Successful plant implementation by FLSmidth
With the increasing need for dams, bridges, housing projects and other infrastructure generating more construction projects, the demand for cement in Nepal is growing year on year. Cement manufacturers are looking to build new plants in order to expand cement production capacity.
In a move that reflects this demand, the Saurabh Group awarded the Sarbottam Cement Plant´s project in Nepal to FLSmidth during the year 2012. The first contract awarded on FLSmidth was for the supply of a clinker production line. This is the first full-scope supply of equipment undertaken by FLSmidth in Nepal.
Clinker production line: Scope of supply
The project supply included everything from the crusher and mills (raw & coal) to pyro-processing, electrical systems and automation as listed below.
òLimestone crusher (Impact - 480 kW)
òLimestone stacker (luffing) & bridge reclaimer, material handling equipment
òRaw mill grinding ATOX 30 & 32.5 RAR air separator
òRaw mill & coal mill bag house & cooler ESP
òFRF silo (16 x 28 m)
òPreheater: 5-stage single string ILC
òRotary kiln (3.15 x 47 m)
òClinker cooler: FLSmidth Cross-Bar® Cooler 6 x 29 with clinker breaker
òCoal mill TIRAX® ball mill (TM30 x 4.5 + 2.30) with air separator RTKM 17.5
òElectrical, automation & instrumentation items (from 33 kW incomer to control system complete design and supply)
"Even as the project execution was going on, we could see that FLSmidth´s team was fulfilling their commitment of lowest thermal and electrical energy consumption, and also honouring the trust that we placed in them through their meticulous planning, effort and cooperation," says Bishnu Prasad Neupane, Managing Director of Sarbottam Cement.
"This project was planned in such a way that there were no hurdles at site for want of drawing or materials, which relieved us of stress and saved our time in follow-up activities with the supplier" adds Bimal Kumar Sawarthia, Finance Director of Sarbottam Cement.
Confidence reposed on FLSmidth with an order for cement grinding system Appreciating FLSmidth´s supply and execution of the clinker production line, Sarbottam Cement immediately issued an order on FLSmidth for a cement grinding system also, and the project got effective since August 2014.
Major equipment supplied under the contract for cement grinding system were:
- Gypsum Crusher: 75 t/h
- VRM OKTMT 25-3 (1300 kW): 70 t/h
- Air Separator ROKSH 50: 146 rpm
- Bag Filter (Jet Pulse): 185,400 m3/h
- 8-spout packing and loading machine: 2,400 bags/h (or) 120 t/h
- All Auxiliary Equipment
- Complete plant Electrical & Automation
The OKTMT vertical roller mill was successfully commissioned on 30th May, 2016. The 1200 tpd cement plant is located about 50 km from Lumbini, the birthplace of the Buddha.
Several ´firsts´ in Nepal
In addition to the fact that Sarbottam Cement is the first project for which equipment is supplied by FLSmidth in Nepal, the Sarbottam Cement plant provides the first ATOXTMT vertical roller mill for raw grinding and OKÖ vertical roller mill for cement grinding at a cement plant in Nepal. Moreover, it is the first Expert Control System (ECSTMT), Intelligent Motor Control Centre (IMCC) and intelligent network system to be installed in Nepal as well. Sarbottam Cement has also installed Nepal´s first thermal power plant.
Project timeline (Clinker production line)
- Signing of the contract: 7th June, 2012
- Effective date of contract: 15th October, 2012
- Completion of engineering: 30th December, 2013
- Supply of major equipment: 6th May, 2014
- Commissioning: December 2014
- First clinker achieved: 11:00 pm on 17th January, 2015
Project timeline (Cement grinding system)
- Signing of the contract: 28th February, 2014
- Effective date of contract: 12th August, 2014
- Commissioning: 30th May, 2016
The Saurabh Group was established in 1964 by well-known businessman Lila Ram Neupane, initially as a trading agency and a fleet of bus services. After coming to Nepal from Myanmar, the group diversified its activities when the founder´s son, Bishnu Prasad Neupane, joined the group in 1986. The group is now mainly involved in the production of cement, steel, tea, spun yarn, PP woven fabrics, calcium carbonates and other products.
This article has been authored by Manoj Mandhana, Deputy General Manager, Cement Division- Project Management, FLSmidth.
(Communication by the management of the company)