TPI Polene cement plant reduces costs and CO2 emissions with unique Metso Outotec solution

Located 100 kms north of Bangkok, in the Saraburi province, lies the TPI Polene Public Company Limited cement plant. TPI Polene is amongst the top three manufacturers and distributors of cement products in all of Thailand, and has an impressive history in regards to plant sustainability.

TPI Polene was the first cement manufacturer to Thailand to be awarded an ISO 9002 Certification for surpassing industrial and environmental protection standards. On top of that, they were also the first cement manufacturer to be awarded the Carbon Label for both Portland cement and the mortar cement products. The Carbon Label demonstrates that the producer has proven data that demonstrates it has significantly reduced CO2 emissions. Additionally, the TPI Polene Group operate Waste Heat Recovery Power Plants, which generate electricity from waste heat emitted from TPI Polene’s 4 cement production plants. They use Refuse Derived Fuel (RDF) as fuel to generate electricity in its RDF-fired power plants. As a result, TPI Polene has become a power plant operator in Thailand, with the largest waste-to-energy power plant operations in the country and a renewable energy to enhance environmental efficiency.

Metso Outotec is built on partnerships

With sustainability in mind and the focus on lowering the carbon footprint of cement production, it is no wonder that TPI Polene has once again chosen to work with Metso Outotec, the partner for positive change. In 2008, our Thailand distributor, Uawithya, organized a series of IPCC seminars for various Thai cement producers. Since we have been working closely together for many years, Uawithya knew our capabilities and took the initiative to arrange for the series of seminars. After learning of the Metso Outotec IPCC offerings, TPI moved forward with Metso Outotec and implemented our IPCC systems into their operation. This was mostly due to the personal involvement of their CEO, Mr. Prachai Leophairatana, who is seen as a visionary leader for industries technology in Thailand.

“TPI Polene is a Public Company Limited with a very technical leadership, so it takes a different and more personal approach to decision making,” says Jorma Kempas – Product Manager, Lokotrack® Solutions, Metso Outotec. “There is always a risk when you try something new, and many stakeholders in big corporations choose to avoid that risk. It was such a smooth process working with him on this project and he could see himself that we were making a difference.”

Operational costs, worker safety and CO2 emissions are challenges faced by most mines and quarries today. While there certainly isn’t a magic remedy that would solve all problems overnight, our in-pit solutions such as IPCC, are widely recognized as a good place to start.

In 2012, we delivered the first IPCC systems to the TPI Polene site, replacing their conventional truck haulage with mobile crusher and belt conveyers. This consisted of three Lokotrack® LT1418E mobile impact crushers and Lokolink belt conveyors, each producing 600-700 tph of 0/80mm limestone for cement production. Metso Outotec also delivered the in-pit conveyors, which convey the crushed rock from Lokolink conveyors to the overland belt conveyor. Since this successful implementation, TPI has reported 50% haul cost saving compared to truck haulage.

New project, same IPCC benefits

Based on their positive experience from the earlier IPCC installation, TPI wanted to utilize the IPCC concept for their upcoming project. The objective was to initiate the typical IPCC benefits, such as lower haulage cost, less dust and exhaust gas emissions, and improved worker safety.

In 2017, TPI launched a project for opening a new deposit to extract shale and andesite to be used for clinker production. Initially, Metso Outotec planned to deliver a Lokotrack® with a jaw crusher. However, since the deposit contains lot of fine material (which appears highly sticky in rainy season) it was decided to use a sizer type of crusher fed by the apron feeder as opposed to a jaw or impact crusher.

It was at this time that Uawithya Mining brought Komatsu Mining and their sizer technology into the loop. As a result of working together with Komatsu, the LT1510RC (ex. LT000E) was developed. Paired with the Lokolink, this duo working in parallel gave TPI Polene the ability to further maximize their operation whilst minimizing their cost & environmental footprint.

The Metso Outotec solution

With the robust and reliable mobile Lokotrack®, the track-mounted construction allows machines to easily move around a production site or between sites if necessary. The TPI Polene cement plant is quite large in size and requires a lot of traffic and movement throughout the vast space. With multiple operating pits, as well as the creation of a completely new pit to extract shale and andesite for clinker production, it was crucial to the site that they focus on optimal plant efficiency.

The LT1510RC (rated up to 1500 tph) is producing 900-1200 tph (depending on type of feed) of 0/300mm material. This is conveyed through the Lokolink conveyors and in-pit conveyors supplied by Komatsu Mining onto the overland conveyors that bring the material into the process plant.

A mobile Lokotrack® with a sizer is directly loaded by a hydraulic excavator. Metso Outotec mobile Lokolink conveyors transfer the crushed material to a shiftable conveyor system. The secondary sizer (by Komatsu) is located at the first transfer point of the fixed conveyors, crushing the material down to less than 50 mm. Overall, material hardness tends to vary between 20 to 200 MPa. 

Overcoming their challenges

It is no secret that sticky feed is a rising global issue in both mining and aggregates production and can cause a variety of issues within the operation. Whether it’s clogging the system, taking the time to clean, or having to start the operation again – sticky feed is a complete nuisance to any operating plant. However, the TPI Polene cement plant has begun to take action against this issue with the implementation of the Metso Outotec IPCC solution.

“The biggest benefit is that even with the sticky material, they are able to produce – this is the main thing,” says Jorma Kempas. “And they are using the IPCC system which has lower cost and is environmentally better than if they were using a conventional truck haul. The site is focusing on sustainability and lower operating cost, which is we also strongly believe in.”

Fuel costs are also a major expense in plant operation. Therefore, low consumption is essential. In using the IPCC systems, as well as the Lokotrack® and Lokolink, the large site is able to further optimize their production and maximize their safety and sustainability - all whilst minimizing cost at the same time.

“It’s important to note the safety aspect too – from a health and safety perspective, it reduces their mobile fleet, so they’ve got less traffic movement on the site, which is much safer,” Kempas explains. “From an environmental perspective, it reduces fuel consumption and the environmental impact of dust emissions. From an operational perspective, it does everything they need it to do and more.”

Empowering clients today & innovating for tomorrow

Following this success, TPI Polene has learned that we can not only deliver these systems, but also implement them responsibly and effectively. Metso Outotec takes great pride in the creation and continuation of our positive working relationship with the customer and distributor. We look forward to the future opportunities that can arise on the back of this project.

“The reputable connection that we have with our distributor Uawithya, and the site itself, is an excellent example in working together,” says Campbell Johnson, Capital Distribution Manager - Asia Pacific, Metso Outotec. “The fact that they continue to choose us, and we are still the one – this speaks volumes on our capabilities. From both a brand position and an operational point of view, the support that we’ve provided constantly to our distributor has helped everything move as smoothly as it has.”

It is always exciting to find a company that exemplifies the same core values as Metso Outotec. With our strong focus on sustainability and helping our customers optimize their operation, our collaboration with TPI Polene is understandably fitting. Through the choices we make together with our customers, we can influence the outcomes and take the industry towards a more responsible use of the world’s previous natural resources. At Metso Outotec, it is our core expertise to help our customers transform the industry. That’s why we are the partner for positive change.