Simplex Infrastructures Limited

Grasim Cement Plant Project, Kotputli

Sulabh Tiwari
Sr. Proj. Engg.
Mechanical Planning

Simplex Infrastructures Ltd.

Plant view from main gate
(Wednesday, August 06, 2008)
Capacity : 8000 TPD
Simplex Infrastructures Ltd.
 Plant view from Top (mining area)
Capacity of the Cement Plant : 800 Tonnes per day.

Simplex Infrastructures Ltd.

 Major Structures
• Pre-heater
• Blending Silo
• Clinker Silo
• Clinker cooler house
• Clinker duct support
• Kiln piers-1,2 & 3
• Raw mill bag house
• Raw mill cyclone
• Coal mill house
• Raw mill hopper
• Raw mill house
• Raw mill stack
• Limestone crusher

Simplex Infrastructures Ltd.

 Major Structures
• Main plant sub station
• Stacker rail
• Dump hopper
• Packing plant
• Central control room
• Fly ash silo
• Cement silo-1 & 2
• Cement mill house
• Water treatment plant
• Boiler
• Chimney(CPP)
• T.G.Building

Simplex Infrastructures Ltd.

Pre-Heater
• Total Quantity : 18902 m3
• Total Height of civil structure : 129 m
• Status : civil structure completed.
• Concrete Equipment : HBT 60C SANY Concrete Pump.
Simplex Infrastructures Ltd.
Major concrete equipment for Pre-Heater
HBT 60C SANY Concrete pump HBT 60C SANY Concrete pump
(Hired) (Owned)
Capacity : 75 m3/hr Capacity : 75 m3/hr

Simplex Infrastructures Ltd.

Concreting of final slab (height = 129 m ) of Pre Heater .

Simplex Infrastructures Ltd.

Other views of Pre-Heater

Simplex Infrastructures Ltd.

 Blending Silo
• Total Quantity :
• Total Height of civil structure : 84 m
• Status : civil structure completed.
• Concrete Equipment : Boom
Simplex Placer, BT
Infrastructures Ltd.40C Concrete Pump.
 Major Concrete Equipment for Blending Silo
Boom Placer (Schwing
Stetter)Owned HBT 40C SANY Concrete pump Owned
Capacity : 30 m3/hr Capacity : 48 m3/hr

Simplex Infrastructures Ltd.

Concreting in Blending Silo

Through SANY BOOM PLACER in the starting stage of around 3 m height

from ground level.

Simplex Infrastructures Ltd.

 Concreting going on through SANY-
VOLVO Boom Placer at Blending Silo

Simplex Infrastructures Ltd.

Concreting at Blending Silo
Through HBT 40C(SANY) Concrete pump at the height of 55m from
ground level.
Simplex Infrastructures Ltd.
 Clinker Silo
• Total Quantity : 12582 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C
Concrete Pump.
Simplex Infrastructures Ltd.
Clinker Silo
Top view of Clinker Silo including Tunnels inside the structure.

Simplex Infrastructures Ltd.

Major Concrete Equipment for Clinker Silo
Boom Placer (SANY-VOLVO) Owned HBT 40C (SANY) Owned
Capacity : 120 m3/hr Capacity : 48 m3/hr

Simplex Infrastructures Ltd.

Clinker Cooler House
• Total Quantity : 2290 m3
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),Boom
Placer(Schwing Stetter)
Simplex Infrastructures Ltd.
Clinker Cooler House & Cooler E.S.P
• Total Quantity (cooler esp) : 882 m3
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO)
Simplex Infrastructures Ltd.
 Concrete Equipment for Clinker Cooler House & Cooler E.S.P.
Structure
Boom Placer(Schwing Stetter)Owned Boom Placer(SANY-VOLVO) Owned
Capacity : 30 m3/hr Capacity : 120 m3/hr

Simplex Infrastructures Ltd.

Kiln Piers
• Total Quantity : 5916 m3
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO)

Simplex Infrastructures Ltd.

Concrete Equipment for Kiln Piers 1,2 & 3

Simplex Infrastructures Ltd.

Completed Kiln Piers 1,2 & 3.

Simplex Infrastructures Ltd.

 KP-III

KP-I
KP-II

Simplex Infrastructures Ltd.

 Raw mill bag house

Raw Mill Bag House

• Total Quantity : 3278 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C
Concrete Pump.

Simplex Infrastructures Ltd.

Raw Mill Cyclone
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C Concrete Pump.

Simplex Infrastructures Ltd.

Raw Mill Hopper
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C Concrete Pump.

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.
Coal Mill House
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C Concrete Pump.

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.
Raw mill house

Raw Mill House

• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C
Concrete Pump.

Simplex Infrastructures Ltd.

Raw Mill House
Concreting at Raw Mill House(column & beam), through SANY Boom
Placer.

Simplex Infrastructures Ltd.

Raw Mill House

Simplex Infrastructures Ltd.

Raw Mill Stack
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C
Concrete Pump.
Simplex Infrastructures Ltd.
Starting stage of Raw Mill Stack through SANY-VOLVO Boom Placer

Simplex Infrastructures Ltd.

 Raw mill stack

Raw Mill Stack

Simplex Infrastructures Ltd.

 Concreting at Raw Mill Stack
through Hoist Winch

Simplex Infrastructures Ltd.

Limestone Crusher
• Total Quantity : 12682 m3
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C
Concrete Pump.
Simplex Infrastructures Ltd.
Simplex Infrastructures Ltd.
 MPSS

Main Plant Sub Station(MPSS)

• Total Quantity : 12682 m3
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C
Concrete Pump.
Simplex Infrastructures Ltd.
Stacker Rail
• Total Quantity : 12682 m3
• Status : civil structure completed.
• Concrete Equipment : Schwing Stetter (BP-350) Concrete Pump.

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.
Simplex Infrastructures Ltd.
Dump Hopper
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT
Simplex Infrastructures 40C
Ltd. Concrete Pump.
Dump Hopper

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.
Packing Plant
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C Concrete Pump.

Simplex Infrastructures Ltd.

 CCR

Central Control Room(CCR)

• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT
Simplex Infrastructures 40C
Ltd. Concrete Pump.
Simplex Infrastructures Ltd.
 Fly ash silo

Fly Ash Silo

• Total Quantity : 12682 m3

• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C Concrete Pump.
Simplex Infrastructures Ltd.
Simplex Infrastructures Ltd.
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT 40C Concrete Pump.

Simplex Infrastructures Ltd.

Cement Silo – 1 & 2
Concreting at Cement Silo through SANY Boom Placer.

Simplex Infrastructures Ltd.

Chimney(Captive power plant)
• Total Quantity : 12682 m3
• Total Height of civil structure :
• Status : civil structure completed.
• Concrete Equipment : Boom Placer(SANY-VOLVO),HBT
Simplex Infrastructures 40C
Ltd. Concrete Pump.
Simplex Infrastructures Ltd.
Concreting of Slab at T.G.Building through Concrete Pump(HBT 60C)
Simplex Infrastructures Ltd.
Thermal Generator Building

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.
Simplex Infrastructures Ltd.
Main Workshop

Tried to manage the space (area) in front of our workshop also we got
enough area for maintenance and repairing at same time.
Simplex Infrastructures Ltd.
Site Office(mechanical)

Simplex Infrastructures Ltd.

 Site Office
We make plans for concreting and requirements of
equipments with the help of site layout(by finding the
minimum path or way to save time)

Simplex Infrastructures Ltd.

Tried to distribute workload properly among all engineers and
mechanics also utilizing the talent of everyone.

Simplex Infrastructures Ltd.

 Equipments
Equipments Make Capacity Quantity(N0s)

• Batching Plant-1 (Schwing Stetter) 30 m3/hr 01

• Batching Plant-2 (MACONS) 45 m3/hr 01
• Batching Plant-3 (MACONS) 45 m3/hr 01
• Placer Boom-1 (SANY-VOLVO) 120 m3/hr 01
• Placer Boom-2 (Schwing Stetter) 30 m3/hr 01
• Concrete Pump (HBT 60C,SANY) 75 m3/hr 01
• Concrete Pump (HBT 40C,SANY) 48 m3/hr 01
• Concrete Pump (Greaves) 30 m3/hr 01
• Tower Crane-1 (Jianglu) 08 ton 01
• Tower Crane-2 & 3 (Jianglu) 10 ton 02
• Loader cum Backhoe (JCB) 02
• Hydra (ACE) 11 ton 07
• Transit Mixer

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.
Simplex Infrastructures Ltd.
Production Plant

Batching Plant – 1 : SCHWING STETTER

Capacity : 30 m3/hr

Batching Plant – 2 : MACONS

Capacity : 45 m3/hr

Batching Plant – 3 : MACONS

Capacity : 45 m3/hr

Simplex Infrastructures Ltd.

Laying Equipment

Transit Mixer
Capacity : 6 m3

Simplex Infrastructures Ltd.

Pouring Equipment

Placer Boom – 1 : SANY-VOLVO

Capacity : 120 m3/hr

With 4(four) boom of 27 m height

Simplex Infrastructures Ltd.

SANY-VOLVO Placer Boom with Skilled Operators.

Simplex Infrastructures Ltd.

SANY Boom Placer in working condition

Simplex Infrastructures Ltd.

Boom Placer – 2 (Schwing Stetter)

Capacity : 30 m3/hr

With 4(four) boom of 22 m

height.

Simplex Infrastructures Ltd.

Concrete Pump (SANY - HBT 60 C)

Capacity : 75 m3/hr

Simplex Infrastructures Ltd.

Concrete Pump (SANY – HBT 40 C)

Capacity : 48 m3/hr

Simplex Infrastructures Ltd.

Concrete Pump (GREAVES)

Capacity : 30 m3/hr

Simplex Infrastructures Ltd.

Hand Mixer

Simplex Infrastructures Ltd.

Major Equipment for Material Lifting, Concreting & Erection

T.C-01
T.C-2 Tower Crane -01 : JIANGLU
Capacity : 08 ton

Tower Crane – 02 : JIANGLU

Capacity : 10 ton
T.C-
03 Tower Crane -03 : JIANGLU
Capacity : 10 ton

Tower Crane -04 : LIBHERR

Capacity : 05 ton

Simplex Infrastructures Ltd.

Shifting & Helping Equipments

Hydra – 1 : ACE
Capacity : 11 ton

Hydra – 2 : ACE
Capacity : 11 ton

Simplex Infrastructures Ltd.

Both Hydra engaged in loading

Simplex Infrastructures Ltd.

Loader cum Backhoe

Loader cum Backhoe : JCB

Simplex Infrastructures Ltd.

Some Important equipments have major roles
in critical situations.

Simplex Infrastructures Ltd.

Simplex Infrastructures Ltd.