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Eagle Materials Expands Its Illinois Cement Plant

Eagle Materials Inc. announced that its Board of Directors has approved a $ 65 million expansion of its Illinois Cement Plant located in LaSalle, Illinois. Humboldt Wedag, Inc., Norcross GA, subsidiary of KHD Humboldt Wedag AG, Cologne, Germany, has been awarded a phased engineering turnkey contract to provide the plant expansion which will increase the plants capacity by about 65% to approximately 1.1 million tons of cement while reducing its manufacturing costs by approximately 20%. The existing plant, which became operational in 1974, has an annual capacity of approximately 670,000 tons of cement. The plant expansion will incorporate state of the art technology which will include the installation of a new vertical roller mill for raw material, the addition of a new preheater with precalciner and a new clinker cooler section with clinker breaker. The existing three station 4.1 m diameter and 59.0 m long rotary kiln will be fitted with a new drive. New core components with KHD technology are: HUMBOLDT preheater PYROCLON-calciner with PYROTOP-mixing chamber PYROSTEP clinker cooler section with clinker breaker. The new Loesche vertical roller mill with a capacity of 225 STPH raw meal will be pre-erected on a concrete pad and rails adjacent to the existing vertical roller mill. During the plant shut down and tie in period the existing roller mill will be dismantled and the new pre-erected mill will be slid into place. Supplementing the existing raw mill cyclones will be a new additional set of cyclones. Other raw mill system auxiliaries such as the feed conveyors, mill lube and hydraulic packages will be pre assembled and installed prior to the plant shutdown for tie in. New raw meal transport and kiln feed system will also be installed. The existing kiln and preheater will be supplemented with a new
PYROTOP

PYROCLON

Fuel input

Existing Preheater

PRPc 4829/4 Preheater & Calciner

KHD Humboldt Wedag PRPc 4829/4 Preheater with PYROCLON Calciner and PYROTOP mixing chamber located in a second tower which will be constructed adjacent to the existing preheater. The new pyro system will also include a new tertiary air duct, ID fan and dust collector. A new KHD Humboldt Wedag PYROSTEP clinker cooler section, clinker breaker and cooler vent baghouse with fan will be added. The existing Raymond 533 coal mill will be equipped with a new classifier and new indirect firing system. These changes in combination with their auxiliaries will increase the plants clinkering capacity from 1900 to 3000 STPD. Start-up of the plant expansion is scheduled for December 2006.

Lafarge North America Increases Finish Grinding Capacity

On November 15, 2004, Lafarge began operation of a new finish grinding system at their Roberta Plant in Calera,Alabama.The new system, which was designed, supplied and installed on a turn-key basis by Humboldt Wedag, Inc. began operation on schedule and met all performance and reliability guarantees. Irondale Industrial Contractors, Inc. was the construction contractor for the project. The contract took 16 months from release of the LOI to start-up. The system is designed to grind 120 t/h of cement using 95 % clinker and 5 % gypsum to a fineness of 3800 Blaine. A 5.0 m diameter x 13 m long ball mill is used for grinding of the clinker. The mill is a Humboldt Wedag two compartment, shell supported ball mill with semi-bolted lifting liners for the first compartment, semi-bolted classifying liners for the second compartment, and an adjustable diaphragm. The grinding system is operated in closed circuit

with a Humboldt Wedag SKS-Z2750 High Efficiency Separator equipped with a recirculation duct. At the beginning of construction, the project team overcame major underground caverns and rock pinnacles during the installation of caissons, and near the end of the project overcame delays caused by the after effects of Hurricane Ivan, to complete the project and start-up on schedule.

New Clinker Grinding Plant For Chettinad Cement at its Karikalli Cement Plant, India
Humboldt Wedag India Ltd. and its holding company, KHD Humboldt Wedag AG, Germany were awarded the contract for engineering and supply of a new 0.5 mio. t/a clinker grinding plant by Chettinad Cement Corporation Ltd. (CCCL), India. The plant will be erected at CCCLs Karikalli cement plant at Karikalli village of Dindigual District in Tamil Nadu. CCCL is operating two cement plants, one at Karikalli and one at Pulliyur. Both plants are equipped with a vertical mill for cement grinding with a capacity of 170 t/h. With the increase of its clinker grinding capacity the customer aims to utilize the full potential of production capabilities at the two existing cement works.The technical considerations favoring the selection of KHDs grinding process with Roller Press/VSK/ball mill are low wear rates, no demand for grinding aid and low water demand ratio of the produced cement. The contract comprises engineering and equipment supply as well as supervision of erection and commissioning for the complete grinding plant. Core components of the grinding system are: Roller Press RP 10-140/110 with 2 x 800 kW motor power VSK-Separator Ball mill, diameter 3.0 m x 10.0 m length, with a 1,100 kW motor and girth gear. The Roller Press will operate with the VSK-Separator and the ball mill in semi-finish-mode. The system is designed for a capacity of 110 t/h of OPC cement with a fineness of 3,000 cm2/g acc. to Blaine. Commissioning of the plant is scheduled for end of 2006.

Feed material Clinker: 94 % Gypsum: 6 %

VSK

110 t/h 3000 cm2/g (BL) OPC

Roller Press

Ball mill

DELIVERY OF THE 60th SIMULEX-STATION

SIMULEX KHDs tailor-made training simulator for the cement industry proves its advanced benefits for cement producers worldwide. Training of operations and production personnel will improve the availability and productivity of the production line.

INAUGURATION CEREMONY GUANGZHO CEMENT PLANT

HIGHLIGHTS

J.G. Zimmermann, CEO of the KHD Humboldt Wedag AG attended the Inauguration Ceremony for the Guangzhou cement plant of Guangzhou Heidelberg Yuexiu Cement, PR China on 2005.04.02. Design and supply of the key components for the new 6,000 t/d clinker line came from KHD:

Clients are the worlds leadingmajor and regional cement producers as well as industry organisations. Clientele is constantly growing. Contact: Gernot Jger Email: Jaeger.G@khd-ag.de

Humboldt preheater Five-stage PYROCLON -calciner + PYROTOP mixing chamber + combustion chamber kiln on two piers PYRORAPID PYRO-JET kiln burner.

Humboldt Wedag, Inc. 400 Technology Parkway Norcross, Georgia 30092 / USA Phone: +1-770-810-7300 Fax: +1-770-810-7343 or 7333 hwi@humboldt-wedag.com Humboldt Wedag Australia Pty. Ltd. Private Bag 30 Mordialloc Vic. 3195 / Australia Phone: +61 -39-580-52 77 Fax: +61 -39-580-1066 humboldt@co31.aone.net.au Humboldt Wedag India Private Ltd. CC-29, 4th Floor, Nehru Enclave New Delhi 100 019 / India Phone: +91-11-622 -7325-28 Fax: +91-11-622-7215-16 marketing@hw-india.com

KHD Humboldt Wedag AG 51170 Cologne / Germany Phone: +49-221-6504-1400 Fax: +49-221-6504-1409 E-mail: info@khd-ag.de www.humboldt-wedag.de

KHD Humboldt Wedag SA Pty. Ltd. P.O.Box 8460, Elandsfontein 1406 36 Wankelstreet, Jetpark / South Africa Phone: +27 -11-397-4660 Fax: +27-11-397-4411 marketing@humboldtwedag.co.za