Cement, Energy and Environment

47 Clinker Plant SN Item Unit Quantity 1 Volume of Concrete M 3 65000 - 75000 2 Weight of Structural Steel for Civil Construction Tons 6000 - 7125 3 Weight of Equipment Tons 11500 - 12500 4 Weight of non standard parts Tons 800 - 1000 Cement Grinding Plant SN Item Unit Quantity 1 Volume of Concrete M 3 25000 - 30000 2 Weight of Structural Steel for Civil Construction Tons 2500 – 3000 3 Weight of Equipment Tons 3000 - 3500 4 Weight of non standard parts Tons 300 - 450 Waste Heat Recovery Power Plant SN Item Unit Quantity 1 Volume of Concrete M 3 8000 - 10000 2 Weight of Structural Steel for Civil Construction Tons 650 – 800 3 Weight of Equipment Tons 3000 - 3200 4 Weight of non standard parts Tons 500 - 600 The above only gives broad Bill of Quantity, however, department / section wise Bill of Quantity should be prepared for progress monitoring based on design & layout. In case of Civil Construction estimated quantity of excavation, building wise / floor wise concrete quantity should be given by the design consultant. 13. Quality Assurance Plan & Inspection In several projects, it is seen that this particular aspect is overlooked considering that it is the responsibility of the equipment supplier towards warranty & guaranty against manufacturing defect. While this is true but to have Quality Assurance Plan from the manufacturer for the main / major equipment at different stages of its manufacturing and having it inspected by the company engineer ensures that you get the right thing for long term trouble free operation. Further, it also ensures timely delivery of equipment. Basically, such inspection should be done by the maintenance staff / operation staff of the company who are going to run the plant after commissioning to get good knowledge of the equipment. 14. Cash Flow For the Project Head to perform his work peacefully & efficiently , the Finance Head must ask for cash flow chart from the Project Head and organises it after due deliberation. The cash flow should synchronise with the Project Implementation Schedule and project progress. Cash Flow / Fund Requirement based on the projected Project Cost and Project Schedule is essential. It can be seen that if activities are well planned and execution follows same, monthly fund requirement would range between 1.5% to 5% only of the total budgeted project cost for the project period of twenty six months with peak going up to 8% in one or two months. 15. Conclusion Three million ton per annum cement plant with 6500/7500 TPD clinker and 10,000 TPD blended cement at present appears to be most optimised economic plant size with reliable and proven equipments available in the market. Depending on the cost of raw materials, power tariff, market price realization, internal rate of return (IRR) can be expected between 35% to 30% at capacity utilization of 85%. The cement grinding unit can be split located as per proximity to the market and availability of the additive material for blended cement production. Implementation period can be reduced from twenty six months to twenty four months, if supplier commits to advance delivery of equipments which should match with handing over of civil fronts for erection by deploying additional construction machineries and manpower. The above illustration is made based on experience in Project Engineering & Management in different companies national as well as international (MNC) and issues / constraints faced while executing the Project has been addressed for guidance and benefit of project executives. *****