Plant Mass Flow

Plant : MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Contract : 1745412_900

Created by : HJ

Approved by : OMa

Approved date :

Doc. No. : 50080091-5.0

Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

List of content Page

Legend 2

Legend of Table of materials properties 3

Table of materials properties 4

Design basis 5

Raw meal Production 6

Clinker Production 7

Cement grinding and dispatch 8

The information transmitted by this document is the proprietary and confidential property of FLSmidth Page 1 of 8
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Legend

The 'Plant Mass Flow' shows storage capacities and mass flow rates on a dry basis throughout the plant. Design
parameters such as densities and moisture content, composition of raw mix and cement are shown in the plant
mass flow.

Plant equipment Definition Examples *

Main machinery Operating rate [t/h] 450 t/h

Average mass flow rate in dry metric tons per

Operating hour [t/h] when plant department is operating
Transports at rated output Operating/Design
operating/design 450/540 t/h
Design Operating × design factor [t/h]

Storages ** Live*** tonnage in dry metric tons [t] 54800 t

Bins ** Live*** capacity in dry metric tons [t] 495 t

Feeder rates are specified by the design mass flow rate in dry Design rate [t/h] (ratio)
Feeders
metric tons per hour [t/h] and ratio (control range) 120 t/h (10:1)

* Examples do not represent current mass flow. They are completely arbitrary.
** Drawn or written sequences of piles and bins do not necessarily reflect the actual layout.
*** Live volume/tonnage is defined as "Maximum available volume/tonnage for the process".

For guaranteed rates refer to the separate annex, "Guaranteed Performances", in the contract.

Process design internal information

Made by HJ
Edition S12
Date 14.Aug.2017
Checked by

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

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Materials properties - legend

Material
Name of material, possibly also containing description such as fineness of a powder
Top size [mm]
Top size is defined as
- in general, square root of 3 (space diagonal of a cube) times the P95 mesh size (95% passing on a square mesh)
- for crusher feed, the space diagonal of the smallest cube that can contain the largest lump of material
Bulk density [dry t/m³]
Pneumatic For use with pneumatic transporting, such as an airlift
Mechanical Same as Loose bulk density; used primarily with mechanical conveyors, such as a belt
Store volume Used to design the volume of contents for piles, silos and bins
Store load Used to design loads of piles, silos and bins
Design moisture [%]
Maximum moisture for design, on wet basis [kg moisture / 100 kg wet material]
Angle of repose [°]
The natural slope of the material
Steel silo cone half angle [°]
If given as single value, it is angle for a round silo outlet. If given as two values divided by a '/', the first value is for
circular, the second is for rectangular
Abrasiveness
Given as either 'Low', 'Medium' or 'High'
Stickiness
Stickiness is either given as 'Free' (free flowing), 'Moderate' (moderately sticky), 'Sticky' or 'Extreme'

Material properties are indicated with the source of the data

a Tender information
b FLS decision
c FLS default value
d FLS lab test value
e Client information

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Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Materials properties See legend for details

Material Top size Bulk density Design Angle of Steel silo Abrasive- Stickiness
pneumatic mechanical store store moisture repose cone half ness
volume load angle

Limestone 1400 b 1.40 c 1.50 c 1.70 c 5.0 b 38 c 20 c Low c Free b

Moderate
Clay at clay hopper (1) 300 b 1.10 c 1.30 c 1.80 d 10.0 e 40 c 5 c Low c b
*)
Clay at mix crusher intake (2) 500 b 1.10 c 1.30 c 1.80 d 10.0 e 40 c 5 c Low c Sticky *) b

Green Iron corrective (Bauxite) 60 b 1.20 b 1.35 c 1.60 d 10.0 b 35 c 10 b High c Moderate b
Red Iron corrective (Laterite) 60 b 1.44 b 1.54 b 2.00 b 10.0 e 38 c 10 b High c Moderate b

Crushed Limestone 150 b 1.40 c 1.50 c 1.70 c 5.0 b 38 c 20 c Low c Free b

Limestone/Clay Mix 150 b 1.40 c 1.50 c 1.73 d 6.0 b 38 c 20 c Low c Moderate b

Raw mill feed 150 b 1.40 c 1.50 c 1.73 d 6.0 b 38 c 20 c Low c Moderate b
Raw meal (12%+90µ) in silo 0.80 c 1.00 c 1.25 c 1.50 c 0.5 b Low c Free c

Raw meal/kiln feed 0.80 c 1.00 c 1.25 c 1.50 c 0.5 b Low c Free c
Filter dust 0.40 c 0.50 c 0.70 c 0.90 c Low c Free c

Clinker 40 b 1.20 c 1.50 c 1.80 c 0.0 b 34 c 45 c High c Free c

Off-standard clinker 40 b 1.20 c 1.50 c 1.80 c 0.0 b 34 c 45 c High c Free c
Clinker cooler dust 1.10 c 1.40 c 1.50 c High c

Gypsum 500 b 1.20 d 1.30 d 1.70 c 16.0 e 40 c 15 c Low c Moderate b

Gypsum to cement mill 25 b 1.20 d 1.30 d 1.70 c 16.0 e 40 c 15 c Low c Moderate b
Limestone to cement mill 150 b 1.40 c 1.50 c 1.70 c 5.0 b 38 c 20 c Low c Free b
Gypsum + LST to cement mill 150 b 1.30 b 1.40 b 1.70 b 10.8 b 38 b 20 b Low b Free b

Cement mill feed 120 b 1.20 c 1.35 c 1.80 c 1.8 b High c Free c
Cement, OPC 3200 Bl 0.90 c 1.10 c 1.40 c 1.60 c Low c Free c

Raw Coal 55 e 0.80 c 0.80 c 1.00 c 12.0 e 38 c 20 c Low c Moderate b

Coal, Feed to mill 55 e 0.80 c 0.80 c 1.00 c 12.0 e 38 c 20 c Low c Moderate b
Coal, Meal and dust 0.35 c 0.60 c 0.60 c 0.80 c 2.0 b Low c Free c
Pet Coke, Feed to mill 55 b 0.80 c 0.90 c 1.00 c 8.0 e 38 c 20 c Low c Free c
Pet Coke, Meal and dust 0.40 c 0.50 c 0.60 c 0.90 c 1.0 b Low c Free c

*) As agreed with MLCF

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Design basis

Raw mix [% w/w dry] Operating Cement mix [% w/w dry] OPC Cement 2 Cement 3 Cement 4 Cement 5

Limestone 69.0 Clinker 90-92

Clay 27.0 Gypsum 3-5
Green Iron corrective (laterite) 2.0 Limestone 5.0
Red Iron corrective (Bauxite) 2.0
Sand

Mix 91.0
HG limestone 5.0

Per time
Department Value Relation Time Comments
(1)

Crushers
Mix crusher, total 52.9 Min Hours Week (7300*7*1.56*0.96 + 7*7300/0.90*0.05)/1500
Mix crusher, of which to cement mill 1.9 Min Hours Week (7*7300/0.9*0.05)/1500
Gypsum Crusher 23.7 Min Hours Week (7300*7/0.9*0.05)/120

Storages
Mix storage 2.85 Days Per pile at max raw meal production (35000/(24*562)/0.91)
HG limestone pile 2.55 Days At max output from mills (3000/(24*562*0.05+24*210*2*0.05))

Raw grinding
Raw mill 20.2 Min Hours Day (7300*1.56/562)
Mix reclaimer 18.9 Hours Day At max mill output over 24 hours (562*24*0.91)/650
Mix bin content 1.0 Hours Mill at design capacity and 91% mix (500/0.91*560)
HG Limestone bin content 8.9 Hours Mill at design capacity and 5% Limestone (225/(0.05*560))
Laterite bin content 20.5 Hours Mill at design capacity and 2% Laterite (230/(0.02*560))
Bauxite bin content 17.8 Hours Mill at design capacity and 2% Bauxite (200/(0.02*560))

Raw meal storage

CF silo 53.7 Hours At 7300 tpd (25500/(7300*1.56))

Coal grindig
Coal mill 20.0 Min Hours Day At 50% coal/50% coke and minimum Heat value
(7300*710/2/5850/48+7300*710/2/7500/32)
Raw coal bin, coal 10.4 Hours At continous coal grinding (2*250/48)
Raw coal bin, coke 7.8 Hours At continous coke grinding (250/32)
Fine coal bin, coal 8.1 Hours At 50% coal with Hv 5850 kcal/kg (150/(7300*710/2/5850/24))
Fine coal bin, coke 10.4 Hours At 50% coke with Hv 7500 kcal/kg (150/(7300*710/2/7500/24))

Clinker storage
Clinker silo 8.2 Days (60000/7300)

Cement grinding
Cement mill 19.3 Min Hours Day At 7300 tpd clinker and 90% clinker in cement (7300/0.9/(2*210))
Clinker feed bin 2.6 Hours At continous cement grinding and 90% clinker (500/(210*0.9))
Gypsum feed bin 12.9 Hours At continous cement grinding and 5% gypsum (135/(210*0.05))
Limestone feed bin 12.9 Hours At continous cement grinding and 5% limestone (135/(210*0.05))

Cement storage
Cement silos 6.2 Days At 7300 tpd clinker and 90% clinker in cement (2*25000/(7300/0.9))
a: Tender information b FLS decision c: FLS default value d FLS lab test value e Client information

Remarks
1 Used where relevant, for example hours per shift or days per year

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Raw meal Production

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Clinker Production

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Plant Mass Flow
Document No. 50080091-5.0

Plant: MAPLE LEAF CEMENT FACTORY LTD.

LINE NO. 3

Cement grinding and dispatch

The information transmitted by this document is the proprietary and confidential property of FLSmidth Page 8 of 8
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.