Construction and reconstruction of cement plants

Due to the increase in the price of “blue” fuel, the cost of cement on the external market has become uncompetitive. As a result, many domestic manufacturers were forced to abandon the most popular “wet” method of cement production and, attracting foreign investments, carry out full or partial modernization of their production facilities to produce cement by the “dry” method. It is this “dry” cement production technology that the Irish company CRH (a network of plants in 35 countries) is implementing at the Kamianets-Podilskyi Cement Plant, and the German company Dyckerhoff at the Zdolbuniv and Mykolaiv Cement Plants.

During 2009-2011, the company Ecorembud performed the modernization of cement production to the “dry” method for CRH at the Kamianets-Podilskyi Cement Plant (reconstruction of the old production facilities with the construction of new ones).

The complex included:

• construction of a raw material filter complete with gas ducts and pipelines;
• construction of fans;
• conditioning silo;
• construction of cyclones for the raw mill;
• clay storage.

At the Zdolbuniv Cement Plant of the company Dyckerhoff, Ecorembud carried out the construction of a new coal powder silo section with the installation of imported equipment using the AGW-2 automatic welding system for horizontal seams on a vertical surface (“Lincoln Electric” – USA), which is designed for and successfully used in tank construction. This allowed the plant manufacturer of metal structures for cylindrical silo parts to simplify and speed up the manufacturing process, as well as ease the delivery of structures to the construction site (sheet delivery).

The main challenges in the construction and modernization of cement production complexes are the scale and complexity of the site. Construction work must be carried out simultaneously in almost all zones of the active enterprise, taking into account overlapping works (dozens of subcontracting organizations are involved).

New buildings in almost all construction zones are mainly designed with metal and are quite tall structures (upper marks from +60.0m to +140.0m), requiring the use of special equipment and detailed development of installation technology considering additional requirements for the manufacture of metal structures. In this case, metal consumption per meter is calculated not in hundreds of kilograms but in tens of tons, since individual structural elements of buildings and equipment weigh from 10 to 200 tons. It should also be noted that 90% of the equipment is imported (supplied by Polisius, Shoih) and is installed in Ukraine for the first time, which required the development and implementation of new installation technologies based on international norms and standards with the participation of leading foreign specialists.

Modernization of cement production to the “dry” method
(reconstruction of old production facilities with construction of new ones)
at JSC “Podilskyi Cement Plant”
/Ukraine, Khmelnytskyi region, Kamianets-Podilskyi city/