The new plant will provide a continuous and reliable supply of high-quality cement products to the Western Australian market thanks to two new 100 ton per hour (tph) ball mill grinding circuits.
Sarens has participated in the project by performing various heavy lifting processes for the installation of two large filtration units and two highly engineered covers for the ball mill building.
The upgrade of the facility will save approximately $19 million in the first year by reducing energy, maintenance and transport costs.
The Kwinana modernisation will reduce the plant's C02 emissions by 20 per cent through the installation of the latest cement production technologies. This is not the only action taken to reduce the plant's carbon footprint, as it will also eliminate the need for heavy vehicles on local roads, which are currently used to transport material for cement production. This is thanks to one of the key objectives of the upgrade, the ability to receive and store bulk raw materials, via Fremantle Port Authority's (FPA) Kwinana Bulk Terminal, directly onto site via a new raw materials feed conveyor system and a fully enclosed 110,000-ton storage shed.
Sarens, world leader in heavy lifting, engineered transport and crane rental services, has been an integral part of this project since day one due to the need to use highly technical engineering to complete various construction tasks. Within the work plan carried out by the company the installation of several plant components stands out: two large filtration units and two highly engineered covers for the ball mill building.
For these actions, Sarens' specialised engineering team selected advanced and versatile equipment, capable of performing all the assigned tasks with alacrity. The LR1350-1/LN crane, capable of lifting up to 350 tons and configured as LDB 66m, was used to lift the 35.1-ton filter. For the rigging, one S17 Spreader beam from Sarens and two lifting beams made specifically for this job were used.
The filtration units are a key part of the plant as they are responsible for ensuring the management and containment of all the environmental impacts of the cement process. The installation has required a great deal of coordination by the Sarens team and other workers, requiring up to 29 lifting points to safely support their own weight.
As part of the work Sarens has performed the installation of two roof sections in one day, a complex job with a load of more than 20 tons. Currently, 12 cranes of different sizes and configurations are still in place for various tasks at the plant.
The expansion project will create a state-of-the-art facility and consolidate Adbri's two cement production plants (Munster and Kwinana) into one plant serving the Western Australian market. Once operational in 2024, cement production will shift from the Munster plant to Kwinana, while lime manufacturing will continue at the Munster facility. The new plant will provide a continuous and reliable supply of high-quality cement products to Western Australia.
SIMPEC, a subsidiary of WestStar, has been appointed by Cockburn Cement for the Kwinana plant modernisation project. The company will provide structural, mechanical, piping, electrical and instrumentation (SMPE&I) support services. The scope of work for the project includes new grinding circuits and raw material storage and reclamation system designed to produce several different cement products for the local market. The facility will incorporate two new 100 ton per hour (tph) ball mill grinding circuits feeding into six new 3,200 ton finished product silos with truck out loading. The construction also includes the assembly of two 100 ton per hour grinding units, a 110,000-ton raw material storage facility and a recovery system.
Among the benefits of the expansion project will be cash cost savings of approximately $19 million in the first year after start-up through reduced energy, maintenance and transportation costs, lowering unit production costs and increasing competitiveness.
The new Kwinana facility will also reduce production costs by replacing the more than 50-year-old cement grinding equipment with a new energy-efficient plant that will reduce future repairs and maintenance costs and eliminate the need to invest in Munster's aging assets.It will also eliminate the double handling of clinker and cement between the two plants and change the method of clinker transfer from road to a conveyor system.
About Sarens
Sarens is the global leader and reference in crane rental, heavy lift and engineered transportation services. With state-of-the-art equipment, value engineering, one of the world's largest inventories of cranes, transporters and special rigging equipment, Sarens offers creative and intelligent solutions to today's heavy lifting and engineering transport challenges.
With more than 100 entities in 65 countries operating without borders, Sarens is an ideal partner for small to large-scale projects. Sarens currently employs 4,543 highly qualified professionals who are ready to serve the needs of any client worldwide and in all market sectors.