Bojnourd Cement Plant Expansion & Modernization

The Bojnourd Cement Company project involves the comprehensive modernization and capacity expansion of an existing cement production facility located in North Khorasan Province, Iran. This project aims to increase production capacity from 3,500 to 7,000 tons per day (TPD) while implementing environmentally friendly technologies and energy efficiency measures. The plant primarily serves regional construction markets and infrastructure projects.

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Project Specification

Key Specifications

Capacity & Output:

Clinker Production:7,000 TPD (~2.3 million t/year)
Cement Production:8,500 TPD (~2.8 million t/year)
Product Types:
- Portland Type I/II (65%)
- Portland Pozzolana (25%)
- Specialty Cements (10%)

Process Parameters:

Kiln Temperature:1,450°C
Fuel Consumption:720 kcal/kg clinker
Power Consumption:85 kWh/t cement

Alternative Fuel Usage: 15% thermal substitution

Project Details

Production Process:

Dry Process Technologywith 5-stage preheater and pre-calciner
Rotary Kiln Systemwith advanced combustion technology
Vertical Roller Millsfor raw material and cement grinding
Automated Packing and Dispatchsystems

Key Systems:

Raw Material Preparation(limestone, clay, iron ore)
Clinker Production Line
Cement Grinding and Storage
Quality Control Laboratory

Operational Challenges

Raw Material Variability: Inconsistent limestone quality requiring blending optimization
Energy Intensity: High thermal and electrical energy consumption
Emissions Control: Meeting stringent environmental standards for NOx, SOx, and dust
Maintenance Management: Rotary equipment reliability and refractory life

Strategic Importance

Supplies 15% of regional cement demand
Reduces import dependencyfor northern Iran construction projects
Creates 300+ direct jobsin underdeveloped region
Promotes use of alternative fuelsfrom agricultural waste

Engineering Opportunities for Sabz Engineering Co.

✅ Detailed Engineering:

Structural designfor equipment foundations and buildings
Pressure vessel designfor cyclones and heat exchangers
Material handling systemsdesign for raw materials and finished products

✅ Software Solutions:

Process optimization softwarefor energy efficiency
Predictive maintenance systemsfor rotary equipment
Quality control data managementsystems

✅ Project Management:

Phased construction planningto maintain production
International equipment procurementcoordination
Commissioning and startupmanagement

Sustainability Features

Waste Heat Recovery: 8 MW power generation from kiln exhaust gases
Alternative Fuel Use: 15% thermal substitution with agricultural waste
Water Recycling: 90% process water reuse
Dust Emission Control: <10 mg/Nm³ with bag filters

Why This Project Fits Sabz Engineering Co.

Leverages structural and mechanical design expertise
Opportunities for energy optimization software development
Experience in industrial project management
Aligns with sustainable engineering practices

Project Economics

Parameter	Value
Investment	$250 million
Payback Period	4-5 years
ROI	22-25%
Cost Reduction	15% energy cost savings

Technical Comparison: Before vs After Modernization

Parameter	Existing	New
Capacity	3,500 TPD	7,000 TPD
Energy Use	850 kcal/kg	720 kcal/kg
CO2 Emissions	0.85 t/t cement	0.72 t/t cement
Automation	Manual control	Full DCS

SEC Scope:

Design + Material take-off + Fabrication Drawing Preparation for 100 Tons Duct & Miscellaneous