Due to the great importance of cement manufacturing in the production of concrete and building materials necessary for architectural development in the country as it is one of the essential and indispensable commodity in building and construction process as well as the urban and economic development in addition to the increasing market demand for this material and its rising prices.
Al-Jamahiriya owns 7 cement production plants in addition to the company owned Al- Borj Cement Plant, which is now at the production phase by the end of 2005, the total design capacity of said plants is approximately 7.5 ton per year of sulfur resistant cement production, used by GMRA and in special uses i.e. the existing design capacity of ordinary Portland cement is 5.1 tons per year.
The following table shows the existing plants and their design capacity.
|
Annual Design Capacity (million ton) |
Plant's Name |
|
1 |
Zleiten Cement Plant |
|
1 |
Lubda Cement Plant |
|
1 |
Suk Al Khoms Cement Plant |
|
0.3 |
Margeb Cement Plant |
|
1 |
Al Haware Cement Plant |
|
0.8 |
Benghazi Cement Plant |
|
1 |
Al Fettaih Cement Plant |
|
1.4 |
Al Borj Cement Plant |
At present, Great Jamahiriya is witnessing a huge development phase in various fields. Cement substance is considered the major element in this development whether in the industrial or construction industry.
First Production Line:
Due to the inability of the company to find the required available cement quantities, whether from its own production units for the production of building materials or for the implementation of projects. The Arab Union Contracting Co. has decided to build a cement plant with an annual production capacity of 1.400.000 tons. Approval has already been obtained from the G.P.C. in this respect to sign a contract with a major firm to achieve and implement this project. Specialized companies in this field have been addressed to submit bides.
F.L.S. Company of Denmark was awarded the contract and a contract was concluded for the supply and erection of the plant operated by heavy fuel oil, with possibility of operating the plant by natural gas, provided that the Arab Union Contracting Company executes the civil works in collaboration with companies doing business with it in the past.
The Company signed a contract with the Intenl. S.S. B. Co. to execute the civil works against recruitment provision of technical and ordinary manpower.
The Arab Union Contracting Co. shall make available materials, equipment and machinery necessary for the execution. A contract was also concluded with the Industrial Research Center to undertake geophysical and mining investigations for raw materials and ones quarries in Majer Area, Modawara Locality, Zleitin in a surface area of 84 Hectares, with 59 Hectares surface area for the first line. Execution has already started in this line since the beginning of Jan. 2003 and the production capacity reached 4.200 tons of Kilnkar i.e. 4.400 tons of Portland cement, amounting to 88.000 bags of cement daily. All installation works have been terminated in this plant (metal, mechanical and electric structures) by the end of March 2005. This line consists of the following:
1- Limestone and mud quarry in Zleiten.
2- Pure limestone quarry in Zleiten.
3- Plaster quarry in Bir Al Ghanum in Al Zawia.
Secondly: Major Plant Sections:
Limestone and Clay Crusher:
1- It total production capacity in raw material is 300 ton/hour. i.e. 10.400 ton each unit. It can crush rocks 1.5 m. long i.e. 2000 kg in weight each rock.
2- Raw Materials Conveyor Chain:
Raw materials produced by crusher are transported to raw materials store by a mechanical chain conveyor from crusher to the raw materials store.
3- Limestone and Clay Storage:
Raw materials produced by crusher are stored in raw materials store having 1.800 sqm. Surface area with storing dimension reaching 52.500 tons of materials:
40.000 tons of materials.
5000 tons of clay.
5.000 ton of marble.
2.500 tons of iron oxide which is purchase from Iron and Steel Factory in Misurata.
4- Raw Mill Feed:
In this section raw mill feed is achieved as per weights specified for different materials by moving (mechanical conveyors and special scales for this phase of production.
5- Raw Mill:
It ahs a production capacity of 330 tons per/h where materials from raw materials store are transported by mill feed and transformed into power aspirated by special fans that take them to harmonization tank by special channels.
6- C.F.Silo:
Storage capacity of this silo in 20.000 tons. It is a concrete silo with 20m diameter and 85.5 m height. In this silo different raw materials are harmonized then crushed by raw materials mill.
7- Pre-heater:
In this section, different raw materials brought from silo are dehydrated and Co2 is removed then transported to the oven.
8- Filters:
In this section gases and dust resulting from heating and burning are precipitated to avoid environment pollution by exhaust this section has been designed executed in accordance with state of the art technology and international standards (not exceeding 30 miligram/ cu m).
9- Kiln:
The oven is about 75 m long with 4.75 m diameter with temperature reaching 1500 oC where various raw materials are burnt and transformed into Kilnkar .
10- Cooler:
In this section Kilnkar produced in 120 oC temperature is cooled by 6 electronic fans with 6.333 cu m/ min capacity.
11- Kilnkar Silos:
The Kilnkar substance produced by cooling operations is transported by conveyors to 2 silos with storage capacity of 20.000 tons each. They cylindrical concrete silos with 25 m diameter and are 45 m high.
12- Cement Mill Feed:
Through this section cement mills are fed by Kilnker and plaster as per weights specified in the approved mixture design.
13- Cement Mills:
This section consist of 3 machines for storing cement, having production capacity of 6000 bag/h) in addition to 6 machines for charging cement trucks of which 3 are mechanical and the others manual.
Experiments of operating this line started after April the same year where 17595 ton of Kilnkar where produced and the plant was officially inaugurated by the Leader of the Revolution, Coln. Muamar Al Qaddafi on 11/05/2005 during celebration of the 37th Anniversary of Great Al Fateh Revolution. Provisional handover of the factory took place on 17/10/2005. Kilnkar produced material during trial period reached 177.840 tons. Effective operation was started on 01/11/2005. the target design production capacity was achieved by 84099 tons increase in target production capacity (see attached file: Cement Plant Production 1) shows plant production of Kilnkar and cement as of start-up till the date of 30/06/2007.
Second Production Line:
This line surface area is 25 Hectares. The Leader of the Revolution, Coln. Muammar Al Qaddafi laid the inauguration foundation for its construction on 11/09/2005 where production capacity of Kilnkar reached 5000 tons i.e. 5200 of Portland cement which is equal to 105000 cement bags daily, so that total production would reach 2.835.000 tons of cement yearly, which represents 1/3 of the production of 7 plants now in operation in Jamahiriya. Civil works were started for this line by the beginning of these works attained on 30/06/07 – 38% i.e. nearly 24.000 Cu m of concrete in some sections of this line. The civil works will be terminated by the end of September 2008 as per the General Schedule Program.