Completed & delivered to site

Q1 2023 Cement plant – Beni Suef

Cement & Clinker

Supply and installation of cement plant production lines

Supply and installation of production line components for cement plants, to specification and on schedule.

Technical Documentation & Operations Gallery

4 high-resolution photos

Client Requirement & Operating Constraints

An operating cement plant needed its production line parts – clinker chutes, conveyor structures and feed hoppers – replaced within a maintenance shutdown of no more than 21 days, with the line back at full capacity on restart.

Strict defined criteria:

  • Full installation inside the planned shutdown window, with no delay.
  • High wear resistance on surfaces in contact with hot clinker.
  • Dimensions matching the existing equipment, with no site modifications.

Mega Steel Scope of Work (Execution Phases)

  1. Phase 01

    Site Survey & Shop Drawings

    Laser survey of the existing equipment and shop drawings matched to every part.

  2. Phase 02

    Prefabrication in the Workshop

    Chutes and structures fabricated as ready-to-install modules to cut site work.

  3. Phase 03

    Wear-Plate Lining

    Abrasion surfaces lined with Hardox plates on replaceable bolts.

  4. Phase 04

    Installation & Commissioning

    Round-the-clock installation crews and a full-load trial run before handover.

Engineering Materials & Alloys Used

Certified, documented engineering

  • Hardox 450 wear plates
  • S355JR structural steel
  • Grade 10.9 high-strength bolts
  • Heat-resistant epoxy coatings

ENGINEERING BOTTLENECKS

The Project’s Complex Engineering Challenges

  • A Very Short Shutdown Window

    Every day of delay meant heavy production losses, and nothing could be measured before the full stop.

  • Hot Clinker Abrasion

    The old parts wore through within months from the clinker’s speed and high temperature.

ENGINEERED RESOLUTION

Innovative Engineering Solutions Applied

  • Numbered Ready-Made Modules

    Every part was pre-assembled and numbered in installation order, finishing the work in 18 days.

  • Replaceable Lining

    Bolted liner plates that are swapped in hours instead of replacing the whole part.

Custom Engineering Fabrication Solutions

Do you have a project that needs pressure vessels or specialised mechanical fabrication?

Send your materials list, engineering drawings or samples for immediate review by our engineers, who will define the best technical path and schedule.