Client:
FL Smidth Inc.

Services:

  • Civil and structural design engineering
  • Project material quantities estimate
  • General contractor bid package
  • Bulk material handling general arrangements

Key project isues:

  • New line in close proximity to existing facility with functional tie-ins
  • Challenging soil conditions
  • Structural design completed on the basis of preliminary mechanical information
  • Steel design adapted to utilizing existing surplus steel members

 Project Features:

  • Increase in plant capacity of approximately 700,000 tons of cement per year
  • 480 STPH FRM raw material mill
  • 7,500 tons capacity blending cilo
  • SLC-D-NOx 5-stage preheater tower with low NOx calciner
  • Kiln gases by-pass
  • 180' ROTAX-2 friction drive rotary kiln
  • High efficiency Multi-Movable Cross-BarTM low emissions cooler
  • ATOX 20 coal mill
  • 170 STPH OK 33-4 clinker mill
  • 750' long pivoting pan conveyor for clinker handling
Ash Grove - Foreman, Arkansas

fls foreman p060908_403_lkg e.jpgAs part of its ongoing modernization effort, Ash Grove Cement Company, the largest US owned cement producer, is expanding the capacity of its Foreman, Arkansas facility by replacing the three existing wet kilns with a new state-of-the-art line. The facility will see an increase of both production and efficiency with updated control technology and fuel systems to lessen the environmental impact. The modernized plant will produce approximately 1.7 million tons cement per year and is scheduled to begin production in mid 2009.

Ash Grove Cement awarded the contract for the supply of equipment and civil/structural design to FLSmidth Inc., and FLSmidth Inc. awarded BIS Frucon Engineering Inc. (BFEI) the contract for civil and structural design. By working in close collaboration, BFEI and FLSmidth Inc. completed the engineering design overcoming several major challenges, and are now working with the selected General Contractor on an accelerated schedule basis.

Major process equipment furnished by FLSmidth Inc. include a FRM mill for raw grinding, Low MOx and low CO 5-stage preheater/calciner, waste fuel burning system with low emissions, friction drive rotary kiln, Multi-Movable Cross-Bar TM cooler, OK mill for finishing grinding and a ATOX mill for coal grinding. The modernization project includes a new longitudinal raw materials storage hall and the upgrade of the existing storage facilities.

As part of the services provided to FLSmidth Inc., BFEI's scope of design included the detailed civil and structural engineering for the entire plant from quarry to the cement load out, general arrangements, drawings for the bulk material handling systems, and preparation of the General Contractor structural bid package and Bill of Materials.