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Increasing capacity at US cement plant

Titan America, one of the largest cement producers in the eastern US, wanted to double production capacity at its cement facility in Miami, Florida. In order to do this, the existing facility had to be shut down and a new modern ‘Pyro’ Processing line built, including the installation of gas, power, water and air services.

Pyro processing is used to increase the economic value of ores, minerals, waste and related materials by changing their mechanical and/or chemical properties through the addition or removal of heat. The new production line used the latest technologies to control emissions and conform to the stringent US environmental standards. The new technology offered Titan savings in operating costs due to the reduction of fuel and power consumption per ton of cement.

"Working together with the team of FLSmidth, Zachry Construction, and Titan, [Amec Foster Wheeler] was instrumental in design and completion of the new production line which was completed two months ahead of schedule and doubled the existing plant capacity."
Tom Dodson, Atlanta Operations Manager

Working closely with Zachry Construction, a privately-owned construction and industrial maintenance service company located in San Antonio, Texas, we were responsible for designing, engineering and supporting the installation of key infrastructure for the plant, including the power distribution network, water and gas piping systems, air supply systems, drainage and plant access routes. By working in a close team with the designers of the process line, FLSmidth, we were able to fully integrate the designs to ensure that the plant operated with maximum efficiency.

The outcome of our project was a facility capable of producing 5,000 tons per day of clinker, double the original production capacity of the plant, delivered two months ahead of schedule. Our experience with the processes and engineering solutions for the facility mean that it will continue to run safely, efficiently and cost-effectively throughout the life of the plant.

Location:Miami, Florida
Client:Titan America
Value:US$2.7 million (Project)
Scope:Balance of plant design
Date:2002 – 2004