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POLYSIUS in the Middle East &

Africa
Case Studies

International Cement Conference - Cemtech -Dubai - March 2011

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MARKET
Middle East and Africa cement industry is undergoing a fast
growth fuelled by
9 Urbanisation: expanding populations in the need of improvement
of living conditions leading to housing, infrastructure, etc.
9 Industrialisation: developing industries also need building
materials
9 Boom on commodities: despite the recent financial crisis, a
sustained boom on commodities and subsequent Mining Capital
Expenditure providing funds for GDP growth and requirement for
building materials

International Cement Conference - Cemtech -Dubai - March 2011

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TRENDS
Other significant trends in the cement industry :
9 Reduction of CAPEX of the cement plant projects. Cement
industry being highly capitalistic, access to funds is a challenge,
particularly after the recent financial crisis leading to debt
reduction policies for the companies
9 Reduction of OPEX: many customers are focusing on more
efficient and innovative solutions to reduce the operating costs
(power and calorific savings, use secondary fuels, increase in
plant availability)
9 Sustainable and environmentally friendly solutions
Challenges to POLYSIUS

Keep High Quality Standards

with Optimized Costs
Equipment Reliability
Innovative Solutions

International Cement Conference - Cemtech -Dubai - March 2011

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DIVERSITY
Remarkable is the variety of our customers, ranging from :
9 major international historical companies (LAFARGE, HOLCIM ,
ITALCEMENTI, etc.)
9 middle-size historical cement companies (VICAT, CIMENTS
MOLINS or SCHWENK ZEMENT, etc.)
9 local players + significant number of new players
9 state owned companies
Corresponding organization, skills, technical and financial resources
vary a lot from a company to another, and accordingly the
requirements and expectations
Challenges to POLYSIUS

Flexibility and Adaptability

Suitable Projects Schemes &
Contractual Set up

International Cement Conference - Cemtech -Dubai - March 2011

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POLYSIUS IN THE
MIDDLE EAST & AFRICA
CASE STUDIES

International Cement Conference - Cemtech -Dubai - March 2011

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EGYPTIAN CEMENT Co - LINE 5 5 300 tpd

ECC Line 5 - Overview of achieved quantities
Mechanical Equipment
11 200 tons
Electrical Equipment
750 tons
Reinforced Concrete
45 000 m3
Structural Steel
5 500 tons
GA & Detailed Drawings
410
Civil & Structural Drawings
1 750

International Cement Conference - Cemtech -Dubai - March 2011

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EGYPTIAN CEMENT Co - LINE 5 5 300 tpd

Main Factors of Success:
9 Fast and controlled project execution thanks to copy plant
concept: reduced CAPEX & time for completion, rapid
production ramp up > improved financial return
9 Largely sized equipment allowing capacity increase of each
line from 4300 to 5300 tpd clinker and no additional raw mill for
line 5 thanks to reserves on first 4 raw mills
9 Civil & Structural Design by POLYSIUS SAS with same
suppliers through long lasting collaboration in France. Policy of
Best Cost
9 Large manufacturing & construction capabilities and efficiency
of OCI
9 Excellent complementarity with OCI, shared values
International Cement Conference - Cemtech -Dubai - March 2011

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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd

MBCC Line 2 - Overview of achieved quantities

Mechanical Equipment
10 400 tons
Electrical Equipment
750 tons
Reinforced Concrete
33 000 m3
Structural Steel
5 500 tons
GA & Detailed Drawings
325
Civil & Structural Drawings
1 150

International Cement Conference - Cemtech -Dubai - March 2011

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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd

MBCC main requirements for Line 2:

9 High quality standards for the supplied equipment
9 Project management of the full scope of supply & works by
one Contractor
9 Reduced investment and controlled overall budget
9 Reduced time for completion

International Cement Conference - Cemtech -Dubai - March 2011

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MISR BENI SUEF CEMENT Co - LINE 2 5 300 tpd

Advantages to MBCC & key criteria of successful project:
9 Secured overall budget thanks to copy plant concept fixed
price for supply contract + guaranteed quantities for concrete
and structural steel
9 Full project management by POLYSIUS as for a turnkey-type
contract of the supply chain (inquiry, procurement, quality
control, coordination, planning, supervision, commissioning
and training)
9 Use of suitable industrial resources in Egypt from civil &
structural design to civil works, steel manufacturing and
erection works
9 Fast plant execution, rapid production ramp up to 5300 tpd of
clinker > profit maximisation
International Cement Conference - Cemtech -Dubai - March 2011

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AL SAFWA CEMENT Co - GREENFIELD PLANT 5 000 tpd

Al Safwa Cement - Overview of achieved
quantities
Mechanical Equipment
13 600 tons
Electrical Equipment
700 tons
Reinforced Concrete
70 000 m3
Structural Steel
6 700 tons
GA & Detailed Drawings
445
Civil & Structural Drawings
1 800

International Cement Conference - Cemtech -Dubai - March 2011

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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE

International Cement Conference - Cemtech -Dubai - March 2011

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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE

The main targets of the project were:
9 Installation of additional 10.000 tpd clinker production capacity
as well as 630 tph cement grinding capacity
9 Implementation of most modern technologies to achieve
highest reliability and energy efficiency
9 Meeting most advanced environmental standards and legal
regulations
9 Execution of the construction works without major influences
on the existing 6 production lines
9 Meeting the challenging time schedule with early cement in
one grinding unit after 16 months

International Cement Conference - Cemtech -Dubai - March 2011

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YAMAMA SAUDI CEMENT Co - 10 000 tpd LINE

YAMAMA SAUDI CEMENT 10 000 tpd - Overview of achieved

quantities
31 000 tons
4 000 tons
72 000 m3
25 000 tons
262
11 000

Mechanical Equipment
Electrical Equipment
Reinforced Concrete
Structural Steel
GA & Detailed Drawings
Civil & Structural Drawings

International Cement Conference - Cemtech -Dubai - March 2011

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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd

International Cement Conference - Cemtech -Dubai - March 2011

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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd

The main requirements of CIMAT were:
9 Efficient raw material preparation thanks to on line analyser, circular
mixing bed and POLAB quality control
9 A balance between energy efficient modern technology, such as raw
grinding vertical roller mill, CC calciner for petcoke firing,
POLYTRACK clinker cooler with intermediate roll crusher, and well
proven solutions such as a cement grinding plant
9 Efficient and environmental friendly solutions such as a single high
temperature integrated bagfilter for both kiln and cooler dedusting
without any use of water and cooling air; pyro processing design to
allow use of secondary fuels
9 Optimized design of multi-compartments cement silos to ensure
flexibility of cement types production and reduced investment costs
9 High quality level of the equipment manufacturing
International Cement Conference - Cemtech -Dubai - March 2011

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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd

Some of our challenges were to:
9 Manage 2 big contracts, with significant constructions
volumes to be achieved in a short period
9 Deal with lengthened delivery times for main machinery at
a period of time (2007 and 2008) where industry was
booming with suppliers backlog at a record high level
9 Deal with corresponding rising prices of metals and
materials
9 Properly select the capabilities of suppliers and contractors
to ensure a proper quality and planning

International Cement Conference - Cemtech -Dubai - March 2011

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CIMENTS DE LATLAS 2 x GREENFIELD PLANTS 3 600 tpd

CIMAT cement plants - Overview of achieved quantities

Ben Ahmed plant
Beni Mellal plant
11 900 tons
12 100 tons
900 tons
900 tons
66 000 m3
68 000 m3
9 500 tons
9 500 tons
830
450
3 350
3 000

Mechanical Equipment
Electrical Equipment
Reinforced Concrete
Structural Steel
GA & Detailed Drawings
Civil & Structural Drawings

International Cement Conference - Cemtech -Dubai - March 2011

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SOTACIB FERIANA WHITE CEMENT LINE 2 1 000 tpd

SOTACIB White cement line 2 - Overview of achieved

quantities
Mechanical Equipment
4 600 tons
Electrical Equipment
200 tons
Reinforced Concrete
12 000 m3
Structural Steel
2 100 tons
GA & Detailed Drawings
440
Civil & Structural Drawings
885

International Cement Conference - Cemtech -Dubai - March 2011

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SOTACIB FERIANA WHITE CEMENT LINE 2 1 000 tpd

Specific competitive advantages to drive SOTACIB decision to
award POLYSIUS SAS were:
9 Innovative POLYSIUS design for white cement pyro processing
with a drum cooler + POLYTRACK grate to ensure high level of
whiteness and reduced heat consumption when comparing to
existing technologies on the market
9 Skills and experience of POLYSIUS SAS in turnkey projects
particularly in Tunisia, where all last major turnkey plant
expansion were achieved by POLYSIUS SAS (upgrading in
Ciments de Djebel Oust, new line n2 for Socit des Ciments
dEndifha and subsequent conversion to petcoke of the same
plants)
9 Strong cultural links that ease communication and mutual
understanding
International Cement Conference - Cemtech -Dubai - March 2011

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SOTACIB KAIROUAN GREENFIELD PLANT 3 600 tpd

International Cement Conference - Cemtech -Dubai - March 2011

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SOCOCIM INDUSTRIES LINE 5 3 600 tpd

International Cement Conference - Cemtech -Dubai - March 2011

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SOCOCIM INDUSTRIES LINE 5 3 600 tpd

SOCOCIM main requirements:

9 Low Operating Cost solutions (low energy consumption
power & heat design to use secondary fuels)
9 Low Capital Expenditure
9 Environmental friendly solutions
9 Turnkey execution
9 Short time for completion

International Cement Conference - Cemtech -Dubai - March 2011

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SOCOCIM INDUSTRIES LINE 5 3 600 tpd

SOCOCIM line 5 - Overview of achieved
quantities
Mechanical Equipment
7 600 tons
Electrical Equipment
500 tons
Reinforced Concrete
41 500 m3
Structural Steel
4 100 tons
GA & Detailed Drawings
520
Civil & Structural
1 400
Drawings

International Cement Conference - Cemtech -Dubai - March 2011

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CIMENTS DU SAHEL LINE 5 3 600 tpd

International Cement Conference - Cemtech -Dubai - March 2011

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OHORONGO CEMENT GREENFIELD PLANT 2 100 tpd

OHORONGO CEMENT plant - Overview of

achieved quantities
Mechanical Equipment
7 600 tons
Electrical Equipment
500 tons
Reinforced Concrete
41 500 m3
Structural Steel
4 100 tons
GA & Detailed Drawings
520
Civil & Structural
1 400
Drawings

International Cement Conference - Cemtech -Dubai - March 2011

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CONCLUSION
9 Variety of our Customers Requirements, Resources, Experience
& Culture
> Each Industrial Project is Specific
9 Our Aim: to Fit Customers Requirements & Resources by
providing a Comprehensive Range of Project Solutions &
Contractual Set up
9 Best Cost strategy > Outstanding quality of POLYSIUS
products and services + optimise the CAPital EXpenditure
9 Efficiency & reliability of our Products + Flexibility & Proximity of
our Services & our Experience in Middle East and Africa > quick
financial return to our customers.
International Cement Conference - Cemtech -Dubai - March 2011

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THANK YOU

International Cement Conference - Cemtech -Dubai - March 2011