Supplying a second line for a Colombian cement plant
When designing the new plant in Barranquilla, Atlántico/Colombia in 2011, it was decided to start with a single production line but to anticipate the addition of a second line at some future point in time. As for the first production line Gebr. Pfeiffer SE was also chosen as supplier of the second one.
Back in 2011, the Ruiseco family started, and was sole owner of their new cement company, Ultracem SAS in Barranquilla, Atlántico/Colombia. At the time, brothers Juan Manuel Ruiseco Gutierrez (CEO) and Nicolas Ruiseco Gutierrez (Executive VP) felt the Colombian cement market was ripe for a new start-up cement plant but they were not sure how long the strong market conditions would last. When designing the new plant, it was decided to start with a single production line but to anticipate the addition of a second line at some future point in time.
For this reason, the material storage area and feed silos were designed to have enough capacity for both productions lines, assuming that extra space would eventually be needed. This design gamble paid off. As the Colombian cement market continued to strengthen over the next few years, the company was able to proceed with commissioning of the second production line at the end of 2015, in order to double their production capacity.
The initial line was supplied by Gebr. Pfeiffer featuring a clinker grinding mill specifically designed to grind a variety of product, ranging from OPC to slag and limestone cements. All equipment was delivered within one year of the contract signing and the erection and start-up was completed in just nine months.
The scope of production line one (Commissioned in October 2013) included the following:
MPS 3350 BC vertical roller mill with patented “Lift and Swing” technology
SLS 2900 BC high efficiency classifier
plant equipment consisting of a bagfilter, fan, hot gas generator, bucket elevator, weigh feeder and two conveyors
feed system with deduster and metal separator
various fabricated parts including a 20 t silo, ducting, dampers and stack
instrumentation
engineering services
As a result of the successful project management, support and execution of the first line, Ultracem had the confidence to stay with Gebr. Pfeiffer for supplying the second line as well. The initial OEM guarantee for production line one was 65 t/h but the plant was actually able to produce close to 100 t/h. For production line two, Ultracem wanted to duplicate the increased production levels. In order to keep within the safety parameters of the equipment, it was agreed to increase the size of both the gearbox and mill motor for each of the production lines. The only changes in scope between the first order and the second one were the increased capacity of the gear box (from 1750 kw to 2000 kw) and mill motor (from 1750 kw to accommodate up to 1950 kw) and increasing the number of packing plant spouts to 14, up from the 8 initially installed on production line one.
Current production rates consist of:
mill production from Line One:
structural cement up to 70 t/h
general use cement up to 90 t/h
mill production from Line Two:
general use cement up to 90 t/h
To date, Ultracem is pleased with their average production rates as they continue to expand their market share in the region.
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