Assiut cement plant

El attar 2019
History Assiut Cement Company

1974 The Egyptian government started erection of the first line of the
plant ( 5000 t/d kiln ) supplied by the Russian Institute of cement.

After changing the supplier to be the Germany supplier, line 1

1985 started production ( 5000 t/d )

1987 Lines 2 and 3 erection was started

(Romanian supply)

1991
Lines 2 and 3 initial operation 3700 t/d each
History Assiut Cement Company
• 1999 CEMEX picked up the plant from the Egyptian government
• 2001 Line 1 upgrading
- Changing cooler
- Changing main burner
- Modifications calciner and kiln inlet
- Changing ID Fans
• 2009 - conversion kiln main ESP to F.F.
• 2015 - Upgrading calciner and kiln hood for firing petcok
• 2002 Line 3 upgrading
- Changing cooler
- Changing main burner
- Changing ID Fans
• 2007 - Upgrading preheater tower
• 2015 - conversion kiln main ESP to F.F.
• 2015 - upgrading calciner for firing petcok
• 2003 Line 2 upgrading
- Changing cooler
- Changing ID Fans
- Changing main burner
2008 - Upgrading preheater tower
2014 - conversion kiln main ESP to F.F.
• 2015 installation coal/petcock mill and dosing system for the three kilns .
One plant with 5.46 M tons cement production, clinker production 4.96 M tons
CEMENT OPERATIONS HIGHLIGHTS

Assiut Cement Company is located in the center

of the Egypt,
• 400 km south of Cairo
• 800 km south from Mediterranean ports
Cement plants 1
Grey cement 100 %
White cement -
Stand alone grinding mills -
Clinker capacity 4.58 M Tons
Wet capacity -
Semi dry capacity -
Dry capacity 100%
Clinker/cement ratio 90.0%
Cement capacity around 5.04 M Tons
( Grey cement )
White cement -
 One plant with max. 5.4 M tons cement production, clinker production 4.96 M tons
CLINKER STORAGE
LIMESTONE CLINKER 6 UNITS
210 CAP.:100,000 T
RECLAMER/ STORAGE CEMENT SILOS 721 – CEMENT BAGGING
M M T/H CAP.:12,000 T CAP. = 6 X
STACKER 4 UNITS 8-SPOUTS
LIMESTONE LIMESTONE CAP. : 10,600 T YEAR ROTOPACKERS
JAW HAMMER CRUSHER 30,000M3 80 T/H 1982 MANUFACTURER:
CRUSHER CAP. : 550 TPH PREROV PREHEATER
VENTOMATIC
CAP. : 550 PREROV O&K RUSSIAN 210 4 STAGES 1 2 CAP. = 4 X 100 TPH
TPH YEAR : 1982 YEAR : 1982 T/H TWO STRING FUEL OIL 1 3 5
LIMESTONE 80 T/H YEAR: 1982
RUSSIAN INLINE CALCINER STORAGE
RECLAMER/
YEAR : 1982 5000TPD 2
M STACKER
NOMINAL
CAP. : 42,000
LIMESTONE HAMMER 80 T/H
M3
CRUSHER
PREROV 1
CAP. : 750 TPH BURNER
RUSSIAN
PREROV: O&K 7000KG/HR 80 T/H
YEAR : 1982 BURNERS
YEAR : 1982
12700KG/H R M 2 BULK LOADING
M 2 UNITS
RAW MEAL 2 x 550kw COOLER 120
CLAY CRUSHER CLAY- TELESCOPIC BULK
BLENDING SILOS 3.6 RPM GRATE TYPE 4X5 T/H
CAP. : 500 TPD TO LINE RECLAMER/STACKER ROTARY KILN LOADERS
CAPACITY: 24,000 CROOS BAR 3
PREROV – CAP. : 9500 M 3 5100TPD NOMINAL CAP. = 2 X 150 TPH
SLOBODA M3 5100TPD NOMINAL
(II & III) PREROV RUSSIAN YEAR 1982
YEAR : 1982 YEAR : 1982 YEAR : 1982

180 CLINKER
T/H STORAGE
FUEL OIL CAP. : 80,000T
M STORAGE
PREHEATER
CLAY 4 STAGES
CRUSHER 180 TWO STRING
CAP. : 300 CLAY- RECLAMER/
STACKER T/H PYROCLONE
TPH CALCINER
PREROV: CAP. : 10,000 T
PREROV :ROMANIAN 4000 T/D
CHIC
YEAR : 1987 YEAR : 1987
BURNER
6500KG/HR

M BURNERS 110 110 110 110

RAW MEAL 8600 KG/HR EACH R M T/H T/H T/H T/H
LIMESTONE LIMESTONE BLENDING SILOS 2 x 310Kw 4
COOLER 1 2 3
HAMMER RECLAMER/ CAPACITY: 2X10,000 3.6 RPM
CRUSHER STACKER T ROTARY KILN GRATE TYPE 4x5 SF
CAP. : 40,000 T YEAR : 1987 4020 TPD NOMINAL CROSS BAR
CAP. : 1000 TPH 4000 TPD NOMINAL
PREROV:O&K PREROV ROMANIAN
YEAR : 1987 TO LINE – 1 YEAR : 1987
CLAY
RECLAMER/STACKER 180 6 UNITS
T/H CEMENT SILOS
FUEL OIL CAP. = 6 X 10,800 CEMENT BAGGING
STORAGE T YEAR 1987 4 UNITS 8-SPOUTS
OUTSIDE THE PLANT PREHEATER
(GAHDAM CLAY 4 STAGES ROTOPACKERS
QUARRY) LIMESTONE 180 TWO STRING MANUFACTURER: GERMANY
2
RECLAMER/ T/H PYROCLONE CAP. = 4 X 100 TPH
1 3 5
STACKER CALCINER YEAR: 1987
M CAP. : 40,000 T 4000 T/D
CLAY RUSHER PREROV ROMANIAN
CAP. : 350 TPH YEAR : 1987
PREROV RUSSIAN BURNER
YEAR : 1982 6500KG/HR

BURNERS BULK LOADING

RAW MEAL 8600 KG/HR EACH R M 2 UNITS TELESCOPIC
M CLAY- RECLAMER/ BLENDING SILOS BULK LOADERS
2 x 310Kw COOLER
CLAY RUSHER STACKER CAPACITY: 2X10,000 3.6 RPM CAP. = 2 X 150 TPH
CAP. : 350 TPH CAP. : 10,000 T T ROTARY KILN GRATE TYPE 4x5 SF YEAR 1987
PREROV RUSSIAN PREROV :ROMANIAN 4500 TPD NOMINAL CROSS BAR
YEAR : 1987
YEAR : 1982 YEAR : 1987 4300 TPD NOMINAL
Assiut quarries limestone & Clay deposits
Limestone quarry & Crusher Current Situation
Limestone quarry & Quality

SiO2 Al2O3 Fe2O3 CaO MgO SO3 K2O Na2O Cl

Level 178 3.44 0.22 0.12 53.07 0.12 0.08 0.009 0.029 0.062
Level 153 3.99 0.31 0.17 52.68 0.20 0.06 0.014 0.014 0.064
Level 120 2.79 0.50 0.23 53.31 0.21 0.06 0.020 0.013 0.049
Total 3.42 0.33 0.17 53.02 0.17 0.07 0.014 0.019 0.059
Chert layer in limestone quarry

Explosive consumption :
Each 2.2. ton limestone needs 13 Kg .explosives materials .
 Clay quarries : Gahdam & Bani Ghaleb Clay Quality
Layer “A’’ Si02 AI203 Fe203 CaO MgO SO3 K20 Na20 CI

Average 54.38 13.41 7.76 6.95 2.46 0.50 0.53 0.80 0.35

Min 58.15 16.73 9.86 8.77 2.90 1.22 0.73 1.57 1.03

Max 49.90 11.48 6.40 3.97 2.11 0.05 0.44 0.40 0.11

Std.Dev. 2.02 1.04 0.85 1.10 0.18 0.24 0.07 0.22 0.19

Layer “B’’ Si02 AI203 Fe203 CaO MgO SO3 K20 Na20 CI

Average 49.22 14.38 9.32 7.58 2.85 0.11 0.66 1.00 0.29

Min 58.20 16.52 10.48 10.70 3.49 0.43 0.90 1.61 0.69

Bani Ghaleb Clay Quarry Max 45.49 12.27 7.71 5.33 2.30 0.04 0.53 0.58 0.07
•The Clay Deposit Is General Brown, Soft, Frequent Lenses of Sand Stone
Std.Dev. 2.14 0.84 0.50 0.92 0.19 0.07 0.07 0.19 0.14
•The Clay deposit is covered by loose detrital young sediments of thickness varying
•The Lithological chemical correlation sections exhibit the sandy calcareous clay
Clay Quality
•The Average Humidity is 8.4%
•The Average Density is 1.8 Ton /M3
•It is connected with Crushers By Road and Transportation by Contractor.
•The Distance Between the Quarry and Crushers is 3 Km
Limestone Crushers& storage area process flow diagram
Limestone & clay storage area
Line # 1 process flow diagram
Line # 2 & 3 process flow diagram
Process flow diagram Line # 2 & 3 open circuit cement mills
Process flow diagram Line # 2 & 3 closed circuit cement mills
THANK YOU