Our Service.
What we do
Overview
CPI has separated its services into four main product areas:
In many cases there is overlap between these different product areas - for example part of the optimisation of a plant might involve providing some form of training. As such, CPI treats each customer request as a unique project and will design the services around the particular challenge and circumstances of the plant in question.
CPI is ideally placed to provide a value-added consultancy service to the cement industry, using the application of technical knowledge and management experience to increase plant profits and develop viable solutions to key issues. Whatever the challenge, our aim is to provide the best possible solutions to satisfy our clients' requirements.
CPI is independent of any cement manufacturer or equipment supplier so that any advice provided is completely impartial and in our clients' best interests. The company values long-term relationships with its clients and actively promotes the development of its clients' own resources, so that its clients will benefit long into the future once an assignment has been completed.
Services we offer
Process Design
- Assessment of raw materials for new kiln line
- Raw materials testing advice for materials handling
- Preparation of tender enquiry documents
- Evaluation of supplier tender offers
- Negotiation with equipment suppliers
- Quarry design and exploitation plan
- Raw mix design
- Plant equipment sizing
- Review of plant drawings and layout
- Fuels selection advice
- Commissioning of new/upgraded plant
- Post-commissioning audit
- Supervision of guarantee tests
Troubleshooting
- Plant audit
- Rating of equipment
- Burner pipe optimisation
- Plant chemistry evaluation
- Reliability strategy guidance
- Shutdown planning support
- Major mechanical engineering solutions
- Materials handling solutions
- Fuel and power consumption reduction
- Kiln/mill output optimisation
- Fuzzy logic optimisation
Product Development & Quality Control
- Cement additives optimisation
- Variability reduction programme
- Cement performance optimisation
Environmental
- CO2 reduction strategies
- Alternative fuels and raw materials selection
- NOx and SO2 reduction strategies
- Pollution abatement equipment optimisation
Management Development
- Management structure and operations review
- Selection process and testing programmes
- Plant Manager mentoring
- Mentoring for all cement plant key positions
- Process Engineer development
Training
- Kiln burner evaluation and training
- Senior management training course
- Cement technology for equipment suppliers
- Process Engineer training
- Laboratory operative training
- Cement technology for non-technical managers
Strategic Development
- Due-diligence assessments
- Advisors to private equity/venture capital groups
- Corporate strategy advisors
- Process Design
- Troubleshooting
- Product Development & Quality Control
- Environmental
- Management Development
- Training
- Strategic Development
- Assessment of raw materials for new kiln line
- Raw materials testing advice for materials handling
- Preparation of tender enquiry documents
- Evaluation of supplier tender offers
- Negotiation with equipment suppliers
- Quarry design and exploitation plan
- Raw mix design
- Plant equipment sizing
- Review of plant drawings and layout
- Fuels selection advice
- Commissioning of new/upgraded plant
- Post-commissioning audit
- Supervision of guarantee tests
- Plant audit
- Rating of equipment
- Burner pipe optimisation
- Plant chemistry evaluation
- Reliability strategy guidance
- Shutdown planning support
- Major mechanical engineering solutions
- Materials handling solutions
- Fuel and power consumption reduction
- Kiln/mill output optimisation
- Fuzzy logic optimisation
- Cement additives optimisation
- Variability reduction programme
- Cement performance optimisation
- CO2 reduction strategies
- Alternative fuels and raw materials selection
- NOx and SO2 reduction strategies
- Pollution abatement equipment optimisation
- Management structure and operations review
- Selection process and testing programmes
- Plant Manager mentoring
- Mentoring for all cement plant key positions
- Process Engineer development
- Kiln burner evaluation and training
- Senior management training course
- Cement technology for equipment suppliers
- Process Engineer training
- Laboratory operative training
- Cement technology for non-technical managers
- Due-diligence assessments
- Advisors to private equity/venture capital groups
- Corporate strategy advisors
Plant Optimisation
Plant optimisation can take a number of forms: it may be that the plant has been recently commissioned and is ramping up to steady state, it may be that there has been a sudden change in the process causing a drop in output or an increase in fuel consumption, or it may be that the plant management wishes to put in place a programme to ensure that the entire manufacturing process is running at its optimum.
CPI has the capabilities to cover all of the above cases and more. It is our firm belief that all equipment and processes on the plant should be running at their optimum level before capital is spent on the plant.
Plant optimisation is not limited to process engineering. Other opportunities exist on the plant in areas such as variability reduction, maintenance management, root cause analysis and production planning.
CPI has the capabilities to cover all of the above cases and more. It is our firm belief that all equipment and processes on the plant should be running at their optimum level before capital is spent on the plant.
Plant optimisation is not limited to process engineering. Other opportunities exist on the plant in areas such as variability reduction, maintenance management, root cause analysis and production planning.
Project Design and Commissioning
There will come a time in any cement plant or company when capital investments are required to continue the development of operations. CPI offers a full range of services to assist its clients in making the right technological investments at the right price.
The process of making capital investments starts with the identification of the strategy. CPI is internationally experienced in strategy development at both plant and corporate level and can assist in the development of the strategy for individual plants and organisations.
Once the strategy has been decided, CPI can provide the technical services for any project - from modifications to upgrades to greenfield sites. Taking the project concept we work for our clients in ensuring that equipment suppliers provide the most appropriate equipment for the project at the correct price.
CPI personnel have been involved with over 50 new build and extension projects representing over 35 million tonnes of new capacity creation, as well as numerous successfully completed feasibility studies in all parts of the world. CPI uses it's technical expertise in all areas - from quarry planning, crushing and raw milling, pyro-processing, cement milling through to packing and dispatch operations - however prefers to leave project management to specialists within that field.
CPI can also offer technical advice on issues such as alternative fuels and raw materials, where the benefits in terms of cost reduction may be obvious but some of the impacts to be taken into consideration may not be so evident. CPI can guide its clients through such projects to ensure that the maximum benefit is gained rapidly, with minimum negative impact upon the existing operation.
We also provide a comprehensive due diligence service for organisations seeking advice for the purchase of new cement plants.
The process of making capital investments starts with the identification of the strategy. CPI is internationally experienced in strategy development at both plant and corporate level and can assist in the development of the strategy for individual plants and organisations.
Once the strategy has been decided, CPI can provide the technical services for any project - from modifications to upgrades to greenfield sites. Taking the project concept we work for our clients in ensuring that equipment suppliers provide the most appropriate equipment for the project at the correct price.
CPI personnel have been involved with over 50 new build and extension projects representing over 35 million tonnes of new capacity creation, as well as numerous successfully completed feasibility studies in all parts of the world. CPI uses it's technical expertise in all areas - from quarry planning, crushing and raw milling, pyro-processing, cement milling through to packing and dispatch operations - however prefers to leave project management to specialists within that field.
CPI can also offer technical advice on issues such as alternative fuels and raw materials, where the benefits in terms of cost reduction may be obvious but some of the impacts to be taken into consideration may not be so evident. CPI can guide its clients through such projects to ensure that the maximum benefit is gained rapidly, with minimum negative impact upon the existing operation.
We also provide a comprehensive due diligence service for organisations seeking advice for the purchase of new cement plants.
Training and Knowledge Transfer
To achieve world-class performance, it is essential to have the necessary skills available at the plant. CPI is regularly invited to conduct technical and interpersonal skills assessments. Once the skills gaps have been identified, training can be arranged and focused specifically on those areas that will impact plant profitability.
Training is much more than sitting in a classroom listening to presentations and as such CPI offers a broad range of specific training and development programmes in a variety of teaching formats. We design our courses around the specific audience of the training, the location of the training, the specific objectives of the training and the manner in which the effectiveness of the training will be measured. We will design our course around your requirements. For example, plant based training involves less disruption to the daily routine, and will permit more people to attend, whereas training at a remote location with a mix of personnel from other locations ensures a more focused approach and presents the opportunity to exchange experiences with others.
Training is much more than sitting in a classroom listening to presentations and as such CPI offers a broad range of specific training and development programmes in a variety of teaching formats. We design our courses around the specific audience of the training, the location of the training, the specific objectives of the training and the manner in which the effectiveness of the training will be measured. We will design our course around your requirements. For example, plant based training involves less disruption to the daily routine, and will permit more people to attend, whereas training at a remote location with a mix of personnel from other locations ensures a more focused approach and presents the opportunity to exchange experiences with others.
Examples of the type and formats of training that we can offer:
Interactive Classroom Training
Normally short sessions of two to three days, aimed at plant based operatives focusing on kiln and mill operations.Modular training courses
The modular format is taken when the aim is to teach a small group a specific area of the plant in detail such that they understand both the theoretical and practical aspect of that area. Examples of modules would be raw milling, pyro-processing, cement milling, cement chemistry etc. Courses would last two or three days and would be split between morning sessions of theoretical presentations and afternoon sessions on plant completing the physical testing of the equipment.Profitability and Performance Courses
Whilst based on a classroom teaching format, the above course focused on how to translate the specific technical parameters associated with the cement manufacturing process into profitability for the company. Therefore, to provide the interaction during the course and to monitor the learning during the course the participants will work through the course with a case study relating to a cement business. The case develops over the week long course and gives the participants options as to how they would develop the business and what decisions they would take to improve performance and profitability based upon the information that they have learnt during the lectures.Mentoring Process & Train the Trainer
The mentoring process is a way of developing individuals or small groups of plant personnel by providing remote support for the individuals interspaced by visit by the CPI Mentor. It can be used for any discipline or for management roles, whereby the CPI Mentor will work progressively through the target areas identified from the skills matrix and will assign certain tasks for the individual to accomplish in between the visits from the Mentor.E-Learning
CPI has developed e-learning training courses for control room operators for a number of clients. Advantages of e-learning programmes include; students can learn at their own pace, the material presented is available for reference at any time, material is focused on specific plant and technology and covers the whole range of technology needed for efficient operation and it can be used to evaluate trainees by identifying and correcting any knowledge gaps. The format is suitable for adaptation for other disciplines such as process engineers, quality control personnel, maintenance etc.Environmental Improvement
No cement business can afford to overlook its environmental obligations. As well as the legal obligations, public perceptions of cement manufacturers are critical to their business performance. It is now an accepted fact that good environmental performance means good business performance.
For example, one of the key factors in a successful alternative fuels programme is a good relationship with the local community that lives around the cement plant. These communities will be much more accepting of alternative fuels if the plant has a good record of environmental performance and has dealt with any environmental incidents with professionalism and transparency.
CPI can provide assistance and recommendations in the optimisation of all emissions protection equipment such as electrostatic precipitators and bag filters. We also have experience in emissions reduction technologies for pollutants such as SO2 and NOx, and extensive experience of environmental legislation and permitting processes around the world.
CPI's extensive experience in plant operations and product quality enables us to audit cement plant operations for CO2 emissions. We can set achievable targets and advise on strategies for minimising greenhouse gas emissions, such as alternative fuels programmes, blended cements and efficiency improvement projects.
For example, one of the key factors in a successful alternative fuels programme is a good relationship with the local community that lives around the cement plant. These communities will be much more accepting of alternative fuels if the plant has a good record of environmental performance and has dealt with any environmental incidents with professionalism and transparency.
CPI can provide assistance and recommendations in the optimisation of all emissions protection equipment such as electrostatic precipitators and bag filters. We also have experience in emissions reduction technologies for pollutants such as SO2 and NOx, and extensive experience of environmental legislation and permitting processes around the world.
CPI's extensive experience in plant operations and product quality enables us to audit cement plant operations for CO2 emissions. We can set achievable targets and advise on strategies for minimising greenhouse gas emissions, such as alternative fuels programmes, blended cements and efficiency improvement projects.
PROFIT FROM OUR EXPERIENCE
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