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Unique Design Concrete Preheater Tower

Preheater tower constructed of concrete with steel floorsConcrete section 105m high (35 storey building)

Additional 10m cyclone structureFootprint 25.3m by 20.4m

1 720 tons steel reinforcing & 9 540 m³ concrete

1 270 tons structural steel for floorsImportant to have ‘vertical’ aspect of preheater constructed when preheater parts started arriving at site

Time savingOnly achieved by utilising concrete & sliding to a special design

Cost effective (+7% saving compared to steel) Aesthetically pleasing Used our product

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In-Line Calciner Plus Six-Stage Preheater

Kiln 4.55m diameter x 54m Calciner 6.6m diameter x 27m

268oC

Cyclones 1-2: 6.9m diameter

Cyclones 3-6: 7.2m diameter

3 Air 2.5m diameter

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Pre-Heater H2

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Pre-Heater H2

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Pre-Heater H3

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Pre-Heater H4

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Pre-Heater H5

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Pre-Heater H6

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Pre-Heater H7

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Pre-Heater H8

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Pre-Heater H9

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Pre-Heater H9

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1200 Metres of Piling Installed

March 2007

1.2metre diameter piles

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Constructed Using 80 ton Slide Platform

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Around the Clock Construction

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Preheater Topped-Out After 58 Days

May 2007

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Preheater Structure Dominates the Skyline

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Mechanical Installation Began Immediately

June 2007

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Kiln Drive Installation Kiln Pier 2

Preheater Steelwork: Level H3

Structural Steel Floor H3

24Steel Fixing in Preheater: Level H3

25MMC Clinker Cooler Frame

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Kiln Shell Arriving on Site

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Kiln 2 LT Substation

New Clinker Return System

Kiln 2 Cooler ESP

Burners Platform

Coal Mill Building

Clinker CoolerKiln Pier 1

New Kiln Shell Sections

August 2007

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Riding Ring Hoisted into Position

29August 2007

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36Raw Mill Building: Sept 2007

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‘Kopanelang’ Contractors Village

Feb 2006

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Contractors Camp Catering Facilities

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28 New Staff Houses Built

Nov 2006

Existing Village

New Houses

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2 Lost Time Injuries Recorded to Date

More than 2 million man

hours worked to dateMore than 2 million man

hours worked to date

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One of PPC’s core values: ‘We assist with up-liftment in communities in which we operate’

Dwaalboom situated near three (very rural) communities Rate of unemployment in area >50%

Important to ensure maximum economic spin-off from the project into the disadvantaged Dwaalboom communities‘Labour’ component comes from these areas only

>40% of staff at site from local communityRecruitment centre built

Daily transport to & from home provided

One good meal per day at site for every worker

Focus on Local Community Involvement

Excellent labour relations between contractors & local community employeesExcellent labour relations between contractors & local community employees

Opening of Holfontein Pension Payout & Recruitment Centre (June 2006)

Batsweledi in the Community

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Jupiter Clinker Milling Facility Upgraded

Jupiter plant commissioned 1970

Mothballed in 1998 (eight years)

Used as bag/bulk cement depot

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Upgrade Programme at Jupiter

Environmental Issues AddressedEnclosed & de-dusted clinker storeEnclosed all dust-generating beltsOverhaul/addition of dust collectorsAutomatic doors to tippler enclosure

Improvements AffectedNew Haver & Boecker packer & Beumer palletiser All spillage eliminated Upgrade of extender-blending facility

Major RefurbishmentsAll electric motors/gearboxes overhauledOverhauled overhead crane, tippler, cement transport system etc.Plant clean up & extensive painting

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Clinker Storage Facility Enclosed

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Raw MillClinker Store

Kiln ESPTippler

Dust Collectors Upgraded

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Other Projects in the Pipeline

Batsweledi project first phase of 20 year modernisation programmeBased on combination of capacity replacement & expansion

New cement milling complex under construction at Hercules plant1Mt/yr capacity Loesche vertical roller mill (3150kW)35kt clinker silo, 10kt cement silo, tippler upgrade Cost~€61mCommissioning planned for July 2009Replace two old mills, maximise product extension (~0.3Mt/yr) &balance clinker/milling capacity in Inland Region

Planned new 1.25Mt/yr factory at Riebeeck (Western Cape) Greenfields projectIn feasibility stage (in middle of EIA approval process)Capital cost estimated at ~€340mCommissioning planned for 2010/2011

Studies underway for next Inland Region expansion

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Summary

Batsweledi PPC’s first new factory in over 20 yearsPart of PPC’s 20 year modernisation programmeMost modern South African cement factory Utilises latest technology Lowest cost producing factoryEnvironmentally friendly & energy efficientProject within budget & on timeSafety is not negotiableCommunity involvement keyOther projects planned to meet country’s future cement demandOnly 6 months to commissioning date & counting!

For ongoing project update refer PPC website: www.ppccement.co.zaFor ongoing project update refer PPC website: www.ppccement.co.za

Thank You

Port Elizabeth Cement Silo