New cement grinding system in Oman

May 9, 2017 Manoj Mandhana

Based on a proven track record of providing highly reliable technology, FLSmidth was awarded its first EPC project in Oman.

Producer of high-quality cement
Oman Cement Company (S.A.O.G), a joint stock company in the Sultanate of Oman, was established in 1978 as a visionary growth of His Majesty Sultan Qaboos Bin Said. Over the years, the company has built an excellent reputation as a producer of high-quality cement, meeting the cement quality standards of Oman, European and American markets. Oman Cement Company (OCC) is the only manufacturing company in Oman to have won the prestigious ‘His Majesty Trophy for Best Factory’ 10 times.

Prime supplier of cement
The OCC cement production facility is located in the Rusayl Industrial Area, 60 km from Port Sultan Qaboos, Muscat, and was first commissioned in 1983. It has continued to expand its facilities, reaching a production capacity of 2.4 million tonnes per year in 2011. Driven by increasing local demand, partly due to infrastructure developments and future exportation prospects, the company decided to add a fifth cement grinding unit to the four ball mills already in operation. This addition was part of OCC’s efforts to enhance its cement production capacity by one million tonnes per year by 2016. Due to its remarkable, reliable track record, FLSmidth was awarded as the prime supplier for this project – its first Engineering, Procurement and Construction (EPC) project in Oman.

Scope of supply
The project’s scope of supply included a full range of equipment for a 150 tonnes-per-hour closed ball mill system, including gypsum storage units, cement bulk loading terminal and two cement silos as well as full electrical, instrumentation, automation systems and safety systems. The layout of the ball mill system allows for additional future expansion of FLSmidth’s equipment including a roller press, packing plant and clinker back feeder.

Encouraging performance
The new ball mill system was commissioned in May 2016 and handed over to the client for full operation. Performance guarantees were successfully achieved without any hurdles leading to smooth performance of the plant.

Project manager at FLSmidth, Manoj Mandhana, is satisfied that the turnkey project has run very smoothly throughout, despite some country-specific challenges.

“We worked closely with OCC and the Muscat municipality to get the necessary workers’ visas and construction permits as part of contractual obligations. Adhering to regulations was time-consuming, but required for successful implementation.” - Manoj Mandhana, Project Manager at FLSmidth

‘Zero Incident’
One million hours worked – zero Lost-Time Injuries (LTIs). This outstanding safety milestone was achieved on 22 November 2015, a year after construction began. It was the result of a dedicated focus on a ‘Zero Incident’ mission, in which the entire project site team adopted a strong approach towards implementing and practicing safety on site.

This collective approach by FLSmidth’s onsite staff supported by the head office helped in aligning the project’s sub-contractor with FLSmidth’s safety values and policies.

Project quantities
Civil works
Excavation - 21,827 m3
PCC - 9,174 m2
Rebar - 1,836 tonnes
Concrete - 15,157 m3
Form work - 32,774 m2
Steel structures - 2,875 tonnes
Cladding - 22,299 m2
Mechanical works
Equipment - 1,850 tonnes
Plate fabrication - 400 tonnes
Thermal insulation - 4,850 m2
Piping - 6,000 m
Electrical works
HT cable - 4,450 m
LT cable - 60,785 m
Control and signal cables - 86,750 m
Number termination - 5,966
Cable tray/ladder - 11,218 m

Manoj Mandhana

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