New Finish Mill System

The scope of the project was the installation of a new roller mill system into an existing cement plant, including the addition of a new additives feed system for the whole plant, and the addition of three new cement storage silos each with a new truck loadout system to largely replace their existing loadout system and improve truck traffic flow on site. The process equipment system and silo system were each a turnkey design-build contract. LVTA served as the Owner’s Engineer, reviewing submittals, ensuring compliance with the contracts, coordinating between the suppliers, and providing design services for the mechanical, civil, and structural Balance-of-Plant (BOP) tie-in work that was not contracted by either of the turnkey contracts. BOP design work scope included pneumatic conveying systems to tie the existing and new mill systems together, transfer tower modifications to tie the new clinker and additives feed systems into the existing systems, cooling water system design, truck wash station design, civil pavement and retaining wall design, and miscellaneous maintenance platform design. Key challenges in this project include the following:

• Organizing and properly communicating the tens of thousands of documents being transmitted over this 3+ year project;
• Difficult retrofit modifications to existing transfer towers to integrate the new mill feed system and additives feed system into the existing plant. 3D scanning was integral in this process due to limited available records of historical constructions and modifications