15 PLANT ASSESSMENT DATA LIST Plant Date 1. General 1 Property map 2 Land title 3 Surrounding land use 4 Plant lay-out 5 Plant age 6 Space & scope for expansion 7 Foundation condi earthquake zone 8 Regulatory agencies & permits 9 Process flow 10 Rainfall 11 Temperature high/low 12 Paving 13 Housekeeping 14 Insurance 15 Power supply 16 Power tariff on/off peak 17 Emergency generator Cement Plant Operations Handbook © 193 ao) | PS Pa = Ba a) 7) au a 2) = mm = | =) Pd C 4) pe18 Water source, consumption & cost 19 Fuel source & cost 20 Availability of waste materials 21 Cement market & seasonal variation 2. Administration & Commercial 1 Manufacturing costs by area & natural expense 2 Manufacturing cost by cement type (bulk/sack) 3 Price by cement type (bulk/sack); price trends; price regulation 4 Data processing 5 Employee numbers (including permanent contract labour) 6 Organisation chart 7 Employee benefits/housing/transport 8 Safety records 9 Purchase procedure, local/import 10 Warehouse value 11 Capital investments approved or planned 3. Quarry 1 Materials type 2 Limestone blasting/ripping, loading, hauling 3 Limestone crushing 194 » Cement Plant Operations Handbook4 Limestone reserves 5 Clay mining, transporting Gdayreseves—‘“—s‘“‘“‘sS™S”S”S”SSSSCSCS 7 Bought in materials 8 Preblend type, ratio, capacity 9 Mobile equipment type, capacity, age, condition 10 Mine planning 4. Drying 1 Raw materials moisture by month 2 Drying method 5. Raw Milling 1 Raw materials storage capacity 2 Mill type & dimensions, rated/absorbed kW 3 Separator type 4 Mill capacity, rated/actual 5 Mill kWh/t 6 Feed & product fineness 7 Discharge conveyor a) ae Pm Pa = > n a) ga WV i) = Pri = om \=) a Ba ae 4 aml 6. Blending 1 Silo type, dimensions, capacities Cement Plant Operations Handbook ° 1952 Blending ratio 3 kWhit 4 Discharge conveying 7. Kiln 1 Kiln feed conveying & metering 2 Kiln type & dimensions 3 Kiln capacity, rated/actual 4 Run factor & downtime analysis 5 Kiln seals, tyre and shell condition 6 Kiln gas analysis 7 Kiln brick life & consumption (kg/t) 8 Kiln roof 9 Precalciner/kiln fuel split, tertiary take-off location 10 Preheater pressure drop 11 Preheater efficiency (dust loss), kiln feed: clinker factor 12 Kiln rings, preheater build-up 13 ID fan build-up 14 Bypass 15 Cooler type & dimensions, clinker breaker 16 Clinker discharge temperature 17 Coal mill/raw mill/tertiary take-off locations 196 * Cement Plant Operations Handbook18 kcal/kg clinker 19 Auxiliary drive 20 Preheater discharge temperature, conditioning tower, kiln de-rating with raw mill down 8. Fuel ‘TFueltypesincludingwastefuels 2Startupack-upful 4Coalproximateanalsis SCoalmilltype&capaty 6 Coal fineness 9. Clinker 1 Clinker conveying from cooler 2 Clinker types 3 Storage capacity covered/outside 10. Finish Mill 1 Mill type & dimensions; rated/absorbed kW 2 Mill capacity rated/actual 3 Mill KWhit 4 Separator type Cement Plant Operations Handbook * 197 "~U e P= ea om > va "A mm 2) 4) = un) = = > a > cs ”n pa5 Product fineness 6 Gypsum type & purity ee eer ee ee 7 Grinding aid 8 Cement discharge temperature 9 Cement conveying 11. Cement 1 Cement types 2 Silo capacity 12. Quality Control 1 Cement specifications 2 Analytical methods 3 Physical test methods 4 Release age 5 Laboratory equipment 6 Quality control sampling methods and frequencies 13. Packing & Distribution 1 Shipment by month 2 Shipment % bulk vs bag 3 Distribution by road, rail, water 4 Point of sale; distribution by plant/customer/contractor 198 * Cement Plant Operations Handbook5 Cement temperature at load-out 6 Packers 7 Bag type, bag weight, bag breakage, palletising 14. Dust Collectors 1 Types 2 Capacity & con 15. Maintenance tPMschedule 2 Predictive maintenance BShopfadliies |. 4 Availability of cranes, machining & motor rewinding 5 Maintenance man hours planned vs break-down, 16, Process 1 kcal/kg total & non-kiln 2 kWh/t total 3 Process engineering resources & records 4 Equipment redundancy is © | fo P= Pa a > — A) a a) A) = mi = =_| \~] ea Be a vA pa 5 Plant bottlenecks 6 Emission limits, dust 7 Emission limits, NOx, SOz, CO, ete Cement Plant Operations Handbook * 19917. Materials Analyses 1 Raw materials 2 Mix design (reconcile with annual consumptions of raw materials) 3 Gypsum (mineral/synthetic) 4 Clinker 5 Cement 6 Cement test certificates 7 Variation - raw materials, pre-blend, raw mill product, kiln feed, cement 18. Plant Capacity Summary Crushing —__tH Raw Milling Coal Milling Kiln Finish Milling Packing Load-out t Days usage Storage capacity of limestone available to raw mill Storage capacity of clay available to raw mill Storage capacities of other raw materials Storage capacity of blending/kiln feed silos Storage capacity of clinker (excluding outside) Storage capacity of cement 200 ¢ Cement Plant Operations Handbook