PT Semen Gresik retrofits Cross-Bar® coolers

Two Cross-Bar® coolers help to lift the capacity of Tuban cement plant’s lines 2 and 3

The newly installed FLSmidth Cross-Bar® cooler

The PT Semen Indonesia Group (PT SMI) has ambitious plans to increase its production capacity across the group to 75 million tons per annum. According to Bambang Tridoso, General Manager of PT Semen Gresik, achieving this capacity will help enable PT SMI to meet the region’s growing market demand. The capacity expansion is based on a multifaceted approach, including construction of new plants, acquisition and plant upgrades.

For PT Semen Gresik’s Tuban plant, this involved upgrading the plant capacity from 7,500 to 9,000 tpd. The upgrade process started with line 1 and included preheater feed splits, new top cyclones, extension of calciners, new ID fans, new burners, refurbishment of existing kiln drives from single drive to dual drive and cooler retrofits, all supplied by FLSmidth.

“Upgrades are particularly important as capacity can be quickly and easily expanded at a reasonable cost,” says Bambang Tridoso. Tuban’s approach to upgrading was based on selecting technology compatible with existing plant operations, benchmarking equipment, and ease of maintenance.

Selection criteria
Work on lines 2 and 3 commenced shortly after the newly upgraded line 1 was commissioned in 2010. Retrofitting coolers on the two lines was an important part of the upgrade process. After an extensive evaluation of several potential cooler suppliers, the choice fell on FLSmidth. According to Bambang Tridoso, FLSmidth was chosen for its extensive experience in cement production processes, tried-and-tested product technology and its competitive pricing: 

“We wanted the cooler supplier to have an established international presence and demonstrate outstanding experience in cement technology with equipment installed in various countries.” - Bambang Tridoso, General Manager of PT Semen Gresik

The FLSmidth Cross-Bar® cooler units being moved from the pre-assembly area

Other important factors were performance guarantees for power consumption, and clinker temperature. Since all other components were already in operation, FLSmidth also needed to commit to a very tight time schedule. Furthermore, PT SMI required that some of the major equipment components were fabricated locally.

Omar Rabia, Sales Manager at FLSmidth, who has worked closely with Tuban since 2010, says, “We demonstrated the ability to reuse existing equipment, specifically the cooler fans, which would contribute significantly to reducing investment costs and payback time.”

The first step involved FLSmidth’s technical specialists working closely with Tuban’s engineering department to determine reusing as much of the existing equipment as possible. This included cooler fans, cooler casing and an ABC™ inlet, which had already been supplied. The primary project would then involve replacing most of the internals of the old grate coolers with FLSmidth’s Cross-Bar coolers.

Fast installation and commissioning
The agreement between FLSmidth and PT SMI involved the Tuban staff performing most of the upgrade themselves. As part of the brief to support with specialist supervision and commissioning assistance, FLSmidth was asked to help with competency transfer.

Three FLSmidth supervisors were onsite to assist and answer questions associated with their specific areas of expertise. The mechanical supervisor helped to ensure equipment was installed correctly and that all tests were carried out according to instructions. The electrical supervisor assisted with wiring and electrical installations, while the commissioning supervisor oversaw start-up and subsequent optimisation of the coolers, including meeting performance guarantees. The plant was restarted vertically without stoppage until performance guarantee testing was complete.

Søren Skov Hansen, Project Manager at FLSmidth, explains how FLSmidth’s supervisors helped to ensure a safe and smooth startup:

“They possess very important core knowledge, with intimate details of how to install and operate equipment. Having this available onsite is highly valuable. Not only does it save time during commissioning, because they are there to answer questions immediately, but it also reduces the risk of problems during the start-up phase.” - Søren Skov Hansen, Project Manager at FLSmidth

The first cooler was erected and commissioned in just 30 days. The only unexpected challenge was a hydraulic pipe leakage, which did not delay the process. The second installation was performed even faster and with no interruptions.

The grate-line was removed from the old cooler

Remote monitoring
To help optimise the coolers’ performance, the plant was monitored in real time remotely via the internet for several weeks following commissioning. Søren Skov Hansen explains that this was an additional service to ensure long-term smooth running of the plant, saying, “It is a very efficient way for us to provide any necessary advice on how Tuban can optimise operations.”

Bambang Tridoso and his colleagues are highly satisfied with the successful retrofit of the two coolers, which increased the overall plant capacity. The upgraded plant lines as well as the addition of a new 9000 tpd line 4, delivered by FLSmidth and commissioned in 2012, has now taken PT SMI a step further on its road towards its long-term goals, and Bambang Tridoso is keen for the relationship with FLSmidth to continue. He concludes, “We would be happy to work with FLSmidth again, because we are familiar with the performance of the equipment, which has demonstrated stable optimal conditions during operation.”


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