Proposed construction and operation of a new cementitious plant located on Portion 192 of Farm Daggafontein 125, Springs

The applicant, Opsibuzz (Pty) Ltd proposes the construction and operation of a new cementitious plant located on Portion 192 of Farm Daggafontein 125, Springs, Johannesburg, City of Ekurhuleni local Municipality (Ward 76).
The site extends over 4.2 hectares and will have a design capacity of 1,314,000 tons per annum, the facility will include the following:
A grinding facility inclusive of a vertical roller mill that will operate at 150tph
A blending Plant
50 000-ton Raw material Storage Facility
4 x mill hoppers (2 x 600 ton and 2 x 300 ton)
6 x cement silos (2000 ton)
1 x fly ash silo (1500 ton)
Laboratory
Workshop,
Cooling Tower,
Weighbridges,
General buildings,
Bagging and Palletising Shed, and
A pollution control dam if necessary
Process description:
Raw Material handling –
Raw materials are received via road and ship and stockpiled in the shed.
Raw materials include Clinker, GBFS, Limestone and Gypsum.
The plant will not produce clinker. Clinker is to be purchased from an external source and then crushed at the facility. The variation in the grades of cement is based on the mixing of clinker in different proportions with extenders such as slag, fly ash, limestone, etc. The main extender in our process is Granulated Blast Furnace Slag (GBFS) which is a non-hazardous by-product sourced locally from the steel making industry.
Materials are to be transferred to the milling / drying area via a conveyor system.
Cement milling / drying –
Materials are extracted from their respective feed bins using weigh feeders. The weights are proportioned according to the pre-programmed recipes.
Larger particles of GBFS are separated by use of a belt magnet and metal detectors which is removed for recycling.
The grinding system employed by Cemza is among the most modern and energy efficient vertical roller mills.
Materials are grinded in the mill via a rotary feeder
Water and grinding aid is dosed into the mills in accurate dosages.
The ground material is passed through the classifier via the hot gas generator. Partially ground material is trapped as it passes through the classifier – these particles are recycled through the mill.
The ground product in powder form is the final product.
Cement storage –
Product is separated via a baghouse filter system.
The product from the filters is lifted to the product storage silos by bucket elevator, air slide and distributor system and material is conveyed into the four storage silos.
Packaging and palletising –
Product is extracted from the silos and is packed with an automated dual packer and palletiser configuration.