In November 2015, Holcim Indonesia and thyssenkrupp Industrial Solutions successfully closed out the two Tuban projects they had undertaken (Figure 1). The two clinker and cement production lines, each with a 4500 tpd clinker production capacity, have been started with an offset time of 20 months. In June 2011, Holcim Indonesia awarded the first clinker production line to ThyssenKrupp Polysius, which has since been merged into thyssenkrupp Industrial Solutions. During the long project and tendering phase several options regarding the split in scope had to be evaluated, until the final scope resulted in a contract on a turnkey basis.
Figure 1. Plant overview.
The Construction Process
Following the material flow, the scope of supply for line 1 starts with a crushing plant for limestone and clay with a total premix capacity of 1000 tph. The downstream PGNAA provides the setpoints for the limestone roller crusher, and for the clay roller crusher, to ensure the suitable chemical composition of the raw material mixture, which is stored in two piles in the premix storage hall. Each pile has a capacity of 28 000 t. For the raw meal grinding process a QUADROPOL QMR2 45/23 provides 330 tph of raw meal. This raw meal is stored in a homogenising silo with a capacity of 8000 t.
Figure 2. Two stage POLRO kiln.
The pyro section consists of a 4-stage one string DOPOL preheater with a two-stage POLRO kiln (Figure 2). A clinker cooler POLYTRACK with intermediate crusher cools the clinker to a temperature of no more than 85°C above ambient temperature. It is then stored in a 60 000 t capacity clinker silo. As coal and gypsum are supplied to the site by marine vessels, a 3.5 km Jetty conveyor transports these materials to the site. All vessel unloading facilities at the Jetty were supplied by Holcim Indonesia. The Indonesian volatile coal is ground in a thyssenkrupp Industrial Solutions roller mill DOROL and stored in two coal bins.
This is part one of a two-part article written for World Cement’s February issue and abridged for the website. Subscribers can read the full issue by signing in, and can also catch up on-the-go via our new app for Apple and Android. Non-subscribers can access a preview of the December 2015 issue here.
Read the article online at: https://www.worldcement.com/special-reports/04022016/tuban-projects-prove-success-part-one/