers (2 units)
- hammer mills inc. model hmis 06-nc/cb
- capacity 600 mtph each
- total weight 164,350 lbs.
- 746kw drive motor, 490rpm, 3/50/2300v

1.4 apron conveyors (2 units)
- length 40'6"
- capacity 600 mtph
- 25hp drive motor

1.5 limestone storage building (1 unit)
- steel frame, metal siding
- length 600'
- storage pile capacity 865,000 cu.ft.

1.6 tripper belt conveyor (1 unit)
- 48" x 612'
- 530 fpm
- capacity 1800 mtph

1.7 limestone reclaiming scrapper (1 unit)
- side mounted type
- capacity 600 mtph
- rate of carriage travel 4-100 fpm
- 94kw drive motor, 1490rpm, 3/50/440v

1.8 belt conveyor (1 unit)
- 36" x 360' centres
- capacity 500 mtph

1.9 belt conveyor (1 unit)
- 36" x 64' centres
- capacity 500 mtph

1.10 clay storage building (1 unit)
- 72' wide x 189' long
- stockpile capacity 34,020 cu.ft.

1.11 clay receiving hopper (1 unit)
- 1760 cu.ft.
- 8'10" wide x 22' long

1.12 clay apron feeder (1 unit)
- 5' wide x 26' long
- 80 mtph

1.13 primary clay crusher/cutter (1 unit)
- capacity 103 mtph
- reduces from 12" to 6"
- 23kw drive motor, 1475rpm, 3/50/460v

1.14 sand receiving hopper
- 8' wide x 14' long
- capacity 400 cu.ft.

1.15 sand feed apron feeder
- 42" wide x 14' centres
- capacity 80 mtph
1.16 dryer feed belt conveyors (2 units)
- 30" x 242' centres
- capacity 80 mtph1.17 clay dryers (2 units)
- kennedy-van-saun rotary dryer
- 11'6" x 100'
- capacity 120 mtph each
- 300kw drive motor, 1467rpm, 3/50/2300v
- oil burner
- combustion air fan, 75hp

1.18 electrostatic precipitators (2 units)
- joy manufacturing co.
- esp, type unitrell
- 100,000 acfm
- i.d. fan 200kw, 1500rpm 3/50/2400v
1.19 dust collectors (2 units)
- baghouse type
- 10000 cfm

1.20 vibrating screens (2 units)
- double deck
- capacity 120 mtph

1.21 bucket elevators (2 units)
- 120 mtph
1.22 secondary clay crusher (1 unit)
- 60hp drive motor

2. raw grinding department:

2.0 steel structure for raw grinding department building (1 unit)
- steel frame, metal siding

2.1 raw material feeding & proportioning
- limestone discharge feeders, 15-150 mtph (2 units)
- clay weigh feeders, 3-30 mtph (2 units)
- silica sand weigh feeders, 0.15-5 mtph (2 units)
- iron sand weigh feeders, 0.17-5 mtph (2 units)
- raw material belt conveyors, 30" x 364', 150 mtph (2 units)

2.2 vertical roller raw mills (2 units)
- fuller loesche lm30.41
- capacity 150 mtph each
- 1120kw drive motor, 983rpm 3/50/2300v
- hot air furnace 82m btu
- combustion air blower, 40hp

2.3 dust collectors (2 units)
- envirotech bag type dust collector, high temperature
- 10 compartments x 336 bags each
- 342,000 acfm
- robinson fan, 1305kw drive, 980rpm 3/50/2400v

2.4 mill product airslides (2 units)
- 16" wide x 108' long, 150 mtph

2.5 raw mill fuller-kinyon pumping stations (2 units)
- fuller-kinyon 12" pumps, 150 mtph, 125hp
- f-k c-508 rotary vane air compressors, 2560 scfm, 300hp

2.6 raw meal homogenizing silo (1 units) (internals only)
- christian pfeiffer ag
- counter flow type
- size 43'4" diameter x 104'10.5" high
- capacity 1900 tons
- concrete structure (not moveable)
- overflow air slides to kiln feed silos (5 units)

3. pyroprocessing department

3.0 steel structure for pyroprocessing department building for kilns, coolers & coal grinding (1 unit)
- steel frame, metal siding

3.1 kiln feed silos (5 units) (internals only)
- concrete structure, not moveable
- size 43'4" diameter x 107'10" high
- capacity 1900 tons
- aeration blowers (5 units)
- silo withdrawal air slides (2 units)

3.2 kiln feed system (2 units)
- fuller pump & compressor, 50-125 mtph

3.3 cyclone preheater & steel structure for same (2 units)
- 4 stage
- capacity 2000 mtpd

3.4 kiln induced draft fans (2 units)
- 233,000 acfm

3.5 rotary kiln
- 4.6m dia. x 73.8m fuller rotary kiln with 3 tire stations ( 2 units)

3.6 reciprocating grate coolers (2 units)
- fuller type 7105-9218/1132
- capacity 2000 mtpd

3.7 clinker drag conveyors (2 units)
- capacity 75 mtph

3.8 gravel bed filters (2 units)
- complete with i.d fans, 174,150 acfm, 1250hp

3.9 vertical coal mills (2 units)
- 3-roller type
- capacity 15 mtph
- 220kw 3/50/2400v

4. miscellanies

4.1 boilers kewanee, (3 units)
-rating: 3348 mbh, 100 hp
-max working pressure steam: 150 psi
-heating surface: 500 sq ft
-max firring rate: 4185 mbh
-valve capacity: 4000 lb/hr

gas oil burner: (2 units, only)
-blower: 3 hp, 8,6 amp
-compressor: 2 hp, 8,8 amp
-oil pump: ¼ hp, 1,4 amp
-oil heater: 4 kw, 10 amp

4.2 sub-stations

4.3 overhead cranes, capacity of each: (total 5 units)

-4.3.1 overhead crane 25 ton (1 unit) (2q-2001-01)
-bridge 2 hp, 1000 rpm
-hoist 12,5 hp – 1500 rpm
-trolley 1,25 hp – 1500 rpm

4.3.2 overhead crane 10 ton (1 unit) (2q-2103-01)
-br