IRANIAN WHITE CEMENT INDUSTRY

and

Summary of Iranian Cement Industry(Feb 2016)

Gray White Total

No. of Cement Plants 70 8 78

No. of cement Kilns 88 9 97

Installed Capacity for Cement(MT/Y) 81.5 1.5 83

Product of Cement (MT/Y)(2014) 69 1 70

Export of Cement(MT) (2014) 19 0.3 19.3

Per Capita Cement Consumption(2014)

700KG 11 KG -

Cement Capacity Under Installation 14 2 16

Iranian White Cement Manufactures(Feb 2016)

No Company Capacity(Ton/Year) Percentage

1 Shargh 326,000 23%

2 Saveh 315,000 22%

3 Neyriz 157,500 11%

4 Benvid 157,500 11%

5 Orumiyeh 157,500 11%

6 Larestan 135,000 9%

7 Ekbatan 120,000 8%

8 Shomal 62,000 4%

Sum 1,430,500 100%

Ghadir Investment and Industrial Development Co.(GIIDC)

SharghCement Co.

Shargh White Cement (326000 T/y)

Gray Cement Plant(2000000 T/y)

Industrial Lime Plant

Ready Mix Plant(Faravardeha)

Shargh Coal Pro.

KordestanCement Co.

DashdestanCement Co.

SepahanCement Co.

GhadirEngineering & Research Co.

Shargh White Cement Co.

Ghadir Investment and

Industrial Development

Co.(GIIDC)

has 5 Cement Plants and

Up to 7% of Iran Gray Cement Production and

More than 23% of Iran white Cement

Production

Shargh White Cement Co.

NOMINAL Capacity: 1000 Ton/Day

Number of Personnel: 157

Packing Type: 25 Kg, 40Kg, 50Kg,1.5 Ton

Address: NE 24 KM, SIMAN ROAD, KHORASAN RAZAVI, IRAN

WWW.SHARGWHITECEMENT.COM

INFO@SHARGWHITECEMENT.COM

TEL: +982188798032

Fax: +982188192605

Raw Materials in White Cement Production

The white cement is considered as one of types of Portland cement (type I) from the chemical and physical characteristics point of view. The raw material used in production of white cement is mostly limestone (80%) and kaolin (20%). A little amount of silica (around 1%) is also used, when required.

The main and important chemical factors in limestone and kaolin should be as follows:

Since both gray and white cement are manufactured in Shargh Cement Complex at the same time, we use the good quality limestone with the low MgO in production of white

cement which enables us production of high quality white cement with a super white grade.

Limestone Kaolin

CaO Fe2O3 MgO Al2O3 Fe2O3 MnO

>52 <0.15 <3 >15 <0.4 <0.01

Technology of White Cement

The technology of white cement is similar to gray cement in an overall view. The main different is cooling system of white clinker.

There are two main technologies for cooling the white clinker as follows:

1- French Technology using the quenching tank system in which the hot clinker is directly discharged from kiln into the quenching tank and submersed in the water. Then the cooled clinker will be conveyed to the dryer which will dry the clinker using the returned hot air form the heat exchanger and the clinker moisture will be reduce from 18% to 0.5%

(in the white cement process there is heat exchanger after the pre-heater which heats the fresh air up to 200˚C)

There are two kinds of Dryer:1.A) Rotary Dryer

1.B) Fluidize bed dryer which is similar to spray dryer in

ceramic industry in which the wet clinker and hot air are

fed into the dryer in a countercurrent direction.

2- FLSmidth Technology using a rotary cooler in which the hot clinker is water sprayed and in this method, there is no need to the hot air for drying the white clinker.

Each of the above technologies has its own advantages and disadvantages.

In Shargh White Cement, we use the second technology from FLSmidth.

Technology of White Cement

Heat exchanger

Rotary Cooler

Energy Consumption

Specific Heat Consumption 1250 Kcal/Kg Clinker

Fuel (Natural Gas) 160 Nm³/ton Clinker

Clinker Temp. in Kiln 1650 Centigrade

Blain surface >3850 Cm2/gr

Specific ElectricalConsumption 120 KWh/ton cement

Compress Air 42 Nm³/ton cement

Clinker Temp. Out from rotary cooler 100 Centigrade

Dust Output <30 mg/Nm3 dry

Water 0.70 m³/ton Clinker

SiO2 Al2O3 Fe2O3 CaO MgO SO3 C3S C3A LSF

22-24 4-5 <0.5 64-67 <3 <1 >53 >11 >92

SMWhiteness

(L*)Free Lime

(%)Liter Weight

>4.5 90-93 <1 >1250

Chemical & Physical Analysis White Clinker

MANUFACTURES TEST CERTIFICATEWhite Clinker – (EN 197-1:2011، ASTM C-150 ،GOST)

Chemical & Physical Analysis White Cement

SiO2 Al2O3 Fe2O3 CaO MgO SO3 C3S C3A K20+Na20

21-23 4-5 <0.5 63-65 <3 <2 >50 >10 <1

Compressive Strength(MPa)Initial Setting

Time(Min)Final Setting

Time(Min)Whiteness

(L*)Free Lime

(%)Blaine

(Cm2/gr)2- Day 7- Day 28- Day

22 --- 55 >110 150-180 90-93 <1 >4000

MANUFACTURES TEST CERTIFICATEWhite Cement– (EN 197-1:2011 ،ASTM C-150)

CEM I -52.5 N

ISO 9001 ISO 14001 OHSAS 18001

Certifications

Certifications

CE 1888 GOST GOST

Export of Cement and Clinker(Feb. 2016)

We have now the complete facilities to deliver any requirement of white cement and clinker from different clients all based on FOB and CIF at any place and any requested packing (P.P bags, Big bags, etc.).

Russia Qatar UAE

Kuwait Saudi Arabia Kazakhstan

Brazil Iraq Turkmenistan

South Africa Afghanistan Australia

seychelles Tajikistan IndiaIranian Market

60%

Export40%

Export of Cement and Clinker

Shargh White Cement

Shargh White Cement Project.

We have executed a white Cement

Project in shargh cement complex

located in north east of Iran by

which a very old gray cement line

with capacity 1200tpd has been

converted into a white cement line

with capacity 1000tpd equipped

with the state of the art

technology form FLSmidth Denmark.

Line 2(1200 tpd)1975-2012

- 2014(1000tpd White Cement)Line 2

No Activity Quantity

1 Concrete 20000 m3

2 Steel structural 2000 ton

3 Dismantling of old equipments 2000 ton

4 Local fabrication equipment 2000 ton

5 Foreign fabrication equipment 1000 ton

6 Erection of equipment 3000 ton

7 Refractory works 1250 ton

8 Insolation 1600 m2

the project was finally executed in 27 months

Project volumes

Raw Mill Department

18

RAW Mill: 1- chamber ball millD=3.8 mL=7.8 mMotor = 1350 KWMill fan: Fixed speed fan (67 KW)Output: 80 ton/hrFineness- residue on sieve 90 micron: 6%

Dismantlingold Equipment and civil structures

19

New Separator InstallationCapacity:240 t/h

20

seprator• RTKM-27.5 (placed on top of flash)

Motor• 83 KW

Separator Fan

• Variable speed fan (415KW)

Flash Dryer Installation

21

Flash: At mill inlet. Height above

feeding point (min.20 m)

D=1575 mm

Heat Exchanger Installation

22

Heat exchanger U600

Upgrading Cooling Tower from1-stage to 2-stage type

23

D=5.8 m, L=24.5 m

Pyro Department

24

Changing length of Kiln from

90m to 72m

Rotary kiln: D=4.2 m, L=72 mDrive: 278 KWOutput: 1000 ton/daySpecific heat consumption : 1300 kcal/kg clinkerLime saturation factor: 93-97Silica ratio: 4-6

Pyro Department

25

Installation of high

efficiency Rotary

Cooler

Clinker Cooler: Rotary: D=3.95 m, L=10 m

Temperature of clinker: max 120C

Whiteness of clinker: min 90

Pyro Department

26

Tire No. 2 Installation

Pyro Department

27

Installation Base two’s

Bearing and Ring

Pyro Department

28

Installing new Burner

FLSmidth Duoflex

280000 MJ/h

Diameter: 1050 mm

Longitude: 4 m

Renovation Pyro Department’s Equipment

29

Renewed Preheater ‘s

emerged Tubes

RenovationPyro Department’s Equipment

30

Replacement Babbitt

bearings and shabring of

raw and cement mill

gearboxes 's bearing

RenovationPyro Department’s Equipment

31

Replace roof cyclones

RenovationPyro Department’s Equipment

32

Installation two new cyclone according to the

FLS

Cement mill Department

33

Cement Mill: 2- chamber ball mill

D=3.8 m

L=13.37 m

Motor=2*1350 KW

Output: 60 ton/hr

Fineness of cement(Blain surface): min 3600

Cement mill Department

34

Separator: SEPAX 300M-122

Motor: 132 KW

Separator fan: Fixed speed fan (290 KW)

Install new separator

Cement mill Department

35

Install New Bag filter

Cement mill Department

36

Installation of the lime Bin

Renovation existing equipment at mill department

37

Replacement of 2 meters shell cement mill, welding and set it

38

Replacement Babbitt of

raw and cement mill

Renovation existing equipment atmill department

39

Install new liners in raw and

cement mills

Renovation existing equipment at mill department

Filtration

40

Install Main Electrostatic participator,

outlet 30 PPM

Be added cooler Electrostatic precipitator

with outlet dust 30 ppm

Renovation of existing equipmentat Packing

41

Install two H & B Packers

Thanks for your attention

Behrooz ZandiManaging Director Of Shargh Complex and

Member of the Board Shargh White Cement

Tel: +989121125818

Tel: +982188798032

Fax: +982188192605

WWW.SHARGWHITECEMENT.COM

Export@sharghwhitecement.com42