tula presentation

TULACEMENT LLC“TulaCement” Limited Liability Company

Tula Cement Plant Project

5000 TPD

CEMENT PRODUCTION PLANT


HeidelbergCement supplement product range with downstream activities such as ready-mixed concrete, concrete products and concrete elements, as well as other related products and services. The core activities of HeidelbergCement include the production and distribution of cement and aggregates, the two essential raw materials for concrete.

In 2008, Group turnover amounted to approximately EUR 14 billion and the Group share of profit reached EUR 1.8 billion.

Around 61,000 employees in more than 2,700 locations make sure on a daily basis that our slogan ”for better building“ is brought to life.

HeidelbergCement

In around 50 countries across the world, the name HeidelbergCement stands for competency and quality.

HeidelbergCement is the global market leader in aggregates and a prominent player in the fields of cement, concrete and other downstream activities, making it one of the world’s largest manufacturers of building materials.


Responsibility for the environment

HeidelbergCement takes its responsibility for the environment seriously. Environmental protection is a central part of our strategy of sustainability. In this regard, climate protection and conservation of resources are our predominant goals. HeidelbergCement is a member of the World Business Council for Sustainable Development (WBCSD) and has committed itself to sustainable cement production. We use natural resources responsibly and our goal is to lower the specific CO2 emission levels of 1990 by 15% by the year 2010. To reach this goal, production procedures are optimised continuously and the use of alternative raw materials and fuels is intensified.

Environmental policy

We endeavour to make a positive contribution to the environment through our products and our land and marine management programmes. We are also committed to the principle of continual improvement in environmental performance, and to the prevention of pollution.

Our environmental policy is to:

comply with all applicable legislation and regulations and to develop and embrace best practice initiatives

monitor, evaluate and continually improve environmental performance through the adoption of comprehensive environmental management systems

respond to the needs and concerns of local communities and their environment

strive towards sustainability, balancing today’s needs with those of the future

improve employee awareness of environmental issues and encourage the sharing of experience and expertise


Environmental values

We recognise that our sites are important to the local community and can provide an environmental asset throughout their operation and afterwards. By careful management and working with stakeholders, we seek to maximise these benefits.

In addition:

we strive to protect and, where possible, enhance the environment around our sites

we plan and implement effective working and restoration of our quarrying operations to ensure sustainable after-use

we work to enhance biodiversity and geodiversity where possible throughout our operations

we support the use of our sites for educational purposes and in particular environmental education

We seek to enhance the benefits to society of using natural resources by:

making effective use of all our mineral resources

using secondary and recycled materials whenever it is economic and technically feasible

monitoring and seeking to reduce energy and water consumption

Sustainability

Our health and safety and environmental policies are underpinned by a commitment to the principles of sustainable development. Building materials are essential to achieving a sustainable society. We supply materials for a wide range of uses including transport, infrastructure, water treatment facilities, housing, schools and hospitals.

We invest in modern technology for processing and manufacturing to improve efficiency and resource conservation. This, together with new designs and material specifications, plays an essential part in delivering our commitment to continual improvement.


Occupational health and safety

Our commitment to occupational health and safety is an integral part of all our business activities and a focal point of our sustainability strategy. With a Group guideline for occupational health and safety, we are establishing our high standards across the Group. We are working continuously to improve occupational health and safety throughout the Group.

Our objective is to minimise the risk of accidents and injury, as well as the risks of occupational illness, by means of increased preventive measures. We improve our high standard in occupational health and safety even further by means of training and technical measures. Many plants have developed management systems for occupational health and safety. We have established an expert group at Group level comprising members from all regions to tackle this topic. The focal areas are the exchange of knowledge concerning accidents, measures to prevent accidents and the circulation of best practice examples.

Occupational Health & Safety Policy

We take our social responsibility seriously as we are convinced that a corporate culture based

on employee-orientation and partnership will lead to the long-term success of HeidelbergCement.

Therefore our commitment to occupational Health & Safety (H&S) is an integral part of all our

business activities. We are continually working to improve our occupational Health & Safety

performance throughout our Group.

We strive for zero risk of accidents, injuries and occupational illnesses by emphasizing prevention.

The Managing Board of HeidelbergCement has developed this policy to cover key roles and

responsibilities and to describe main processes, tools, and key performance indicators.

However, it is the responsibility and duty of each and every person to take care of Health & Safety measures, to follow all relevant rules, regulations and work instructions and to use appropriate personal protective equipment as required by applicable law.


THE CEMENT MANUFACTURING PROCESSAll over the world, cement is one of the most important building materials.Whether for houses, bridges or tunnels, we cannot imagine our modern world without it. Join us for a short tour to experience how cement is made: starting with the extraction of raw materials and ending with the finished product.

TULACEMENT LLC“TulaCement” Limited Liability Company THE CEMENT MANUFACTURING PROCESS

BLASTING : The most important raw materials for making cement are limestone, clay and marl. These are extracted from quarries by blasting or by ripping using heavy machinery.

TRANSPORT : Wheel loaders and dumper trucks transport the raw materials to the crushing installations.

CRUSHING AND TRANSPORTATION : There the rock is broken down to roughly the size used in road metalling. The raw materials, after crushing, are transported to the plant by conveyor.

Quarry face

1. BLASTING 2. TRANSPORT

Quarry

3. CRUSHING & TRANSPORTATION

crushing

conveyor

dumper

storage at the plant

loader


STORE AND HOMOGENISATION : The crushed material is transported into the raw material storage of the cement plant by conveyor-belts, cableways or railways and also in exceptional cases with trucks. Once there it is stored in blending beds and homogenised.

RAW GRINDING : The desired raw mix of crushed raw material and the additional components required for the type of cement, e.g. silica sand and iron ore, is prepared using metering devices. Roller grinding mills grind the mixture to a fine powder at the same time as drying it, before it is conveyed to the raw meal silos for further homogenisation.

BURNING : The burning of the raw meal at approx. 1,450°C is carried out in preheater kilns that work by varying methods, the main difference being in the preparation and preheating of the kiln feed. By chemical conversion, a process known as sintering, a new product is formed: clinker. After burning, the clinker is cooled down with air fans.

Raw grinding and burning

1. RAW GRINDING

2. BURNING

conveyor Raw mix

kiln

cooling

preheating

clinker

storage at the plant

Raw mill

THE CEMENT MANUFACTURING PROCESS


GRINDING : After burning, the clinker is cooled down and stored in clinker silos. From there the clinker is conveyed to ball mills or roller presses, in which it is ground down to very fine cement, with the addition of gypsum and anhydrite, as well as other additives, depending on the use to which the cement is to be put.

STORAGE, PACKING, DISPATCH : The finished cement is stored in separate silos, depending on type and strength class. From there it is mainly loaded in bulk form from terminals onto rail or road vehicles as well as onto ships. Only a small proportion of the cement reaches the customer in the form of bags that have been filled by rotary packers and stacked by automatic palletising systems.

Grinding, storage, packing, dispatch

1. GRINDING

2. STORAGE, PACKING, DISPATCH

clinker storage

Gypsum and the secondary additives are added to the clinker.

silos

dispatch

bags

Finish grinding

THE CEMENT MANUFACTURING PROCESS


HeidelbergCement entered the Russian market in 2001 by the acquisition of the Cesla cement plant in the St. Petersburg area in Northwest Russia.

In 2006 HeidelbergCement acquired a majority stake in the aggregates and precast concrete manufacturer Gurovo Beton located in the Tula region south of Moscow. At this location a new cement plant is currently being built with a production capacity of 2 million tonnes. This plant will supply the greater Moscow region, Russia’s biggest cement market.


LIMESTONE & CLAY CRUSHER

CAPACITY: 1.200 t/h

The max. product size of the primary crusher will be 90 mm with 97% being below 75 mm under all working conditions.

Central dedusting and compressed air system will be included.

LIMESTONE & CLAY CRUSHER HeidelbergCement – Canakkale/Turkey


RAW MATERIAL CIRCULAR STORAGE

CAPACITY: 42.000 t

D: 98 m. H: 33 m.

The storage will provide weather proof cover. Designed by environmentally friendly.

RAW MATERIAL CIRCULAR STORAGE

HeidelbergCement – Canakkale/Turkey


RAW MEAL COMPONENT DOSING

38 * 12 * H:50 m.

LIMESTONE&CLAY CAPACITY : 800 t

STANDBY CAPACITY : 250 t

HG LIMESTONE CAPACITY : 250 t

IRON ORE CAPACITY : 250 t

Each silo shall include dedusting to central filter systems.

RAW MEAL COMPONENT DOSING



RAW MILL GRINDING

CAPACITY: 380 t/h

The mill building shall provide weather protection and reduce noise emissions as far as required.

Foundation for the mill shall consider the special requirements of sub soil conditions. The mill will create a wide frequency range of vibration with peaks in lower frequencies. These frequencies are transmitted by the existing soil conditions over long distances and can activate buildings, equipment or instrumentation to unacceptable vibrations.

RAW MILL GRINDING



PROCESS FILTER

CAPACITY: 1.230.000 m3/h

The process filter will be a bag filter. Gas/cloth ratio ≤ 1 m3/m2 minute. Special care will be taken to avoid condensation of water or acid-water on clean gas side. Clean gas temperature will not be less than 25°C above SO3-dewpoint.

Compressed air system will be provided for the filter separately.

PROCESS FILTER



COAL MILL GRINDING

MILL CAPACITY: 35 t/h

53 * 18 * H: 35 m.

COAL BIN CAP: 170 t

PULV COAL BIN: 350 m3

The mill building shall provide weather protection and reduce noise emissions as far as required.

COAL MILL GRINDING



RAW MEAL HOMOGENEZING SILO

CAPACITY: 12.500 t

D: 22.5 H: 60 m. (47-60)

RAW MEAL HOMOGENEZING SILO



COAL IRON HG LMESTONE GYPUSM SLAG STORAGE

COAL CAPACITY : 12.400 t

IRON ORE CAPACITY : 5.000 t

HG LIMESTONE CAPACITY : 4.000 t

GYPSUM CAPACITY : 6.000 t

SLAG CAPACITY : 7.300 t

37 * 310 * H:21 m. (7-15-21)

COAL IRON HG LMESTONE GYPUSM SLAG STORAGE



COOLING TOWER

CAPACITY: 930.000 m3/h

The arrangement of cooling tower will be after the preheater fan.

The conventional spillback nozzles will be provided.

COOLING TOWER



PREHEATER AND CALCINER

CAPACITY: 5.000 t/day

16 * 25 * H:92 m.

PREHEATER AND CALCINER



KILN


Ø:5 L:72

KILN



CLINKER COOLER


Target for the cooler is to recuperate as much as possible heat from the clinker and to cool down the clinker to 65 °C above ambient temperature for all size of clinker.

CLINKER COOLER



CLINKER STORAGE

CAPACITY: 125.000 ton

D:60 H: 65m (30-65)

OFF SPEC. CLINKER STORAGE

CAPACITY: 1.500 t

D:12 H:42 (25-42)

CLINKER STORAGE



CEMENT MILL & CEMENT SILOS

GRINDING CAPACITY: 3*110 = 330 t/h

54 * 39 * H: 37 m.

CEMENT SILOS CAPACITY: 4*15.000 = 60.000 t

4*Ø: 22.5 H: 56 m. (45-56)CEMENT MILL



TERMINAL AREA

Cement Packing & Packing Cement Dispatch (Truck)CAPACITY: 2.400 bags/h

Cement Packing & Packing Cement Dispatch (Truck)CAPACITY: 4*300 = 1.200 t

Cement Silos Reloading CAPACITY: 2*1.800 = 3.600 t

Cement Silos & Bulk Cement Dispatch (Train) CAPACITY: 2*1.800 = 3.600 t

Gypsum Crushing CAPACITY: 200 t/h

Coal,iron Ore,and Hg Unloading CAPACITY: 1.000 t/h


Thanks for Your Attentions.Ali Osman ParlakProject Manager

Lean is TEAM WORK.Not something somebody can do alone…

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