Project Name Optimization of Cement Manufacturing Process

Betterfound Cement Corporation Project Number Sheet 1

Head Office: State Center II Ortigas Avenue, Mandaluyong City REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form 52830-19-26
1 General Information

Owners Name Banton, Sherry B.; Palaje, Merciline Joy S.; Serrano, Claudine Spark M.; Valencia, Jonnabelle A.

Process Unit Name Cement Manufacturing Plant

Plant Location Purok 1, Brgy. Kilicao, Daraga, Albay

Correspondance Contacts
Address Head Office: State Center II Ortigas Avenue, Mandaluyong City
Telephone / Fax 482-0605
E-mail contactus@betterfound.com
comrel@betterfound.com

2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill PRV Pressure relief valve
prefix as defined here, followed by three- B Boiler H Heater (fired or electric) R Reactor
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander SP Sample point
indicated CT Cooling tower M Motor T Storage tank
D Dryer ME Miscellaneous equipment V Vessel (including columns)
First digit - process section E Exchanger MX Mixer
Second & third digits - equipment count F Filter, classifier P Pump

4 Primary Products

Product Name Ordinary Portland Cement Pozzolanic Portland Cement

Product Grade OPC 53 PPC
MSDS Form Number 65997-15-1 66984-13-2

Production Rate
Metric tons per year 3285000 1642500
Metric tons per day 4500 4500
Other units

Product Purity (wt%) 100 100

Product shipment mode Land: Trucks and Train
Water: Cargo vessels
Additional Specifications Composition:
Tricalcium silicate: 55-70%
Dicalcium silicate: 5-20%
Tricalcium aluminate: 2-10%
Gypsum: 2-5%
Calcium Oxide: <0.5%
Tetracalcium aluminoferrite: 5-15%
Land: Trucks and Train
Water: Cargo vessels
Composition:
Tricalcium silicate: 55-70%
Dicalcium silicate: 5-20%
Tricalcium aluminate: 2-10%
Gypsum: 2-5%
Calcium Oxide: <0.5%
Tetracalcium aluminoferrite: 5

5 Primary Raw Materials

(Attach additional sheets if needed)
Feedstock name Ores Gypsum (CaSO4-2H2O)
Limestone Clay Iron Ore
Feedstock grade
MSDS form number 13397-24-5

Feedstock availability
Metric tons per year 10117800 164250
Metric tons per day 27720 450
Other units

Feedstock price ($/kg) N/A N/A N/A $2.00-2.27

(Default: open market price)

Known feedstock impurities Name %w/w Name ppmw Name ppmw Name ppmw
SiO2 0.5 – 3 SiO2 3 – 50 SiO2 37-78
Al2O3 + TiO2 0.1-1 Al2O3 + TiO2 2 – 20 Al2O3 + TiO2 0.5-3
Fe2O3 + Mn2O3 0.1-0.5 Fe2O3 + Mn2O3 0.5 - 10 Fe2O3 + Mn2O3 0.5-2
CaO 52-55 CaO 52-55 CaO 0.1-3
MgO 0.5-5 MgO 0.5-5 MgO 0.5
K2O 0.3 K2O 3.5 K2O 1
CO2 + H2O 40-44 CO2 + H2O 2 – 42 CO2 + H2O 5
SO3 0.1 SO3 0.1 - 4 SO3 0.5
Na2O 0.1 Na2O 0.2 Na2O 0.5
Additional specifications

6 Site Information

Low ambient temperature (C) 25

6

High ambient temperature (C) 35

Hight ambient relative humidity (%)
Site elevation (m) 300 m above sea level
Maximum wind loading (km/h)
Other site design requirements
 Project Name
Company Name Project Number Sheet 2
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS
Form XXXXX-YY-ZZ
7 Utility Information

Fuel Gas
Gas source or operation mode natural gas
Supply header temperature (C)
Supply header pressure (kPa (a))
Net calorific value (kJ/kg) 41858
Marginal availability (kg/h)
Marginal fuel cost ($/GJ) 2.05
Sulfur content (wppm)
Nitrogen content (wppm) 3.2
Chlorine content (wppm)
Gas composition (vol%)
H2O
O2 0.02
N2 1
CO n/a
CO2 0.5
H2S
H2 trace
CH4 95
C2H4 0.8
C2H6 3.2
C3H6 0.01
C3H8 0.2
C4H8 0.03
iC4H10 0.03
nC4H10 0.01
C5H10 0.01
C5+ 0.01

Fuel Oil
Fuel source or operation mode Rubber/tyres
Supply header temperature (C)
Supply headder pressure (kPa (a))
Net calorific value (kJ/kg) 33486.4
Marginal availability (kg/h)
Marginal fuel cost ($/GJ) 450
Fuel viscosity at C
Fuel viscosity at C
Flash point (C) 260-316
Pour point (C)
Sulfur content (wppm) .0.8
Nitrogen content (wppm) 0.3
Ash content (wt %) 2.2

Steam
Steam header classification VHP HP MP LP
Operating pressure (kPa (a))
Operating temperature (C)
Mechanical design pressure (kPa (a))
Mechanical design temperature (C)
Marginal availability (kg/h)
Marginal cost ($/metric ton)

Coolants
Coolant classification Cooling Tower Water Once-Through Water Chilled Water
Operating pressure (kPa (a))
Supply temperature (C)
Maximum return temperature (C)
Marginal availability (kg/h)
Marginal cost ($)
Marginal cost units

Process Water Feeds

Water feed stream Raw Water Process Water Boiler Feed Water Condensate
Supply pressure (kPa (a))
Supply temperature (C)
Marginal availability (kg/h)
Marginal cost ($/metric ton)
Total dissolved solids (wt%)
Hardness as CaCO3 (ppmw)
Chloride as Cl (ppmw)
Metallurgy

Electric power
Power range (kW)
Voltage (V) 145000
Phase 3
Frequency (Hz)
Marginal availability (kW)
Marginal cost ($/kWh)

Plant air streams

Air stream Plant Air Instrument Air Plant Nitrogen
Header pressure (kPa (a))
Header temperature (C)
Moisture (ppmw)
Marginal availability (kg/h)
Marginal cost ($/Normal m3)