Unique processes and best practices

Cement manufacturing operations Holcim Philippines, Inc.

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.

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 societys future. From a 40-year history dating back to its roots in Union 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 worlds 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 18001Occupational Health and Safety Management System, ISO 14001Environmental Management System, and ISO 9001Quality Management System standards.
Market areas Ilocos and Cordillera regions Central Luzon, Northern and Western Palawan, and export markets Southern and Central and export markets Mindanao, ARMM,

Our four plants supply cement in key regions across the archipelago, producing over 7 million metric tons of cement in a year.

La Union
Rated capacity Kiln 2,400 TPD

Bulacan

Lugait

Davao

(tons/day-TPD) Cement

5,500 TPD

Kiln 2: 4,000 TPD 340 TPH

Kiln 1: 1,960 TPD

3,500 TPD

(tons/hour-TPH)

120 TPH

(combined)

380 TPH

(combined)

(combined)

280 TPH

NCR, and the Southern Tagalog region

Cagayan Valley,

Mindanao, Panay Islands,

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Profile

Cement Manufacturing Process

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. 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 elemental composition of raw materials, ensuring their 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 limestone and clay. In manufacturing concrete, it performs as a binding agent when combined with gravel, powdered 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. 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. Pre-blended materials heated up to 1,4500C produce clinker, which is finally ground with other cementitious ingredients to form cement products. The whole mix is meticulously calculated by robotic technology. Next comes homogenization, achieved by passing the mixture through blending silos. Quarrying
Limestone and shale are extracted from the quarry by open pit method, through drilling and blasting techniques.

Cutting-edge technology and a skilled workforce ensure smooth and efficient operations.

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.

Raw Milling

The pre-blended materials, corrective materials, and other alternative raw materials are proportioned, milled and dried, producing raw meal.

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 1450C.

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

Line 2 in the Lugait plant controls factors like temperature and ingredient proportions, from the Central Control Room.

Holcim Philippines

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) 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.

We commit to sustainable environmental performance, pursuing responsibility and transparency in all areas of plant operations.

Julius Tuting takes control

Mechanical Engineer Julius Tuting enjoys his post as Line 2 Process Control Operator at the Lugait Plant, supervising the cement manufacturing process. simulator operations and manufacturing processes. He shares his expertise, from problems and trouble shooting, to planning the annual 12-day shutdown. No wonder Line 2 is one of the most efficient cement metric tons of clinker per day. Skilled operators like Julius keep things running smoothly. production lines in the country, churning out 4,000

Continuous Emission Monitoring Systems (CEMS) Continuous Emission Monitoring Systems are installed in all plants, ensuring that all emissions are kept at the minimum levels accepted under the Clean Air Act. Occupational Health and Safety (OH&S) Strict enforcement of global safety standards target zero risk for all employees and surrounding communities. 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.

Green beginnings
Minimizing the impact of a supply chain that harnesses resources from deep underground is a chief concern at Holcim. In Davao, a comprehensive environmental protection plan is being carried out to rehabilitate and monitor areas where the activities of Holcim may have had significant environmental effects. 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. Together, Martin and Dom have restored biodiversity in the forests of Davao and improved the quality of life in four host communities. Because of their passionate performance and their dedication to environmental conservation, people living near the Holcim plant in Davao can keep their mountains green.

Stationed at the Central Control Room, Julius monitors all materials are at their exact proportion, every machine is operating at the right speed, and precise temperatures are utilized in every cement mix.

every step of the process. This means making sure

Another key element in plant operations is people management. As an instructor during off-plant seminars, Julius orients fellow employees on kiln

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Holcim Philippines, Inc. L3 PHINMA Plaza 39 Plaza Drive, Rockwell Center Makati City 1211 Philippines

Phone +63 2 898 1980 Fax +63 2 870 0300 http://www.holcim.com/ph

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