AsiAn cement plAnt

INTERNATIONAL CEMENT REVIEW JUne 2012

in myanmar, there are seven states and seven divisions. shan state is the largest state in terms of land area and it can

be sub-divided in to three parts: eastern, northern and southern shan state. Dragon cement’s plant is the first wet-process rotary kiln cement facility to be built in southern shan state. it is owned by Dragon cement company ltd (Dccl) and is under the umbrella of the Ruby Dragon group of companies.

the parent company was founded at 1995 and has had a wide variety of businesses involved in the mining of precious gemstones, gold and antimony ore as well as the manufacture of wine, companies that polish jade and ruby stones, a sugar mill, plus involvement in agriculture and vegetable foodstuffs, soft drinks and an 84-room resort hotel and travel tour business.

the company has two cement production lines supplied by Jiangsu pengfei Group of china. erection was started on 1 January 2010 and the first line was commissioned on 5 February 2011. the second line is still being installed to produce cement to the en 197-1:2000 standard. the plant produces cem i 42.5n portland cement that can be supplied to the customer either in bulk or in 50kg bags.

Dccl’s market share in southern shan state is about 75 per cent and about 85 per cent in Kayah state. it has some 820 fully-trained staff.

Plant sitethe site is located at pinlaung township, southern shan state. its geographic

coordinates are 96° 40’ 13"e longitude and 20° 27’ 50"n latitude. the plant is situated close to the Aungban-loaikaw highway and about 8km from the nearest railway station, giving it a strategic position for transportation. the total site area is about 730 acres and has a very gentle slope but only a small overall height difference and so is very suitable for the construction of a cement plant.

IInside the Dragonby Thaung Myint, Dragon Cement Co Ltd, Myanmar

Following on from the full international cement report on the lesser- known market of Myanmar in April’s issue, Thuang Myint returns to give a unique glimpse into cement production at one of the country’s newest cement producers – Dragon Cement. As well as describing the plant and the production process, he offers a full breakdown of the chemical compositions of fuel and raw materials that are used at the facility.

Dragon cement plant, shan state, myanmar

Table 1: climate conditions

Average annual temperature (°c) 23.8maximum temperature (°c) 31.6mininum temperature (°c) 3.7Average annual rainfall (mm) 1897Average annual wind speed (m/s) 2.16perennial leading wind direction ne at winter sW at monsoonelevation above sea level (m) 1259

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AsiAn cement plAnt

JUne 2012 INTERNATIONAL CEMENT REVIEW

Raw materialsLimestoneFor this project, 317,451.89tpa of limestone is required. Dccl owns a limestone mine, which is 1km from the plant site. After being exploited and crushed, limestone is conveyed to the plant site by belt conveyor. the total limestone reserve of the mine is about 10mt, which can serve the plant for more than 30 years. the average chemical composition of limestone is shown in table 3.

Sandstonethe sandstone (see table 4) comes from a mine located about 1km from the plant site and has an abundant reserve. After the project was put into production, sandstone consumption was approximately 41,459tpa.

ClayAfter the cement plant was completed, 37,605tpa of clay materials was required (table 4), which again comes from a mine near the plant site and has enough reserves for the life of the cement plant.

Iron orethe plant needs 4857tpa of iron ore (see table 5). it receives supplies by truck from the local iron works, which is located 24km away from the cement plant site at pinlaung.

Table 2: list of main process equipment at Dragon Cement

SN Name Model Capacity (tph) Qty Remarks

1 Jaw crusher (first stage) peF600×900 210 1 limestone crushing Hammer crusher (second stage) pc1618 200~280 1 2 Wet raw mill f2.6x13m 42 2 raw-slurry grinding3 Air swept steel ball coal mill f2.4x4.75m 10 2 coal grinding4 Wet-process rotary kiln 3.3/3.5x125m 400tpd 2 clinker sintering5 single tube drum cooler f3.0x32m 25 2 clinker cooling6 Raw coal drying machine f2.4x18m 15 2 raw coal drying7 cement ball mill (close circuit) f2.6x10m 28 2 cement grinding8 inline packer Four spouts 60 2 cement packing

Table 3: average chemical composition of limestone

Loss SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O Cl SO3 Total(%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)

42.67 1.07 0.13 0.15 54.82 0.34 0.03 0.02 0.016 - 99.25

Table 4: average chemical composition of clay and sandstone

Chemical Loss SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O Cl SO3 Totalcomposition (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)

clay 14.69 52.33 13.79 5.91 10.59 0.99 1.01 0.08 0.02 - 99.41sandstone 3.79 78.82 8.70 5.12 0.69 1.80 1.03 0.04 0.001 - 99.99

Table 5: average chemical composition of iron ore

Loss SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O Cl SO3 Total(%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)12.66 16.15 21.55 47.46 00.06 0.02 0.34 0.03 - - 98.27

View of the first wet kiln line at Dragon cement

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AsiAn cement plAnt

INTERNATIONAL CEMENT REVIEW JUne 2012

GypsumAt Dccl cement production required 9969.15tpa of gypsum (see table 6), which is located at the maukmae gypsum mine, some 230km from the plant site and transported by truck.

Raw coal (see tables 7 & 8)plant consumption of raw coal is 186,276tpa. some 180,255tpa is used by the kiln and 6020tpa is used for drying. the plant uses lignite coal, from fixed mines selected by Dccl. coal reserves are abundant and transported by truck.

Power sourcethe annual electric power consumption is 2640×104kWh. the total installed

capacity is 11,573kW, the calculated load is 7949kW and the total installed capacity of power transformer is 2×6300kVA. power

is state supplied through the electric network from Kalaw, the local transformer substation and transmitted through 66kV aerial cables. the transmission distance is about 25km. Water sourceDaily water consumption of the plant is 6104.64m3, of which 5924.64m3 is used in cement production and 150m3 is for general living use. circulating water consumption is 394.3m3 and the supplemental water is 1062.3m3.

Water for production use comes from

Table 8: coal ash chemical composition

Loss SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O Cl SO3 Total(%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)

0.00 29.58 16.18 13.21 17.27 1.85 - - - 17.64 95.73

Table 6: chemical composition of gypsum

Loss (%) CaO (%) SO3 (%) Total (%)4.82 39.71 53.95 98.48

Table 7: lignite coal industrial analysis data

Aad (%) Mt (%) Vad (%) FCad (%) St,ad (%) Qnet, ad (kJ/kg)

19.81 18.50 34.95 21.09 5.65 13,537

top left: Dragon cement’s crusher hammer

top right: raw materials are fed to the agitator to make a slurry that can be fed to the wet-process kiln

Bottom: two electrostatic precipitators at Dragon cement

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AsiAn cement plAnt

JUne 2012 INTERNATIONAL CEMENT REVIEW

a close by river, some 0.5km away. its water flow is more than 3m3/s in low flow seasons. Water for general living use will be provided by a spring near the plant site.

Wet-process production systemAll raw materials (except limestone) and fuel are transported to the plant by truck and stored in a combined storage house or sheds. two stages of crushing are carried out for limestone and a single-stage crushing for gypsum and raw coal. the raw materials are fed to a wet mill to grind after being homogenised in raw slurry silos. Raw slurry is drained into a mixing basin and stored for kiln use.

meanwhile, an air-swept steel ball coal mill is used to prepare coal powder for kiln fuel. this coal powder is stored in a dedicated bin at the kiln head. the wet kiln manufactures the clinker that is cooled through a single tube cooler.

subsequently, the clinker is conveyed into the combined storage house. it is then ground by a closed cement mill system, and stored in silos and packed by a stationary four-spout packer. Bagged cement is stored in a finished storage house and bulk cement is stored in bulk loading silos. ________I

Table 12: modules, mineral content and chemical composition of clinker

Chemical composition (%) siO2 21.66 Al2O3 4.98 Fe2O3 3.69 caO 65.28 mgO 0.94 K2O 0.31 na2O 0.04 sO3 1.73 cl 0.02

Modulus KH (Ksk) 0.900 sm (silica acid ratio) 2.50 Am (alumina ratio) 1.35

Mineral content (%) c3s 57.46 c2s 18.71 c3A 6.96 c4AF 11.21

Quantity of liquid phase (%) 1450°c 26.25

Table 11: modules and chemical composition of raw slurry

Chemical composition (%) loss 36.09 siO2 13.29 Al2O3 2.40 Fe2O3 1.70 caO 45.05 mgO 0.54 K2O 0.22 na2O 0.03 sO3 0.18 cl 0.01

Sulphur alkali ratio molsO3/(molK2O+molna2O/2) 0.78

Modulus KH (Ksk) 1.087 sm (silica acid ratio) 3.243 Am (alumina ratio) 1.418

Table 10: cement proportioning

Cement Type Clinker (%) Gypsum (%)cem i 425 n 97 3

Table 9: theoretical consumption quota of fuel and raw materials

Consumption of raw materials on dry basis Fuel consumption quota (t/t clinker) (t/t clinker)limestone sandstone clay iron ore For kiln use1.170 0.142 0.126 0.017 0.509

Dragon cement’s logo

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