The cement grinding plant is designed with a capacity of 260 tph. Two cement silos, each with 10 000 t capacity, and one silo with 5000 t storage capacity, provide the flexibility to either bulk load cement into silo trucks or to further transport the cement to the packing plant. The packing plant consists of two Rotor packers, each designed to fill 3600 bags per hour. These bags are then either transported to the truck loading station or, alternatively, to a palletising plant where the bags can be automatically put on pallets. Quality control of the different products during the production process is supported by the thyssenkrupp Industrial Solutions POLAB system, which consists of field samplers, a pneumatic conveying system from the field to the laboratory and analysing devices located in the laboratory. To effectively address the needs of this scope of supply, thyssenkrupp Industrial Solutions involved its Asia Pacific office in Singapore in the contract execution and founded the Jakarta office, which was assigned to the coordination of the local fabrication and the construction works.
At the beginning of the site activities, Holcim and thyssenkrupp Industrial Solutions shared the same site office, which is now used as the Holcim CSR office to provide a closer relationship with the local community. When selecting local contractors for important site activities, the Human Resources team focused on recruiting from nearby villages. Due to the focus on safe working conditions applied by both parties, the Lost Time Incident figures could be kept at a low level for the complete project duration.
Figure 3. Jetty for coal and gypsum discharge and cement loading.
Even before the first clinker and cement production line was fully operational, Holcim Indonesia also awarded the second line to thyssenkrupp Industrial Solutions. With the exception of the crushing plant and the palletising plant, the scope of supply for the second line was identical to the first one. To provide the possibility of shipping cement using marine vessels, one of the 10 000 t cement silos for line 2 was located close to the Jetty (Figure 3).
The challenges of conducting the performance tests on the first line while simultaneously conducting construction work on the second were managed by the Holcim and thyssenkrupp Industrial Solutions site teams using a high level of cooperation and communication. After the last performance test for line 2 was conducted in May 2015, Holcim launched the common inauguration of the two production lines in August 2015. Following a Holcim internal plant audit, Holcim and Industrial Solutions have conducted a two-day common After Action Review meeting to exchange what they have learnt and suggest possible improvements. Having completed the last punch list items, thyssenkrupp Industrial Solutions has already cleared the Tuban site and has handed over their site office to Holcim. This office will now be used for the Holcim internal EVE-program, which provides the opportunity to gain hands-on, technical experience in the cement production process to 15 young students each year. This program qualifies talented young students to join further studies and also for a career within the organisation of Holcim Indonesia.
This is part two 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/05022016/tuban-projects-prove-success-part-two/