Stateoftheart White Cement production:

two production lines of 1500 tpd clinker each

at Sinai White Cement.
CEMTECH - Dubai, March 6th 2011

www.sinaiwhitecement.com

INDEX

INDEX OF THE PRESENTATION

1.Cementir Holding & Sinai White Cement
2.Sinai White Cement Social Responsibility
3.White Cement Applications
4.White Cement Market Overview
5.Sinai White Cement Total Quality System
6.Plant Technical Overview
7.Second Production Line Project: Capacity doubling

P. Bossi

Cementir Holding

Cementir Holding Organization Structure

P. Bossi

Cementir Holding

CEMENTIR HOLDING
Manufactures and distributes white and grey cement, aggregates, ready-mix
concrete and concrete products in many countries worldwide.
Has operations in 13 countries;
20 cement production and concrete production plants of which 4 in Italy, 4
in Turkey, 1 in Denmark, 5 in Portugal (JV CRH), 1 in Egypt, 3 in the USA (2 JV
Heidelberg and Cemex), 1 in China and 1 in Malaysia
110 ready-mix concrete plants of which 6 in Italy, 90 in Scandinavia and 14
in Turkey

P. Bossi

Group Overview

Cementir Holding operates production plants in 13 countries ~ 15 mt of

cement capacity; 3.1 m of Rmc and 4.1 m of aggregates

DENMARK - SCANDINAVIA
Grey cement capacity: 2,100,000 t
White cement capacity: 850,000 t
RMC sales: 1,800,000 m3
Aggregates sales: 4,100,000 m3
Terminals: 9
TURKEY
Grey cement capacity: 5,400,000 t
RMC sales: 12400,000 m3
ITALY
Grey cement capacity: 4,300,000 t
RMC sales: 120,000 m3
Terminals: 3

EGYPT
White cement capacity: 1,100,000 t

PORTUGAL
Cement products plants: 5 ***

USA
White cement capacity: 260,000 t *
Cement products plants: 1
Terminals: 1

ICELAND
Terminals: 1

MALAYSIA
White cement capacity: 200,000 t

POLAND
Terminals: 1
THE NETHERLANDS
Terminals: 1

CHINA
White cement capacity: 500,000 t **

*In JV with Heidelberg and Cemex (Cementir Holding holds a 24,5% stake)
** Incremental 500,000 tons from Q1 2010
*** In JV at 50% with Secil

Cementir Holding

P. Bossi

Cementir Holding, through its subsidiary Aalborg Portland, is:

- world leader in white cement (1 producer in Denmark, Egypt,
Malaysia and China)
-1st cement producer in Denmark
-1st ready mix concrete producer in Scandinavia
-2nd cement producer in Scandinavia
Cementir Holding has also the following competitive positions :
- 3rd cement and ready-mix producer in Turkey (Cimentas)
- 4th cement and ready-mix producer in Italy (Cementir)
The Product portfoglio breakdown is: cement 64%, ready-mix and
aggregates 32%, other 4%.

P. Bossi

Cementir Holding

Cementir Holding, through Aalborg Portland Group, has the

global leadership with more than 3 m tons of production capacity.
6760

4450
4025

3750

1595 1995

2160
North America

1861
China

Europe
Middle East

50

1285

1288

South / North Asia

(excl. China)

65

Carribean

1610

650

1411

Africa

398

955

457

East Asia

Latin America

0 0

37

Oceania**

Global capacity *

: 19,515,000 t

Global consumption * : 15,287,000 t

- White cement is a niche product sold globally

- Global white demand has grown around 5-6% in the last 10 years
- White cement capacity tends to be inland, less subject to imports and raw materials scarcity limits new
capacity additions
- White cement is used mainly for decoration and repairs and maintenance work

* Source: Cementir Holding estimates

** The white cement produced in Oceania contains so much iron that the whiteness does not exceed 90%
(called off-white), so that it is not included

Cementir Holding

P. Bossi

R&D
2 state-of-the-art research and development centers
in Italy and in Denmark
SWC like all the other companies of the group enjoy the
technical and quality support, with more than 50 years
experience, of Cementir in Italy (Rome ) and of Aalborg in
Denmark

P. Bossi

SWC Corporate

SINAI WHITE CEMENT CO.

SWC was incorporated in 1999
The Plant was established in the Sinai Peninsula
approx. 50km from the city of Al Arish
SWC entered in the market with its first bag of
white cement in November 2001 when the plant
started production with a capacity of 410,000 MT
of clinker per year.
In 2004 Cementir Holding, became owner of
Aalborg Portland Group and took over the
management of SWC purchasing 57% of
company shares.
P. Bossi

SWC Corporate

10

SWC Shareholder Composition:

Aalborg Portland : 57%
Sinai Grey : 24%
IFU : 14%
Sama Group : 4%
Dr. Hassan Kamel Rateb : 1%

P. Bossi

Social Responsibility

11

Environmental
SWC

complies

with

European

energy

and

environmental

requirements: in the plant all equipments in both kilns meets the

international environmental and safety standards.
The plant has converted from the use of oil to gas as primary fuel
The company has implemented an environmental reporting system and
participates in the online environmental monitoring system that allows
the central authorities to supervise plant operation and emissions

P. Bossi

Social Responsibility

12

Social & Economic

Through creation of jobs and support for local initiatives the company has a
significant positive social and economic impact in this area.
To support the local economy, SWC uses local contractors and companies to
transport all type of materials
SWC contributed in the creation of a police station, a mosque and a new village
in the desert improving the quality of the life in the area
SWC is committed in the increase of the level of the education in the area by
supporting construction of schools and by providing scholarships in the local
university

P. Bossi

Product - Applications

Tiles & Terrazzo

Precast Concrete

Dry Mix

Artificial Stones

13

P. Bossi

Product - Applications

Bricks & Blocks

Ready Mix

14

Concrete Structures

Interlock Blocks
P. Bossi

Product - Applications

15

Finishing works

GRC

Outdoor Art

Mortar
P. Bossi

Products

16

SWC Cement Production Types

Type
EN 197-1-CEM I 52.5 N
EN 197-1-CEM II/B-LL 42.5 N
EN 197-1- CEM II/A-LL 52.5 N
EN 197-1-CEM I- 42,5 Dark White

P. Bossi

Products - Brands
Domestic Market Brands:

17

White Portland Cement

New Sinai

Sinai Super White

P. Bossi

Products - Brands

18

Export Market Brands:

Aalborg White Cement -CEMI

Aalborg White Cement -CEMII

Sinai White Portland Cement CEMII

Aalborg Jumbo White

P. Bossi

Sales Overview

19

Export
SWC is exporting white cement of premium quality to 28 countries and has
existing markets located in the Middle East, Africa, Asia and Europe.
SWC always adapts to meet the ongoing changing needs of its customers
and provide individually customized solutions.
SWC created a successful relationship in the international business
environment.
SWC offers client care services through Commercial support (payment
terms/short lead time of production), Logistical support (shipping/just-intime delivery) and Technical support (use of products/ quality of products)

P. Bossi

Sales Overview

20

SWC
exports
to 28
countries
around
the world

P. Bossi

10

Sales Overview

21

Egypt Domestic Market

The Egyptian market has been growing over the last 5 years, on the
back of the high activity experienced in the construction and real
estate sectors. Egypts cement consumption has been growing at
a CAGR of 6% over the past 40 years although most of the world
markets were in crisis and this is seen to continue for the future.
It is expected that the Egyptian market will consume 450.000 tons
during the year 2011.
Sinai White Cement is covering all the governorates of Egypt for
its high quality and its economic value.
P. Bossi

Sales Overview

22

Sinai White Cement stabilized at 60% domestic market share

in the last two years.
500000
450000
400000
350000
300000
250000

Market Capacity

200000
150000
100000
50000
0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

P. Bossi

11

Products - Logistics

23

Packing:
SWC provides several choices of packing for its customers that include:
25 / 50 Kg bags
Sling bags
Jumbo bags
Shrink Wrap
Containers
Bulk
SWC takes pride in its packing quality and as such can offer 'Shrink Wrapping' as an outstanding
method protecting its products from various harsh weather conditions.

Delivery (for export market):

Main Ports:
1. El Arish: Bulk and all type of bags
2. Port Said: Containers and all type of bags
3. El Sokhna: Containers and all type of bags
4. Adabey: General Cargo and all type of bags
5. Alexandria: Containers and all type of bags

P. Bossi

Quality

24

Situated near some of the purest raw material sources in the world,
SWC plant was designed to deliver products with highest strengths and
maximum performance.
The high product quality of SWC is monitored by a comprehensive and
well-proven quality control system that covers every facet starting
from raw materials and process phases to finished products.
Modern technology and computerized controlling are vital elements
in the quality control system, in accordance with EN 197.
The unique raw materials and advanced production technology that was
developed over many decades made the foundation on which SWC has
won worldwide acclaim for its superior quality

P. Bossi

12

Quality

25

Production Technology
Aalborg Technical Centre have developed several methods for
modelling clinker burning and cement grinding.
Equipment includes several laboratory furnaces for small scale
burning of cement clinker for burnability testing, clinker reactivity,
the distribution of minor components and their impact on
performance and colour.
Laboratory grinding of the clinker to test the cement
performance is also performed where full scale production trials
are deemed too costly.

P. Bossi

Quality

26

SWC Products Main Certification

EGYPTIAN STANDARDS
ES : 4756 1 / 2009
EUROPEAN STANDARDS
EN 197 1 : 2000

P. Bossi

13

Quality

27

Cement testing is routinely performed according to the

relevant EN standards
The following properties
are tested:
Compressive strength
Water demand
Setting time
Fineness (Blaine)
Mortar expansion
Chemical composition
Particle size distribution
Cement colour
Water soluble Chromium

Chemical analysis:
In addition to the standardized
testing of cement, water, fuels, raw
materials
and
intermediate
products
in
production
are
analysed on a regular basis.
These analyses include particle size
distributions, chemical analyses,
heat values of alternative fuels and
raw materials, etc.

P. Bossi

Quality

28

Domestic Certification Body:

Egyptian Organization for Standardization

and Quality

P. Bossi

14

Quality

29

Foreign Certification Bodies

MATERILPRTIFUNGSANASTALT
BERLIN GERMANY

LGAI TECHNOLOGICAL CENTER

BARCELONA SPAIN

P. Bossi

Quality

30

Foreign Certification Bodies

Russian Certification: Sanitary-Epidemiological Conclusion

Certificate for the AAlborg White Portland white cement issued
by Department of Federal Service for Supervision in the Sphere of
Protection of Consumer Rights and Human Welfare.
P. Bossi

15

Plant Overview

31

Plant Data
Plant Design Specifications

Units

Designer

Line I

Line II

FLS

FLS

Annual capacity design /

actual

t/y

440,000 /
500,000

440,000 /
500,000

Clinker capacity design /

actual

t/d

1300 /
1500

1300 /
1500

Heat consumption

kcal/kg ck

1,270

1250

H. Oil / Natural Gas

H. Oil / Natural Gas

kcal/kg fuel

9,600

9,600

kcal/Nm3

8,700

8,700

Type of fuels
Fuel oil

LCV

Natural gas LCV

P. Bossi

Plant Overview

32

Raw Material Conveyor

P. Bossi

16

Plant Overview

33

Raw Materials
Raw Materials

Sources

Supplier

High Grade Limestone

SWC quarry

Kaolin

South Sinai Kaolin

ASCOM
ASCOM

Sand

South Sinai White Sand

ASCOM

CaF2

Imported from Iran

Golden triangle

Raw Mix design

Raw Materials Percentages

Units

Value

High Grade Limestone

81.00

White Sand

12.00

Kaolin

6.00

CaF2

P. Bossi

Plant Overview

34

Limestone Storage

Limestone storage

Units

One Silo for Each Line

Sinai

Capacity

ton

7,000

Total Capacity

ton

14,000

Silo

P. Bossi

17

Plant Overview

35

Raw Mill feeding

Hoppers
Capacity,
ton

Raw Mill Hoppers for Each Line

Units

Limestone Silo

Ton

7000

Kaolin Hopper

Ton

140

Additive Hopper

Ton

170

Sand Slurry Turbo Mixer

m3

20

P. Bossi

Plant Overview
4 Sand Mills Two per Line

Units

Type

36

Value
Slurry Mill

Sand Mill

Open Circuit
No. of Compartment

Type of Discharge
Type of lining
The Mill Drive

1
End
Rubber

KW

Type of Grinding Media

700
Flint Pebbles

S. P. Consumption

KWh/t

Charge Diameters

mm

63
32 to 16

No. of Mills

Capacity / Mill

t/h

2
5

of the Mill

2.9

Length of the Mill

16

Fineness on 45

3 Wet Sieve

Water Added

45-55

Ground Sand Tank Capacity

ton

30 ton

P. Bossi

18

Plant Overview

37

2 Raw Mills (ATOX)

Raw Mill

Units

Type

Value
ATOX 25 Vertical Mill

No. of Rollers

Production rate

t/h

3 rollers
90

Mill Drive Power

KW

600
3

Wear Rate

gm/t

Fineness on 90

Grind-ability Power

KWh/t

The Classifier

RAR 30, SEPAX Type

The Mill Exhaust Gas Fan

KW

Moisture in Raw Materials

1000
6

Kiln Exhaust Gases For

Drying

58 to 60

Dust emission from the

Stack

mg/Nm3

50 (Wet)

P. Bossi

Plant Overview

38

2 Pre-heater Towers

Pre-heater

Units

Value

No. of Stages

No. of Strings

Type of Cyclones

FLS Low Pressure

Diameter of Cyclones
C1

4.60

C2

4.60

C3

4.60

C4

4.60

P. Bossi

19

Plant Overview

39

2 Kilns
Kiln

Units

Value

Diameter

3.75

Length

57

No. of supports

Kiln Drive

KW

132

Kiln Inclination

Kiln Speed

rpm

3.6

Kiln Volume

m3

515

Kiln Load

t ck/24 h/m2

1.9

Cross section thermal Load

G.cal/m2.h

3.9

L/D ratio inside Lining

17

Capacity : Design / Actual

TPD

1300/1500

Heat Consumption

kcal/kg ck

1270

P. Bossi

Plant Overview

40

Clinker Coolers
Line 1 Cooler

Line 2 Cooler

Type

Grate Cooler Folax

# of Grates

# of cooling Fans

Area
Grate Load

m2

39.9
2

t/m .24h

25.06

Speed

3 to 30 stroke/min

Crusher

Hammer crusher at
cooler exit

Cooler De-dusting

Hot EP , 50 mg/Nm3

Type
Diameter

FLS Rotary Cooler

3.95

Speed

6 rpm

Length

10

Crusher

Crusher at cooler exit

De-dusting

Hot EP 50mg/Nm3

Clinker Quenching is in the Kiln on Line 1

Clinker Quenching is in the Cooler on Line 2

P. Bossi

20

Plant Overview

41

Clinker Storage Silos

Ck Storage
Type

Units
Concrete

Line 1

Value
Silo
1 Silo

Line 2

2 Silos

Diameter

Height

35

ton

20000 ea.

Capacity
Withdrawal
Total Capacity

20

2 conveyors per silo

ton

60000 tons

P. Bossi

Plant Overview

42

Cement Mill Feed Hoppers

Hoppers
Capacity, ton

Mill Hoppers

Units

Clinker

m3

100

Gypsum

m3

50

Additive

m3

50

P. Bossi

21

Plant Overview

43

Cement Mill
Unit
s

Cement Mill
Type

Value
FLS UMS 42x 14.5

No. of Mills

Capacity Des./Actual

t/h

80 / 90

Mill Diameter

4.1

Mill Length

14.50

No. of compartment

Power

KW

3579

Mill Charge

mm

80 to 15

Dynamic Separator
Type

UMS 2 compartment mill

SEPAX 335M-222

P. Bossi

Plant Overview

44

Cement Storage
Cement silos

Units

Supplier

Value
FLS

Number of silos

Internal diameter

17

Internal height

39.5 / 35 Effective

Capacity

ton

10,000ea.

Total capacity

ton

20,000

Steel Silo
Capacity
Total Capacity

Units
ton

Value
2,500
22,500

P. Bossi

22

Plant Overview

45

Packing and Dispatch Area

Packing

Units

Paper Bags

Value
bags

Type

VENTOMATIC

Number of packing machine

Number of spouts/machine

Capacity of each machine

t/day

2400

Jumbo Bags

t/day

To Truck or Palletizer (sling Bags)

Type

500
FLS

Number of Packing Machine

Bag Mass

ton

1.5

t/day

800

t/day

2400

Sent to Truck or Storage

Capacity
Ventomatic Palletless
Shrink Wrapped Cubes

P. Bossi

Dispatch Overview

46

Final Product

P. Bossi

23

Line II Project

47

2006
Decision to build the second line
The production of the plant was fully utilized in 2006 and the
future growth in the demand of the high quality products locally
and on the export markets required further capacity.

P. Bossi

Line II Project

48

The Quarry & Raw Material

SWC is situated near some of the purest

raw material sources in the world.
The viable raw material sources exist in the
quarry owned by SWC for more than 100
Years production (with double capacity: 1,2
million tpy).
P. Bossi

24

Line II Project

49

Available Operation & Maintenance Experience

The experience of operating line no. 1 has been successfully
achieved with ASEC as Maintenance & Operations Contractor
and ASCOM as quarry-contractor.

P. Bossi

Line II Project

50

Several auxiliary building were already available as workshop,

control room, laboratory, main substation, canteen, dressing room,
and the packing plant were already extended.

P. Bossi

25

Line II Project

51

Based on:
1. Growth in the demand
2. Availability of appropriate raw materials of sufficient
quantity and quality owned by company.
The Board of Directors of SWC decided to complete a feasibility
study for an expansion of the SWC Plant with the aim of doubling
plant capacity from 600,000 tones to 1,200,000 tons white
cement.

P. Bossi

Line II Project

52

Type Of Contract For Line II - Alternatives

Line 1 was built in 1999 with a Turnkey Contract (TC) with FLS/ASEC and the
preferred solution for the second line was again a TC-solution.
3 TC bids were obtained, but all of them were over the expected budget and
this was considered to be the contractors contingencies for their risk in a TC.
Based on this it was decided to pursue a self managed execution of the project
The first step was to select a project management company and RHI was
selected due to their cement experience and knowledge of the Egyptian
contractors.

P. Bossi

26

Line II Project

53

Risk Of A Self Managed Contract

The risk with a self managed contract compared to a TC is the
management of the different contractors who will be involved
in the project, and who only will be responsible for their own
contract.
To minimize this problem it was agreed with RHI to try to split the
project up into different packages, where the contractor would be
responsible for erection and local manufactories of equipment
for their defined scope of the project.
P. Bossi

Line II Project

54

Self Managed VS Turnkey Contract

DISADVANTAGES
Contract negotiation with many (main) contractors (RHI,FLS, ASA
ESACO and Shotmet) instead of one.
Elaborate BID-documents to be sent to min. 3 suppliers for direct
purchase. Evaluate the received offers and placing purchase orders.
Coordination at site between the different contractors to avoid that a
eventual delay of one contractor would result in claim from another.
Monthly report of progress and budget follow-up.
ADVANTAGES
Savings of approximately 10 % compared to a Turnkey Contract.
RESULTS
All production guaranties has been achieved.

P. Bossi

27

Line II Project
Conclusion On Self Managed Contract

55

1. With a strong Project Management team is it possible to

do a Self Manage project and obtain the savings compared
to a Turnkey Contract.
2. It is important to be very critical in setting up
prequalification demand, for involved contractors and
suppliers.
3. Application of delay penalties are difficult and small, as
they are related to the contract value of a contractor and not
the whole project cost as it would have been the case in a
Turnkey Contract.
P. Bossi

Line II Project

56

SCHEDULE
Project Timeline Goals
Contract in Force 29th November 2006
Raw Mill Production 11th October 2008 (22 months)
Kiln Production 28th November 2008 (24 months)
85 % of guaranteed kiln production 28th December 2008
(25 months)

P. Bossi

28

Line II Project

57

In November 2006 contracts for the 2nd Production

Line were signed
F.L.Smidth-Design and process equipment supplies, manufactory drawings,
and inspection of local manufactures and supervision of erection and commission
(40% cost)
RHI-Project management and civil design (5% cost)
ASEC-Automation for electrical deliveries, erection and commission (11% cost)
ESACO-Civil work, local fabrication and mechanical erection (21% cost)
Shotmet- Local fabrication and mechanical erection (6% cost)
Direct purchase (by RHI) BID documents sent to min. 3 suppliers: 17% cost

P. Bossi

Line II Project

58

P. Bossi

29

Line II Project

59

P. Bossi

Line II Project

60

Environmental compliance
To achieve our high request of environmental compliance the plant is equipped
with:

1) Separate grinding mills

for sand
Wet mills for sand grinding to
avoid possible silicosis.

P. Bossi

30

Line II Project

61

2) Electrostatic Precipitators
Emission Guarantee of < 50 mg

P. Bossi

Line II Project

62

3) Baghouse Dust Collectors

Jet Pulse baghouses at transfer points

P. Bossi

31

Line II Project

63

Equipment and Capacity

Equipment

Description

Capacity

2 Sand Mills

Pebble media

6 tph

Vertical Raw Mill

Atox 25 with RAR Sepax 30

90 tph

Preheater

Four Stage FLS Low pressure

Four 4.6 m cyclones

Kiln Design / actual

FLS 3 tire, 3.75 x 57

1300 / 1500 tpd

Cooler

FLS Rotary

3.95 x 10, 6 rpm

Clinker Silos (2)

Concrete

20,000 tons

Cement Mill

FLS UMS 42 x 14.5

80 tph

Cement Silo

Concrete with Truck Loading

10,000 tons

P. Bossi

Line II Project

64

ATOX Raw Mill

Capacity of 90 tph, with 600 kw motor.

P. Bossi

32

Line II Project

65

Preheated with
Calciner

Capacity of 1500 tpd,

4-Preheater cyclones 4.6 m diameter

P. Bossi

Line II Project

66

Rotary Kiln

3 Support, 57m x 3.75m

Girth Gear Electric Drive
Design Capacity: 1300 tpd
Actual Capacity: 1500 tpd

P. Bossi

33

Line II Project

67

Rotary Cooler

10m x 3.95m

P. Bossi

Line II Project

68

Clinker Silos

Two Concrete Silos 20,000 ton

capacity per Silo

P. Bossi

34

Line II Project

69

Cement Mill

FLS UMS 42 x 14.5

3579 kw drive
Side mounted Flender Gear

P. Bossi

Line II Project

70

Cement Silo

Capacity of 10,000 tons, Truck

Loading and Withdrawal for
Packaged Products

P. Bossi

35

Line II Project

71

Completed Line

P. Bossi

Line II Project

72

Production Capacity Increase

The new line started production in October 2008
SWC became the main producer of white cement in Egypt
By the end of 2009 SWC has reached a production capacity of
1.2 Million MT of high quality white cement

P. Bossi

36

Financial Overview

73

The project was completed within the

approved budget of 90 M USD
P. Bossi

SWC Plant

74

FULL PLANT
1,000,000 TPY Clincker capacity
1,200,000 TPY Cement capacity
2 x 3800 kw cement mills
2 x Ventomatic 8 spout packing machines
1 Ventomatic jumbo bag packing machine
Ability to ship bulk white clinker

P. Bossi

37

Both Production Lines

75

P. Bossi

Cemtech Dubai, March 2011

76

THANK YOU

www.sinaiwhitecement.com
P. Bossi

38