The focus of the Arizona Portland Cement project was to install a new Polysius “Quadropol” Roller Mill, which at the time was the largest of its kind in the world. Supplementing this installation was a new set of additive bins, feed conveying system, process gas ducts, four cement cyclones, airslide conveyors, dust collection and a pneumatic conveying system.
This project posed several structural design challenges. Much of the equipment was located above the roller mill, yet the project required an open column free area around the mill and room for an 80 tonne pneumatic hoist to operate. A series of truss structures above the mill became the solution. Additionally, the height and weight of the roller mill tower required a 14-foot deep concrete foundation, installed next to an existing building and several cement bins, all vital to daily plant operations.
M3 designed a 110,000 square foot A-frame enclosure building to house the clinker stockpile. Before the enclosure, it was an open stockpile with environmental concerns. Along the building ridge, a new tripper conveyor was installed to evenly distribute the clinker transported via new conveyors from the kiln area. A new surge bin and electrical room addition completed the project.
During the project, it was discovered that an old 500-foot long x 16-foot diameter kiln made of 1 ½-inch thick steel plate was no longer in use and needed to be removed. Most of the kiln shell was relocated and reused as a stockpile reclaim tunnel. The remainder of the kiln was turned upright and used as a bin. This plant liability was turned into an asset, and saved the project money.