Unique Design Concrete Preheater Tower

z Preheater tower constructed of concrete with steel floors

z Concrete section 105m high (35 storey building)
z Additional 10m cyclone structure
z Footprint 25.3m by 20.4m
z 1 720 tons steel reinforcing & 9 540 m³ concrete

z 1 270 tons structural steel for floors

z Important to have ‘vertical’ aspect of preheater constructed
when preheater parts started arriving at site
z Time saving
z Only achieved by utilising concrete & sliding to a special design
z Cost effective (+7% saving compared to steel)
z Aesthetically pleasing
z Used our product
1
In-Line Calciner Plus Six-Stage Preheater

Cyclones 1-2: 6.9m diameter

Cyclones 3-6: 7.2m diameter

268oC
3 Air 2.5m diameter

Kiln 4.55m diameter x 54m Calciner 6.6m diameter x 27m 2

Pre-Heater
H2

3
Pre-Heater
H2

4
Pre-Heater
H3

5
Pre-Heater
H4

6
Pre-Heater
H5

7
Pre-Heater
H6

8
Pre-Heater
H7

9
Pre-Heater
H8

10
Pre-Heater
H9

11
Pre-Heater
H9

12
 1200 Metres of Piling Installed

1.2metre diameter piles

March 2007 13
Constructed Using 80 ton Slide Platform

14
15
Around the Clock Construction

16
17
18
19
Preheater Topped-Out After 58 Days

May 2007 20
Preheater Structure Dominates the Skyline

21
Mechanical Installation Began Immediately

June 2007 22
 Structural Steel Floor H3

Kiln Drive Installation

Kiln Pier 2

Preheater Steelwork: Level H3

23
Steel Fixing in Preheater: Level H3
24
MMC Clinker Cooler Frame
25
Kiln Shell Arriving on Site

26
 Kiln 2 Cooler ESP
Kiln 2 LT Substation

New Clinker
Return System

Burners Platform

Clinker Cooler
Kiln Pier 1

Coal Mill Building

New Kiln Shell
Sections

August 200727
Riding Ring Hoisted into Position

28
August 2007 29
30
31
32
33
34
35
Raw Mill Building: Sept 2007 36
‘Kopanelang’ Contractors Village

Feb 2006 37
Contractors Camp Catering Facilities

38
 28 New Staff Houses Built

Existing Village

New Houses

Nov 2006 39
2 Lost Time Injuries Recorded to Date

Morethan
More than22million
millionman
man
hoursworked
hours workedtotodate
date 40
 Focus on Local Community Involvement

z One of PPC’s core values:

z ‘We assist with up-liftment in communities in which we operate’
z Dwaalboom situated near three (very rural) communities
z Rate of unemployment in area >50%

z Important to ensure maximum economic spin-off from the

project into the disadvantaged Dwaalboom communities
z ‘Labour’ component comes from these areas only
z >40% of staff at site from local community
z Recruitment centre built
z Daily transport to & from home provided

z One good meal per day at site for every worker

Excellentlabour
Excellent labourrelations
relationsbetween
betweencontractors
contractors&&local
localcommunity
communityemployees
employees
41
Batsweledi in the Community

Opening of Holfontein
Pension Payout &
Recruitment Centre
(June 2006)
Jupiter Clinker Milling Facility Upgraded

Jupiter plant commissioned 1970

Mothballed in 1998 (eight years)

Used as bag/bulk cement depot

43
 Upgrade Programme at Jupiter

z Environmental Issues Addressed

z Enclosed & de-dusted clinker store
z Enclosed all dust-generating belts
z Overhaul/addition of dust collectors
z Automatic doors to tippler enclosure
z Improvements Affected
z New Haver & Boecker packer &
Beumer palletiser
z All spillage eliminated
z Upgrade of extender-blending facility
z Major Refurbishments
z All electric motors/gearboxes overhauled
z Overhauled overhead crane, tippler,
cement transport system etc.
z Plant clean up & extensive painting

44
Clinker Storage Facility Enclosed

45
 Dust Collectors Upgraded

Clinker Store Raw Mill

Tippler Kiln ESP 46

 Other Projects in the Pipeline

z Batsweledi project first phase of 20 year modernisation programme

z Based on combination of capacity replacement & expansion
z New cement milling complex under construction at Hercules plant
z 1Mt/yr capacity Loesche vertical roller mill (3150kW)
z 35kt clinker silo, 10kt cement silo, tippler upgrade
z Cost~€61m
z Commissioning planned for July 2009
z Replace two old mills, maximise product extension (~0.3Mt/yr) &
balance clinker/milling capacity in Inland Region
z Planned new 1.25Mt/yr factory at Riebeeck (Western Cape)
z Greenfields project
z In feasibility stage (in middle of EIA approval process)
z Capital cost estimated at ~€340m
z Commissioning planned for 2010/2011
z Studies underway for next Inland Region expansion
47
 Summary

z Batsweledi PPC’s first new factory in over 20 years

z Part of PPC’s 20 year modernisation programme
z Most modern South African cement factory
z Utilises latest technology
z Lowest cost producing factory
z Environmentally friendly & energy efficient
z Project within budget & on time
z Safety is not negotiable
z Community involvement key
z Other projects planned to meet country’s future
cement demand
z Only 6 months to commissioning date & counting!

Forongoing
For ongoingproject
projectupdate
updaterefer
referPPC
PPCwebsite:
website:www.ppccement.co.za
www.ppccement.co.za
48
 Thank You

Port Elizabeth Cement Silo