ABB are a supplier of, and also responsible to engineer, the electrical and process control equipment throughout the new Holcim Settat cement plant in Morocco. Holcim S.A. is realizing the Settat cement plant in different phases. The plant is located about 70km south of Casablanca, Morocco.
In 2004 Holcim decided to build the packing plant at the Settat location and concluded at the end of 2004 to establish a complete cement factory by expanding, in two steps, a new cement grinding plant and a clinker production line.
The packing plant has been in operation since the middle of 2005. The grinding plant will have a capacity of 1.7 Mio tons of cement/year. Operation is scheduled for the third quarter of 2006. The planned clinker production capacity will be 4’000 t/day and the operation is scheduled to start in late 2007. The quarry is located about 25 km from the main plant and the limestone will be transported using a railway between the two locations. The loading and unloading stations form part of the project.
ABB engineered, supplied, installed and commissioned the complete electrical equipment for the packing plant. The main supply included a temporary 60kV substation, the medium- and low voltage distribution package with all motor control centers, the process control system, lighting and cables. The packing plant went into operation after a demanding short construction period on schedule. The cement is produced in the other Moroccan Holcim plants in Fès and Oujda and delivered by railway to Settat. To cope with the production of the new plant, the expansion of the packing plant with two additional silos, an additional packing line and a palletizer has been under construction since the middle of 2005.
The 60 kV main substation was awarded to Elecam, a Moroccan company, whereas ABB supplies the high voltage distribution, main transformers and medium voltage distribution including a Scada control system for supervision of the Main Substation.
For cement grinding and clinker production the process and electrical equipment is contracted within one package and was awarded to CBMI Construction Co. Ltd, a Chinese OEM. ABB delivers the medium voltage distribution, the low voltage motor control centers, the medium and low voltage motors and drives and the process control system. The technologies used are well proven in other installations and help to keep electrical energy consumption as low as possible.
For the cooler application a multi-drive system will be installed, since it has been successfully in operation at other Holcim sites.