Project Name Optimization of Cement Manufacturing Process

Betterfound Cement Corporation Project Number Sheet 1

Head Office: State Center II Ortigas Avenue, Mandaluyong City REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS

Form 52830-19-26
1 General Information

Owners Name Banton, Sherry B.; Palaje, Merciline Joy S.; Serrano, Claudine Spark M.; Valencia, Jonnabelle A.

Process Unit Name Cement Manufacturing Plant

Plant Location Purok 1, Brgy. Kilicao, Daraga, Albay

Correspondance Contacts
Address Head Office: State Center II Ortigas Avenue, Mandaluyong City
Telephone / Fax 482-0605
E-mail contactus@betterfound.com
comrel@betterfound.com

2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill PRV Pressure relief valve
prefix as defined here, followed by three- B Boiler H Heater (fired or electric) R Reactor
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander SP Sample point
indicated CT Cooling tower M Motor T Storage tank
D Dryer ME Miscellaneous equipment V Vessel (including columns)
First digit - process section E Exchanger MX Mixer
Second & third digits - equipment count F Filter, classifier P Pump

4 Primary Products

Product Name Ordinary Portland Cement Pozzolanic Portland Cement

Product Grade OPC 53 PPC
MSDS Form Number 65997-15-1 66984-13-2

Production Rate
Metric tons per year 1839600 1526430
Metric tons per day 5,040 4,182
Other units

Product Purity (wt%) 100 100

Product shipment mode Land: Trucks and Train Land: Trucks and Train
Water: Cargo vessels Water: Cargo vessels
Additional Specifications Chemical Composi% Chemical Composit%
SiO2 19-24 SiO2 45-55
Al2O3 4.0-9.0 Al2O3 25-30
Fe2O3 1.6-6 Fe2O3 5.0-10.0
CaO 60-67 CaO 2.0-6.0
MgO not>5 MgO 2.0-3.0
SO3 not>3 SO3 0.5-3

State Solid State Solid

Density Density
Bulk Density, kg/m3 3.1 Bulk Density, kg/m3 3.15
Relative Density, kg 1,404 Relative Density, kg 1,300
Compressive strength Compressive strength
At 2 days (Mpa) 11.3 At 2 days (Mpa) 28
At 28 days (Mpa) 16.9 At 28 days (Mpa) 58
Soundness Letchate0-2 Soundness Letchatel1
Fineness % 85.4 Fineness % 86.2
pH 12 pH 12
Boiling Point 1000 C Boiling Point 1000 C
Appearance Gray Appearance Gray

5 Primary Raw Materials

(Attach additional sheets if needed)
Feedstock name Ores (from Mining Operation)
Limestone Clay Iron Ore
Feedstock grade
MSDS form number

Feedstock availability
Metric tons per year 5,787,819.60
Metric tons per day 15,857.04
Other units

Feedstock price ($/kg) N/A N/A N/A

(Default: open market price)

Feedstock Chemical Composition Name % tph Name % tph Name % tph

SiO2 5 28.080175 SiO2 37 31.780151 SiO2 3 0.396426
Al2O3 + TiO2 0.9 5.0544315 Al2O3 + TiO2 8.5 7.3008455 Al2O3 + 2.2 0.2907124
Fe2O3 + Mn2O3 0.4 2.246414 Fe2O3 + Mn2O3 5 Jan-00 TiO2
Fe2O3 + 53 7.003526
CaO 55 308.881925 CaO 25 21.473075 CaO 28 3.699976
MgO 0.3 1.6848105 MgO 5 4.294615 MgO 0.5 0.066071
K2O 0.3 1.6848105 K2O 0.5 0.4294615 K2O 3.5 0.462497
Na2O 0.1 0.5616035 Na2O 0.3 0.2576769 Na2O 0.2 0.0264284
SO3 0.1 0.5616035 SO3 3 2.576769 SO3 0.3 0.0396426
Co2 + H2O 37.9 212.8477265 Co2 + H2O 15.7 13.4850911 Co2 + H2O 9.3 1.2289206
 TOTAL 100 561.6035 TOTAL 100 85.8923 TOTAL 100 13.2142

Additional specifications Primary Raw Materials will be acquired from Mining Operations

6 Site Information

Low ambient temperature (C) 25

High ambient temperature (C) 35
Hight ambient relative humidity (%) 60
Site elevation (m) 300 m above sea level
Maximum wind loading (km/h) 36
Other site design requirements
 Project Name
Company Name Project Number Sheet 2
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS

Form XXXXX-YY-ZZ
7 Utility Information

Fuel Gas
Gas source or operation mode natural gas
Supply header temperature (C) 35
Supply header pressure (kPa (a))
Net calorific value (kJ/kg) 41858
Marginal availability (kg/h)
Marginal fuel cost ($/GJ) 2.05
Sulfur content (wppm) 1.3
Nitrogen content (wppm) 3.2
Chlorine content (wppm) 0.5
Gas composition (vol%)
H2O
O2 0.02
N2 1
CO n/a
CO2 0.5
H2S
H2 trace
CH4 95
C2H4 0.8
C2H6 3.2
C3H6 0.01
C3H8 0.2
C4H8 0.03
iC4H10 0.03
nC4H10 0.01
C5H10 0.01
C5+ 0.01

Fuel Oil
Fuel source or operation mode Rubber/tyres
Supply header temperature (C)
Supply headder pressure (kPa (a))
Net calorific value (kJ/kg) 33486.4
Marginal availability (kg/h)
Marginal fuel cost ($/GJ) 450
Fuel viscosity at C
Fuel viscosity at C
Flash point (C) 260-316
Pour point (C)
Sulfur content (wppm) .0.8
Nitrogen content (wppm) 0.3
Ash content (wt %) 2.2

Steam
Steam header classification VHP HP MP LP
Operating pressure (kPa (a))
Operating temperature (C)
Mechanical design pressure (kPa (a))
Mechanical design temperature (C)
Marginal availability (kg/h)
Marginal cost ($/metric ton)

Coolants
Coolant classification Cooling Tower Water Once-Through Water Chilled Water
Operating pressure (kPa (a))
Supply temperature (C)
Maximum return temperature (C)
Marginal availability (kg/h)
Marginal cost ($)
Marginal cost units

Process Water Feeds

Water feed stream Raw Water Process Water Boiler Feed Water Condensate
Supply pressure (kPa (a))
Supply temperature (C)
Marginal availability (kg/h)
Marginal cost ($/metric ton)
Total dissolved solids (wt%)
Hardness as CaCO3 (ppmw)
Chloride as Cl (ppmw)
Metallurgy

Electric power
Power range (kW) 2699
Voltage (V) 145000
Phase 3
Frequency (Hz)
Marginal availability (kW)
Marginal cost ($/kWh)

Plant air streams

Air stream Plant Air Instrument Air Plant Nitrogen
Header pressure (kPa (a))
Header temperature (C)
Moisture (ppmw)
Marginal availability (kg/h)
Marginal cost ($/Normal m3)
 SECONDARY RAW MATERIALS

Feedstock name Correctives

Sand Iron
Feedstock grade
MSDS form number

Feedstock availability
Metric tons per year 570863.65
Metric tons per day 1,564.01
Other units

Feedstock price ($/kg) N/A N/A

(Default: open market price)

Known feedstock impurities Name % %w/w Name ppmw

SiO2 94 14.67584 SiO2 3 – 50
Al2O3 + TiO2 0 0 Al2O3 + 2 – 20
Fe2O3 + Mn2O3 3.38 52.7706 TiO2
Fe2O3 + 0.5 - 10
CaO 0.7 0.109288 Mn2O3
CaO 52-55
MgO 0.5 0.078063 MgO 0.5-5
K2O 0.5 0.078063 K2O 3.5
Na2O 0.05 0.007806 CO2 + H2O 2 – 42
SO3 0.37 0.057767 SO3 0.1 - 4
Co2 + H2O 1 0.156126
TOTAL 100 15.6126 Na2O 0.2
Additional specifications
 Gypsum (CaSO4-2H2O) Fly Ash
Bauxite

13397-24-5 13397-24-5

87,600 436,143
240 1,194.91

N/A $2.00-2.27 $0.04

Name ppmw Name ppmw Name ppmw

SiO2 37-78
Al2O3 + 0.5-3
TiO2
Fe2O3 + 0.5-2
Mn2O3
CaO 0.1-3
MgO 0.5
K2O 1
CO2 + H2O 5
SO3 0.5

Na2O 0.5