The study of raw materials

• Research and estimation of resources in terms of qualities and quantities:
• Bibliographic study
• Visits to the various sites
• Definition of additional exploration work
• Estimation of the qualities and quantities of the different resources (lifetime of the deposits)
• 3D geological modeling of deposits
• Definition of the raw mix

The preliminary geotechnical study of the site selected for the establishment of the plant

Market study:

• Cement market of the country of interest
• Consumption history
  • Current situation:
    • Types of cement
    • Geographical segmentation of consumption
    • Production – Import – Export
    • Tax system
  • Economic evaluation:
    • Gross domestic product
    • Demography
    • Major works
  • Sales price history
  • Current and future capacities
  • Current and future market estimation
• Cement market in the region:
  • History and forecast of consumption and capacity
  • History and forecast of import and export
  • Estimation of export potential
• Conclusion :
  • Sales forecast on the local market
  • Export sales forecast

The technical study:

• Local conditions
  • PLANT location and access
  • Climatic and seismic conditions
  • Water supply
  • Power supply
  • Fuel supply
  • Environmental protection
• Plant process definitions
  • Calculation of raw mix
  • PLANT production capacity and expansion possibilities
  • Definition of the quality of the manufactured cements
  • Study and choice of manufacturing processes
  • PLANT master plan
  • Mass flow diagrams and storage capacities
  • Workshop flowsheets
  • Choice of fuels and definition of their characteristics
• Definition of process equipment
  • Quarry equipment and machinery
  • Primary and secondary crushing
  • Storage of raw materials and additives
  • Crushing and homogenization of the raw mix
  • Cooking: preheater, kiln and cooler
  • Main dust removal
  • Clinker storage and retake
  • Cement grinding and storage
  • Bagging, dispatch
  • Fuel preparation (coal, oil, gas, alternatives, etc.)
  • PLANT utilities (industrial water, compressed air)
• Electricity and Automation
  • Definition of power and electrical consumption of the PLANT
  • Establishment of diagrams for medium and low voltage electrical principles
  • Definition of automation principles
  • Definition of the connection between the PLANT and the external electrical network or a power plant on SITE
• Civil engineering
  • Location of the PLANT, the quarries and their accesses
  • Traffic plan in the PLANT
  • Development of the PLANT platform (general earthworks, levelling, fencing, drainage)
• General schedule for carrying out the PROJECT
  • Studies
  • Manufacturing – Deliveries
  • Works – Erection
  • Tests and Acceptances

Environmental and social impact assessment (ESA) 

• Description of the proposed industrial development
• Background information
• Description of the Existing Environment – the Baseline
• Prediction of impact and evaluation of significant environmental effects
• Mitigation measures

The financial study:

• The PROJECT summary matrix:
  • Investment budget
  • Production costs (variable costs and fixed costs)
  • Selling price
  • Financing plan
• The IRR (Internal Rate of Return) and the IRR on equity
• Break-Even Point
• Tables of the various financial states covering the considered operating period of 20 years:
  • Cash flow for financial planning (for controlling the synchronization of financial flows)
  • Net income statement (net revenue table)
  • Forecast balance sheets
• The graph of financial flows
• A sensitivity analysis to assess the variation in the value of the internal rate of return, depending on the various values ​​assigned to the following parameters: total investment, selling price and manufacturing cost
• The interpretation, comments, and recommendations arising from the results obtained from the various simulations