Project-Description-Report - Mabuhay Cement Processing Plant Project

Project Description for Scoping
Mabuhay Cement Processing Plant Expansion

Mabuhay FilCement Inc.
Table of Contents
1 Basic Project Information.............................................................................................................2
1.1 Project Information..............................................................................................................2
1.2 Proponent Profile.................................................................................................................2
2 Project Description.......................................................................................................................2
2.1 Project Rationale..................................................................................................................2
2.2 Project Location and Area....................................................................................................3
2.3 Project Components.............................................................................................................6
2.4 Resource Requirement.........................................................................................................9
2.5 Project Duration: (4th Quarter 2017 to 4th Quarter 2019) 2 years and 4 months..............11
2.5.1 Timeframe of Project Phases......................................................................................11
3 Project Cost: (Php) Approximately 200,000,000.00..............................................................11
3.1 Site Development Plant (Existing)......................................................................................12
3.2 Site Development Plan (Proposed Expansion)...................................................................13
4 Project Methodology.................................................................................................................14
4.1 Pre-Operation Phase..........................................................................................................14
4.2 Operational Phase..............................................................................................................14
4.3 Decommissioning / Abandonment Phase..........................................................................17
5 Actual Site Photos......................................................................................................................18
Prepared by
1
PROJECT DESCRIPTION FOR SCOPING (PDS)
1 Basic Project Information
1.1 Project Information
Project Name Mabuhay Cement Processing Plant Project

Project Location Brgy. South Poblacion, Municipality of San Fernando, Cebu
Nature of the Project Cement Processing Plant
Total Project Land Area 55,000 sq.m.
Total Net Development Area 31,559 sq.m.
1.2 Proponent Profile
Proponent Name Mabuhay Filcement Incorporated

Office Address Dona Emilia Benedicto Building, No. 7 E. Benedicto St., Cebu City
Authorized Signatory and Enrison Benedicto
Representative Chief Executive Officer
Landline 032 255 3201, 032 255 8200
email address [email protected], [email protected],
[email protected]
TIN 118-886-322
2 Project Description
Mabuhay Cement Processing Plant Project is an existing cement processing plant located at Brgy.
South Poblacion, Municipality of San Fernando, Cebu. As a response to the growing supply
demand for cement materials in the local and national scene, Mabuhay Filcement Inc., an all-
Filipino corporation with its Chairman of the Board, Consul Enrique L. Benedicto, plans to
increase their production capacity in the said processing plant. Also, the project expansion still
aims to continually promote countryside development, provide employment and livelihood to
the locals and at same time so it can generate income to both local and national government.
The operation of the cement processing plant will continually be of solely Filipino ways and
culture but with the state-of-the-art technology that would bring about sustainable
development.
2.1 Project Rationale

The country nowadays is open to industrialization and infrastructure development, which is
brought about by both the Private sectors and the Philippine Government Infrastructure
projects. Cement is a critical component of Infrastructure development. The forecast for the
local demand for cement may continue to increase in the coming years.
Prepared by
2
Cement Demand (in million metric tons) According to 2015 Annual Cement Industry
Report of Cement Manufacturers' Association of the Philippines, Inc. (CeMAP)
The Mabuhay Filcement Inc. (MFI) as an all-Filipino corporation which manufactures cement
products, would like to take part to the advancement of nation building by providing affordable
and good quality cement, and increase its production capacity to help sustain the increasing
demand. Its plant operation is also aimed at promoting countryside development, providing
employment and livelihood to the locals and at same time generate income to both local and
national government. Such development will also address the industrial needs of the growing
countryside.
The management of the plant/quarry operations will solely be “Filipinized”, as to methods and
cultural sensitivity, and the operations, through its advanced technology and methodology,
would bring about sustainable development in the host community in particular, and the
country in general.
The cement plant has already been operating for almost 5 years now and, is continually
developing and improving in its processes, capacity and structures. From the feasibility study
that was conducted, expanding its components and capacity was found out to be economically
feasible especially with the growing market of cement; Thus, the expansion is set. This expansion
component will be set up and incorporated with the existing structures, as will be outlined
hereunder.
2.2 Project Location and Area

The project site is within the political jurisdiction of Barangay South Poblacion, San Fernando
located along the National Highway. The area is classified as Special Industrial Zone or Industrial
Zone III by the Sangguninag Bayan of municipality. The existing plant is approximately within
geographical coordinates: 10° 9'42.59"N North latitude and 123°42'16.54"E East longitude. The
area is approximately 350 aerial meters going south from San Fernando Municipal Hall along the
Natalio B. Bacalso S National Highway. The proposed expansion project will be established within
Lot 3, Psu007-01-000057, containing an area of 5.5 hectares The site location map is shown in
the figure below.
Prepared by
3
Illustration 1: Vicinity Map
LANDMARK DISTANCE
San Fernando Municipal Hall 350 m
Taiheiyo Cement Philippines Port 650 m
San Isidro Labrador Church 340 m
Taiheiyo Cement Philippines, Inc. 390 m
Geographic Coordinates of the Project Area:

CORNER LATITUDE LONGITUDE
1 N 10º09’53.211” E 123º42'13.723”
2 N 10º09'45.326” E 123º42'16.854”
3 N 10º09'39.368” E 123º42'13.123”
4 N 10º09'49.724” E 123º42'09.256”
Prepared by
4
Drone Site Photos Taken on January 27, 2018
Prepared by
5
2.3 Project Components
Existing Facilities Proposed Expansion

5.5 hectares
Brgy. South Poblacion, Municipality of San Fernando, Cebu
Production Facilities (Main Component) area Production Facilities (Main Component) area
= 6,958 sq.m. TOTAL = 14,000 sq.m.
Support Facilities area Support Facilities area
= 8,380 sq.m. TOTAL = 17,559 sq.m.
Dry process:
Dry process: Additional 700,000 Metric Tons Per Year
500,000 Metric Tons Per Year of Clinker TOTAL 1,200,000 Metric Tons Per Year
include milling and crushing activities include milling and crushing activities
30,000 bags of cement 2,600,000 Metric Tons Per Year Finished Cement
120,000 bags of cement per day
Prepared by
6
Existing Facilities with Approved ECC
Existing Facilities Area (sq.m.) Remarks

A. Production Facilities (Main Component)
1. Coal Stacker/Storage 1300 Existing/Operational
2. Limestone Stacker/Storage 1292 Existing/Operational
3. Limestone Crusher 777 Existing/Operational
4. Raw Mill 262 Existing/Operational
5. Raw meal Silo 260 Existing/Operational
6. (2) Electrostatic Precipitator 254 Existing/Operational
7. Pre-heater Tower 200 Existing/Operational
8. Rotary Kiln 619 Existing/Operational
9. AQC-Kiln Hood & Grate Cooler 180 Existing/Operational
10. Unburn Clinker Silo 134 Existing/Operational
11. Clinker Stacker/Storage 707 Existing/Operational
12. Cement Silo 1 215 Existing/Operational
13. Pack House 1 & 2 306 Existing/Operational
14. Finish Mill 1& 2 452 Existing/Operational
TOTAL 6958 sq.m.
B. Support Facilities
1. Electric Power Substations 530 Supplied by VECO
2. Machine Shop Building & Warehouse 2100 Existing/Operational
3. Waste Water Treatment Facility 225 Existing/Operational
4. Solid Waste / MRF 350 Existing/Operational
5. Canteen 225 Existing/Operational
6. (2) Water Pump 50 Existing/Operational
7. Parking Area 4000 Existing/Operational
8. Administrative Building 550 Existing/Operational
9. Staff House 350 Existing/Operational
TOTAL 8380 sq.m.
Prepared by
7
Additional Facilities without ECC

Facilities Area (sq.m.) Remarks
A. Production Facilities
1.Pozzolan Storage 1000 Existing/Operational
2. Gypsum Storage 365 Existing/Operational
3. Clay Storage 450 Existing/Operational
4.Copper Slug Storage 500 Existing/Operational
5. Silica Storage 624 Existing/Operational
6. Spray Tower 49 Existing/Operational
7. Coal Mill 163 Existing/Operational
8. Coal Tube Mill 76 Existing/Operational
9. Finish Mill Clinker and Additive Bin 70 Existing/Operational
10. Finish Mill 3 800 Existing/Operational
11. Finish Mill 4 800 Existing/Operational
15. Packhouse 3 140 Existing/Operational
16. Packhouse 4 170 Existing/Operational
17. Finish Mill 5 800 Proposal
18. Packhouse 5 170 Proposal
19. Cement Silo 5 150 Proposal
20. Tonner Bag Storage 200 Proposal
TOTAL 7042 sq.m.
B. Support Facilities
1.Water Reservoir 1 288 Existing/Operational
2. Water Reservoir 2 47 Existing/Operational
3. CCR Building / QA Building 240 Existing/Operational
4.Cement Bag Storage 115 Existing/Operational
5. (6) Rainwater Catchment Tank 30 Existing/Operational
6. (3) Truck scale 400 Existing/Operational
7. Diesel Tank Area 30 Existing/Operational
8. Main Station Building 120 Existing/Operational
9 Switch Yard/Main Power Station 200 Existing/Operational
10. VECO Metering Station 240 Existing/Operational
11. Motor Pool Area 180 Existing/Operational
12. CCR Room 20 Existing/Operational
13. Compost Area 10 Existing/Operational
14. Satellite Nursery 10 Existing/Operational
15. MCC & Power Substation 40 Existing/Operational
16. Air Compressor House 79 Existing/Operational
17. Road Network 4000 Existing/Operational
18. Green Belt Area 2000 Existing/Operational
19. Drainage Systems 1000 Existing/Operational
20. (6) Comfort Rooms with Septic Tanks 70 Existing/Operational
21. Water recycling tank 40 Proposal
22. Hazardous Waste Facility 20 Proposal
TOTAL 9179 sq.m.
Prepared by
8
Plant Description
Gross Area 55,000 sq.m.
Excluded Area 0 sq.m.
Net Area for Development 31,559 sq.m. (57.38%)
Area Distribution
Production Facilities (Main Component) 6,958 sq.m. (12.65%)
Support Facilities 8,380 sq.m. (15.24%)
Additional Production Facilities 7,042 sq.m. (12.8%)
Additional Support Facilities 9,179 sq.m. (16.69%)
Open Space 23,441 sq.m. (42.62%)
Total Lot Area 55,000 sq.m.
2.4 Resource Requirement

Water
Based on the hydro-geologic data from the San Fernando Water Works data Geo-Resistivity Report, a
portion of the plant site is sitting on an area with a geomorphologic feature known as Quaternary
Alluvium. This type of aquifer deposits has water yield generally ranges from 50 to 150 L/s.
The water supply of the cement plant is mainly sourced by its internal deep wells. The pumped water
in the deep well is then stored to the water reservoirs. From the water reservoir, the water is pumped
going to a treatment tank (softener) to remove its water hardness. The treated water is then utilized in
the plant operations for absorbing gas & dispersed solid particles in a spray tower and for cooling
motors as to heat transfer. The used water in the cooling process is then recycled and is pumped going
to a water tank. The water in the tank is allowed to cool before returning it back to the process. Other
uses of water in the plant site is for domestic purposes, equipment wash water, civil works &
construction use, road sprinkling, plant watering, and cleaning/hygiene purposes. As of the present
operations, the water usage of the plant is about 40 cu.m per day.
Domestic Water Use
Prepared by
9
Industrial Water Balance
Note: Since the cement processing uses the Dry Process Technology, no industrial waste water will be
generated from the system. The water will be continuously recycled in the closed system and will only
loss about 33 cu.m/day (12% of the consumption) due to heat or evaporation and equipment washings
and laboratory usage. This volume loss will be replenished from the water sourced from deep well.
Energy/Power
To operate the cement manufacturing plant, a significant huge amount of electric power is needed to
operate different kinds of machineries, equipment, and light fixtures. During a normal operation (i.e.
there is clinkering operation) the power consumption of the plant is 12 megawatt (MW) per month.
But if there is no clinkering operation (termed as shutdown) and only the finish mill (grinding mill) is
operating in the process, the power consumption lowers down to 6 MW per month.
Prepared by
10
The power requirement of the cement plant is currently supplied by Global Energy Supply Corporation
(GBP Corporation), and the distribution wheeling services are provided by Visayan Electric Company
(VECO).
2.5 Project Duration: (4th Quarter 2017 to 4th Quarter 2019) 2 years and 4 months
2.5.1 Timeframe of Project Phases

Schedule Duration
PROJECT PREPARATION STAGE
Developing an initial project briefing. This may include; considering
feedback from previous projects, defining overall spatial 1 month
requirement, carrying out surveys and quantifying the budget.
Carrying out feasibility studies 2 months
Undertaking project risk assessment, including; planning risks,
1 month
programs and procurement strategy
Social preparation works 2 weeks
Application for other necessary national and local government
permits once the project’s Environmental Compliance Certificate 6 months
will be released
PROJECT DEVELOPMENT STAGE
Civil Works 12 months
Mechanical Installations 6 months
Electrical Installations 4 months
Construction of cement plant expansion support facilities 4 months
Construction of pollution control devices 3 months
Construction of wastewater treatment facility 2 months
Construction of rainwater cistern tank 2 months
Air and Water Installation 3 months
OPERATIONAL STAGE 5 months
Buffer / Tree Planting 2 months
Commissioning Stage 3 months
Note: The overall project duration from preparation to operational stage takes about 3 years and 6
months for the cement plant expansion project to commence.
3 Project Cost: (Php) Approximately 200,000,000.00
Prepared by
11
Project Description for Scoping Mabuhay Cement Processing PlantExpansion
3.1 Site Development Plan
Prepared by 12
4 Project Methodology
4.1 Pre-Operation Phase

This stage involves the preparation of the plant for the receiving of the raw materials to begin with
the manufacturing process. In which, the control room, the plant machinery, pollution control
devices, health and safety materials and equipment and labor force be fully equipped, maintained
and functional at high response rate to defer delays and errors to occur in the production process.
It is important that prior to operation,
4.2 Operational Phase

The manufacturing technology and engineering design used employs a dry process/
technology. This is operated with one (1) Central Room using the Programmable Logic
Controllers (PLC) and adopting the different kinds of Analog Measuring Sensing Instruments,
where the plant can attain 99% efficiency for the production output, as well as for the
pollution control equipment. The technology can be considered efficient, environment-
friendly and brings about sustainable development.
The following are the major steps in cement manufacturing;
1) Crushing - Materials in the forms of boulders brought to the crushing plant should not
exceed 600 mm in diameter to avoid problems in handling. The materials will be crushed
down to the particles with maximum diameter of 75 mm using a hammer mill. Crushed
materials will be transported to silos or tents for storage. The materials containing high
moisture are fed into the roller mill through a triple flap gate to prevent air leakage into
the mill.
2) Raw Milling - Hot gas for drying the raw materials are supplied from the suspension pre-
heaters or from hot generators. A variable speed will induce draft fan that pulls the
pulverized materials from the mill passing through a separator to attain the desired
fineness then through a bank of cyclones. The cyclones underflow will then be conveyed
to the raw meal silo for storage and homogenization. The cyclone overflow goes to the
electrostatic precipitator (EP) for collection. The collected materials are then conveyed to
the kiln feed bin or the raw meal silo for blending.
3) Kiln Heating - Kiln feed is withdrawn from the raw meal silo through air slides across a
flow control gate and is routed to a bucket elevator which supplies the kiln feed bin. The
first stage in Kiln process is the Pre-heating and pre-calcining of the raw meal. The fuel
used in the riser duct is coal. Industrial fuel oil will only be used as back-up or during
startups. Oxygen for combustion is provided by a tertiary air source of hot air that has
been recuperated from the clinker cooler. The material is 90% calcined at its levels with
the pre-heaters and the kiln. The product from the Kiln process is termed Clinker.
The pre-heater exhaust gas exits through a duct induced by a draft fan and passes
through a conditioning tower fitted with a water spray system prior to entering the
electrostatic precipitator.
4) Clinker Cooling - The clinker drops from the kiln into a stepped gate and into the
reciprocating grate cooler. Clinker temperature at the inlet is approximately 1370 degrees
Prepared by
13
centigrade and outlet temperature is 60 degrees centigrade above ambient.
The hot recuperated air from the cooler is routed to a riser duct as tertiary air and the
remainder is vented to the electrostatic precipitator for dusting.
Clinker is conveyed by grate plates and crushed by a clinker crusher to a maximum

particle size of 30 mm.
5) Finish Milling – The clinker material as well as other cement additives will pass through a
proportioning weigh feeder, then the proportioned materials will then be routed to a
common belt conveyor into the bucket elevator feeding the ball mills. The pulverized
material will then pass through a separator then a series of cyclones. The reject fine
particles will be thrown in the dust collector system and the product material will pass
through the product airslide into the bucket elevator going to cement silos storing the
finished product cement.
6) Cement Packing - Cement is withdrawn from the cement silos through an air slide going to
the bucket elevator and routed to the pack house. The transported materials are
distributed to different packing bins prior to dispatching. Cement is dispatched by bulk
truck, big bags (1 Ton) and 40-kilogram cement bags.
Packing of 40-kilogram cement bags is done by automatic roto packing machine then
down to a receiving belt conveyor and a telescopic conveyor for dispatching. Packing
machine overflow is reclaimed by screw conveyor through a bucket elevator and returned
to the distributing bins. Transfer points are equipped with dedusting system to the bag
house. Collected materials from bag houses are returned likewise to the bins.
7) Loading and Unloading Operations – Bags of cement (40 kilogram or 1 tonner) will be
transported through trucks stockpiled in a pallet going to the local market. For Bulk
loading, Cement is withdrawn from cement silos and transported in a belt conveyor fully
covered.
Prepared by
14
Project Description for Scoping Mabuhay Cement Processing PlantExpansion
Illustration 2: Cement Manufacturing Process Flow Chart Pollution Control Devices in every stages
Prepared by 15
4.3 Decommissioning / Abandonment Phase

With the nature of the project, abandonment is unlikely to happen. The cement processing plant intends
to continuously cater to the continually rapidly rising demand for cement worldwide.
However in extreme cases, where major and destructive natural calamities take place, the project may
need to be abandoned particularly when irrepairable damages on the plant takes place or should the
government declare to abandon all cement plant projects which is unlikely to happen as well.
In the event of such unwanted or unlikely scenario, the management of Mabuhay FilCement. Inc. in
coordination with third parties and Local Government units, have prepared to execute the following
activities as follows:
1) Cutting off of power and water line
2) Removal of debris or loose materials
3) Removal of cement manufacturing machinery/components
4) Disposal/Collection of Hazardous and Toxic material
5) Dismantling of temporary or light weight structures
6) Demolition of building structure (optional; if structural integrity is not compromised)
7) Hauling of construction debris (steel, concrete, roofing materials, etc.)
8) Housekeeping/Clearing of area
9) Replanting (within area)
10) Setting up of perimeter fence to prevent illegal settlers to enter
Likewise, Mabuhay FilCement Inc. may have to do the following management plan to minimize the
negative impacts of the abandonment to the environment.
Projected Cost
Pollution Management/ Measure Responsible Group
(at present cost)
Immediate hauling of debris and Mabuhay FilCement Inc. P 75,000-150,000
destroyed materials within the property and hired material
Dust haulers
Generation
Use of personnel protective equipment Mabuhay FilCement Inc. P 50,000
(PPE) during dismantling or demolition safety officers
activity
Waste recovery and selling/ disposal of Third party recyclers. No cost on the part
recyclable materials (They can sell or give the of the project
recyclables)
Waste segregation and provision of Mabuhay FilCement Inc. P 30,000
temporary Material Recovery Facilty and third party recyclers
(MRF) and collection area
Solid wastes Disposal of residual wastes to the Mabuhay FilCement Inc. P700-P1000 per ton
functional future sanitary landfill and LGU
Proper treatment and disposal of bulk Contracted hazardous P5,000-10,000/ton

and hazardous waste treaters and bulk
wastes managers
Prepared by
16
5 Actual Site Photos
Prepared by
17
Prepared by
18
Prepared by
19
Prepared by
20
Prepared by
21
Prepared by
22
Prepared by
23
Prepared by
24
Prepared by
25

Project-Description-Report - Mabuhay Cement Processing Plant Project

Uploaded by

Copyright:

Available Formats

Project-Description-Report - Mabuhay Cement Processing Plant Project

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Project-Description-Report - Mabuhay Cement Processing Plant Project

Uploaded by

Copyright:

Available Formats

Project Description for Scoping

Mabuhay Cement Processing Plant Expansion

PROJECT DESCRIPTION FOR SCOPING (PDS)

1 Basic Project Information

1.1 Project Information

Project Name Mabuhay Cement Processing Plant Project

1.2 Proponent Profile

Proponent Name Mabuhay Filcement Incorporated

2.1 Project Rationale

2.2 Project Location and Area

Illustration 1: Vicinity Map

Geographic Coordinates of the Project Area:

Drone Site Photos Taken on January 27, 2018

2.3 Project Components

Existing Facilities Proposed Expansion

Existing Facilities with Approved ECC

Existing Facilities Area (sq.m.) Remarks

Additional Facilities without ECC

2.4 Resource Requirement

Domestic Water Use

Industrial Water Balance

2.5.1 Timeframe of Project Phases

3 Project Cost: (Php) Approximately 200,000,000.00

3.1 Site Development Plan

4.1 Pre-Operation Phase

4.2 Operational Phase

The following are the major steps in cement manufacturing;

centigrade and outlet temperature is 60 degrees centigrade above ambient.

Clinker is conveyed by grate plates and crushed by a clinker crusher to a maximum

4.3 Decommissioning / Abandonment Phase

Proper treatment and disposal of bulk Contracted hazardous P5,000-10,000/ton

5 Actual Site Photos

You might also like