International Cement Review
Burak GÖKÇAN, Sintek Group/Technical Deputy General Manager
ICR speaks with Sintek Group’s Technical Deputy General Manager, Burak Gökçan, about the group’s role and achievements in the largest single-kiln investment in the Turkish cement sector.
ICR: Welcome, and thank you for joining us today. Could you please introduce yourself and your role in Sintek Group?
Burak Gökçan (BG): Hello, I am Burak Gökçan. Currently, I hold the position of Technical Deputy General Manager at Sintek Group, continuing to not only drive our commitment to excellence and innovation in projects but also to highlight our ongoing dedication to advancing industry standards both in Turkey and globally. We continuously excel at executing projects within Turkey and across international borders. Recently, as Sintek Group, we are proud of the completion of the investment in the second line at the Medcem Cement Plant, the largest single-kiln facility in Turkey and Europe. We work as a family at Sintek Group, fostering a collaborative and supportive environment that drives our collective success.
ICR: Could you provide an overview of the scope of work that Sintek Group has delivered for this project?
BG: Certainly. Sintek Group was entrusted with several critical components of this project, including construction works, mechanical equipment manufacturing, supply and installation, technological manufacturing and assembly, structural steel manufacturing and erection, and commissioning services. Our holistic approach ensured that each facet of the project was executed with the highest level of expertise and precision.
ICR: What makes this project particularly significant in terms of its scale and technology?
BG: This project stands out as the largest cement plant investment in Turkey and Europe to be carried out by a single main contractor. The new integrated production line boasts a clinker capacity of 9000tpd, incorporating cutting edge technology that significantly enhances the plant’s production capabilities. This scale and technological sophistication set a new standard in the industry.
ICR: Can you share some impressive statistics about the project?
BG: Absolutely. We utilised a total of 133,235t of concrete and 22,000t of structural steel, with the total steel and equipment assembly weight reaching 38,200t. We also executed over 10km of piling applications for soil improvement. These figures highlight the magnitude and complexity of the work involved.
Furthermore, the project includes Turkey’s largest raw mill with a capacity of 735tph, as well as the country’s largest raw meal silo with a capacity of 30,000t.
ICR: What are the benefits of implementing this new production line for Medcem and the cement industry in Turkey?
BG: The new production line modernises the plant’s technology and increases its production capacity, making a substantial contribution to the Turkish cement industry. By enhancing efficiency and output, Medcem is better positioned to meet the growing demands of both domestic and international markets.
ICR: Can you highlight some key capacities and features of the second production line?
BG: The new production line incorporates numerous advanced features, including an 800 TPH capacity crusher, a 60,000-ton capacity pre-homogenized stockpile, a 735 TPH vertical raw mill, a 1,116,000 m³/h raw mill-kiln system filter, and a 9,000 TPD kiln line. Additionally, there are advanced components such as a 1,240,050 m³/h clinker cooling electro filter, a 66 TPH vertical coal mill, and a 130,000-ton capacity 67 m diameter clinker stockpile unit.
Sustainable Project
ICR: Can you tell us about the environmental considerations taken into account for this project?
BG: We integrated several environmentally friendly practices, such as using energy efficient machinery and processes, and ensuring waste management protocols were strictly followed to minimise the environmental impact. Our goal was to not only comply with environmental regulations but also to set a higher standard for sustainable practices in the industry.
Project implementation
ICR: What have been the most challenging aspects of managing this project, and how has Sintek Group ensured that it stayed on schedule and within budget while implementing necessary safety measures?
BG: The most challenging aspect of managing this project has been coordinating the various complex tasks and ensuring each phase met the stringent standards required. We encountered logistical challenges, technical intricacies and the critical need to maintain continuous communication among all stakeholders. However, through the dedication of our team and meticulous planning, we have ensured the project remains on schedule and within scope.
We employed rigorous project management practices, regular progress monitoring and effective communication among all stakeholders. This approach helped us stay within budget and meet our deadlines. By identifying potential issues early and addressing them promptly, we maintained a smooth workflow throughout the project. Safety was our top priority, emphasised through comprehensive protocols, regular training, and ongoing audits, all reflecting our commitment to “Protect Your Health, Protect Your Job.”
ICR: How important was stakeholder communication in the success of this project?
BG: Effective stakeholder communication was fundamental to the project’s success. We maintained regular updates and transparent communication channels with all stakeholders, including Medcem management, our subcontractors and the local community. This ensured everyone was informed and aligned with the project’s goals and progress, facilitating a collaborative and supportive environment.
ICR: What are your thoughts as the project nears completion?
BG: As we approach the end of this project, I am extremely proud of what we have achieved. The commissioning works for the clinker line have begun and we are on track to complete the cement unit as well. This project is a testament to the hard work and expertise of the entire Sintek Group team. It has been a challenging yet rewarding journey, and we are excited to see the positive impact this new production line will have on Medcem and the cement industry.
Sintek’s operations
ICR: As an EPC supplier, do you have standard plant designs for various capacities that customers can select from, or do you approach each project uniquely?
BG: At Sintek, we specialise in delivering customised solutions tailored to each customer’s specific needs. Our strength lies in our extensive experience over the past 15 years, which has made us well-known among all major technology suppliers. This allows us to direct them according to our clients’ requirements, ensuring a bespoke approach to every project.
ICR: When the order book is very full, do you aim to keep as much work in-house as possible, or do you prefer to subcontract certain parts of projects that may be time-consuming or less profitable?
BG: Generally, we work with subcontractors. These subcontractors, with whom we have maintained long standing relationships, have become integral parts of our operations. This approach allows us to maintain flexibility and efficiency, ensuring that we can meet project demands effectively.
ICR: How large are Sintek’s equipment manufacturing sites and where are they located?
BG: Our main workshop, located in Ankara, spans a total area of 11,500m2. It has a production capacity of 1500tpm of structural steel and 1000tpm of mechanical fabrication.
In addition, we have the capability to quickly mobilise and set up on-site workshops for non-technical parts at the project location, ensuring seamless project execution.
ICR: What is the Turkish skilled labour market like for cement engineers and maintenance staff?
BG: Over the past 20 years, more than 20 integrated cement plants and over 20 grinding facilities have been established in Turkey. In 2004 the installed cement production capacity was 50-55Mta, which has increased to 110Mta by 2024. This dynamic market has resulted in a significant pool of skilled and experienced professionals in the cement industry.
Looking ahead
ICR: What are Sintek Group’s future plans and ambitions following the completion of this project?
BG: Following the successful completion of the Medcem Line 2 project, Sintek Group is looking ahead with great enthusiasm and ambition. Building on our achievements, we aim to expand our footprint both domestically and internationally, leveraging the expertise and experience we have gained. We are keen to explore new markets and take on projects that push the boundaries of innovation and efficiency.
Overall, Sintek Group’s future is geared towards growth, innovation, and excellence. We are excited about the opportunities that lie ahead and are confident in our ability to achieve our ambitious goals while continuing to deliver exceptional value to our clients and the industry as a whole.
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