CEMENT DIVISION IBESE LINE I Commissioning : Jan 2011 IBESE LINE II Commissioning: Feb 2011 TOTAL CAPACITY Line I+II = 6 Million T OBAJANA LINE 3 Commissioning: Jul-2011 OCP Total Capacity (I+II+III and Debottlenecking) by July 2011= 10.25 Mi T BCC Capacity after debottlenecking and Expansion= 3.75 Mi Tons GRAND TOTAL OCP: 10.25+IBESE : 6.00+BCC:3.75= 20.0 MiTons EXPECTED PRODUCTION BY JULY 2011 20 Million Tons NIGERIA CEMENT CONSUMPTION 2009 MILLION TONS 6.9 Mil Tons 7.9 Mil Tons IMPORTS PRODUCTION DANGOTE 54% WAPCO 12% FLOUR MILLS 12% ASHAKA 5% IBETO 3% ATLAS 4% SOKOTO 1% OTHERS 9% 2009 CEMENT MARKET SHARE TOTAL CONSUMPTION 1,610 646 397 3,300 1,370 - 500 1,000 1,500 2,000 2,500 3,000 3,500 WAPCO ASHAKA SOKOTO OBAJANA BENUE 0 0 0 '
CEMENT SUPPLY BY LOCAL PRODUCERS (2006-2009) LAGOS 22% OBAJANA 46% PORTHARCOURT 13% BENUE 19% 2009 DANGOTE CEMENT SUPPLY OBAJANA CLINKER & CEMENT PRODUCTION
264969 210835 282002 269516 248446 254340 254340 294673 352779 317338 352779 407273 0 50000 100000 150000 200000 250000 300000 350000 400000 450000 Clinker Cement Linear (Cement) 0 50000 100000 150000 200000 250000 300000 350000 400000 450000 Partial Shut down of one Kiln due to high clinker stock Clinker Cement Cement projected Clinker stock This is the projected clinker stock if we had not stopped the kilns in Feb and March OBAJANA CLINKER & CEMENT PRODUCTION Cement projected & Clinker Build up
OBAJANA CLINKER CEMENT STOCKS Clinker Stock, 219000 Cement in Silos, 35000 Cement in Ware Houses, 52000 LS High Grade, 110000 Cement Equalent, 536200 Semi finished, finished product stocks And Cement Equivalent Clinker Stock Cement in Silos Cement in Ware Houses LS High Grade Obajana Plant Market Strength Location Distribution network Volume Quality of product Obajana OCP FACT SHEET Commissioned with 5 million tons per annum of installed capacity, largest plant in sub-Saharan Africa All raw materials required to produce cement are available at the facility except Gypsum US$1.2 Billion investment 135 MW captive gas power plant with 90 km gas pipeline Limestone quarry with associated 8.5 km conveyor belt and estimated reserves of 450 million tonnes 13m high dam impounding a reservoir with a total storage capacity of 5.1 million m3 328 units housing complex for staff Logistic fleet of 1000 trucks Vast limestone deposits About 1,200 employees Airstrip suitable for B 737 aircraft
HISTORY Plant (line 1) erection work completed end of 2006
OCP line 1 commissioning trial started December 2006
Commissioning trials continued into January 2007
Official commissioning ceremony held may 12, 2007
Commissioning of line 2 was completed in July 2007.
Proposed line 3 of 2.5 million tons at Obajana in progress
Raw material mining Mixing bed Fuller Roller Mill Silo ILC Pre-calciner Kiln OK MILL Auto Packers Rotor Packers Cement Silos Clinker Silo 2000 T/H 400 T/H 4X10,000 MT 2x75,000 MT 2X5,000 TPD 4X140 T/H 2X450 T/H 15,000 TPD 165,000 MT 2x25,800 MT OBAJANA CEMENT PLC LOCATION Obajana Cement Factory is located at Obajana, Kogi State, about 400 km north-east of Lagos, towards the capital Abuja in Central Nigeria Obajana LONG Mixing Bed for storage and material blending, capacity = 165,000 tons Fuller Roller Mill (FRM) Plant for Rawmeal Grinding into Fine powder, capacity = 450 t/h HOMOGENIZING SILO FOR STORAGE OF RAWMEAL AFTER GRINDING CAPACITY = 25,800 TONS The The ILC Precalciner FLS Kiln with SF-Cooler Guaranteed capacity = 5000 tons per day CLINKER STORAGE SILO CAPACITY = 75,000 TONS CEMENT SILOS 4 NOS, 2 PER LINE CAPACITY 10,000 TONS EACH TOTAL CAPACITY = 40,000 TONS H & B ROTO-PACKER 6 NOS. CAPACITY 15,000 TPD
BAGS BULK JUMBO
AUTO-PACKER 15 NOS COMBINED CAPACITY 15,000 TONS PER DAY (500 TRUCKS PER DAY) OBAJANA PLANT SALIENT FEATURES Single largest plant in sub-Saharan Africa having a capacity of 5 million tones per annum cement.
The plant is centrally located in Nigeria, just about 220km from the Federal Capital City, Abuja.
High capacity vertical roller mills with low power consumption
The plant is equipped with a captive power plant of 135 MW capacity which utilizes natural gas or AGO
The plant is equipped with modern and proven cutting edge cement technology which include:
Gamma Matrix on-line analyzer for material quality control right from mines,
Robo Laboratory for automatic sampling, analysis and correction, Expert Control & Supervision (ECS) automation with operator console that allows for operation, control and continuous monitoring of the kiln, rawmill, and cement mill plants from the central control room in auto-mode.
photos on how we built the plant OBAJANA PLANT SITE OCTOBER 2002 SHARING OUR OBAJANA EXPERIENCE IN PHOTOS GRADING WORK IN PROGRESS APRIL 2003 EXCAVATION IN PROGRESS OCTOBER 2003 RAW MATERIAL MINING OVERLAND BELT CONVEYOR FOUNDATIONS OVERLAND BELT CONVEYOR ERECTION OVERLAND BELT CONVEYOR ERECTION COMPLETED OBAJANA PLANT SITE RAW MATERIAL STORAGE OCT-03 NOV-03 JAN-04 MAR-04 Excavation Depth-7ft. RAW MATERIAL STORAGE FOUNDATION RAW MATERIAL STORAGE SHED OBAJANA PLANT SITE RAW MATERIAL GRINDING OCT-03 NOV-03 DEC-03 MAR-04 Excavation Depth-14ft. OBAJANA PLANT SITE RAW MEAL SILO SEP-03 OCT-03 DEC-03 MAR-04 Excavation Depth-14ft. OBAJANA PLANT SITE PREHEATER OCT-03 DEC-03 FEB-04 MAR-04 Excavation Depth-16.5 ft. KILN COOLER INSTALLATION OBAJANA PLANT SITE CLINKER STORAGE OCT-03 DEC-03 JAN-04 MAR-04 Excavation Depth-26 ft. OBAJANA PLANT SITE CEMENT MILL NOV-03 DEC-03 JAN-04 MAR-04 Excavation Depth-33 ft. CEMENT MILLS CEMENT PACKING PLANT LAYING OF GAS PIPE LINE GAS PIPE LINE WORK IN PROGRESS AJAOKUTA TO OBAJANA
PILING OF PREHEATER TOWER LINE 02 AUG 04- CLINKER SILO CONSTRUCTION
OBAJANA PLANT SITE WATER DAM MAR-03 FEB-04 OCT-03 NOV-04 JAN-05 WATER DAM WATER DAM COMPLETED OBAJANA CEMENT HOUSING ESTATE OVERALL VIEW OF PLANT SITE CENTRAL CONTROL ROOM A PANAROMIC VIEW OF THE PLANT TRUCK PARKING AREA WELCOME TO BENUE CEMENT COMPANY PLC GBOKO. Benue State
PLANT SITE DATA RAINFALL :- 1300 MM ANNUAL AVERAGE WIND VELOCITY :- 41 M/Sec TEMPERATURE :- MAXIMUM - 40 DEG. C MINIMUM - 15 DEG. C AVERAGE - 32 DEG. C HUMIDITY :- MAXIMUM - 85 % MINIMUM - 65 % LATITUDE :- 7 0 22 LONGITUDE :- 9 0 3 SITE ELEVATION ABOVE SEA LEVEL :- 150 MTR.
PLANT CAPACITY BEFORE 2004 TOTAL PLANT CAPACITY :0.9 MILLION TONS ANNUM (MTPA) NO. OF PRODUCTION LINES :- TWO(0.45 MTPA EACH) LOCATION :- 72KM,MAKURDI GBOKO EXPRESSWAY BENUE STATE NIGERIA NEAREST AIRPORT :- MAKURDI PLANT DESIGNED BY :- CEMENTIA ENGINEERING ZURICH PLANT SUPPLIED BY :- M/S KHD GERMANY PHYSICAL POSSESSION OF THE PLANT WAS TAKEN BY ON
FRIDAY 06.02.2004 NEW PLANT HISTORY PLANT COMMISSIONING HISTORY PLANT COMMISIONED IN :- YEAR 1980 Line-II Commissioned after upgrade:- JANUARY 08 New DGs commissioned:- DECEMBER 07 Line-I Commissioned after upgrade:- AUGUST 08. MINES DATA LEASE AREA PROSPECTED :- 307 HECTARES RESERVE UP TO 100 MTRS :- 250 M.M. TONS RESERVE UP TO 30 MTRS :- 130 M.M. TONS LEASE TO BE PROSPECTED :-520 HECTARES MINES EQUIPMENT DATA LOADING EQUIPMENT CAPACITY AVAIL. (NOS.) EXCAVATORS (5.7& 7.0)M 3 2 CAT HAMMER ROCK BREAKER (330DL) 1.1 M 3