Dr. George R. Gouda

Ph.D., M.S., B.Sc

Dr. George Gouda World Cement Industry Consultant & Specialist

World Cement Industry Consultant & Specialist

Web Sites:    www.cementindustryconsultant.com
      www.cementspecialist.com
 www.goudacement.com

E-mail: georgegouda@gmail.com
Phone : +1(301)299-2064    Mobile : +1(301)502-1400
Maryland, USA

     Over 50 continuous years of experience (including Graduate Studies) covering all the different aspects of the Cement Industry field including:

Technical, Process, Environment, Operation, Project Development and Financing

  • Cement Industry projects development, raw materials exploration, prospection and their suitability's for Cement industry, plant site selection, technical aspects, process and engineering, environment assessment report, market studies, project cost, feasibility studies and appraisal reports, Cement project financing and fund raising, financial projections, bid information, contract negotiation and condition, construction, erection of equipment, operation, sintering the raw mix, production, energy consumption, quality and quantity controls, clinker microstructure, different types and kinds of Cement, audit and due diligence, production cost, Cement pricing and margins, accounting, financial reports, Cement marketing and sales, plant management and profitability, etc.

  • The most informed and experienced in the Cement industry field worldwide. Traveled extensively through out the World during my tenure with The International Finance Corporation (IFC) / The World Bank Group, Washington DC, for several projects related to the Cement industry; and during my work with Fuller Company, USA (currently F.L. Smidth, USA.

  • Worked in many different countries with different cultures.

  • Holding Ph.D. and M.S. degrees from The Pennsylvania State University, Pennsylvania, USA. Theses were in the Cement FIELD.

  • Selected by UNDP, USTDA and the WORLD BANK for special missions related to the Cement Industry including traveling to several countries to appraise and evaluate the national Cement industry and proposed new projects.

  • Worked as a Cement industry consultant with several International Financial Institutions for appraising and evaluating several Cement industry projects.

  • Published and written several technical papers, related to Cement; published in different International Cement and Concrete Magazines and the International Congress on Chemistry of Cement.

  • Wrote more than 200 reports related to the Cement industry and building materials.

  • For more than 12 years, was a member of The Executive Committee and was Program Chairman for the International Cement Microscopy Association, USA. In addition, was the Editor/Co-Editor of the Annual Proceeding. 

CONSULTING SERVICES IN THE CEMENT INDUSTRY

Continuous 50 years expertise and experience in the Cement industry field permits me to offer an unlimited scope of CEMENT INDUSTRY CONSULTANCY SERVICES; either for a short term or for long term. The following are a few of this expertise:

I-              Greenfield Cement Industry Projects/Cement Industry Project Development:

Pre-Project Phase:

  • Cement Industry Raw Materials: investigate, explore and evaluate  the Cement raw materials; quantitatively and qualitatively. Assessing the reserves and their suitability to the Cement Industry.

  • Shareholders/Company Structure and Development: including the company legal structure, formation, capital requirement and debt : equity ratio.

  • Prepare All the Required Reports: including the raw materials, feasibility study and the environment assessment reports. The feasibility report includes all the technical information, infrastructure, plant site and size, equipment sizing, energy resources, market study, project cost, project schedule, organization chart and required manpower, financing structure, expected production cost, financing projection, etc.

  • Prepare Investment Appraisal Report: raising funds, if it is required.

Intermediate Project Phase:

  • Prepare the site and prepare applications for all the required approvals.

  • Apply for the loan to the financing institutions and negotiate with the financing institutions for loan approval. Sign the loan contract.

  • Prepare the Bid Documents; Select the successful bidder, Contract negotiations and Conditions.

  • Advise the project sponsor/s.

  • Arrange for the different contractors.

Project Implementation Phase - Construction & Equipment Installation:

  • Represent the project sponsor on the site. Supervise the civil work, construction, equipment erection and installation. Keep track and record of all the activities.

  • Implement the project progress according to the budget and the schedule to avoid overruns and delays.

  • Participate in training the plant personnel.

               Plant Commission, Operation and Production Phase:

  • Supervise the dry run test of the plant. Commission the different equipment to insure that the designed capacity is reached and is according  to the contract/design levels.

  • The consulting services could be extended after the plant start-up and commissioning.
     

II-            Existing Cement Plants-
Production Improvements/Rehabilitation
:

My extensive experience in the CEMENT INDUSTRY, gives me the opportunity to offer this experience to the existing Cement industry plants. These include, but not limited to, the following:

  • Raw materials evaluation, suitability of the raw mix for the Cement industry, and quarry operation

  • Sintering behavior of the raw mix. Evaluation of the alkalies and chlorine cycles, dusty clinker and clinker agglomeration. Improve the raw mix design to increase the kiln production, reduce the fuel consumption and improve the clinker quality

  • Cement plant operation, process efficiency, productivity improvements; qualitative and quantitative. Cement production according to the market and the customer requirements

  • Heat and material balances. Temperature profiles and pressure drop through the pyroprocessing process

  • Production trouble shooting including improvements and production optimization

  • Cement plant rehabilitation, improvements and upgrading to increase the productivity per employee

  • Grinding media distribution in the ball mills, Cement temperature exist the Cement mill. Cement storage to avoid its agglomeration

  • Review the clinker/Cement chemistry, ratio, modulus, properties and composition.

  • Improvement the produced Cement qualitatively and quantitatively. Review the quality and quantity procedures.

  • Energy audit and optimization. Review the existing plant operation

  • Review the plant maintenance, housekeeping and the consumables consumptions

  • Review the plant organization chart and the productivity per employee

  • Using waste fuel

  • Utilization and safe storage of the different kinds of kiln dust

  • Production of different Cement types and qualities that meet different applications to increase the company Cement production volume

  • Reviewing and reducing the production cost, to be comparable with the most efficient Cement plant, and increasing the plant profitability

  • Customize a training program suitable to the plant requirements;   including technical, operational, environmental, health and safety, financial and daily, weekly and monthly reports

  • Environmental audit, primary and secondary dust collectors’ efficiency and reduce the dust emission

  • Review and Improve the plant health and safety aspects

  • Evaluation the clinker microstructures by different microscopes   techniques

  • Cement temperature exist the Cement mill. Cement storage to avoid its agglomeration

  • Sales and Market studies.

  • Country Cement industry sector study and evaluation; including existing production facilities, production cost and Cement pricing, environment, etc.

The above are some of the different expertise and experience that could be offered to the Cement Industry Field.  Below is more information.


SUMMARY CV

With over 50 years of experience in all aspects of the CEMENT industry, Dr. Gouda has established a consulting firm in the US to offer his "extensive hands on" in the industry for both greenfield and existing cement plants, throughout the world.


This expertise covers: raw material prospecting and evaluation, raw mix design and burnability, production, operation, maintenance, quality and quantity controls, environment, health and safety aspects, clinker microstructure, general lay-out and engineering, sales and marketing, production cost and methods of cost savings, process including heat and materials balance, equipment sizing, selection and sourcing project implementation and progress of the construction/erection of greenfield cement plants, feasibility (including technical, commercial and financial) and appraisal studies (for financial institutes), environmental assessment, market studies, equipment list for new plants, tender documents, bids evaluation, contract negotiation, plant valuation and financial plan and projections.

From 1987 to 1999, Dr. Gouda was with The International Finance Corporation (IFC) /The World bank, Washington DC. He was the cement specialist and was in charge of about 35 cement, ceramic tiles and aggregate projects, throughout different developing countries and financed by IFC. The total capacity of these plants exceeded 40 million tons annually and included the largest cement plant capacity in the world. During this period, Dr. Gouda travelled extensively throughout the world to:

  1. Appraise and evaluate the new projects, discuss with the sponsor all the technical aspects, raw materials, plant site, project and production cost, market and cement prices, environment, management and training, and project implementation.
  2. Supervise the existing projects in the portfolio, to review their operation, environment, production cost, cement prices, profitability and market.

Dr. Gouda is a specialist in financing cement projects and putting together the financial plan. He has strong contacts and is well known in the cement field worldwide. During the period with IFC, he published several papers related to IFC and the Cement Industry, as well as writing about 200 reports.

In 1982, Dr. Gouda joined Kuwait Institute For Scientific Research (KISR). He held the position of Manager of the Materials application Department. He developed and initiated several research activities relating to indigenous raw materials, building/construction and cementitious materials.

In 1975, Dr. Gouda joined Fuller company of USA. as a Senior Process Engineer, then as a manager of The Cement Technology Department. He promoted the technical expertise of Fuller company, did the process calculation (materials and heat balances) for several cement plants and evaluated the clinker microstructure of several clients of Fuller by the Scanning Electron Microscope (SEM). He extensively published several technical papers related to raw mix, burnability, process design and clinker grinding and microstructure.

In 1970, Dr. Gouda joined The Pennsylvania State University, Pennsylvania, USA, as a Graduate assistant to conduct graduate studies and research for MS. and Ph.D. in Ceramic Science. He obtained his MS. in 1972 and his Ph.D. in 1975. His thesis were all in Cement. During his research, he obtained the highest strength for a cement paste in the World, by using the hot pressing technique. He evaluated the microstructure morphology of the cement paste by using the SEM, from early ages to four years old. He published several papers, during this period.

In 1966, Dr. Gouda was delegated officially from The Egyptian Government to the Algerian Ministry of Industry and Energy, Algeria, in a specially designated position to head and supervise a mission for prospecting and selecting raw materials for new cement plants in several locations though out the country.

Dr. Gouda received his B.Sc. degree in Chemistry from The Faculty of Science, Cairo University, Cairo, Egypt, in 1957. He joined The Arabian Cement Co. (who had the third suspension preheater plant in the world, at that time), Jeddah, Saudi Arabia (after spending a few months at Helwan Portland Cement, Helwan, Egypt) in a position responsible for quality and quantity control of the plant and served as the technical manager of the plant. In 1962 Dr. Gouda returned to Helwan Portland Cement and held responsibility of quality and quantity controls and prospecting of raw materials for a new Cement Plant in Egypt. He carried out several studies on the Egyptian raw materials for new cement plants.

Beside, the above positions and during 1980-1987, Dr. Gouda worked as a consultant for The World Bank and United Nation Development Program (UNDP). He travelled on several special Cement assignments for both organisations for a period ranging from one to six months to several countries, including Turkey, Burma, Tunisia, China and India.

Dr. Gouda is active world wide. He travelled extensively during the last two and half decades. He was a member of the Executive Committee of THE INTERNATIONAL CEMENT MICROSCOPY ASSOCIATION, Texas, USA., where he was Co-editor of the annual Proceeding and Program Chairman from 1981 until 1994. Prior to his appointment to IFC, he published over than 60 technical papers in different international Cement magazines and the International Congress on Chemistry of Cement. Also, he has written more than 150 reports related to Cement and building materials. He is experienced in evaluating the Clinker microstructure by SEM.

Those who are interested in discussing potential consulting needs, please contact Dr. Gouda at the below coordinates.

E-Mail georgegouda@gmail.com