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Construction of a new cement plant

Investment proposal
  

Project name

Construction of a new cement plant with a capacity from 1 million tons to 1.5 million tons of cement per year in the Surkhandarya region Sherobod district.

Objective of the project

Production of cement of various grades (dry method)

Sphere / industry

Construction
Project Schedule Project implementation schedule The period from the beginning of construction and commissioning of the project, from the moment of attracting investments is 17 month.
Project location The cement plant construction area is located in Surkhandarya region, Sherobod district, Vondob mahalla.

Information about project participants:

Initiator Name: OOO “FABULLO STROY SERVIS”Legal address: Surkhandarya region, rn.  Zharkurgan, makhallya Қustepa.Service Bank: JSCB Alokabank Regional Branch, INN: 206576943Contact phone: +998907474630E-mail: ruziev@surxon-sq.comFounders: 1. Gaimov Akbar Kakhramonovich – 50% 2. Kadirov Ulugbek Tuhtashevich – 50%
Collaborator (branch office)
The total cost of the project From 100.0 million USD to 200.0 million USD

Estimated sources of funding:

Own funds

From 20.0 million USD to  30.0 million USD

Commercial bank loans

 Maybe

Foreign direct investment required

 From 100.0 million USD to  200.0 million USD

The composition of the main costs

– construction and installation work – 53.6 million USD

 – basic equipment (including installation supervision and components and transportation) – 130.0 million USD

 – raw materials for the launch period (3-6 months) – 6 million USD

 – equipment – 10 million USD

 – other – 0.4 million USD

Projected profitability

35%

Repayment period,predictable payback period

5 years

Cash flow  
Characteristics planned for production

 

Name of the product

Measurement

Amount

1

Portland cement brand 400 D0

Thousand tones

100,0

2

Portland cement brand 400 D20

Thousand tones

400,0

3

 High strength Portland cement without additives grade 500, 600

Thousand tones

500

4

Portland cement for airfield and road surfaces without additives brand 400, 500

Thousand tones

200

5

Portland cement grouting (normal, heavy and lightweight for cold and hot wells)

Thousand tones

200

6

Sulfate-resistant Portland cement and slag Portland cement grade 400, 500, 600

Thousand tones

100

 

Total:

Thousand tones

1500,0

Design capacity / size

1.5 million tons of cement per year

Contribution to the project by the initiator

The contribution of the initiator of the project is to assist in the implementation of the project on the basis of which it is received:

1)Allotment of land of 55 hectares for the construction of a cement plant by the decision of the regional governor Surkhandarya region and preliminary work on construction.

2)The project Proponent started the construction of infrastructure for this project: provide electricity, gas, water, railway and road.

3)Obtained a license to extract raw materials for cement plants:

I. licences field “Beshbulak” –

25 hectares of limestone from the state geological Committee. proven reserves

217 million so-called Possible reserves increment.

II.licenses for mining deposits “Beshbulak” –

25 hectares of clay from the state geological Committee. proven reserves of 50 million so-called Possible reserves increment.

III.mining licenses in the field “Tostao” – 5 ha gypsum.

proven reserves of 17 million so-called Possible reserves increment.

IV.Negotiations on coal purchase

V. The ferrous component will be purchased in the Navai region and will be imported.

Current project status

Included in the State Investment Program of the Surkhandarya region.

Information about the initiator of the project
 

Full name of the company

LLC «FABULLO STROY SERVIS»

Details, address, contacts Name: OOO “FABULLO STROY SERVIS”Legal address: Surkhandarya region, rn.  Zharkurgan, makhallya Қustepa.Service Bank: JSCB Alokabank Regional Branch, INN: 206576943Contact phone: +998907474630E-mail: ruziev@surxon-sq.comFounders:
Date of foundation of the enterprise 2004
Statutory fund 363 065 300 soum
Founders and distribution of shares 1. Gaimov Akbar Kakhramonovich – 50% 2. Kadirov Ulugbek Tuhtashevich – 50%
Information about the founders
 

Full name 1. Gaimov Akbar Kakhramonovich 2. Kadirov Ulugbek Tuhtashevich
Contact number

+998907474630

Email

E-mail: ruziev@surxon-sq.com

Contact of the performer from the MIFT
 

Full name

Department of investment policy in road transport infrastructure, housing and communal construction and water management

Position

Department

Contact number

+99871 2524220 / +998712524223

Email

info@mift.uz

General information
  

Number and types of jobs created

Total jobs: 350 people, of which:

 – Administration: – 12 people

 – Engineering: – 50 people

 – Main production: – 165 people

 – Support service – 65 people

 – Career management – 58 people.

Impact of the project on the environment (project EIS), including the expected types and volumes of waste, the place of their disposal Environmental requirements are established by the project on environmental impact of the State Committee for Nature Protection of the Republic of Uzbekistan. Emission requirements – maximum dust content of not more than 40 mg / Nm3 at the outlet of electric and bag filters. The category of environmental impact is the emissions of combustion products in the furnace and dust waste during the grinding of raw materials and cement.  The method of their disposal are bag and bake electrostatic precipitators. Conclusions of the Republican State Committee for Ecology and Environmental Protection No. 01-01 / 10-08-208 of February 14, 2019
Information about the land for construction of the enterprise

Based on the decision of the governor of the Surkhandarya region of 12.12.2018

 No. K-871 land allotment of 55 hectares.

Existing infrastructure

Around the industrial site there are:

 -high-voltage electric networks – distance up to 400m.

 – water supply network – well 0.2 km;

 – natural gas networks – 12 km;

 – highways – 5 km;

 – railway line – 3.5 km.

Required infrastructure It is necessary to provide the industrial site of the plant: – electricity – power 30 MW. -technical and drinking water – 1.3 and 0.9 3 million m3 per year -fuel (coal) – 178 thousand tons  in year. – railway – the volume of transportation is 1.0 million tons.  in year – road – transportation volume – 0.5 million tons  in year
Upcoming construction works In accordance with the issued technical conditions, it is necessary to develop working projects to provide the industrial site of the plant with external engineering communications. According to the developed working projects, construction and installation work is ahead.
Design and estimate documentation Information gathering work in progress
Electricity demand (kWh), Integrated power (kWh / s or mW / h) Installed power – 30 mWPower Consumption -20 mW
Water requirement (cubic meters per m) The daily water requirement is 14742 m3 (circulating water) for technological purposes, of which 4219.2 m3 are net water consumption, for domestic needs – 300 m3,  Annual – 1 307.9 thousand m3, for domestic needs – 93 thousand m3.
Gas demand (t / m) 20,000 cubic meters per hour
Coal demand (cube/m) Heat consumption for clinker preparation 3471 kJ / kg.  Coal consumption per 1 ton of clinker is 127.5 kg.  Total annual coal demand will be – 177 862 tons.
Market analysis, productions definition (works, services),marketing researches
  

Types of products

 

Name of the product

Measurement

Amount

1

Portland cement brand 400 D0

Thousand tones

100,0

2

Portland cement brand 400 D20

Thousand tones

400,0

3

 High strength Portland cement without additives grade 500, 600

Thousand tones

500

4

Portland cement for airfield and road surfaces without additives brand 400, 500

Thousand tones

200

5

Portland cement grouting (normal, heavy and lightweight for cold and hot wells)

Thousand tones

200

6

Sulfate-resistant Portland cement and slag Portland cement grade 400, 500, 600

Thousand tones

100

 

Total:

Thousand tones

1500,0

Annual finished production from 1 million tons to 1.5 million tons of cement per year
Estimated sales markets and their shares:
Import 70%
Export 30%
Cost of production

 

Name of the product

Measurement

Export price

$

Domestic price

$

1

Portland cement brand 400 D0

Thousand   

tons

55

60,3

2

Portland cement brand 400 D20

Thousand tons

50

62.2

3

 High strength Portland cement without additives grade 500, 600

Thousand tons

100

 

4

Portland cement for airfield and road surfaces without additives brand 400, 500

Thousand tons

90

76,9

5

Portland cement grouting (normal, heavy and lightweight for cold and hot wells)

Thousand tons

100

83,3

6

Sulfate-resistant Portland cement and slag Portland cement grade 400, 500, 600

Thousand tons

100

85,9

 

Total:

Thousand tons

55

60,3

The need for raw materials (per year)

Name of the product

Measurement

Consumption rate

Limestone

tons

1,1814

 Clay

tons

0,1518

 Glandular component

tons

0,1267

 Gypsum

tons

0,0615

 Additives

tons

0,1290

 

 

1,46

Market volume The expected market share of Uzbekistan in cement will amount to 15.0 million tons of cement per year in consumption. The planned sales volume of the new plant is 67% in the domestic market.  This will be 1 million tons of cement. The expected market share will be – 7% (50 million US dollars), and the rest for export – (25 million US dollars).
Expected market share The expected market share of Uzbekistan in cement will amount to 15.0 million tons of cement per year in consumption.
Main competitors The main competitors are five large plants: – JSC “Kizilkumcement” – 3.0 million tons of cement per year. – JSC “Akhangaran cement” – 1.7 million tons of cement per year. – JSC Kuvasoy Cement – 0.93 million tons of cement per year. – “Jizzak Cement Plant” AGMK – 0.73 million per year. – “Sherabad Cement Plant” AGMK – 1.3 million per year.
Key competitive advantages Given the growth of industry and civil engineering, the need for cement in the Surkhandarya region, Kashqadarya and Bukhara regions is expected to 1.0 million tons in year.  It should be borne in mind that the cost of production will be reduced by reducing the cost of fuel and transportation of raw materials. A very close shoulder for exporting products is Afghanistan.
Key target consumer groups Consumers: -Organization of civil engineering (residential complexes, schools, hospitals, etc.) -Organization of industrial construction (high-rise buildings, bridges, dams, factories, etc.) – Private consumer (private homes, etc.)
Sales structure by target consumer groups Realization of finished products is carried out through the Uzbek commodity and raw materials exchange.

Pricing strategy

Prices are based on the average consumer prices for cement in the domestic and foreign markets.

The cost structure of the final product

 

Average cost of 1 tons. cement –  50 USD eq.

Availability of patents, licenses, certificates in accordance with current legislation

There is a license for wholesale trade, a license has been obtained for the industrial extraction of raw materials.

Availability of a formed base of potential customers with a confirmed willingness to purchase products

There is an agreement with local legal consumers

Accessibility marketing research No barriers
Production technology and parameters of main equipment
  

Type of equipment and country of origin

Determined by the investor

Manufacturer

China

Cost of

from 1 million tons to 1.5 million tons of cement per year

Power usage

Market price

Installed power

30 mW / hour

Overall dimensions of the equipment

1-1.5 million tons

Main equipment weight

The weight of the main equipment is specified when designing a cement plant.

Main equipment units (lines)

The main equipment units (lines)  1. Averaging warehouses for raw materials. 2. Raw mill. 3. Silo of raw meal. 4. Five-stage heat exchanger. 5. Rotating horizontal oven. 6. The grate fridge. 7. Tent warehouse clinker. 8. Cement Mill 9. Cement silos10. Packing

Number of working hours per year

 

Duty cycle

Operating mode day-and-night 310 days a year, 3 shifts of 8 hours per shift