Impressive cement terminal at the port of Malmö, Sweden

As a general contractor, HAVER & BOECKER’s subsidiary company IBAU HAMBURG led the construction of a cement terminal for CEMENTA HeidelbergCement Group at the port of Malmo¨, Sweden (please see ‘IBAU HAMBURG hands over cement terminal’ on p58 of the May issue of DCI). When approaching the Copenhagen, Denmark airport at night, it is possible to see the distinct skyline of the multi-chamber silo, which is fed by a mechanical-pneumatic ship unloading system, is 100 metres tall, has a diameter of 26 metres and contains 30,000 tonnes of cement. Automatic loading of tanker trucks and wagons is done 365 days a year.

• CS7 process control system with CEMAT, as to HeidelbergCement standard;
• gas-isolated medium voltage switchgear, 11kV;
• dry-type transformer 1,600kVA;
• low voltage main distributor with compensation;
• switching and control cabinet with S7-400/ET 200M, as to HeidelbergCement standard;
• electrical grounding and lightning protection;
• cable and installation material;
• IT network and infrastructure;
• video-monitoring of the loading stations as well as the entrances and exits;
• interior and exterior lighting; and y engineering and complete electrical installation and start-up.

During the planning phase, IBAU worked in close co-operation with Heidelberger Technology Center in Brussels and it was decided that the control room in the multi-chamber silo would be moved to Level 1.This offered the advantage of considerably reduced cable paths through silo walls. Because space for the switching and control cabinets, energy distribution and transformers was limited, HAVER & BOECKER opted for maintenance-free, gas-isolated medium switchgear.
The electrical installation involved a number of demanding challenges for the personnel. Installation of the cable works and laying the cable in the bucket conveyor tower - from Level 0 to 100 metres – required special cranes and had to be carried out by workers who weren’t afraid of heights.
One challenge for the automation systems supplied by HAVER & BOECKER was adapting the PCS7 process control system to the silo processes so that clear and well-arranged process groups resulted and thus allowed easy operation and rapid fault detection.(Fig. 4). The tanker trucks and wagons are automatically loaded according to the shipping orders thanks to the data exchange between the process control unit and the shipping system provided by CEMENTA AB. By co-operating closely with Heidelberger Technology Center Brussels, the processes were optimized so that the terminal could be operated without operating personnel.
After the start-up of the facility, the terminal was successfully handed over to CEMENTA AB in March, 2012, after almost two years of planning and construction work.
HAVER & BOECKER is grateful to Heidelberger Technology Center Brussels, CEMENTA AB, the terminal operator, IBAU and all subcontractors for the excellent co-operation. Without such a performance such a short time would not have been possible.