Modular magic

Within the last few years, modular cement grinding plants have attracted the interest of investors and operators. Modular plants can be implemented within schedules of 12 months. Transport costs for raw materials and final products can be reduced, as the modular plants do not require as much space as compared to large, stationary plants and can therefore be located closer to the relevant infrastructure. Another increasingly important aspect is the impact on the environment, which is considerably lower with modular plants.

In regions lacking construction materials, small grinding units can be very important, with regard to availability, prices, and the logistics. Moreover, the manageable construction period is another incentive for investors.

New concepts aiming at the cost-effective handling of raw materials and the reduction of transport costs have been developed by Intercem, all of which will considerably lower a plant’s impact on the environment.

In highly industrialised countries, larger production units still dominate. But many regions are still a long way from this level of industrialisation. There are still many areas, which are underserved with construction materials and, as a consequence, cement prices are very high. Smaller grinding units might be highly attractive, especially from a logistical point of view. The reduction of transport costs for raw materials, as well as for cement and other finished products, has a positive influence on cement prices.

The decision for the development of local grinding capacities depends on many different preconditions. The basis is the demand for cement and cement-containing binding agents in the relevant region. It is also of crucial importance that the necessary raw materials, local companies with expertise in parts production and assembly, and sufficiently trained personnel are all available. Of course, a reliable energy supply and transport routes are also essential. Political stability in the region in question will also influence the decision of potential investors. When all these preconditions are met, the development and construction of local, modular grinding capacities can be started. The manageable timeframe and costs are arguments for the construction of a modular grinding system, with schedules of about 12 months for the completion of a project being feasible.

The modular grinding system developed by Intercem, InterMod, enables the realisation of production capacities of 20 – 50 tph. With InterMod, a complete grinding station is supplied, mainly on the basis of a 40 in. container size. It can be assembled and commissioned within 4 to 6 weeks onsite. Here, only reliable, tried-and-tested aggregates are used, which contributes to the economic efficiency and high availability of the plant with easy handling and service.

The possibility to also integrate used and refurbished (second hand) ball mills is a further opportunity to save costs and – not to forget – to act sustainably. In cases where only new elements are requested, a new ball mill is of course the other recommendable option.

As an alternative to ball mills, vertical roller mills (VRMs) can also be employed for modular grinding plants, where VRMs may allow higher capacities than ball mills, depending on their size.

In the same short period of time, the modular plants can be disassembled and stored, or rebuilt, in another location. This enables the operator to react in a flexible way to economic, cultural, political, or environmental modifications.

The modular grinding plant InterMod is well suited to pave the way for the first steps of – among others – cement traders and/or investors from outside the industry into the manufacture of cements and binding agents. Cement can be produced exactly where it is needed, in sufficient quantities and to the required quality. Traders can produce their own cement and react flexibly to customers’ needs; they become independent from suppliers and can adapt to changing local circumstances.

Here are the advantages of modular grinding plants at a glance:

• Flexible, built-up in modules
• Fast delivery
• Pre-assembled/quick installation
• Compact design
• Minor civil works
• Removable
• Low investment cost
• Small plot size
• Latest technology

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Read the article online at: https://www.worldcement.com/special-reports/19052023/modular-magic/