Unique processes and best practices Cement manufacturing operations
Holcim Philippines, Inc.
Holcim Philippines
Profile
Plant operations Each plant is equipped with state-of-the-art technology and the latest emissions monitoring system, operating under strict global standards for safety, efficiency, and quality.
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Building a strong presence Holcim Philippines takes pride in being the leading cement company in the country. With a workforce of over 1,300, Holcim Philippines upholds its commitment to help build foundations for society’s future. From a 40-year history dating back to its roots in Union
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Our four plants supply cement in key regions across the archipelago, producing over 7 million metric tons of cement in a year.
Cement Corporation, under The PHINMA Group, Holcim Philippines continues its operations with a renewed spirit, inspired and strengthened by the Holcim global network. Holcim is one of the world’s leading suppliers of cement, aggregates, concrete, and construction-related services. By giving back to society, we contribute to a growing economy and to building stronger and more prosperous communities. Our people and technology aim to make a difference in many lives. With passionate and skilled employees, new and stronger product offerings, and efficient operations, Holcim paves the way to an even stronger future. Cement production capabilities Holcim invests its people, its time, its resources, and its technologies in bringing top-quality cement to the market. With state-of-the-art equipment and capabilities at par with global standards, Holcim meets production goals while keeping people safe and the environment protected. A commitment to quality Holcim Philippines operates four plants in key areas around the country. Together these plants produce an annual capacity of more than 7 million metric tons of clinker and 8.7 million metric tons of cement. All plants are certified to OHSAS 18001—Occupational Health and Safety Management System, ISO 14001—Environmental Management
System,
and
ISO
9001—Quality
La Union
Bulacan
2,400 TPD
5,500 TPD
Cement
120 TPH
380 TPH
Market areas
Ilocos and Cordillera
Lugait
Davao
Kiln 1: 1,960 TPD
3,500 TPD
340 TPH
280 TPH
Rated capacity Kiln
(tons/day-TPD)
(tons/hour-TPH)
(combined)
Kiln 2: 4,000 TPD
(combined)
(combined)
Northern and Western
Southern and Central
Palawan, and export
and export markets
Management System standards.
regions
Central Luzon,
Cagayan Valley,
Mindanao, Panay Islands,
Tagalog region
markets
NCR, and the Southern
Mindanao, ARMM,
Cement Manufacturing Process 4
The production line: a model of efficiency A passion for precision Skilled people A strong and dedicated workforce runs our four plants. Engineers, operators, and mechanics undergo rigorous and continuous training, resulting in maximum efficiency and excellence in operations.
Cutting-edge technology and a skilled workforce ensure smooth and efficient operations.
Optimum efficiency Our production processes are supported by strict process and product quality control. A passion for accuracy ensures that the line operations in our local manufacturing plants are up to par with strict local and international standards. Prompt Gamma Neutron Activation Analysis (PGNAA) Plant operators apply PGNAA to determine the
Quarrying
Limestone and shale are extracted from the quarry by open pit method, through drilling and blasting techniques.
Crushing
Limestone and shale boulders are reduced through compression or impact crushing.
Transporting
The crushed materials are transported to a stockyard where the materials are pre-homogenized.
Pre-Blending
The limestone and clay or shale are pre-homogenized in a blending bed.
elemental composition of raw materials, ensuring their
Raw Milling
The pre-blended materials, corrective materials, and other alternative raw materials are proportioned, milled and dried, producing raw meal.
exact proportions. With precision technology, skilled people, and a disposition to accuracy, our processes run smoothly.
From the earth to our hands Cement is a construction material made from natural
The whole mix is meticulously calculated by robotic
limestone and clay. In manufacturing concrete, it performs
technology. Next comes homogenization, achieved by
as a binding agent when combined with gravel, powdered
passing the mixture through blending silos.
stone, and water. Concrete comes second to water as the most consumed material on earth, with two to three tons per annum for each person on the planet.
Pre-blended materials heated up to 1,4500C produce clinker, which is finally ground with other cementitious ingredients to form cement products.
The process starts with the extraction of limestone and clay drilled and blasted from mountains. These quarried components are then crushed by jaw and impact crushers. Silica, pyrite cinder, and alternative raw materials are then ground in large mills to a powder.
Homogenizing
The raw meal then undergoes final homogenization by pneumatic aeration.
Clinker Processing
The calcined raw mix enters the rotary kiln at a temperature from 900 to 1000 degrees; lime reacts with silica in stages and clinker minerals are finally formed at 1450°C.
Storing
After the molten clinker is quickly air- cooled, it is transported by bucket conveyors to the shaded storage.
Cement Milling
Clinker, together with about 5% gypsum, is finely ground at the tube mill. The powder product is now called cement.
Packing and Delivery
Cement is packed and delivered in bags or in bulk by truck or ship.
Social and Environment
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Holcim helps restore biodiversity in its communities, especially in areas where mining activity has consumed natural resources.
Responsible operations Holcim is dedicated to protecting the environment and monitoring how plant operations affect host communities. This commitment allows safe working and living conditions for employees and residents in our community. We comply with strict regulations to maintain a health-friendly environment. Quarry Scheduling Optimization (QSO)
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We commit to sustainable environmental performance, pursuing responsibility and transparency in all areas of plant operations.
The manufacturing starts with quarrying of limestone and shale. Holcim uses a Quarry Scheduling Optimization (QSO) program to carefully assess the proper areas to mine within a specific time period. Alternative Fuels and Raw Materials (AFR) By using waste materials as alternative fuel or raw materials, we are able to help industries and local government units manage their waste in an ecologically sound manner. This also reduces our dependence on nonrenewable energy and minerals. Continuous Emission Monitoring Systems (CEMS)
Julius Tuting takes control
Continuous Emission Monitoring Systems are installed
Mechanical Engineer Julius Tuting enjoys his post as
simulator operations and manufacturing processes.
supervising the cement manufacturing process.
shooting, to planning the annual 12-day shutdown.
Line 2 Process Control Operator at the Lugait Plant,
Stationed at the Central Control Room, Julius monitors
every step of the process. This means making sure all materials are at their exact proportion, every machine is operating at the right speed, and precise temperatures are utilized in every cement mix.
Another key element in plant operations is people management. As an instructor during off-plant
seminars, Julius orients fellow employees on kiln
in all plants, ensuring that all emissions are kept at the
He shares his expertise, from problems and trouble
minimum levels accepted under the Clean Air Act.
No wonder Line 2 is one of the most efficient cement
Occupational Health and Safety (OH&S)
metric tons of clinker per day. Skilled operators like
risk for all employees and surrounding communities.
production lines in the country, churning out 4,000 Julius keep things running smoothly.
Strict enforcement of global safety standards target zero
Social responsibility Our plants are committed to improving the quality of life of our employees and of the people in our communities through sustainable community programs. Monitoring and reporting We monitor and report our environmental, social, and operational performance with local NGOs, government agencies, and residents, in a transparent manner.
Holcim Philippines
Holcim Philippines
Line 2 in the Lugait plant controls factors like temperature and ingredient proportions, from the Central Control Room.
Green beginnings Minimizing the impact of a supply chain that harnesses
Together, Martin and Dom have restored biodiversity
resources from deep underground is a chief concern
in the forests of Davao and improved the quality of life
at Holcim. In Davao, a comprehensive environmental
in four host communities. Because of their passionate
protection plan is being carried out to rehabilitate and
performance and their dedication to environmental
monitor areas where the activities of Holcim may have
conservation, people living near the Holcim plant in Davao
had significant environmental effects.
can keep their mountains green.
In the middle of this endeavor is forester Martin Obrero. Along with Dominador Andres of Holcim Davao, the team has successfully rehabilitated more than 36 hectares of mined out quarry areas with more than 170,000 indigenous trees. Annually, the team stretches its resources, facilitating seedling propagation, nursery building, fertilizing, and siltation control.
Holcim Philippines, Inc.
Phone +63 2 898 1980
L3 PHINMA Plaza
Fax +63 2 870 0300
39 Plaza Drive, Rockwell Center
http://www.holcim.com/ph
Makati City 1211 Philippines
La Union Plant Quirino, Bacnotan, La Union (072) 888-4252 Bulacan Plant Matictic, Norzagaray, Bulacan (02) 732-2230 Lugait Plant Lugait, Misamis Oriental (063) 225-8000 Davao Plant Bo. Ilang, Davao City (082) 238-0451 to 55