IMS (Integrated Milling System)

PORTABLE CEMENT GRINDING PLANT

IMSATEC GmbH

Grinding Plant

IMS (Integrated Milling System) CONCEPT

Mini Cement grinding plants with greater efficiency in the cement market. Grinding plants with the following characteristics: 1. Completely transportable containers equivalent to 25 structures. 2. Minimal civil works. 3. Fast and easy installation: 8 weeks. 4. Using cutting edge technology equipment that generate high technical and economic advantages: - Low power consumption when compared to ball mills. 34 vs. 45 kW / t. - Ease of drying in the same facility. Previous solutions require additional drying. - Ability to separately grind the clinkers and additives, significantly increasing the participation of the latter in the final product. - Makes it easy to deliver products tailored to consumer needs. - Installation is environmentally friendly. 5. Simple operation and easy to switch between multiple cement specifications

Scope

To build a cement grinding plant integrating equipment from several Western suppliers

The plant capacity will be 145,000 tons per year, and it will produce cement Type I and cement Type III

Assembly time of the plant will last ten months and will have cutting edge technology

The plant will use Limestone and Slag as cement additives. These materials will be ground in the same cement mi. The former will come from mines in the region and the latter will be imported.

Clinker and Slag will be imported from a foreign country.

Plant Configuration

The plant will produce 145,000 tons of cement per year (15.000 tpy cement Type III and 130.000 tpy cement Type I)

The plant consists mainly of:

• Storage hoppers and dosing of clinker, gypsum, limestone and pozzolanic materials

• Vertical grinding mill of last generation Swing Mill developed by First Class European Mill Manufacturer and Imsatec to optimize grinding different types of materials in a single mill

• Conveyor systems

• Emission control system (bag filters), the latest technology to minimize emissions.

• Cement and additives storage in 50 tons silo

• Packing line 30 tph

• Automation and control system.

• All the above components are arranged on structures based on standard shipping container, for easy transport and reassembly

Swing Mill

Operational advantages: • Low energy consumption per ton of cement. • Capacibility to dry high moistrure material

feed. • Ability to be fed with rocks up to 100 mm size

minimizing the requirement for preliminary crushing.

• Plant distribution is simple and compact, reducing space and internal transportation

• Easy operation and high efficiency • Easy access for maintenance • The whole grinding circuit is an integrated

unit that produces an appropiate granulometric distribution

• Possibility of grinding several additive materials for cement with Blaine up to 6,000

Cement and additives can be ground and dried separately, if required, in the same vertical roller mill called Swing Mill, a latest technology called a Swing mill

Emissions handling and recovery of products

These activities will be accomplished by a single integrated “jet pulse” type bag filter In each case the calculations take into account the quantity of air that must be handled, which determines the required filter area and bag size, ensuring minimal dust emissions ( 10 mg/m3 vs. 50 mg/m3 norm)

Storage and dispensing of raw materials

The raw materials for cement are stored in a yard and are deposited in

the hoppers with a front end loader. From the hoppers the materials go

to the grinding. The project requires 5 hoppers:

• 1 for clinker with 25 tons

storage capacity

• 1 for gypsum with 5 tons

storage capacity

• 1 for additive ( slag) with

25 tons capacity

• 1 for limestone with 5 tons

capacity

Cement and Additives Storage

The project includes four transportable silos of 50 tons capacity with screw conveyor discharge and dosing in a Coriollis Blending System which sends the proper proportions to the mixer

Cement blending system for a ¨Taylor Made¨ production

DUST AND MEAL BLENDING

Cement blending system for a ¨Tailor Made¨ production

Packaging and Delivering

The discharge from the mixer is sent to a hopper which feeds a screw conveyor, which in turn feeds a conveyor belt that carries the material to the bucket elevator. This feeds a hopper whose discharge is an in-lineal manual packer with 2 spouts and a capacity of 30 tph. The bags of cement can be delivered to the truck by a belt single conveyor.

IMS (Integrated Milling System)

GREEN SOLUTION

IMSATEC GmbH

ENVIRONMENTAL AND SOCIAL IMPACT

Energy saving and efficiency. • The vertical mills have a power consumption between 25% and 35% below than that of a ball mill, resulting in an optimization of energy consumption and emissions per unit of production, thereby reducing production costs and improving competitiveness the company. • With less consumption there will be less pressure on the regional electric generating system, thus having a positive environmental impact, especially in regions where fossil fuels are used for power generation. • The rational and efficient use of energy resources produces a product using less energy and generating less pollution.

GREEN SOLUTION

REPLACMENT WASTE AS RAW MATERIAL IN CEMENT

• Solution oriented to Clinker substitution in the cement composition, resulting in reduced environmental impact due to lower emissions of greenhouse gases. Since each ton of clinker produced generates between 0.8 and 1.6 tons of

CO2, depending on the technology used, our solution has a beneficial impact, which is even more marked in countries that use the wet process or other low

efficiency technologies in the production of clinker.

GREEN SOLUTION

• This solution uses industry waste such as blast furnace slag, fly ash from

thermal plants, ceramic and brick waste, paper sludge, construction and

demolition waste and waste from nickel industry, which have a composition

similar to that of the typical materials used as cement additives. These

materials can replace both clinker and the natural raw materials such as

limestone, pozzolan among others, thus reducing the exploitation of natural resources. • Allows the production of cement with a lower clinker ratio, withou

compromising the quality or performance of the final product.

GREEN SOLUTION

• More production, reduced space • The modular design allows the facility to work in several different locations over its life. • The plant has an easily transportable design using standardized modules (platforms, containers, flat-racks ...) The assembly of the modules is fast, as all fixtures are pre preinstalled within each module. • The simplicity of the solution leads to an optimization in transport and storage, resulting in lower energy requirements and environmental load. • The optimization of the installation area results in better utilization of the site compared a traditional plant; the land requirement is up to 10 times less. • The modular, small footprint concept allows placement of the plant closer to

production inputs and / or final markets, reducing raw material transport time

and cost, and cost delivery of the finished product. Thus reducing the

consumption of fossil fuels by reducing the burden on land transport.

GREEN SOLUTION

ALTERNATIVE SOURCE OF ENERGY

• the use of renewable energy or green energy arises, to feed the source of

basic services such as lighting and power plant for offices, using solar cells and solar and wind farms posts autonomous lighting

GREEN SOLUTION

INNOVATIVE GRINDING TECHNIQUE

• This type of mill is designed to grind any non-metallic mineral and has been developed jointly by First Class European Mill

Manufacturer and Imsatec, optimizing industrial processes in

the area of construction and opening the possibility of using

multiple industrial waste materials and minerals whose sources

are near the market.

GREEN SOLUTION

CLEAN TECHNOLOGY • All equipment and plant components are equipped with filters to control emissions of particulate material, Manufacturer guarantees maximum 20 mg / m³ far below international standards and in normal operation

emissions are less than 10 mg / m³.

GREEN SOLUTION

• CONCLUSIONS AND RECOMMENDATIONS: The design of this plant is perfectly in step with current environmental trends, enabling the sector to actively participate in forums for the discussion and negotiation of the future lines of action in environmental legislations at national level. The aim is to be proactive within the sector, contributing to its continuous improvement, while at the same time producing a to quality product that is respectful to the environment.

GREEN SOLUTION

Integrated Power System and Transmission Control

Integrated Power System and Transmission Control

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Imsatec GmbH

Roentgenstrasse 1B

D – 30890 Barsinghausen

GERMANY

Tel. +49 – 5105 – 77879 0

Fax. +49 – 5105 77879 20

E-Mail: info@imsatec.de

Contact

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