overview

Mechanical installation of a cement production line in Kolomna (RU)

Industry

Stone/Earth/Cement

Status

completed

Country

Kolomna, Russia

Services

Construction management & supervision, Mechanical assembly, Project Management

15,000 tonnes of technological equipment, 30,000 drawings, approx. 2,000 lorries and 320 SGS employees at peak times – this describes the major project at Shurovo Cement in Kolomna. Our #SGSteam was responsible for the mechanical assembly of the clinker production line.

320

Employees

Months of construction time

21.500

Tonnes of equipment

Project data

Commissioner: AE&E Austria GmbH & Co KG
Customer: Shurovo Cement | Holcim Group
Industry: Stone/Earth/Cement
Construction location: Kolomna, Russia
Contruction period: 14 months
Contributors: at peak times 320 SGS employees

Scope of delivery & service

Mechanical assembly of a clinker production line and assembly of 6,500 tonnes of conveyor systems, including the silo filling system and unloaders, coal mills and several dust extraction systems.

Assembly of:

Crusher plant including conveyor belts
6.2 km non-stop tubular belt conveyor 2,500 tonnes
Limestone and mixed material storage halls – material delivery – receivers 1,100 t
Raw mill
Preheating & precalcination
Dry rotary kiln
Thermal insulation 25,000 m²
Bag filter systems (kiln/mill and clinker dust extraction)
Conversion of cement mills
Cement silos
Coal storage, transport 580 t and grinding
Slag drying system 380 t

Our scope of services

The #SGSteam was responsible for the mechanical assembly of the cement production line and the installation of 6,500 tonnes of conveyor systems, including the silo filling system and unloaders, coal mills and several dust extraction systems.

About the project

Mechanical installation of one of the largest drying kilns in Russia. Some project highlights include:

One dry rotary kiln replaces two wet rotary kilns.
Cement capacity increased from one million to 2.1 million tonnes per year.
Energy consumption reduced from 120 to 100 kWh/t.
Heat energy consumption reduced from 6000 kJ/kg to 3400 kJ/kg.

A project of this size and complexity naturally presents a multitude of challenges. Thanks to our local branch and Western European specialists, we completed the project on time and with the usual SGS quality. Our strong international presence once again proved to be a major advantage for our customer.

Christian Gittmaier

Managing Director Key Account Management, SGS Industrial Services GmbH

Challenges are necessary to be successful

The installation of the most important elements of the production line was completed within a year. A customised database was created to manage the logistical effort. This enabled more than 2,000 truckloads to be safely stored and transported. Working hand in hand as a team with concrete, steel and equipment builders was crucial to the success of the project. During the main phase of the project, the availability of construction cranes and the rights of use for the construction sites changed on a daily basis. This required a high degree of flexibility. Added to this was the limited space available – 4,000 tonnes of equipment had to be accommodated in less than 100 m² in the preheater area. Careful planning and good coordination ensured safe working conditions and adherence to a tight schedule. Another factor was the high dead weight of one of the kiln components, which weighed 180 tonnes. Our #SGSteam managed the heavy lift with two mobile cranes, each with a capacity of 500 tonnes.

About our customer Shurovo Cement / Holcim

Shurovo Cement is a subsidiary of the global building materials group Holcim Ltd., whose core areas are cement, gravel and concrete. The company, with around 63,000 employees worldwide, offers innovative and sustainable building solutions.