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Welcome to the July-August 2017 issue of Global Cement Magazine - the worlds (+44) (0) 1372 840967
most widely-read cement magazine. As well as the latest global cement news, this
issue contains our annual look at the Top 10 global cement producers. The top two
multinationals, LafargeHolcim and HeidelbergCement have both contracted over the Web Editor
David Perilli
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that they completed in 2015 and 2016. Cemex, meanwhile, has actually expanded its (+44) (0) 1372 840952
cement capacity over the past 12 months in a reversal of its recent trend. However, the
direction that Cemex is taking is to increasingly concentrate its assets in the Americas.
Commercial Director
In the past two years it has left seven European and Asian markets. It is in the process Paul Brown
of trying to leave the Croatian markets too. Meanwhile, Cemex recently increased its paul.brown@propubs.com
stake close to home in Jamaica, Barbados and Trinidad & Tobago after it ramped up Mobile: (+44) (0) 7767 475998
its holding in Trinidad Cement. The major Chinese cement producers continue to be
too big in the face of domestic oversupply. Anhui Conch, the worlds largest cement Business Development Executive
producer by installed capacity has reacted by actively expanding into foreign markets Sren Rothfahl
in an attempt to maintain growth. It is already present in Indonesia and Myanmar and soeren.rothfahl@propubs.com
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will produce cement in Cambodia before the end of 2017. It is also exploring options in
Uzbekistan and Russia. Turn to Page 10 to get the full Top 10 run-down.
Company manager
Elsewhere in this issue we have technical articles on heavy-duty bearings (Page 28), Sally Hope
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low-capex ways to reduce fan noise (Page 24), as well as a very interesting look at the
Egyptian cement sectors numerous new coal grinding installations (Page 61).
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There are also reviews from the IEEE-IAS/PCA Cement Conference in Calgary, Jane Coley
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www.GlobalCement.com Global Cement Magazine July-August 2017 5

GLOBAL CEMENT CONTENTS Subscribe Ad Index
88.7Mt/yr
2.4%
313Mt/yr
8.3%
Global Cement articles

278Mt/yr
7.4% China
Resources
81.3Mt/yr
193Mt/yr 2.2%
5.1%
Top 10
1340Mt/yr 176.2Mt/yr
Others 38% 4.7%
10 Top 10 cement producer profiles

2223Mt/yr Taiwan Cement
10
69.0Mt/yr 1.8%
62%
52.7Mt/yr
1.3%
45.2Mt/yr
1.2%
45.0Mt/yr
1.2%
Our annual look at the Top 10 global cement producers.
18 Packaging cement the sustainable way

The sustainability aspects of different cement packaging
materials are compared...
24 Fan and stack noise control - Stealth

18 and efficiency
Peter Wilson of the Industrial Noise & Vibration Centre looks at
fast and low-capex ways to mitigate excessive fan noise.
28 Spherical roller bearings in tougher

environments of heavy industries
The Timken Company outlines the need for new spherical
24
roller bearings to meet the demands of the cement sector.
32 In discussion: Chris Stern, Carbicrete CEO

Carbicrete uses steel slag and CO2 to make construction blocks
that compete with traditional concrete.
34 Global Slag Conference 2017 - Reviewed

Robert McCaffrey reports from the 12th Global Slag Conference
28
& Exhibition, which took place in Dsseldorf, Germany.
38 Product and contract news

UNTHA XR waste shredder hits one million operational
hours; Cemengal updates; FLSmidth orders for Power Cement.
32 European cement
39 European cement news
An update on France; UK CPA frustrated at

political deadlock; New Karsdorf manager.
44 In discussion: Michel McKittrick, Ecocem

We discuss the rapid rise of Irish GGBS producer Ecocem, its
34
current operations and plans for the future.
48 Brexit: Not about uncertainty, but priorities

As EU/UK Brexit talks get underway, the MPAs Aurelie
Delannoy assesses the situation for the construction sector.
50 interpack 2017 in pictures

Photographic highlights from the 2017 running of interpack.
38
6 Global Cement Magazine July-August 2017 www.GlobalCement.com
GLOBAL CEMENT CONTENTS
Cement in the Americas

52 American cement news

Gloria expands lime plant; Three charged in Maceo debacle;
Votorantim revenues down.
39
55 IEEE-IAS/PCA Conference 2017 - Reviewed
David Perilli reports on the main themes of the IEEE-IAS/PCA
Cement Conference in Calgary, Canada.
Asian cement 44
57 Asian cement news
Cement sales up in Indonesia; Iranian producers urged to
target Russia; Local resistance to plant continues in Myanmar.
Middle East and African cement

48
59 Middle East and African cement news
PPC blames poor year on downgrade; New Iraqi plant;
Israel investigates dumping.
61 The rise of coal mills in the 55

Egyptian cement sector
Osama Aly Ahmed and Khaled Ramadan Osman outline the
rapidly-developing coal mill sector in Egypt.
Regulars and comment 57

17 Subscription form for Global Cement Magazine
Use this form to subscribe to Global Cement Magazine,
or subscribe online at www.GlobalCement.com.
64 Global Cement prices
59
Cement prices from around the world: Subscribers to Global
Cement Magazine receive additional information.
65 The Last Word

This issue: Spam holds up a mirror to our society. Its not pretty.
66 Advertiser Index & Forthcoming issue features

A list of advertisers and editorial preview for next two issues.
61
GLOBAL CEMENT: DIARY
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10-13 October 2017, Antalya, Turkey
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25-26 October 2017, Krakw, Poland
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GLOBAL CEMENT: TOP 10 PROFILES Contents Subscribe Ad Index
Peter Edwards, Global Cement Magzine
Top 10 cement producer profiles
The global cement industry has seen a number of major combinations and divestments over
the past two years, including the merger of Lafarge and Holcim, the acquisition of Italcementi
by HeidelbergCement, the resultant sale of assets from both deals and other transactions.
Here, Global Cement takes the opportunity to look at the top 10 global cement producers,
with a focus on how the situation has changed over the past 12 months.
A lot has changed in the global cement industry

over the past 18 months, first due to the comple-
tion of the LafargeHolcim mega-merger and then the
Introduction and summary statistics
Figure 1 shows the Top 10 global cement produc-

takeover of Italcementi by HeidelbergCement. Both ers by installed integrated cement capacity in 2017,
of these companies have shrunk in capacity terms in according to the Global Cement Directory 2017, sub-
the past 12 months due to minor asset sales. sequent research and the publicly-available reports of
Chinese cement producers.
88.7Mt/yr
2.4%
313Mt/yr
8.3%
278Mt/yr
7.4% China
Resources
81.3Mt/yr
193Mt/yr 2.2%
Right - Figure 1: Top 10 cement 5.1%
Top 10
producers in 2017, by installed
1340Mt/yr 176.2Mt/yr
integrated cement capacity. 38%
Others 4.7%
Source: Global Cement Directory
2017, Global Cement research 2223Mt/yr Taiwan Cement
69.0Mt/yr 1.8%
and company reports. 62%
52.7Mt/yr
1.3%
45.2Mt/yr
1.2%
45.0Mt/yr
Rank Producer Integrated Share of global 1.2%
capacity (Mt/yr) capacity (%)
1 Anhui Conch 313 8.3
2 LafargeHolcim 278 7.4 Between them, the Top 10 producers share
Right - Table 1: Top 10 cement 3 HeidelbergCement 193 5.1 1340Mt/yr of integrated cement production
producers in 2017, by installed capacity. This is enough to claim around 38%
integrated cement capacity. 4 CNBM 176.2 4.7
of the total 3563.4Mt/yr of integrated cement
Source: Global Cement 5 Cemex 88.7 2.4
Directory 2017 and capacity worldwide.
Chinese company reports. 6 China Resources 81.3 2.2 As a result of using company data for
7 Taiwan Cement 69.0 1.8 Chinese companies we have arrived at a
8 Ultratech Cement 52.7 1.3 slightly different order compared to our July-
August 2016 article. A correction from the
9 Eurocement 45.2 1.2
previous article has introduced Indias Ultratech
10 Votorantim 45.0 1.2 Cement at the expense of Buzzi Unicem.

GLOBAL CEMENT: TOP 10 PROFILES
1. Anhui Conch
Anhui Conch was founded in 1997 and grew rapidly as
Chinas cement consumption rose in the early 2000s. Like
other Chinese producers, it has been forced to adjust to
falling demand, although its sheer size and entry into other
markets have helped to insulate it more than others.
HQ China
Integrated capacity 313Mt/yr
2016 Cement sales 277Mt Current market Future market
2016 Revenue US$8.2bn
A nhui Conch is the largest cement company in

2017. At the end of 2016 the group said that
it had clinker and cement production capacities of
results are in contrast to its ones for the first nine
months of 2016, in which it reported small declines
in its revenue and net profit.
244Mt/yr and 313Mt/yr respectively.
During 2016 Anhui Conch completed the Chinese to regional player
construction of six clinker production lines at The vast bulk of Anhui Conchs income comes from
Yingjiangyunhan Cement and Yiyang Conch Ce- China but it is the most internationally diverse
ment and it completed 18 cement grinding plants at Chinese producer. It is growing player abroad, with
Wenshan Conch Cement and Ganzhou Conch Ce- interests in south and central Asia. In May 2016
ment. It additionally purchased the assets of Anhui Anhui Conch officially launched the second produc-
Chaodong Cement. tion line at a greenfield cement plant project in South
Outside of China the group completed lines in Kalimantan at its Indonesian subsidiary PT Conch
Indonesia and Myanmar, started building plant pro- South Kalimantan. The plant is now able to produce
jects in Indonesia, Cambodia and Laos and started 3200t/day (1Mt/yr) of cement.
early work on new projects in Russia, Myanmar
and Uzbekistan.
Financial situation
Anhui Conch is the most
Anhui Conch returned to rising sales revenues and
geographically diverse
profit in 2016 after a problematic year in 2015 beset Chinese cement producer...
by a poor market for cement. Its revenue rose by 9.7%
year-on-year to US$8.12bn in 2016 from US$7.40bn
in 2015. Its sales volumes of cement and clinker A second Indonesian plant, this time in Manok-
rose by 8% to 277Mt. Its net profit rose by 14% to wari, West Papua, had been slated to start production
US$1.24bn from US$1.09bn. in July 2016 but no specific announcement has since
The group says that its adoption of a flexible mar- been forthcoming. The 1.5Mt/yr facility is due to
keting strategy for different regions and plants and be operated by PT Conch-SDIC Papua Cement
a focus on lowering production costs delivered sales Indonesia, a joint venture between Anhui Conch and
growth and operating savings. However, its full year the Indonesian State Development and Investment
Corporation. The company also pro-
vided an update on the development
of its Cambodian plant in June 2016,
when it stated that production would
begin within 2017.
In March 2017, Anhui Conch Left: Chinese producers are
looked to continue its growth into increasingly looking abroad for
growth as the domestic market
Central Asia when it met with repre-
falters. The image shows the
sentatives of the Umar Corporation launch of the second line at
in Uzbekistan. The company is in PT Conch South Kalimantan,
ongoing discussions regarding the Indonesia in May 2016.
construction of a 2Mt/yr cement
plant in Samarkand, as part of Chinas
government-sponsored plans to ex-
pand its industries internationally.

2. LafargeHolcim
LafargeHolcim has endured a somewhat rocky start in the
two years since the merger of Lafarge and Holcim. It has
seen production fall as a result of assets sold and subdued
demand in some regions. A turnaround may have begun,
but the transition to a new CEO could prolong uncertainty.
HQ Switzerland
2016 Cement sales 233Mt
L afargeHolcim traces its history back to the found-

ing of Lafarge, in France in 1848 and Holcim in
Switzerland in 1912. Each company grew separately
Going forward, LafargeHolcim has decided to
focus on four new strategic pillars: Lean-ness,
Commercial Transformation, Cost Leadership and
through expansions and acquisitions around the Sustainability. In its 2016 Annual Report it states
world to become leading global cement producers in that the group will become asset light by optimising
their own rights by the turn of the 21st Century. its current asset base, better leveraging its industrial
The groups merged in July 2015 as they both footprint, reducing its capital expenditure and ex-
sought to maintain their leading positions, prompted ploring new growth opportunities with lower capital
by their complementary geographical spreads of expenditure. Future growth will be focused on low-
assets and a desire to consolidate in an uncertain capital intensive business models that enable the firm
global market. The time up to the merger was not to access more of the value chain.
without its hurdles, with Lafarge shareholders In the first quarter of 2017, LafargeHolcims net
eventually having to accept a minority stake in the sales rose by 5.3% year-on-year to Euro5.21bn due to
new entity. Both groups were forced to sell assets in higher prices and rising aggregate volumes. Its results
various countries to comply with local competition were presented on a like-for-like basis adjusted for
legislation, although LafargeHolcim remains beset by the groups divestments in 2016. Operating earnings
over-capacity. before interest, taxation, depreciation and amorti-
According to the Global Cement Directory 2017 sation (EBITDA) increased by 8.8% to Euro652m.
LafargeHolcims headline capacity has come down However, cement sales volumes remained flat at
from 287.6Mt/yr in 2016 to 277.9Mt/yr in 2017. This 48.1Mt for the period and even this was bolstered by
has been due to asset sales in Saudi Arabia, Sri Lanka a strong performance in March 2017.
and South Korea. By region the group reported falling cement sales
volumes on a like-for-like basis in Latin America,
Financial situation Middle East Africa and North America. In Asia
LafargeHolcims net sales took a tumble of 8.7% to Pacific cement sales volumes were stagnant but it re-
Euro26.9bn in 2016 from Euro29.5bn in 2015. Al- ported challenging market conditions in Indonesia
though on a like-for-like basis it says they declined and Malaysia and a slowing market in Philippines.
by just 1.7%. However, its adjusted operating earning However, it said that the impact of demonetisation
before interest, taxation, depreciation and amortisa- in India had abated in the period and was now fully
tion (EBITDA) rose by 1.3% to Euro5.83bn from behind the business.
Euro5.75bn, with a higher improvement rate on a
like-for-like basis. Recent events
The groups sales volumes of cement fell by 8.8% Just when it appeared that LafargeHolcim had
to 233Mt from 256Mt, with decreases in all regions. reached a new normal, the group was destabilised
It reported that production overcapacity hit cement by the April 2017 announcement that CEO Eric
volumes and prices in Indonesia, Brazil continued Olsen would leave the company on 15 July 2017. His
to face challenging operating conditions with its decision followed an internal investigation at the
ongoing recession and both Nigeria and Egypt faced company that showed that the companys cement
difficult markets in the period. Of particular note, its plant in Syria had paid-off local militias in order
sales volumes fell in North America due to an eco- to stay open. Olsen stated at the time, While I was
nomic downturn in Western Canada and a strong absolutely not involved in, nor even aware of, any
fourth quarter in 2015 to measure against. Operat- wrongdoing I believe my departure will contribute to
ing EBITDA rose on a constant basis in Europe and bringing back serenity to a company that has been
North America only. exposed for months on this case. He will shortly be
replaced by the CEO of Sika AG Jan Jenisch.

3. HeidelbergCement
Germany-based HeidelbergCement rose up the global
cement capacity rankings in 2016 when it acquired Italian
rival Italcementi. It has been bolstered by its new assets,
selling only limited capacity as the result of competition
requirements in the US and Belgium.
HQ Germany
F ollowing what CEO Bernd Scheifele described as

by far the best year for HeidelbergCement since
the financial crisis, in 2015, the German multina-
tion. In the groups Asia area sales volumes rose but
revenue and operating income fell in 2016 due to a
significant fall in prices in Indonesia and Thailand.
tional saw further improvement in 2016 following Finally, in the Africa-Eastern Mediterranean Basin
its acquisition of Italcementi. Its revenue rose by 13% the market picture was mixed with small increases
year-on-year to Euro15.2bn in 2016 from Euro13.5bn in sales volumes, a drop in sales revenue and a slight
in 2015. Its cement sales volumes rose by 28% to 104Mt increase in operating income due to increased market
from 81.1Mt and its operating income rose by 7% to competition in Sub-Saharan countries.
Euro2bn from Euro1.85bn. However, on a pro- In the first quarter of 2017, pro-forma sales
forma basis, taking into account the contributions of revenues were stagnant on a like-for-like basis at
Italcementi in 2015 and 2016, the groups sales rev- Euro3.78bn in the first quarter of 2017. Its cement
enue fell slightly and cement sales volumes and sales volumes also remained static on a like-for-like
operating income rose far less steeply. basis at 27.8Mt. However, the group described its
By region, HeidelbergCements Western and fortunes as mixed in its emerging markets, reporting
Southern Europe division reported rising sales vol- sales declines in Thailand, Bangladesh and Egypt.
umes of cement but falling revenue and operating
income. Improving markets in Germany and the Recent news
UK were offset by weak demand in Italy, France and In July 2016 HeidelbergCement offloaded its Belgian
Spain and the falling value of the British Pound versus unit Compagnie des Ciments Belges (CCB) to Italys
the Euro. By contrast, revenue, cement volumes and Cementir, reducing its international capacity total by
operating income were all up in the Northern and 2.5Mt/yr. The sale of the Essroc Martinsburg plant in
Eastern Europe-Central Asia area with a particular West Virginia, USA to Colombias Cementos Argos in
emphasis in Norway. Notably, demand growth was October 2016 removed a further 1.8Mt/yr from the
also reported in Russia, driven by markets in Moscow headline amount.
and St Petersburg. In April 2017 the European Commission (EC)
In North America financial figures rose in 2016 blocked a proposed takeover of Cemex Croatia by
but revenue fell in the last quarter of the year. Strong HeidelbergCement and Schwenk under the Euro-
sales were recorded in the north and south of the pean Union Merger Regulation due to concerns that
US but a drop in sales volumes was noted in the the takeover would have reduced competition in the
Canadian Prairie provinces due to falling oil produc- cement market and increased prices in Croatia.
4. CNBM
CNBM, founded in 2004, is one of the youngest companies in
the Top 10. Like domestic rival Anhui Conch, it grew rapidly
in the 2000s as Chinas cement demand rose. It operates its
cement capacity solely in China via a number of subsidiaries.
HQ China
Integrated capacity 176.2Mt/yr

C hina National Building Materials (CNBM) is

the fourth-largest cement producer in 2017,
with 94 cement plants and 176.2Mt/yr of cement
mandated supply-side reforms. It added that despite
a grim national economy the cement sector under-
went a weak recovery as reforms kicked in, leading
capacity. It operates its cement interests via: 1. China to growth in cement prices.
United (100% stake): Encompassing capacity from
more than 30 subsidiaries in Shandong, Jiangsu, Recent events
Henan, Hebei, Anhui and Sichuan Provinces; South Japans Mitsubishi Materials has signed an agreement
Cement (80% stake): Active in Zhejiang, Shanghai, to sell its 66.7% stake in Yantai Mitsubishi Cement in
Jiangsu, Anhui, Hunan, Jiangxi and Guangxi Prov- Shandong to a subsidiary of China National Building
inces; North Cement (70% stake): A joint venture Material (CNBM). The interaction will add 1.2Mt/yr
with Liaoyuan Jingang Cement and Hony Capital of cement production capacity to CNBMs total when
Management; Southwest Cement (70% stake): it is completed.
Capacity operated via Chongqing Kehua Group, In August 2016, the Assets Supervision and
Sichuan Lisen, Yunnan Simao Jianfeng Cement and Administration Commission has announced the
Guizhou Taian Cement and others. reorganisation of the China National Building
Materials Group Corporation (CNBM) and China
Financial situation National Materials Group Corporation (Sinoma).
CNBMs sales revenue rose by 1% year-on-year to The commission did not provide further details on
US$14.8bn in 2016 from US$14.6bn in 2015. Its the merger. The merger is part of Chinese state efforts
profit rose by 1% to US$410m from US$406m. The to improve the efficiency and competitiveness of its
groups sales of cement and clinker grew by 4.2% to state-owned enterprises.
291Mt in 2016. Elsewhere, Russias Eurocement Group is in dis-
Despite earlier reporting falls in operating rev- cussions with CNBM with respect to it becoming a
enue and profit of over 5% for the first nine months of shareholder of Eurocement. However, this discus-
2016 the cement producer attributed the turnaround sion appears to have been on hold since around
to production efficiencies and adherence to state- October 2016.
5. Cemex
Mexicos Cemex increased its cement capacity marginally
in 2017, bringing to an end a period of contraction. It is
considering purchasing assets in Brazil and will enter the
Peruvian market shortly as it continues in its attempts to
offload its Croatian assets.
HQ Mexico
Integrated Capacity 88.7Mt/yr
2016 Cement sales 66.7Mt
2016 Revenue US$13.4bn = Active market = Entering market
T he modern-day Cementos Mexicanos (Cemex)

can trace its history back to 1906 and the founding
of Cementos Hidalgo in northern Mexico. It merged
operating earnings before interest, taxation, de-
preciation and amortisation (EBITDA) rise by 6%
year-on-year to US$2.75bn from US$2.59bn in 2015.
with Cementos Portland Monterrey, renaming as On a like-for-like basis adjusted for investments, di-
Cemex in 1931. It expanded to Spanish-speaking vestments and currency fluctuations it rose by 15%.
nations, including Spain, Venezuela, Panama, Co- Its net sales fell by 3% to US$13.4bn from US$13.8bn,
lombia, the Dominican Republic and Costa Rica in although on a like-for-like basis they rose by 4%.
the 1990s, as well as Egypt, the US and the Philip- Sales volumes of cement remained stable at 66.7Mt.
pines. In the 2000s expansion continued into Europe The company hailed a 10-year high in net income for
via the acquisition of RMC (2003), as well as Thailand 2016 and said that sales had increased on a like-for-
(2001) and Puerto Rico (2002). It gained further as- like basis in the fourth quarter due to higher prices
sets through the acquisition of Australias Rinker in and higher volumes in Mexico, the UK and Germany.
2007. In 2017 Cemex is the fifth-largest producer, In the first quarter of 2017, Cemexs net sales were
with 88.7Mt/yr of cement production capacity. hit by poor sales in the US, Europe and Asia, the
Middle East and Africa. Its overall net sales rose by
Financial situation 1% year-on-year to US$3.14bn in the quarter from
Cemex saw its profit rise in 2016, reporting that its US$3.11bn in the same period of 2016. However, net

Anzeige_BW_09_00:Anzeigenentwurf 06.03.2009 18:32 Uhr Seite 1
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sales fell by 2% to US$936.8m in the US, by 2% to (CGC). It sold a stake of 13.5% in the company, leav-
US$978.6m in Europe and by 20% to US$366m in ing it with 9.5%. GCC separately bought Cemexs
Asia, Middle East and Africa. The groups overall ce- 0.9Mt/yr Odessa cement plant in Texas, US. In Sep-
ment sales remained stagnant at 15.6Mt. tember 2016 it also offloaded the 1.0Mt/yr Fairborn
cement plant in Ohio to Eagle Materials, as well as a
Recent news and events number of related assets for US$400m.
Cemex has been involved in various cement plant More recently, it has been mulling the purchase
transactions over the past 12 months. In January of InterCement from Camargo Corra. No informa-
2017 it was successful in its bid to take over Trinidad tion has been forthcoming about this potential deal
Cement via indirect subsidiary Sierra Trading. This since March 2017, but it would mean Cemex gaining
gives it control over cement production assets in a foothold in Brazil for the first time.
Trinidad & Tobago, Jamaica and Barbados. Finally, Cemex has been unable to sell its opera-
Cemex has also reduced its stake in fellow Mexi- tions in Croatia due to EC competition concerns, as
can cement producer Grupo Cementos de Chihuahua outlined on Page 13.
6. China Resources Cement 7. Taiwan Cement
S tate-owned China Resources Cement runs 44

clinker lines and 93 grinding plants across seven
Provinces in the far south and north east of China.
T aiwan Cement was established in 1946. It is the
seventh-largest cement producer in 2017, with
69Mt/yr of cement capacity in Taiwan and China.
It has added two grinding plants and two integrated
HQ Taiwan
plants in the past 12 months.
Integrated Capacity 69Mt/yr
HQ China 2016 Revenue US$3.1bn
Capacity 81.3Mt/yr
2016 Sales 80.0Mt
8. Ultratech Cement
I ndias largest cement producer is one of

the few that also operates abroad, in the
UAE, Bahrain and Bangladesh. Its sales have
9. Eurocement
risen in recent quarters as Indias cement
market concentrates. F ounded in 2002,
Eurocement is the largest producer of cement in
Russia. It also operates in Uzbekistan, Ukraine and
Georgia. It recently announced the construction of
HQ India
a new 2Mt/yr integrated plant in Uzbekistan.
Capacity 52.7Mt/yr
2016 Revenue US$4.13bn HQ Russia
Capacity 45.2Mt/yr
2016 Sales Does not disclose
2016 Revenue Does not disclose
10. Votorantim Cimentos
B razils Votorantim Cimentos saw its cement sales volumes fall by

14% to US$731m in the first quarter of 2017.
HQ Brazil
Capacity 45.0Mt/yr

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GLOBAL CEMENT: BAGGING Contents Subscribe Ad Index
Markus Grabenweger & Sigrid Eder, Starlinger & Co. GmbH
Packaging cement the sustainable way

Cement packaging is a significant factor for cement producers and sellers regarding product
protection, shelf appearance, cost margins and sustainability targets. An independent study
compared the environmental impact of paper cement sacks, sewn cement sacks made of
recycled polypropylene tape fabric, and hot-air welded AD*STAR cement sacks made of
coated polypropylene tape fabric. The results are presented below...
T he Life Cycle Assessment (LCA), carried out by

the German PE INTERNATIONAL AG (now
thinkstep AG) and commissioned by the Austrian
cement bag used in Saudi Arabia. Although they are
mostly produced in the country, the paper and glue
have to be imported from Europe. To achieve the
machinery supplier Starlinger & Co. GmbH, com- necessary strength, the sack weight is comparatively
pared sewn sacks made in China and kraft paper high. However, sack ruptures can occur easily if bags
sacks made in Saudi Arabia with AD*STAR sacks are dropped or dragged on uneven surfaces. Bags are
produced in both countries respectively. In the also prone to changes in humidity.
course of the study the entire life cycle of the cement
sacks, from production and transport to the cement AD*STAR sacks
plant, the use phase of the sacks, to their end-of-life AD*STAR sacks are block bottom valve sacks made
phase, was reviewed. All sacks had a filling capacity of woven and coated polypropylene tape fabric. They
of 50kg cement (See Table 1). are produced exclusively on Starlinger machinery.
The sack bottom and top are closed in a special
Chinese cement bags conversion process by means of hot air welding. The
In China, sewn woven sacks made of polypropylene use of high-grade virgin polypropylene for fabric
(PP) tape fabric are the most widely used packaging production and the tight sealing of the bottom and
for cement. They are manufactured using varying top of the sack ensure low levels of breakage, even
amounts of recycled polypropylene, sometimes up during rough handling, dropping and contact with
to 100%. PP-coated tubular fabric is cut and sewn, water. They are used globally, particularly in African
mostly by hand, in sack factories. The recycled mate- and South East Asian countries.
rial used to produce the sacks is, in most
cases, severely degenerated. It has been
re-used various times and often contains
high quantities of other mineral fillers from
Right: AD*STAR cement sacks previous applications. This means the sack
are made of robust PP tape fabric is rather brittle and breaks easily. To
fabric. The sack bottom and
top are closed by means of a increase the sack strength, the fabric weight
specially-developed sealing is increased. The sewing process also weak-
technology. Starlinger. ens the material by up to 50%.
Saudi Arabian cement bags

Below - Table 1: Technical Two- and three-layer kraft paper sacks with
specifications of the sacks used a block bottom shape are the predominant
in the LCA.
Country Type of sack Weight (g) Capacity (kg) Main material

China, AD*STAR block bottom valve sacks, welded 70.58 50 Coated woven polypropylene tape fabric (virgin material)
Saudi Arabia
China Woven PP sacks, sewn (50% recycled content) 75.91 50 Coated woven polypropylene tape fabric, produced out of 50% post-consumer
waste and 50% virgin material
Woven PP sacks, sewn (100% recycled content) 75.91 50 Coated woven polypropylene tape fabric, produced out of 100% post-consumer
waste
Saudi Arabia Paper block bottom sacks, pasted (2-layers) 145.0 50 Kraft paper
Paper block bottom sacks, pasted (3-layers) 165.0 50
18 Global CementMagazine July-August 2017 www.GlobalCement.com

GLOBAL CEMENT: BAGGING
Impact category Description

Global warming potential Includes greenhouse gases causing climate change,
excluding biogenic carbon (i.e. CO2 emissions related to the natural carbon cycle).
Acidification potential Relates to emissions causing acidifying effects such as acid rain or the decline of forests.
Left - Table 2: Impact
Ozone depletion potential Considers ozone depletion in the higher atmosphere.
categories indicated
Photochemical ozone Analyses ozone formation in the lower atmosphere, which causes summer smog. in Figures 1 & 2.
creation potential Closely connected to air quality.
Energy consumption Includes energy consumed from both non-renewable sources such as fossil energy carriers
non-renewable/renewable sources (including nuclear energy) and renewable energy carriers such as solid or liquid biofuels.
Fresh water consumption Considers the man-made removal of water from its watershed (surface or ground water,
not rain water) through shipment or evaporation.
Life cycle phases of the cement sacks

For the life cycle assessment, the CML impact
assessment methodology framework from the
Centrum voor Milieuwetenschappen at Leiden Left: Sewn Chinese
cement sacks made of
University, the Netherlands, was selected. The
recycled PP.
impact categories used in this study represent Starlinger.
internationally-accepted LCA indicators (Table

2). One metric tonne of cement of average quality
was taken as a functional unit for the study. All
primary and secondary data was collected specific
to the countries under study. Where country spe-
cific data was unavailable, proxy data was used.
Geographical representativeness is considered
to be good. All primary data was collected or
assumed for 2013. The life cycle phases of each of
the sack types were defined as:
Left: Broken
Production of sacks including the transport of paper cement bags.
Apidach Jansawang,
raw materials to the production plant;
Dreamstime
Transport of sacks to the cement plant;
Use phase of sacks Also includes sack breakage

and other losses in the entire logistics chain (in-
cluding a specified recovery rate of cement at the
plant and during transport), as well as produc- Energy supply The electricity grid mixes used in
tion of cement to compensate for losses. The cement the production phase were regionalised according
datasets, including all upstream environmental to the local energy supply situations.
burdens, were regionalised for Chinese and Saudi
Arabian conditions; Low breakage rates - smaller CO2 equivalent
The term breakage rate refers to the percentage
End-of-life of sacks Final treatment of cement of cement lost due to sack breakage in the entire
sacks. Analysis based on 20 x 50kg sacks needed for life cycle of the respective sacks. The study showed
the packaging of 1t of cement, plus reproduction of that the low breakage rates in the course of the use
broken sacks during filling. Net flows, e.g. emissions phase are a decisive factor for the positive results of
from uncontrolled incineration are also considered; AD*STAR sacks.
As no reliable data was available from official
End-of-Life Credits Electricity and thermal sources and in-depth product knowledge is needed
energy production by means of incineration, sub- for the determination of an applicable breakage rate
stitution potentials resulting from the net flow of for the different types and qualities of sacks during
recyclable materials in the end of life of cement their entire life cycle, the study included interviews
sacks. The end-of-life credits were adapted to the with experts from the local packaging and cement
regional situation in order to represent realistic industries in China and Saudi Arabia. This ensured
conditions; that the estimations for the breakage rates assessed
are realistic and have a valid basis.

China: low quality
Global Warming Potential impairs performance
In China, the worlds big-

gest cement producer,
Ozone Layer
Fresh Depletion Potential around 20 billion sewn
water use cement sacks made of PP
tape fabric with recycled
Right - Figure 1: AD*STAR content are produced
cement sacks compared to sewn every year. In the study,
cement sacks made of recycled sewn coated polypro-
PP in China (based on data pylene sacks made of
researched by thinkstep AG).
Starlinger. 50% virgin material and
50% recycled material,
Primary and sacks made of 100%
Acidification
Energy Demand Potential recycled material were an-
alysed. These are currently
the most widely-used sack
types for packaging ce-
Photochemical Ozone ment in China. The sacks
Creation Potential have an extremely thin
coating and are some-
times partially uncoated,
which reduces their shelf
A breakage rate of 1% was assumed for AD*STAR life. Together with non-existent coating, the sewn
sacks, 3.8% for woven PP sacks with 50% recycled top and bottom seams account for increased cement
content, 4.4% for woven PP sacks with 100% recycled losses during the entire transport chain.
content, 2.8% for two-layer paper sacks and 2.3% The study concludes that AD*STAR sacks pro-
for three-layer paper sacks. The study applies the duced in China create lower environmental burdens
breakage rates considering that 90% of the cement in each impact category than the sewn sacks made of
lost at the plant as well as 20% (Saudi Arabia) and polypropylene with portions of recycled content. The
50% (China) of the cement lost during transport and latter show significantly higher impacts for ozone
handling is recovered. depletion, blue water consumption, land occupation
Regional differences of the AD*STAR sacks be- and primary energy from renewable resources than
tween Saudi Arabia and China are considered in the AD*STAR sacks.
study with a number of factors, of which the region- Regarding the global warming potential, the envi-
alisation of the cement datasets, the electricity grid ronmental impact during the use phase of the sacks
mix, upstream supply chain of PP, and the end-of-life is strongly dependent on the breakage rate. With
scenarios are the most important. breakage rates of up to 4.4%, the sewn polypropyl-
For the production of the AD*STAR sacks ana- ene sacks with recycled content have a substantially
lysed in the study, 100% virgin material was used higher environmental impact than AD*STAR sacks.
both in China and Saudi Arabia. Due to the special More cement is lost during the use phase and has to
production process, AD*STAR sacks are extremely be compensated by additional production.
robust despite their very low weight (See Table AD*STAR sacks, in turn, are extremely robust.
1) which also accounts for raw material savings The sensitivity analysis of the breakage rates during
during production. the use phase showed that the global warming poten-
Because of the strength and resistance of tial of both types of sewn polypropylene sacks would
AD*STAR sacks, the cement losses caused by sack still be higher even if they had the same breakage rate
breakage and other losses are below 1% in the entire as AD*STAR sacks.
use phase, while for paper sacks and sewn woven Changing over to AD*STAR sacks would not only
sacks the cement losses are 2.3-4.4%. These compara- reduce CO2 emissions caused during production and
tively high rates are caused by the rough handling thus relieve the environment, but it would also con-
and low automation in the logistic chains, especially tribute to the automation of the entire cement filling
in China. In many cases sacks are loaded, unloaded and transport chain. Currently, the manufacture and
and stacked by hand multiple times before reaching handling of the sewn woven PP sacks involves a lot
their final destination. If the more robust AD*STAR of manual activity starting with the sewing of the
sacks are used, less cement is lost (and must be re- sacks in the production phase and the resultant size
placed), and less packaging is needed. Consequently, differences that cause problems on automatic fill-
less greenhouse gas is produced. ing lines, from putting them onto the spout during
the cement filling process, to stacking, storing and

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21 Aixergee-Xavier July-Aug 2017.indd 1 30/06/2017 15:44

Global Warming Potential renewable primary en-

ergy demand shows lower
potentials for paper sacks
than for AD*STAR sacks.
Ozone Layer
Fresh Depletion Potential
This is because the poly-
water use propylene used for the
production of AD*STAR
Right - Figure 1: AD*STAR
sacks represents a non-
cement sacks compared to renewable resource,
cement sacks made of kraft whereas kraft paper that
paper in Saudi Arabia (based serves as input for the
on data researched by thinkstep
AG). Starlinger.
paper sacks is based on
renewable resources.
Primary For Saudi Arabia,
Acidification
Energy Demand Potential switching over to the
more robust AD*STAR
sacks would not only pre-
vent the loss of countless
Photochemical Ozone
tons of cement caused
Creation Potential by sack rupture, but
also greatly reduce raw
material input for sack
production and avoid
transporting. Considering the current investments in long transport routes. In addition, the entire value
modernising the Chinese cement sector, the use of created by both raw material and sack production
AD*STAR sacks, which are produced automatically would remain within the country.
on sack conversion lines and allow fully automated
handling of the packaged cement, would seem a pru- Conclusion
dent step. The study clearly shows that AD*STAR sacks have
lower global warming potential than paper sacks or
Saudi Arabia: Import of kraft paper drives sewn PP sacks. In China and Saudi Arabia, AD*STAR
up environmental impact sacks not only show the lowest values regarding global
In Saudi Arabia paper and glue imported from warming potential, they are also the environmentally
Europe are used for the production of cement pack- friendlier packaging option in terms of acidification
aging. Two- and three-layer kraft paper cement sacks potential, ozone depletion potential, photochemical
are on the market and were used for this study. ozone creation potential, as well as energy and fresh
The global warming potential of both AD*STAR water consumption.
sacks and paper sacks in Saudi Arabia is dominated The study was reviewed by an independent review
by emissions during the use phase of the product. panel consisting of representatives from the inter-
As the paper sacks show higher breakage rates than nationally-operating German inspection company
AD*STAR sacks, more cement is lost, resulting in a Dekra, which held the chairmanship of the panel, as
higher impact. well as Lafarge France and Canada, Dr Werner Envi-
The production phase represents the second larg- ronment & Development from Switzerland, and the
est driver, in this case especially with regard to the Austrian trading company Sack Agency.
AD*STAR sacks, while the production phase of paper With this comparative life cycle assessment on
sacks has less impact. Transportation contributes cement sacks, Starlinger & Co. GmbH has presented
more to the global warming potential of paper sacks a carefully researched and detailed study in accord-
than to the AD*STAR sacks produced in Saudi Ara- ance with the standards EN ISO 14040 and EN ISO
bia because the raw materials for the paper sacks have 14044, said Dr Frank Werner of Dr Werner Environ-
to be shipped. In total, the two-layered paper sacks ment & Development. In the course of the critical
produced in Saudi Arabia perform worst in terms of review the life cycle analysis experts of the review
global warming potential, while the AD*STAR sacks panel have surveyed and discussed the study and the
show the lowest values. data and stipulations it is based upon in depth with
Ozone depletion, eutrophication, blue water the authors of the life cycle analysis. Based on this
consumption, land occupation as well as renewable comprehensive examination of the study I consider
primary energy show higher values for the paper sacks its results and conclusions sound.
in comparison to AD*STAR sacks. Only the non-

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GLOBAL CEMENT: FANS Contents Subscribe Ad Index
Peter Wilson, Industrial Noise and Vibration Centre
Fan and stack noise control Stealth and efficiency
Solving large fan noise problems has conventionally involved many days or weeks of
downtime, high capital expenditure and a reduction in system efficiency. There is now an
elegant alternative that can be installed in hours at a fraction of the cost - and that can
actually improve system efficiency
Sound clip 1 -
Cement works
T raditional noise control techniques assume that
the noise generated by the fan is an immuta-
ble fact. As a result, most typical fan noise control
racing car and aircraft designers develop sophisti-
cated aerodynamic aids that enhance performance
by controlling air flow around the vehicle. Moreover,
stack before- projects are based on high cost, antediluvian pallia- fan efficiency is intimately related to fan noise due to
and-after tive techniques that havent changed since the 19th the fact that the minimum noise occurs when the fan
Century. The only noise control options that are is operating at maximum efficiency - noise is caused
considered revolve around attempts to reduce the by energy wasted as turbulence.
noise energy escaping from the system by using si- Where applicable, this approach can mean that
lencers, lagging and enclosures. This is very costly in it may be possible to dispense with conventional
terms of capital expenditure, installation downtime silencers entirely, increasing the efficiency gains still
and increased maintenance and running costs, the further, by as much as 20%. Moreover, the INVC can
latter due to the effect that silencers can have on evaluate the options for most fan systems anywhere
system efficiency. on the planet from a couple of photographs and a
The Industrial Noise and Vibration Centre smartphone recording sent by email.
Sound clip 2 - (INVC) has developed a game-changing alternative
Extract fan technology based on a deep understanding of the How well does it work in practice?
before-and- noise generation mechanisms in fans. Coupled with Process extract fan: The 6MW variable speed fan
after Computational Fluid Dynamic (CFD) modelling, shown in Figure 2 generated such high levels of low
this is then used to design retro-fit aerodynamic frequency tonal noise that working in the control
aids that change the flow within the system to reduce room was almost unbearable. Considerable resources
fan noise at source. This is similar to the way that had already been spent on lagging to try to contain
the problem with little success. The next step
would have been to cost the installation of
inlet and exhaust silencers which would have
required moving the fan.
Sound clip 3 -
Fan noise analysis by email
Oxidiser fans
before-and- Based on INVCs extensive experience
after with fan noise control, it has developed
technology that allows it to evaluate the
silencing options for any fan anywhere
via email. All the end user needs is a
smartphone. INVC combines informa-
tion from photographs and drawings
of the fan / stack system with mechani-
cal features (fan speed and number of
blades) and an analysis of smartphone
audio or video to determine the options.
Sites anywhere in the world with fan
noise problems can get an evaluation
Right - Figure 1: Industrial of whether there are alternative options
facilities like cement plants
to conventional silencing that could cut
are full of large and often
noisy fans. costs by 80% within a few days.

GLOBAL CEMENT: FANS
Far left - Figure 2: Flow

model, 6MW fan.
Left - Figure 3: Dryer fan.
50
40
30
dB (A)
20 Left - Figure 4: Noise

reduction signature overlay for
system shown in Figure 3.
10
-10
0 50 100 150 200 250 300 350 400 450 500
Narrow band frequency (Hz)
Not surprisingly, the problem. The quote for

aerodynamic silencing op- Acoustic camouflage conventional silencing in-
tion was chosen instead. Acoustic camouflage is an inno- cluding structural steelwork
A sophisticated computer vative solution to some difficult and stack modifications was
model of the fan was created environmental noise problems Euro115,000 plus weeks
as the basis for the design where sound with character of costly downtime. The
of the aerodynamic inserts. causes complaints. It can either engineers also considered
This resulted in a 17dB re- be used in conjunction with noise that silencers would cause
duction in the typical 190Hz control measures or where noise an unacceptable reduction
blade pass tone and 12dB control would be too expensive or in fan efficiency, which
of attenuation at the first impractical. Based on research into was not in keeping with
harmonic. In principle, the the subjective response of people the companys drive to
whole project - information to noise characteristics, Acoustic reduce its energy use and
capture, design, manufac- Camouflage uses bespoke sound carbon footprint.
ture and install - could have signatures from an array of loud- After online research for
been completed within a speakers to camouflage noise alternatives, the company
month. nuisance features in the noise from forwarded the fan details
the perception of complainants. In and audio recordings to
Dryer fan: The noise from one project, INVC eliminated noise INVC, which analysed them
the fan / stack system complaints by increasing the over- and assessed the options. The
shown in Figure 3 created all noise level by 8dB(A). airflow inside the fan was
an environmental noise then modelled and an aero-

GLOBAL CEMENT: FANS
Placebo silencers
Some industries are so wedded to the
concept that silencers are necessary that,
despite solving a serious environmental
dryer noise problem for the manufacturer
using low cost aerodynamic technology,
INVC still had to fit unnecessary placebo
silencers in order to get paid
Above - Figure 6: Placebo silencers installed at an industrial facility.
dynamic insert designed to be fitted inside

the fan casing. This was manufactured and
installed by a local mechanical contractor in
a matter of hours during a normal shut-down
period, meaning that zero additional down-
time was incurred.
Post modification, the problem fan noise Refinery fans: In another example, using aerody-
was eliminated (20dB attenuation, See Figure 4) at namic technology to silence five 1.4MW fans at a
around 10% of the cost and without the reduced effi- refinery (15dB attenuation) saved over US$1m from
ciency of silencers. Instead, there was a 6% reduction the US$1.25m capital cost quoted for conventional
in fan energy consumption, which meant that the silencers. Installation also required negligible down-
noise control project paid for itself in 10 months. time and there was no effect on fan performance.
Cement works Converting existing system elements into silencers

It is often possible to design retro-
fit components that convert parts
of the existing system into effective
silencers. At the cement plant shown
in Figure 5, a plant upgrade created
a very serious noise problem over
a wide area that had to be solved
very quickly. Conventional silencing
would have required an unaccepta-
ble extended shutdown period. The
INVCs alternative was to design a
set of tuned stack silencer elements
that were prefabricated off site and
then installed via existing access
doors over a weekend. These reduced
the overall noise by 19dB(A) with no
effect on system efficiency at a tiny
Above - Figure 5: A cement plant at which a significant environmental
fraction of the cost of conventional noise issue was solved quickly and with low capital expenditure.
silencing.
Industrial Noise and Vibration Centre (INVC)

The INVC is a multi-award winning engineering consultancy specialising in developing elegant engineer-
ing solutions to noise problems instead of relying on conventional (and high cost) palliative techniques.
Innovative INVC fan noise control technology is increasingly being used to solve fan noise problems across
the world as it typically provides capital cost savings of around 80%, needs ~10% of the down-time to fit
and it improves system efficiency compared with conventional silencing.

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GLOBAL CEMENT: BEARINGS Contents Subscribe Ad Index
John Rhodes & Karen Clever, The Timken Company
Spherical roller bearings in tougher environments

of heavy industries
Authors from The Timken Company explain the need for new spherical roller bearings to
meet the needs of tougher environments and the increased demands of heavy industry.
A s the cement industry faces ever more punish-

ing conditions, plant and equipment operators
increasingly look to suppliers and manufacturers
Most bearings are intended to carry either a radial
load that acts perpendicular to the shaft or an axial
load (also called thrust load) that acts parallel to the
to generate new operational efficiencies. The goal is shaft. Spherical roller bearings, however, must toler-
measurable gains in performance, productivity and ate combined loads where moderate-to-high radial
profitability, resulting from improvements to existing and axial forces are at work.
systems, processes and assets. Spherical roller bearings are used not only
Timken launched an intensive improvement ef- where shaft misalignments are common, but where
fort to meet increased load, speed and temperature contamination, shock and vibration are constant
requirements for bearings operating in critical ap- challenges. Their robust design and higher tolerance
plications. This article explores new expectations for for misalignment is especially suited to the cement
key applications, particularly in the cement industry, industry.
advances in spherical roller bearing technology and
the design and testing of Timken High Performance High-performance parameters
Spherical Roller Bearings. When speaking of spherical roller bearings, the term
high performance can relate to an increase in bear-
The case for spherical roller bearings ing service life. This offers the potential to downsize
Spherical roller bearings are a special class of roller other component selections while maintaining
bearings that are relied on in many demanding ap- current levels of system performance. This means
plications. These self-aligning, double-row radial smaller pieces of equipment and systems that work
bearings are designed with an inner and outer ring more efficiently, as well as increased power density
and barrel shaped rollers that are separated by a that translates through to greater power throughput
cage, allowing for greater load-carrying capacity and longer system life.
and dynamic angular misalignment ability when High performance can also refer to a reduction
Below: Industry expectations
push the limits of durability and compared to other common bearing types, including in heat generation. Bearings that function at lower
production in heavy industry. tapered and cylindrical bearings. temperatures under demanding conditions create the
potential for increased efficiency
and higher speeds of operation.
Lower temperatures reduce the
oxidation rate and deterioration of
oils, greases and films, extending
lubrication and thus bearing ser-
vice life.
While the basic functionality of
todays spherical roller bearings re-
mains fundamentally similar to that
introduced in the 1950s, continu-
ous improvements to performance
have been a focal point for bearing
manufacturers. The research and
development effort from Timken
progressed with the market to
meet the growing size and power
requirements of heavy machinery
and gear-driven equipment.

GLOBAL CEMENT: BEARINGS
() ratio, where equals the predicted operating

oil film thickness divided by the composite surface
roughness. Improvement in ratio has been well
documented as increasing bearing fatigue life pre-
dictions, as represented by the a3l lubrication factor
increase in factor-based life calculations.6-8 Specifica- Left -Figure 2: Timken
tions on micro texture were employed beyond those Spherical Roller Bearings allow
associated with composite roughness to ensure the for good load-carrying capacity.
desired ratio is achieved in operation. The im-
provement in surface texture also sets the stage for
potential reduced heat generation by allowing the se-
lection of reduced viscosity lubricants that still meet
adequate operating ratios.
Cage construction
Key design elements Cages (also called retainers) serve several purposes
Objectives for design optimisation of the in the proper operation of a rolling element bearing,
Timken Spherical Roller Bearing included: 1. Greater including separating the rolling elements to prevent
load-carrying capability; 2. Reduced operating tem- roller-on-roller contact and wear. Cages also align the
perature, and; 3. Extended service life. Activities were rolling elements on the inner ring outside the oper-
focused around: 1. Optimising internal geometries ating load zone to minimise roller sliding, skidding
to maximise roller length and dynamic capacity; and skewing.
2. Improving surface finishes to support higher ratings An advanced cage design methodology was
and increased lubrication ratios; 3. Strengthening incorporated into the Timken High-Performance
cage design to reduce wear; 4. Enhancing lubrication Spherical Roller Bearing, resulting in the Timken EJ
flow to rolling contact surfaces, and; 5. Improving steel cage. At elevated speeds, a steel cage can provide
heat dissipation. an advantage over brass due to its lower mass and re-
As a standard element of any continuous improve- duced roller/cage contact. The EJ cage is also nitrided
ment endeavour, Timken also set out to reduce design (surface hardened) for improved wear resistance and
complexity where the potential for simpler and/or fatigue strength.
fewer components was presented. The new design incorporates many aspects of
The design of the new high-performance bear- existing Timken steel cages, including inner ring pi-
ing follows the ISO standard for bearing boundary loting, low mass, low inertia, an individual cage for
dimensions for inner diameter (ID), outer diameter each row and no separate centre ring for roller axial
(OD) and width, allowing for general interchange- positioning. It also introduces slots in the outboard
ability with other bearings. The standard does not, face of the cage. The symmetrical openings are ori-
however, dictate cage design or internal geometry. ented between the cage pockets to facilitate lubricant
flow in and out of the inner ring raceway. This helps
Internal geometry to assure lubricant availability to these rolling contact
At the heart of the spherical roller bearing design surfaces to generate a satisfactory film, while further
is the inner ring geometry, which requires precise reducing the potential for extreme heat due to viscous
design specification and manufacturing consistency. shear from excessive lubricant supply.
The inner ring allows a complex interaction between
the bearing contact angle and raceway profile,1 which Cage guidance
must be specified to produce the most efficient race- The EJ design includes two independent cages (one
way-roller dynamics. for each row of rollers), which are assembled into an
Timken extended the parameters of the Timken individual bearing. This allows each path of cage and
P900 Tapered Roller Bearing to the new spherical rollers to operate independently. The window-style
design. The P900 relies on optimised geometries, spe- pocket construction reduces bending stresses. The
cial finishes and high-quality materials to achieve an cage is guided on the inner ring and runs above pitch.
increased power density (bearing capacity to weight This increases cage stiffness and reduces stress under
ratio) and provide an efficient solution.2-5 The macro high shock load or acceleration.
raceway profile contact geometry minimises the op- For bearings with an OD > 400mm, the cage and
portunity to develop conditions in which contact roller mass can become substantial and negatively
stresses are concentrated at one location, thereby impact on bearing heat generation and operating
reducing rolling contact fatigue life. temperatures. To counter this, the bore of larger EJ
The micro raceway texture was also improved by steel cage is profiled to minimise friction and associ-
reducing the composite surface roughness. This has ated heat generation from contact with the inner ring
a direct effect on increasing the operating lambda pilot surface.

GLOBAL CEMENT: BEARINGS
Roller guidance
temperature to a specified elevated level. The intent
Rollers are guided by the edges of the cage pocket is to test the bearing rolling contact surfaces in an
for smaller bearings (OD < 400mm). For larger sizes, accelerated manner relative to surface and subsur-
the pocket is contoured with four pads (strategically face fatigue modes. The influence of bearing design,
located on the bridge surface) that contact and orient material, heat treatment, geometry, surface profile
the rollers coming into and out of the bearing operat- and texture have a combined impact on life testing
ing load zone. This interaction minimises potential with the first-in-four format used to develop the test
for negative roller skew and its associated increase in Weibull statistics.
friction torque and operating temperature. Timken SYBER analytical modelling software is
used to establish the predicted bearing performance
based on the bearing metrology and test
conditions. Test results are evaluated using
Weibull statistics regarding L15.91 life and the
associated 65% confidence bands to establish
test performance. The Weibull result is then
Right: Timken Spherical compared to the SYBER predictions, and an
Roller Bearings are used where
shaft misalignments,
assessment is made regarding acceptability
contamination, shock and of the resultant life ratio. These ratios are re-
vibration present challenges. viewed to determine their degree of support
for intended rating performance levels.
Validation results indicated that the
Timken High Performance Spherical Roller
Bearing achieved an increased dynamic load
rating of 18% and a 17% thermal speed rating
increase, relative to previous Timken spherical
roller bearing designs.
Conclusion
The results validate a high-performance
spherical roller bearing design that could meet
No central guide ring the escalating load, speed and temperature re-
Given these precise cage pocket interactions, a central quirements of heavy duty industrial machines
guide ring is not required to axially position the roll- and equipment.
ers in the EJ design. Without a guide ring, the friction
generated between the rollers and ring is eliminated, References
equating to cooler-running bearings. Less friction 1. Harris, T.A. & Kotzalas, M.N.: Rolling Bearing Analysis, 5th Ed
also means less energy is needed to move the bearing Advanced Concepts of Bearing Technology, 2007.
initially and to keep it moving. 2. Moyer, C.A.; Nixon, H.P. & Bhatia, R.R.: Tapered Roller Bearing
Eliminating the guide ring further creates extra Performance for the 1990s, SAE Paper #881232, SAE International,
space within the design envelope to accommodate 1988.
longer rollers, meaning increased load capacity. Al- 3. Stover, J.D.; Kolarik, R.V. & Keener, D.M.: The Detection of
ternatively, lubricant flow between the roller paths is Aluminum Oxide Stringers in Steel Using an Ultrasonic Measur-
improved by increasing available void volume. ing Method, Proc. 31st Mechanical Working and Steel Processing
Conference, pp. 431 440, 1990.
Design validation 4. Hoeprich, M.R.: Numerical Procedure for Designing Rolling
Validation of the Timken High-Performance Spheri- Element Contact Geometry as a Function of Load Cycle, SAE Paper
cal Roller Bearing design was extensive. It included #850764, SAE International, 1985.
standardised fatigue life testing to confirm dura- 5. Moyer, C.A. & Bahney, L.L.: Modifying the Lambda Ratio to
bility under strenuous and accelerated operating Functional Line Contacts, STLE Tribology Transactions, Vol. 33, No.
conditions, as well as testing on different platforms to 4, pp. 535 542, 1990.
verify bearing heat generation response as measured 6. Danner, C. H.: Fatigue Life of Tapered Roller Bearings under
by outer ring temperature. Minimal Lubricant Films, ASLE Transactions, Vol. 13, No. 4, pp. 241
251, 1970.
Methodology and modelling 7. Zaretsky, E.V. (Ed.): Life Adjustment Factors for Ball and Roller
Timkens standard life testing is completed in a first- Bearings, An Engineering Design Guide, 1971.
in-four arrangement. The bearings are tested under 8. Zhou, R.S.: Surface Topography and Fatigue Life of Rolling
an elevated load and speed condition using a circu- Contact Bearings, STLE Tribology Transactions, Vol. 36, No. 3, pp.
lating oil lubrication system that controls the inlet oil 329 340, 1993.

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GLOBAL CEMENT: SLAG Contents Subscribe Ad Index
Interview by Peter Edwards, Global Cement Magazine
In discussion: Chris Stern, Carbicrete CEO

Carbicrete, based in Montreal, Canada, has developed a way to produce cement-free, CO2-
negative construction blocks using technology that replaces cement with steel slag. The
process uses CO2 during the curing process, permanently sequestering a kilogram of CO2 in
every construction block. The company been short-listed for the NRG COSIA Carbon XPRIZE.
Carbicretes CEO Chris Stern recently took the time to speak to Global Cement...
Global Cement (GC): Can you introduce the yet, but we think that the process can handle a much
Carbicrete process? lower concentration. We have tested this by diluting
down the pure CO2 stream with other gases.
Chris Stern (CS): We have come up with a new
binder and process for making pre-cast structures GC: Why is it called Carbicrete?
that would previously have been made using cement-
based concrete. It was invented at McGill University, CS: The name is made up of three elements. The two
which, like Carbicrete, is located in Montreal. The most obvious are Carb- from carbon dioxide, and
process was co-invented by Mehrdad Mahoutian, -crete from concrete. In the middle is bi from the
who is now the Chief Technical Officer at Carbicrete. latin for two, because of the expression killing two
Originally the researchers at McGill were looking birds with one stone. We are knocking out CO2 while
at how to use CO2 to cure cement in pre-cast con- making use of a steel by-product. Two problems,
crete structures. They then decided to look at other one solution.
materials that could potentially be carbonated in a
similar way. Steel slag was on that GC: What scale are you pres-
list, which led to what became ently operating at?
the Carbicrete process. Note that
the Carbicrete process does not CS: As I mentioned earlier, we
use iron slag, which is the main are at a fairly small, pre-indus-
type of slag used by producers of trial scale at the moment and
slag cements. Steel slag is a non- are currently seeking our first
hydraulic slag, which is why it industrial partners. We will do
can be cured with CO2. While it pilot production after we have
can replicate dry-cast and pre-cast announced our partnerships.
structures, it cannot be used as a
Right: A construction
block made using the replacement for ready-mixed uses. GC: What are the advantages
Carbicrete process. of the Carbicrete process
GC: Can you go into the process compared to traditional block
in more detail? making processes?
CS: While I wish to avoid going CS: First and foremost it is actu-
into too much detail, ground
ally CO2-negative. Not only does
steel slag, aggregate and water the process avoid CO2 produc-
are mixed and placed into the tion by not using cement, it will
desired mould. They are then absorb CO2 from industrial pro-
placed in a chamber that is under cesses that would otherwise be
an atmosphere of CO2. There is no emitted to the atmosphere.
conventional cement used. Based on just the material cost savings, we expect
The curing process takes place at low tempera- the process to produce pre-cast products at 10-20%
tures and pressures. It is not a high-energy process. lower cost than traditional cement-based processes.
The blocks cure by absorbing the CO2, around 18kg In jurisdictions where there is a price connected to
per block. CO2 emissions, the Carbicrete process will really
While we currently have been using very pure come into its own from an economic standpoint.
CO2 gas from the major suppliers, we could also use From the perspective of the manufacturer there
partly cleaned up waste gas / CO2 from an industrial are also advantages with respect to the process. It
facility. We have not conducted an industrial trial takes far less time to cure a block using the Carbicrete

GLOBAL CEMENT: SLAG
Left: Close-up detail of a block

made using the Carbicrete
process. The Carbicrete process
has been said to produce a bet-
ter finish, along with a number
of other benefits.
Not only does the process avoid CO2 production by not using cement,
it will absorb CO2 that would otherwise be emitted...
process than it does with an equivalent cement-based make sure that the storage silo can accommodate the
block. For example, if a regular block takes 12hr to steel slag but otherwise, youre good to go. In terms
cure, the Carbicrete block will take 4-6hr. of economics there is a benefit from using steel slag
The blocks are also strong. A minimum strength instead of cement. The producer would have to make
specification for a regular construction masonry sure that they can source a good quality steel slag on
unit (CMU) is 15MPa. A cement-based CMU a consistent basis.
is around 20-22MPa and a Carbicrete block is
30-35MPa, which is much better. GC: What sort of timescale are you talking about?
GC: Is there an actual need to have such a high CS: I hope that we will have products brought out by
strength if the CMU specification states 15MPa? our partners during 2017. Ultimately we are building
Could you not reduce the amount of material used, these relationships, and the company itself, on the
either by making smaller blocks or increasing the basis that there are cost savings to be had. The im-
amount of aggregate? petus to change to sustainable processes is not quite
there yet. We need the economics to work to be suc-
CS: I suppose that you could use the process to do cessful in the current operating environment.
that but you would then reduce its ability to take up
CO2. Climate change is here and we want to com- GC: Are there any barriers in the standards that
bat that. I think that the superior strength could be limit the uptake of Carbicrete?
described as a nice bonus.
Some other benefits that I want to point out are CS: The blocks pass the strength test, the two-hour
that some in the sector have said that the product has fire test and were shown to be 20% more durable
a better finish. We also had a mason build a wall for a during freeze-thaw cycles, which is really important
fire test we carried out, in which he saw no difference in Canada. It will be fairly straightforward to get
compared to conventional blocks in terms of their accreditation. The most important thing is going to
weight or workability. The blocks were previously be convincing people to trust this new product. This
more dense, but we reduced it to help with transpor- is a hump that we have to get over. We are doing
tation CO2 emissions as well as workability for those large amounts of promotion in the mainstream and
lifting them. specialist media. We are talking to some celebrities
about endorsement at the moment and will con-
GC: How will Carbicrete be rolled out into the real duct some more public-facing advertising in the
world? longer term.
CS: The next step is to get a market pull from LEED- GC: Do you think that this technology could be
based builders and initiate relationships with concrete altered for ready-mix applications?
block producers that want to do things differently. We
are in discussions with some of these, as I mentioned. CS: I do not think that thats on the cards but the pre-
Our preference is to work with the largest producers cast sector is already a really big target. Carbicrete is
so that our process can have the largest possible im- not a silver bullet, but it is a bullet. Perhaps its a steel
pact it can. slag bullet, that can help to tackle CO2 emissions, but
A key selling point of our sales pitch to producers it is not going to be able to do everything by itself.
is that it is not a huge step to alter your process from
one that makes conventional bricks to one that makes GC: Chris Stern, thank you for your time today.
Carbicrete bricks. It comes down to exchanging the
curing chamber to one that accepts CO2. You have to CS: You are very welcome indeed!

GLOBAL SLAG: EVENT REVIEW Contents Subscribe Ad Index
Robert McCaffrey, Global Cement Magazine
Global Slag Conference 2017 - Reviewed
The 12th Global Slag Conference & Exhibition has successfully taken place in Dsseldorf,
Germany, attracting 130 delegates from 29 countries to listen to 19 presentations over two
days, alongside an exhibition of slag-related services and equipment. The 13th Global Slag
Conference will take place in North America in April 2018.
C harlie Zeynel of ZAG International started the

conference with a stark statement: Demand is
exceeding supply: we are running out of slag. There
Michael Connolly of TMS International LLC next
gave details of the status of slag and slag products in
the USA. He pointed out that Mr Trump has told his
is way too much clinker production capacity in the administration to do what it can to oil the wheels
world right now and people ought to be thinking of industry, and has mandated his officials to repeal
about building grinding stations rather than new 75% of Federal regulations. However, it is the states
clinker production capacity. Most of the iron and that regulate non-hazardous materials including slag
steel producers have sold out their slag and pricing products. A number of states have recognised that
has changed dramatically. The US cement market slag is not a waste but is a product, provided that it
is now growing at 5-8%/year for the next ten or 15 is not discarded. Michael went through some of the
years, but freight rates have leapt from historic lows regulations of the different states, pointing out that
and are now once again a major factor in delivered the use of slag products in some states requires ex-
costs, having increased by around 35% from 2016 tremely onerous stipulations (for example in Illinois,
to 2017. Imports into the US may be problematic in where written notice is required to be given to adja-
the coming years. Charlie pointed out that the ques- cent landowners that industrial byproducts are being
tion of the ownership of the slag is critical, since the used in any project). In general, regulations vary
owner has the power to decide on pricing and alloca- wildly from state to state, from almost outright bans
tion. However, the ownership of the slag is not always to widespread use. Through diligent advocacy work,
clear. Blast furnaces are no longer being built, so that US companies and other organisations - notably the
the supply of blast furnace slag will not increase. National Slag Association - are gradually persuading
China dominates in this area, as in so many others: regulators that slag products are a good idea.
it produces 60% of the global total of pig iron each Christian Kohl of Kallanish Commodities next
year and an equally large proportion of the global spoke about trends in steel supply. Christian pointed
total of slag. Around 360Mt of blast furnace slag out that there has been a recovery in prices for steel
(BFS) is produced worldwide each year, with 75% products in the last 18 months, starting in spring
1: Delegates listen to one of this being granulated to produce around 250Mt 2016 and with a strong kick in autumn 2016. He
of 19 presentations during
the conference. of granulated BFS. China produces 170Mt of this suggested that prices started to rise once some par-
GBFS, Japan 30Mt and the rest of the world produces ticular large buyers entered the market, causing a
the remainder - 50Mt. Japan uses the majority of its stampede, but steel prices were also backed by iron
2: Charlie Zeynel of ZAG Inter- own GBFS, with only around 10Mt made available ore price increases. European efforts to stem a tide
national opened proceedings
with a stark statement: We are for export. Slag product prices are inexorably moving of imports of steel products from Asia also helped
running out of slag. upwards - thats if you can find the product to buy. to boost steel prices in Europe, although these tariffs
1 2

GLOBAL SLAG: EVENT REVIEW
3 4 5
have not been universally popular with steel buyers. slag through the introduction of coal as a reducing 3: InsPyros Els Nagels
Global crude steel production was 1.6bnt in 2016, agent, during electrical heating and bottom stirring. presentation on non-ferrous
slag beneficiation was
with China producing 800Mt - which, if true, is well The reduction of the iron oxides in the slag to iron voted best by delegates.
beyond what was needed. The Chinese government metal allows high recovery of remaining metal in
now plans to reduce its capacity to a more sensible the molten slag. The subsequent dry solidification of
total of around 150Mt by 2020.
Tony Murray presented on behalf of 6: Frank Dardemann 4: Thomas Reiche of the
of Dsseldorf-based slag grind- FEhS - Institute for Building
Smithers Pira on key market trends for ing expert Loesche presents Materials opened a special FEhS
slag and non-ferrous slags, to 2027. Tony to the audience. session of four presentations.
suggested the key trend will be that the
global supply of BFS will reduce over the
next decade due to the closure of Chi-
nese blast furnaces.
Frank Dardemann of Loesche next
introduced a new process for the produc-
tion of cement clinker from steelmaking
slag. Frank pointed out that other uses
of slag have much lower value compared
to using slag products to substitute for
cement clinker, so that using steel slag as 6 7
a supplementary cementitious material
makes a lot of sense - if it can be done.
Alite (C3S) is the main active component of clinker, the molten slag generates the crystal structure, while 7: Delegates from Gambarotta
and the new process is designed to optimise the also allowing energy recovery from the cooling of the in discussion with other at-
cooling and composition of the slag to create a high molten slag. The solidification can be accomplished tendees during a networking
coffee break.
proportion of alite in the final steel slag. The ratio of by thin-film open dumping, with BSSF, or with dry
SiO2 and CaO must be optimised to form alite, while granulation using a rotating disc. Finally, Frank said 8: Christian Kohl of Kallanish
MnO content must be between 1-5% and the MgO that the grinding step increases surface area and Commodities makes a point
content must be below 5%. The cooling time of the hydraulic activity, while at the same allowing fur- during his talk about steel
trends.
slag should be on the scale of seconds to minutes. ther recovery of metal from the treated slag. Frank
The beneficiation of the slag starts when it is still pointed out that the economics of the process are 9: The Gala Dinner was at the
molten, through the reduction of iron oxides in the positive. At the same time, by using the steelmaking Classic Remise classic car centre.
8 9

GLOBAL SLAG: EVENT REVIEW
10: Kawasaki Heavy Industries

Masashi Takahashi (left) and
Bunpei Suzue (right) on the
company stand.
11: Evin Zozan (left) and David

Algermissen (right) of the FEhS -
Institute for Building Materials.
10 11
12: Chad Rogers of Kress

Corporation, right, in discussion
with visitors to his exhibition
stand.
13: The slag grinding team from

Gebr. Pfeiffer.
12 13
14: Stefan Seemann (left) and

York Reichardt (right) of Hum-
boldt Wedag. Stefan Seemann
presented on the topic of the
companys roller presses.
15: Frank Dardemann (left) of

Loesche takes a question on the
company stand.
16: The Global Slag field trip

visited the Dyckerhoff Lengerich
cement plant, which boasts
spectacular views from its 14 15 16
preheater tower...
slag as an alternative steel slag clinker (or slinker as Hatch dry slag atomisation process. Janice suggested
17: As shown by this colour- it was dubbed) rather than using a normal clinker that water granulation of slag involves complex sys-
fully decorated Feldbinder bulk
cement tanker, Dyckerhoff has reduces the CO2 output of the final cement by 589kg. tem design, high use of water, has explosion potential
recently celebrated its 150th Janice Bolen of Canadian company Hatch next and pollution potential. Dry slag granulation avoids
anniversary. spoke about recent developments in the Ecomaister- many of these downsides, through using...
Scan the QR code below or enter the bit.ly

code into your browser to read more about the
Global Slag Conference & Exhibition and see the
conference photo gallery....
See more
http://bit.ly/
2tnmCBu
17

14. TMB International Technical Seminar & Exhibition
14. TMB International
10-13 Technical
October Seminar & Exhibition
2017
14. TMB 10-13
International October
Technical 2017
Seminar & Exhibition
10-13
Kaya Palazzo Golf October
Resort, 2017
Belek, Antalya/ Turkey
Kaya Palazzo Golf Resort, Belek, Antalya/ Turkey
10-13
Kaya Palazzo Golf October
Resort, 2017Antalya/ Turkey
Belek,
Kaya Palazzo Golf Resort, Belek, Antalya/ Turkey
Main
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Gala Dinner: Ersel
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GLOBAL CEMENT NEWS: PRODUCTS & CONTRACTS Contents
Algeria: Another Gebr. Pfeiffer mill

Morocco/Indonesia: Cemengal
for Saoura Cement
updates on recent projects
T he Saoura Cement Company has ordered an
MVR 5000 R-4 mill from Gebr. Pfeiffer for a new
cement plant at Bechar. The 350t/hr raw cement C emengal says that a modular and port-
able Plug&Grind XL grinding station it is
mill will grind material to a fineness of 12% R90m supplying for LafargeHolcim in Layoune,
and the drive will have a power of 3800kW. De- Morocco is proceeding to schedule. No de-
livery for the mill is scheduled for the first half of tails regarding cost have been disclosed but
2018. The MVR mill is the fourth that Gebr. Pfeiffer the model has a cement production capac-
has received an order for in Algeria. ity of up to 0.22Mt/yr and a total installed
power of around 1500kW.
Menwhile, Cemengal has completed
Iraq: MAN Diesel & Turbo supplies the commissioning of a new modular
six engines to Chinese contractor Plug&Grind XL grinding station for Cemindo
in Benkulu, Indonesia. This is the third
G ermanys MAN Diesel & Turbo has delivered

six MAN 18V32/40 engines, including gensets
and mechanical equipment to CGGC-UN Power Co
such unit that Cemindo has installed in
the country.
Above: The Plug&Grind XL system from Cemengal offers producers the flexibility
(Gezhouba Group) in Samawah. CGGC is acting as to move grinding plants between sites in response to shifting demand patterns.
the engineering, procurement and construction
(EPC) contractor in a project building a 50MW cap-
tive power plant for a cement plant to be operated
by Kairat Al Abar Iraqi (KAAI). The engines will run Austria: UNTHA XR waste shredder
on heavy fuel oil (HFO) in base load mode. The ce- hits one million operational hours
ment plant is being built by Chinas Sinoma.
Pakistan: Power Cement orders

T he Austrian-headquartered shredding specialist UNTHA has just
dispatched its 150th waste shredder. The XR mobil-e is heading
to France where, when commissioned, it will process 25t/hr of com-
production line from FLSmidth mercial and industrial waste down to a size of 80mm or less.
Since its inception, the XR series has gone on to be installed in
P ower Cement has ordered a 7700t/day pro-

duction line from FLSmidth for its plant at
Nooriabad. The new line will be the third kiln at
waste processing facilities worldwide. Continued innovation means
the equipment has remained at the forefront of the industrial shred-
ding market. The XR technology has now racked up more than one
the site, run by Arif Habib Group. The engineer- million operational hours in waste to energy, cement installations
ing, procurement and supply contract includes and complex recycling plants.
a complete range of equipment from crushing
to packing and cement loading. No value for the
order has been disclosed.
The order includes an ATOX 55 vertical mill Above: UNTHA has
for raw grinding, an ATOX 25 vertical mill for coal dispatched its 150th
grinding, an EV 250x250 Hammer Impact Crusher, XR waste shredder
to a French client.
stacker and reclaimer systems for storage, a The design has now
ROTAX-2 rotary kiln with low NOx ILC calciner, a reached more than
JETFLEX burner prepared for future refuse-derived one million operating
fuel (RDF) use, an FLSmidth Cross-Bar cooler and hours across all
installations.
two OK 39-4 vertical mills for cement grinding.
Commissioning for the project is scheduled for the
end of 2018.
Germany: Record orders for Scheuch

Honduras: Cementos del Norte awards Fives
S cheuch Group says that it completed its 2016
2017 fiscal year with an order intake of over
flash dryer contract
Euro200m, its highest incoming order value ever
since the company was founded in 1963. The air
and environmental engineering company intends
F rances Fives has won a contract to supply an FCB Flash dryer for
Cementos del Nortes Bijao plant. The dryer will be installed on
an existing ball mill that was supplied and installed by Fives FCB in
to set up a branch office in Germany concentrating 2001 for a production capacity of 90t/hr of pozzolanic cement. Since
on the metal industry and to strengthen the links then the pozzolana content and moisture rate have increased. Once
between its two new subsidiaries in the US. operational the grinding plants drying capacity will rise.

CEMENT NEWS: EUROPE
Comment: An update on France
2017 is an anniversary
year for the French
cement industry as it marks the
bicentenary of Louis Vicats pio-
neering work into the creation of
artificial cement. The company
that bears his name, Vicat, is a major
force in the global cement industry to this day. However, the
French industry has suffered since the global financial crash
in 2007, with steadily declining production volumes, despite
a bounce in 2011. Lafarge was only able to maintain its inter-
national status through a merger with Switzerlands Holcim in
2015 and the arguments surrounding that merger of equals
are still playing out now with the resignation of the groups
chief executive officer in April 2017.
Thankfully, the industry started to recover in 2016 and
the signs are positive that this will continue into 2017 with
the presidential elections concluded. Sensing the rebound in Casting a
confident glance
2016, the head of the French building federation (FFB) placed
growth in construction materials volumes at 1.9% in December
2016 with a forecast of 3.4% growth for 2017 based on new
at the future!
residential housing. Naturally he used his position to lobby the
politicians in the run-up to the election and the FFB had carried
on in this vein, haranguing the new administration with 112 (!)
proposals to rebuild France.
The major cement producers broadly agreed with the
outlook in 2016, with LafargeHolcim describing the local con-
struction sector as growing slightly despite subdued public
spending on infrastructure and HeidelbergCement concurring.
Vicat was more effusive pointing to its 6% rise in sales volumes
to 2.9Mt in the domestic and export markets. It pinned the
recovery down to the last quarter of 2015. However, it noted
that the rise in volumes had compensated for a fall in prices
due in part to the increased exports. On this point, although
its outside the scope of this column, it would be fascinating
to know how much the European Union Emissions Trading
Scheme is stoking the French cement industrys recovery
through exports. HARDTOP Bimetal Castings provide
Investment has been returning to the market though with
Ecocem Frances order of a Loesche mill for a slag cement mill it
high wear resistance
is building in Dunkirk, the inauguration of a new tyre recycling increased durability
unit at Lafarge Frances Martres plant and the start of a gasifier reduced overall costs
project at Vicats Crechy plant in 2016. More recently Lafarge
France reported to the French press in May 2017 that it was
high efficiency
starting to consider contractors for a new production line at reduced expense for maintenance
the Martres plant, although there are fears that it might choose minimised downtime
a Chinese provider.
So far in 2017 the situation is on a knife-edge with La-
raised production
fargeHolcim, HeidelbergCement and Vicat all reporting slight added profit
declines in sale volumes or earnings that they have blamed
on the weather. However, LafargeHolcim did mention grow-
ing momentum towards the end of the period, offering
some hope. As seen above the fundamentals for the French Reichelstrasse 23
cement industry are all ready and present for growth. Now D-39124 Magdeburg
with the new pro-business europhile president installed in of- Germany
fice, the industry should be about to flower in time for Louis
Vicats anniversary.
phone: +49 (0) 391 532969-0
fax: +49 (0) 391 532969-21
e-mail: sales@hardtop-gmbh.com
Global Cement Magazine July-August 2017 39 web: www.hardtop-gmbh.com
RUSSIG Frdertechnik GmbH & Co. KG
od
en ers
fo
uc
Auf dem Tigge 58 D-59269 Beckum
t
r
Tel. +49 (0) 2521-14091 Fax -13621
GLOBAL CEMENT NEWS: EUROPE Contents Subscribe Ad Index

H H H C F DD:8 5 6
Europe/Belgium: Cembureau names new President and Vice President

GIK (INTERNATIONAL) TRADE LIMITED
G onalo Salazar 5Leite
LARKRISE, MANOR hasWALK,
been WEYBRIDGE, SURREY KT13 8SD, ENGLAND.
appointed as the president of / 820026
TELEPHONE: +44-1932-856243
FAX NO.: +44-1932-856244
CembureauEVENING
, the European cement as-
PHONE: +44-1932-843099
sociation,E-for
Mail:a GIK@BTINTERNET.COM
two-year term at the
associations general+44
MOBILE: assembly held on
-7768-361540 VAT No. GB 409 8508 32
9 June 2017 in Paris. The vice-chairman
WWW.GIKINTERNATIONAL.CO.UK
of Secil has served as the associations
WE ARE A MAJORsince
vice-president SUPPLIER
2015. HeOF SPARES AND EQUIPMENT TO THE CEMENT INDUSTRY.
succeeds
HEREDaniel
WE LIST SOME OF THE ITEMS
Gauthier, the former chief execu-WE ARE ABLE TO SUPPLY:
ABB tive officer (CEO) Western Europe-Africa DRILLING EQUIPMENT LUHR FILTER
AERZEN MACHINES
and member of the managing board DUNLOP/BTR
of BELTING LURGI
ALFA LAVAL
HeidelbergCement, in the role. ELE MILLTRONICS
ALLDOS ELECTRICAL
Above: GonaloITEMS
Salazar Leite, the new president Above:PIV
Raoul de Parisot, the new vice-president
ANTONInPILLER
addition, Raoul de Parisot, advi- ENDRESS AND
of Cembureau. HAUSER POLLRICH
of Cembureau.
ARLsor to Vicats chairman and CEO, has ERWIN SICK ALL TYPES OF PUMPS
ATLAS
been COPCO
elected as the vice-president ALL of TYPES OF FILTERS REMA TIP TOP
AUMA FISONS ROTEX
AUMUND
CembureauCHAINS
for a two-year term. HARTMANN AND BRAUN
Germany/Austria: Cemtec suppliesSAACKE 170t mill
AVELING LeiteBARFORD
said that he intends to focus HAUSHAN SCHENCK
BEUMER HAUSHERR emtec DRILLING SCHEUCH
on supporting the industry on the path
BAUER
BBC towards its low-carbon targets, framing
BEARINGS
the associations European Union (EU)
HAZEMAG
HEKO C has transported a 170t cement
SEW
quarters in Enns, Austria to a client inSIEMENS
HERION diameter of 4.6m, an outside diameter ofSOLYVENT
grinding mill from its head-
Bavaria. The mill had an internal
5.2m and a length VENTEC of over 17m.
BOGE HIBON STAHL
CATERPILLAR
policy discussions in a wider interna-
HPI TEREX
The mill could not be carried on motorways, forcing the use of minor
CLARKE
tional VME
context and contributing to the HYDAC roads and waterways, including the River UNTERTAGE
Danube. Extra vehicles were
COMPRESSOR
true image ofSPARES
the industry. INGERSOLL needed RAND
to help with inclines of nearly 14% VAG andARMATUREN
a number of electrical and
CONVEYOR BELTING KSB VENTOMATIC
ALL TYPES OF CRUSHERS LINCOLN HELION
telephone cables had to be removed. TheVOITH time was eight days.
transport
DE LIMON FUHME LOUISE VOLVO
AND MANY MORE...WE SUPPLY ALL TYPES OF EQUIPMENT FROM THE FACTORY TO HEAVY EQUIPMENT.
IF YOU HAVE ANY ENQUIRIES FOR ABOVE ITEMS PLEASE CONTACT US ANYTIME, WE WILL BE HAPPY TO QUOTE.
Visiting cement equipment

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CEMENT NEWS: EUROPE
France: Judiciary launches LafargeHolcim

Syria enquiry
T he French judiciary has launched an inquiry into the

Syrian conduct of LafargeHolcim. Three judges, one deal-
ing with anti-terrorism matters and two financial judges, will
handle the probe, which opened on 9 June 2017, according
to Agence France Presse. The prosecutors will examine the
financing of a terrorist enterprise and whether the actions
of the building materials producer had endangered lives.
LafargeHolcim admitted in March 2017 that its staff at
a cement plant in Syria in 2013 and 2014 had struck deals
with armed groups, following an investigation by the French
newspaper La Monde in mid-2016. It is also alleged that deconox
Lafarge, one of the companies that merged to become
LafargeHolcim in 2015, purchased oil in Syria, in violation of
international sanctions. The groups chief executive officer
Eric Olsen then resigned after the completion of a review
into the affair in April 2017 despite not being found person-
ally culpable or even aware of the situation. However, the
review found that selected members of group management
had been aware of the situation at the time.
Germany: New cement division

head for BEUMER
M ichael Brachthuser has been appointed as the

head of Beumer Groups cement division. The 61-
year old was appointed to the role on 1 October 2016.
In this function, he controls and coordinates the global
competence center for this industry. The mechanical
engineer is responsible for the sales of the product
portfolio, the strategic development and strengthening
of the international sales team, the optimisation of the
overall sales structure and for smooth communication
between the group companies throughout the world.
Prior to joining Beumer, Brachthuser worked as
the sales manager for a plant engineering company
in the cement and ore industry, for an international
power plant builder and a supplier of equipment and
services for the
cement industry.
Beumer says that,
with Brachthusers SCHEUCH
appointment,
has added a highly
it
CLEAN SOLUTIONS
experienced spe-
cialist to its team. FOR THE INDUSTRIAL MINERALS INDUSTRIES
As an international market leader in the ventilation and

Left: Michael Brachthuser environmental technology sector, Scheuch GmbH always
is the new manager of the keeps up to date with the latest industry technology.
cement business sector at
the BEUMER Group.
The company provides trend-setting
complete solutions for dust filtration
and exhaust gas cleaning for the entire
Scheuch GmbH
cement production process. With the Weierfing 68
innovative emc, deconox and xmercury 4971 Aurolzmnster
Austria
systems, the Austria-based company Phone +43 / 7752 / 905 0
Fax +43 / 7752 / 905 65000
is once again proving itself to be a
Global Cement Magazine July-August 2017 41 global pioneer in the industry.
E-Mail office@scheuch.com
Web www. scheuch.com
PT17_210x297_INT_EN_Global_Cement_Magazine_BAU.indd 1 29.03.17 15:23
NEWS: EUROPE
UK: CPA frustrated at political deadlock
T he UK Construction Products Association (CPA) has
INTER-
expressed frustration about the political deadlock
that has resulted from the UK general election that
took place on 8 June 2017. The result saw Theresa Mays
NATIONAL
Conservative Party emerge as the largest single party
but without a majority in the House of Commons. It
is currently attempting to rule with support from the
VDZ
Democratic Unionist Party in a non-formal coalition.
From a business perspective, this is frustrating, said
Diana Montgomery, the chief executive of the CPA. We
CONGRESS
need certainty and clarity in order to address the serious
challenges and opportunities facing UK construction
over the next few years. Montgomery raised concerns
over the delivery of the governments National Infra-
structure and Construction Pipeline, the government
procurement process and its policy levers to address
skills and housing shortages and the costs of energy and
26 28
business rates to business. She added that she feared September Duesseldorf
that the industry was facing a period of greater insta-
bility at a critical time for our industry.
2018 Germany
Germany: New Karsdorf manager
O pterra, the German subsidiary of Irelands

CRH, has announced a change of plant man-
ager at its Karsdorf plant. Berthold Perschall, 50,
took over from Giuseppe De Donno on 1 June 2017.
De Donno has been in the post since July 2015 and
has left the company to pursue a new professional
challenge.
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Global Cement Magazine July-August 2017 43 www.vdz-congress.org
GLOBAL CEMENT: INTERVIEW Contents Subscribe Ad Index
Interview by Peter Edwards, Global Cement Magazine
In discussion: Michel McKittrick, Ecocem Ireland
The Irish slag cement producer Ecocem has been bucking the trend of cement sector
consolidation in Europe over the past few years as it has expanded both its production
base and product range. The company endured a tough time during the recession in
Ireland but has now positioned itself strongly for future challenges. Global Cement recently
caught up with Ecocem Irelands Managing Director Michel McKittrick to hear about the
past, present and future of the company...
Ecocem - Introduction and development It has been a very busy two years for Ecocem
Ireland. April 2016 saw the opening of our first UK
Global Cement (GC): Please describe the origins of import terminal in Runcorn, Cheshire and April
Ecocem and how it has developed over the years. 2017 subsequently saw the opening of our second
import facility in Sheerness, Kent. The capacity of the
Michel McKittrick (MM): Ecocem is an Irish-owned Runcorn facility was doubled in April 2017 due to
and headquartered company. It was established in the demands of the market. The Ecocem Group has
2000 by Donal ORiain who is still the Managing also seen the opening of an import terminal in Gvle,
Director of the Ecocem Group. He identified the op- Sweden and a manufacturing plant in Dunkirk,
portunities to use ground granulated blast furnace France is due to be operational at the end of 2017,
slag (GGBS) for construction projects in Ireland, further increasing the groups capacity.
France and the Netherlands.
The first plant to come online was the Orcem plant GC: Can you go into the Irish story in a bit
in Moerdijk in the Netherlands. It began operating in more detail?
2002. The Dublin plant in Ireland came online in 2003.
That plant was the first major supplier of GGBS to the MM: The Irish market has been a rollercoaster to
Irish market as only a very small amount had been say the least. Almost as soon as the Dublin plant was
imported up until that point. The barriers to entry commissioned in 2003 we entered the Celtic Tiger
were not too severe, as the UK market had been using period to around 2007, when growth was strong in
GGBS for a long time. The timing of the entry into the economy and infrastructure developments were
Ireland was good in that the economy was growing numerous. The country was investing massively,
strongly at the time. In 2007 the French construction particulary in highways and housing projects. Al-
materials group Saint-Gobain took a 30% stake in most 95,000 homes were built in 2006 alone. In that
the overall company and in 2009 the third produc- four year period, Ecocem grew from just entering
tion facility opened in Fos-sur-Mer in the south the market to running at full capacity, around
of France. 0.35Mt/yr.
Profile: Michel McKittrick

Michel McKittrick has been Managing Director of Ecocem Ireland,
which also covers Ecocem Groups UK activities, since October 2016.
Before taking up this position, he worked for the Irish arm of UK-based
engineering consultant Atkins. I was there for 16 years, from my graduate
days up until I moved to Ecocem, he explains. I worked in pretty much
every area that Atkins covers in Ireland, from highway projects to civil
works, the energy sector, asset management and management roles.
When asked why he made the switch, Michel replies, Ecocem was a
company that I had dealings with for around five years while working at
Atkins. It struck me as a company that was strong in Ireland commercially
and the culture that I had been exposed to while working with its staff was
very attractive. I liked aspects of the engineering consulting game but it
can be very frustrating when you work on a project that takes 10 years.
Above: Michel McKittrick, Managing
Director of Ecocem Ireland. Ecocem was a step change for me, a new and totally different challenge.

GLOBAL CEMENT: INTERVIEW
I think that something that also helps is that we are

selling one major product and we constantly highlight
its benefits. This is not a side-line for Ecocem and that
is apparent to our clients and the wider public.
Left: Ecocem has been
The advantages of the product are very appealing
selling bagged CEM III/A and
too, be they technical, architectural or environmental. bagged GGBS in Ireland
These three areas tick a lot of boxes for different types and the UK since 2013.
of people: engineers, architects, quantity surveyors,
farmers. People see it as a premium product and as-
sume that it has a premium price. When they hear
that they can have all of these advantages and that it
Of course, subsequently the country had an over- costs less than conventional concrete, we have a really
supply of houses and a massive crash in 2008. This strong selling position that convinces specifiers.
led to a Euro64bn bailout by the Troika (EU, IMF
and ECB) and our sales fell by 60-65%. At this point Technical
the company had to diversify to survive. Previously it GC: What are Ecocems products?
had been a case of import, grind, sell, with a strong
focus on the construction sector. We had to change MM: As well as GGBS we sell the two CEM III prod-
and entered the bagged market, for example, as well ucts that I mentioned, plus two admixtures. We make
as starting production of CEM III-A and CEM III C, these to facilitate greater early strength development
which is for back-filling of mines. We developed a for our pre-cast clients. This enables them to produce
full-time Innovation Department with PhD students using more GGBS and keeps the production sched-
and post-doctoral fellows at universities in Ireland ules the same as that of conventional OPC-based
and France. They look at a range of potential applica- cements.
tions: mortars, pre-cast, roof tiles, tile adhesives, soil
stabilisation and others. We already sell into these GC: Where does the slag come from?
areas but they are trying to identify ways to optimise
our product for each, as well as maximising the use of MM: We have a long-term partnership with Arce-
slag across the board. lorMittal, which supplies GGBS to us from France.
Since 2014 or so we have entered a third period in The group is also supplied by TATA and Edersa
Ireland of gradual growth. There is a new infrastruc- from Spain.
ture plan on the horizon and now we have a housing
shortage, especially around Dublin. The public fi- GC: Do you anticipate GGBS supply problems
nances are largely in order too. There is also a sense going forward?
that the EU is finding its feet again after a number
of set-backs. For example, the election of Emmanuel MM: Some producers have problems at the moment
Macron as the new French President adds some much and others will have problems in the future. There are
welcomed stability. deficiencies in Germany already and I understand
That said, the economy faces threats from a that independent concrete manufacturers will be
number of angles. We have significant direct foreign unable to produce CEM III there in the second half
investment from the United States, which is possibly of 2017.
something that could change due to
the Trump Administration. And, of
course, on the other side of Ireland is
the UK, where Brexit is hanging over
us. Its a dynamic that I wish we did
not have to deal with.
GC: How has the company grown Left: The Ecocem grinding plant
so fast since 2013, given the shaky in Dublin was the first facility to
economic fundamentals? supply GGBS to the Irish market
in appreciable quantities. It can
produce 0.35Mt/yr of GGBS.
MM: The growth has not been with-
out its challenges but we have had a
lot of support from our partners, par-
ticularly ArcelorMittal, with which
we have a long-term GGBS supply
contract at group level. We have also
had help from the banks.
www.GlobalCement.com Global CementMagazine July-August 2017 45

GLOBAL CEMENT: INTERVIEW
MM: Ecocem views it as a byproduct and its

production is carefully controlled. First, its
characteristics are closely monitored at the iron
plant. Secondly, the grinding at our sites ensures
that it meets the required specification. GGBS
is definitely not a waste. The important thing
is that we all reduce the need to manufacture
traditional cement and therefore reduce global
CO2 emissions.
GC: At our Global Slag Conference we recently

heard that, the moment one labels GGBS as a
Above: The Orcem terminal in Right: Work is nearing byproduct, some of the CO2 emissions that
Moerdijk, the Netherlands, was completion on a terminal in
came from the iron production step should be
Ecocem Groups first GGBS grinding Dunkirk, France. It will produce
plant. The capacity of the ball mill 0.75Mt/yr of GGBS once taken into consideration in the slag. What is
has recently been increased from operational by the end of 2017. your view on that stance?
55t/hr to over 100t/hr through the Ecocem is in nei-
addition of a KHD roller press.
ther of the above two MM: I dont buy into that to be honest. The reason is
camps due to our sup- that it is going to be produced as part of iron produ-
Below: The Sheerness import terminal in Kent, UK was opened in April 2017. ply agreement with tion. We can either use it or send it to landfill. There
ArcelorMittal, TATA is no call for us to take the CO2 emissions on the chin.
and others. Indeed
our French company Markets and future
is 30% owned by GC: How does Ecocem supply to customers?
ArcelorMittal. It will
continue to make MM: Bagged cement is sold to builders merchants
GGBS available to and we advertise on that basis to the trade and the
all three facilities, as wider public. The bulk products are sold to concrete
well as Dunkirk in manufacturers. They come to us, receive dry bulk and
the future. take it to their own stockpiles. We have previously
delivered to actual job sites but that is not how we
GC: What are the en- normally operate.
vironmental benefits
of Ecocems GGBS GC: What are the companys plans in the period
compared to conven- to 2020?
tional materials?
MM: I already mentioned the progress with the
MM: Ecocem Ire- Dunkirk project in France, which is an exciting
lands GGBS has site for us. It will be used to supply the Grand Paris
an Environmental Express rail project in France, which is building new
Product Declaration rail lines, motorways and other infrastructure in the
(EPD) provided to us period to 2030.
externally on an an- We are also attempting our first project outside of
nual basis. The EPD Europe, in the US. We have applied to set up a GGBS
states that the GGBS mill in Vallejo, California but it is facing some local
has an embodied CO2 opposition. However, in the past month a council
output of 42kg/t. That meeting was held and the result was fairly positive
compares to CEM I, from our perspective. The council agreed to conduct
at around 850kg/t or the environmental report, which was previously not
CEM II at 750kg/t. something it wanted to finalise. It has now seen sense
Regardless of what you and we should have more news to report on that front
Above: Ecocems Runcorn are comparing it to, we at the start of 2018. There are some other plans in
terminal in Cheshire, UK has a are at a massive envi- discussion but those are internal at the moment.
total silo capacity of 14,000t.
ronmental advantage.
GC: Michel McKittrick, thank you for your time.
GC: Does Ecocem view GGBS as a waste or a
byproduct? MM: You are most welcome!

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GLOBAL CEMENT: UK Contents Subscribe Ad Index
Aurelie Delannoy, Mineral Products Association
Brexit: Not about uncertainty, but priorities
This is a make-or-break moment for economists and government alike: trying to draw a
vision for the future of the UK economy at a time when the nation is redefining the very
foundations of its relationship with the rest of the world. One year on from the historical
vote on Britain leaving the EU, there is no doubt that the levels of emotion and uncertainty
still run high, but so do the opportunities. The UK economy, construction and mineral
products markets have all defied some pre-referendum expectations and have remained
resilient so far in this pre-Brexit period, but only by setting the right priorities will the
government ensure continued prosperity for the years to come. As Dame Margaret
Drabble, an English novelist, put it When nothing is sure, everything is possible. This article
will review the issues impacting on shorter and longer term prospects for the UK economy
and construction-related mineral products markets.
We cannot even be certain

2016 may have been one of the worst years
in history for economic policy and un-
certainty but, in many ways, 2017 started on a more
about the level of uncertainty!
stable and positive note. Domestically, the politics
of Brexit moved forward after the Prime Minister projects, such as the National Infrastructure Com-
Theresa May delivered her Lancaster House Speech mission and major projects such as Crossrail, the
and officially triggered Article 50, laying out the HS2 rail link, the Thames Tideway Tunnel and the
ground for the formal exit negotiations to begin. The Hinkley Point C nuclear power station are gradually
Conservative governments political focus also shifted being implemented. Housing has taken many years
to creating the right environment for the UK econ- to rise up the political agenda, due to a shortage of
omy to prosper. Consultations were launched on the affordable housing and the need to increase build-
Above: Aurelie Delannoy, Chief
Economist and Policy Executive at Housing White Paper to help reform the housing ing rates becoming ever more apparent. While such
the Mineral Products Association. market and increase the supply of new homes and on a policy developments could and should provide a
Green Paper for a new Industrial Strategy, which looks better long-term platform for the development of the
at how improvements to skills, research and infra- mineral products industry, there are also more im-
structure could drive much-needed long-term growth mediate challenges.
in productivity.
Elsewhere, the rise of nostalgic nationalism in A look back at 2016
Europe had slowed almost to a halt after the defeats In 2016 a feature of the UK economy, construction
of far-right contenders in Austria, the Netherlands and mineral products markets was their apparent
and France and the outlook for global economic resilience in the face of the anticipated economic
growth has significantly improved. fallout from the Brexit Referendum vote. The UK
This relative sense of stability was quickly knocked economy grew by 1.8% in 2016, driven by services
back by the announcement of a new General Election and, most particularly, consumer-facing industries
that was to be held on 8 June 2017. This was unex- such as retail, restaurants and hotels. This consumer-
pected, given repeated claims by Mrs May that there driven growth was helped by low inflation, good
would be no early election. This highlights that, these employment conditions, moderate pay growth and
days, we cannot even be certain about the level of historically low interest rates. Meanwhile, Brexit-
uncertainty! related uncertainty impacted on business investment
Regardless of the result, which has left the coun- plans in the run-up to the Referendum and resulted
try with a minority Conservative administration (for in an overall decline in business investment in 2016.
now), one area of economic policy that united all This resilience was also seen in construction,
major political parties remains the merits of infra- which grew by 2.4% in 2016 thanks to private hous-
structure investment and the need for an increase in ing and commercial office building. This was slower
housing supply. The slow recovery from the financial than the rates of growth seen in 2014 and 2015, but
crisis and the need to manage the UK economy after after two years of strong recovery, current trends
Brexit, has had the effect of putting more focus on may simply be viewed as a return to a more normal
policies that could drive greater economic growth, a regime. In addition, across construction mineral
break away from the dogma of austerity. Structures products markets to date, it is hard to find evidence
have been set up to identify, generate and fund of a slowdown in 2016, with sales volumes of aggre-

GLOBAL CEMENT: UK
gates, ready-mixed concrete and mortar up between critically on the performance of the housing and
4-4.5% in 2016 compared to the previous year, fol- infrastructure sectors, as the risks to medium-term
lowed by further growth in the first quarter of 2017. contributions from commercial and industrial con-
structions are tilted on the downside.
Headaches for forecasters While there is huge underlying demand for
This resilience has caused headaches for economists housing regardless of Brexit, there is also a huge
and forecasters alike, as they find themselves hav- problem of affordability or lack of affordability. The
ing to defend their role in understanding economic affordability of new housing has been subsidised by
policy. Their expertise is being directly challenged. the Governments Help to Buy scheme, which has
Contrary to some politically-motivated claims, supported 40% of recent new home sales. In these
most economists had not actually predicted the UK circumstances, the potential for much higher levels
economy to fall into a recession, but had indeed of housebuilding looks limited and the best that
anticipated a significant slowdown in the face of can be expected looks to be modest growth in the
Brexit-related uncertainties. Whats more, the error medium term.
margins and potential risks communicated around Higher infrastructure activity depends largely on
any central forecast were and still are unusually high, the progress of major schemes now underway or in
sometimes misunderstood and often simply ignored. the pipeline and the implementation of Highways
Pre-referendum forecasts of GDP growth rates of Englands Road Investment Strategy. There is no
2.3-2.5%/yr to 2020 (in the event of a Remain deci- question about the need for significant long-term
sion) have now been replaced with more subdued investment in energy generation and transmission
growth rates of 1.7% in 2017 and 1.3% in 2018, be- capacity, and Hinkley Point C will eventually contrib-
fore rising to around 2.0%/yr in 2019 and 2020. The ute to some of that much needed additional capacity.
referendum-induced Sterling depreciation is pushing The rail sector will be boosted by HS2 work in 2018,
up inflation and this is ex- and a back-loaded roads
pected to depress household programme should start to
spending, as prices rise faster have more significant impacts
than incomes. The continued on aggregates and related
uncertainty about the UKs markets from 2018, although
future economic model is this is subject to Highways
expected to inhibit business Englands ability to deliver the
investment in the short term, programme on schedule.
which will not help stagnant Applying these forecasts to
productivity. The low economic growth rate of 0.2% construction-related mineral products markets sug-
in the first quarter of 2017 is a probable early sign of gest that the strong recovery in sales volumes seen
these factors starting to make their presence felt. since 2013 will begin to flatten out in 2017 and 2018
These forecasts are made, of course, under the before picking up in 2019. By 2019, sales volumes of
looming shadow of the Brexit negotiations. While the ready-mixed concrete are expected to be 5% higher
long-term effects of Brexit on the UK economy are than in 2016, 4% for aggregates and by 9% for mortar
still being debated by Prime Minister May, economic volumes. Of course, markets could be subject to both
theory suggests that the level of trade and trade open- political and economic fallout. Furthermore, wider
ness are important determinants for growth and considerations also raise the question of the UKs
productivity. Unless the UK negotiates an unfettered capacity to build planned projects, especially if we
free trade agreement with the EU, increased trade factor in a potentially stricter immigration policy that
barriers and potentially lower levels of trade will could exacerbate existing skills shortages. However,
impact negatively on future growth. Additionally, the there remain structural reasons for substantial future
UK Government will also have to quickly renegotiate demands for mineral products.
existing EU trade agreements with third countries On the whole, and no matter the uncertainty
that the country will lose access to after Brexit. around these outlooks, the government has repeat-
Finally, existing free trade agreements between edly indicated that Brexit could create opportunities.
developed countries take no account of the service It is indeed a crucial time to reset economic thinking
sector, including financial services, which could have and policy. Sluggish productivity growth has been a
a particularly negative impact on the UK economy, in long standing issue for the UK economy and should
which 80% of output is due to services. be a top priority. As such, continued improvements
The latest forecasts for construction predict that in both public and private investment, including in
this economic background will have a similarly infrastructure and housing, should help. Success or
depressing impact on construction markets in the failure in ensuring economic prosperity is not about
short term, with slower growth of 1.0-1.5% in 2017- the uncertainty we face, but instead it is about the
18, before accelerating to around 2.0% in 2019. The priorities that we set.
realisation of such modest growth, however, depends
www.GlobalCement.com Global CementMagazine July-August 2017 49

GLOBAL CEMENT: EVENT REVIEW Contents Subscribe Ad Index
Global Cement staff
interpack 2017 - Reviewed
Interpack, the triennial and worlds largest packaging fair, took place in Dsseldorf May 4-10.
Reportedly 74% of the approximately 170,500 visitors travelled to Dsseldorf from abroad.
The 2865 exhibitors from 60 countries were spread over 19 exhibition halls. In alphabetical
order, Global Cement takes a look at some of the exhibitors most relevant to the building
materials sector.
1: The Arodo Bvba stand wel- Arodo Bvba BSW Machinery Handels-GmbH
comed building materials visitors
from around the world. Arodo specialises in the design of packing systems Manufacturer of FFS machines for sacks. (Part of
for complete packing lines and manufactures dos- Windmller & Hlscher KG Maschinenfabrik.)
ing, weighing, bagging, palletising and stretchhood
systems. Development, design and Concetti S.p.A.
manufacturing of the machines take An Italian manufacturer of (F)FS machines for bags,
place at the 115-staff head-office in palletisers, and big-bag filling systems, whose stand
Arendonk, Belgium. is shown below, Concetti presented its IGF automatic
Arodo produces bag filling machines bagging system, which, due to its small size, can be
for 1-5kg and 5-50kg for all bag types retrofitted into existing
and claims to be the only producer able plants; its IPF Bagging
to vacuum-pack large bags for products systems for small open-
1 like cement. It sells the product under mouth bags; its big-bag
the Arovac name and has supplied to fillings systems and its
numerous major cement and other building materi- Continua FFS packaging
als producers. system.
4
2: Gregor Baumeister of the
Beumer Group demonstrates the Beumer Group GmbH & Co. KG Condepols S.A.
Beumer Bag Tester, a portable Beumer Groups new Beumer Overall Operation This Spanish company, manufacturer of FIBC bulk
no-maintenance testing unit. Monitoring (BOOM) app enables staff to maintain containers also known as big bags, agricultural mesh,
an overview of relevant packaging line param- a range of industrial textiles and WPC, attracted visi-
eters on mobile devices, showing the status tors attention with its wide range of big bags.
quo of availability, performance and quality Among the products on display, visitors could see
levels as well as energy and compressed-air for themselves the most common big bags, such as
consumption, thus taking a further step the versions with one and four straps (D1 and D4
towards Industry 4.0. The BOOM app, adapt- respectively) and the most technical versions, such as
able to customers specific requirements, big bag Type C or Aquabag. Visitors to the stand, pic-
shows all filling, palletising and packaging tured below, were also present to see the latest model
lines with their most important parameters, launched by the company: The M-Cube, which is a
2 giving staff important data on the entire lines big bag with an automatic aperture.
effectiveness: its availability, performance and
quality or that of single machines, energy
and compressed-air consumption. Customers can
3: Bocedi Officina Srls impres-
sive stand at interpack 2017 was quickly evaluate all data, displaying them in a target-
popular with visitors. performance comparison or diagram.
5
Bocedi Officina Srl
The company has a 45-year history in
construction of end-of-line systems, Goldpack Zlatorog oprema d.o.o.
manufacturing shrink hood machines Goldpack is a Slovenian company specialising in the
and strapping and banding equipment fields of palletising (bags, packages, trays, boxes, bot-
and offers packaging line project plan- tles, kegs, shingles, rock wool etc.), stretch wrapping,
ning. Pallet sizes from 350x450mm to conveying, depalletising and shrink wrapping.
3
over 3600x1400mm can be handled.

GLOBAL CEMENT: EVENT REVIEW
Haver & Boecker Starlinger

Haver & Boecker (left) Starlinger leads the world market in
launched its Quattro System the field of machinery and process
Monitoring product, which technology for woven plastic sack
is a smart system that allows production, with the widest range of
real-time production and woven sack plant machinery and the
maintenance information on biggest range of possible products. 9
packing machines to be viewed Its product range covers all types
on a variety of devices, either of machinery for the production of 9: The Starlinger team at
6 locally or remotely via a secure modern woven polypropylene sacks, from extrusion interpack 2017.
connection. The system allows and winding to weaving, coating, printing, tubing,
machines to be operated more slitting, conversion, baling and recycling.
profitably and processes to be laid out and planned
more intelligently, and can also be retrofitted. TMI
Haver & Boecker also featured its newly- The company recorded a 20% increase
developed Roto-Packer RVT packing system and in business contacts, compared to
Elementra inline packer. Its subsidiary Newtec Bag interpack in 2014. TMI featured its
Palletizing displayed the Terram 1000 bag palletiser. high-speed Ilersac W bagger and the
The Feige Integra semi-automatic machines for Ilerpal W palletiser, two pieces of
filling of paper bags or canisters attracted special equipment initially designed to bag and
attention. An enormous flow of visitors at the fair palletise plastic raffia (WPP) but which
graced the Haver & Boecker stand, keeping the teams are also able to work with paper, PE and 10
hands full, while the number of promising enquiries BOPP as well. In addition, interpack
ensured an excellent atmosphere. gave TMI the opportunity to bring 10: The very active TMI stand at
interpack 2017, which was 20%
together its distributors from around the world, cur- busier than in 2014.
Mllers Group - Maschinenfabrik Mllers rently numbering around twenty, as well as resuming
At interpack 2017 Mllers presented its innovations contact with many customers who visited the stand.
in consistently secure palletising and packaging,
including pallet-free packaging, in a space cover- Trapo AG
ing 450m2. According to Trapo AG proudly celebrated its 60th
Norbert Frenzel, Director anniversary on May 11th 2017, with
of Sales Mllers Group, over 200 guests present. The company
The extremely stable, reports that its building material sack
self-supporting, palletless palletisers stack precisely, neatly and
dispatch units (pictured compactly, even at maximum speed
right) impress with sig- and are individually matched to 11
nificantly lower packaging customers palletising needs. Exist-
costs - up to 60% savings ing systems can also be retrofitted
11: Trapos stand featured
are possible if the empty 7 with the latest control technology. The company advanced robots for packaging
pallet is omitted. addressed the hot topic of human-robot collabora- automation.
tion, and also demonstrated 24 volt technology for
Mondi secure handling of goods of up to 200kg weight.
Among other products, the Mondi team at interpack
12: The focal point at the W&H
(pictured below) showed the Hybrid Pro, a pasted Windmller & Hlscher KG Maschinenfabrik
interpack booth was the TOPAS
valve bag with a water-repellent outer ply for high- W&H is a prominent producer of FFS machines for SL FFS line with new Easy Control
speed filling of moisture-sensitive goods like cement. sacks, palletising machines, stretch hood machines, automation and operating mod-
ules that increase the machines
Mondi also manufactures a range of packing, sealing big-bag production lines and associated equipment,
intelligence.
and palletising systems for its bags. Over 2000 visi- along with its subsidiary companies
tors came to Mondis stand, and many of them took Garant Maschinen and BSW Machin-
the time to enjoy the ice cream cones served at the ery. As a specialist in machinery for
stand - wrapped in paper sleeves produced by Mondi. the production of flexible packaging,
said Chief Sales Officer Peter Stein-
beck, interpack is one of the most
8 important international trade shows
for W&H. This year, that importance
was underscored by the large num-
ber of international visitors and the
high-quality discussions we had at the
12
Windmller & Hlscher booth.

NEWS Contents
Peru: Gloria expands

lime plant
G rupo Gloria says that a

US$80m upgrade project at
its Cal & Cemento Sur lime plant
at Caracoto-Juliaca near Puno is
underway. Construction of a sixth
line at the site is scheduled for
completion for the end of 2017, ac-
cording to the Gestin newspaper.
The new line will increase produc-
tion by 1000t/day to 2000t/day.
The investment follows a US$120m
investment since 2012 that will see
the plants production capacity rise
Chain Conveyors Silo Dischargers
Conveying up to 1,000 t/h Discharging up to 1,000 t/h to 1Mt/yr by the end of 2017 from
just 0.13Mt/yr in 2013.
Mexico: New GCC CFO
G rupo Cementos de Chihua-

hua (GCC) has appointed Luis
Carlos Arias Laso as its new Chief
Financial Officer. Luis Carlos Arias
has worked for GCC since 1996 in
the Planning, Finance and Corpo-
rate Treasury functions.
Dominican Republic:
Sales up 7.5%
A ccording to Rayza Rodriguez,

the new president of Adocem,
the cement industry of the Domini-
can Republic recorded a 7.5% rise
in sales during 2016 compared to
2015, whereas it grew by 3.5% in
the first quarter of 2017.
US: Cemex terminals achieve Energy Star Challenge Dominican Republic: New
for Industry status local president for Cemex
T wo Cemex USA terminals in California have achieved the Environmen-

tal Protection Agencys (EPA) Energy Star Challenge for Industry status
by reducing their energy consumption by more than 10% each. The San
A lejandro Ramirez Cantu has
been appointed as the presi-
dent of Cemex Dominican Republic.
Diego terminal achieved a 12.2% reduction in 2016, compared to the prior Ramirez succeeds Carlos Emilio Gon-
year. The La Mirada terminal achieved a 23.2% reduction year-on-year. The zalez, who has held the position
Energy Star Challenge for Industry is a national call-to-action to improve since 2011, according to the Diario
energy efficiency by 10% within five years. Libre newspaper. Ramirez will also
The La Mirada and San Diego terminals reduced their energy consump- be responsible for the operations of
tion by completing projects and executing strategies to improve their Cemex in the Bahamas and Haiti. He
onsite energy intensity. Workers were educated on energy-management has worked for the building materi-
practices and procedures for the proper operation of plant equipment. Out- als producer since 2000, managing
dated light bulbs at the terminals were replaced with more energy-efficient operations in Thailand, Puerto Rico
LED lighting. The process of enhancing lighting at the terminals continues and Costa Rica.
in 2017.

CEMENT NEWS
French Guiana: Cementos Argos to

supply cement for Ariane 6 launch pad
C olombias Cementos Argos plans to supply 21,000t

of cement for a launch pad for the Ariane 6
launcher being built by the European Space Agency.
The Vicat - King
Argos is providing three different types of cement for German production
the project, which is scheduled for completion in 2018
and inauguration in 2020. The project has a budget of excellent performance
Euro600m and around 800 personnel are working on
the construction site.
US: HarbisonWalker starts work on Vicat apparatus,

refractory plant different models acc. to
EN, DIN, ASTM, BS
H arbisonWalker International has broken ground
on its new monolithic refractory plant at the Point
Industrial Park in South Point, Lawrence County, Ohio.
The US$30m plant was first announced in February
2017 and will be operational by early 2018. It will have
a production capacity of 80,000t/yr.
Automatic Vicat apparatus

Colombia: Three charged in Cemex acc. to EN 196-3, DIN 1164,
Maceo debacle ASTM C187
230 V / 50 Hz,
T he Office of the Attorney General is preparing
to present charges against three individuals in-
volved in the sale of property in Maceo, Antioquia
with delay timer
to Cemex for a new cement plant project. They

are Edgar Ramirez Martinez, the former deputy
director of Planning at Cemex, Camilo Gonzalez
Tellez, the former legal director of Cemex Colom-
bia and Eugenio Correa Diaz, the representative of
CI Calizas, which sold the property to the cement Computer controlled Vicat apparatus
producer, according to the El Tiempo newspaper. with 6 or 8 measuring places
The former employees of Cemex allegedly paid
acc. to EN 196-3, EN 480-2,
US$13.7m to Correa, despite being aware of the
fact that the property, which formerly belonged
ASTM 191, test method B
to the deceased businessman Jose Aldemar 230 V / 50 Hz
Moncada, was in the process of being expropri-
ated over unpaid taxes. It is also alleged that the
funds never reached the accounts of CI Calizas,
having been primarily used to pay off debts
of Aldemar Moncada.
TESTING Bluhm & Feuerherdt GmbH

Motzener Strae 26b 12277 Berlin / Germany
Phone: +49 30 710 96 45-0
Global Cement Magazine 53 www.testing.de info@testing.de
GLOBAL CEMENT NEWS: THE AMERICAS
US: Ada completes upgrade US: March shipments marginally down
T he Holcim US Ada plant in

Oklahoma, a member of Lafarge-
Holcim, has seen the completion of
T otal shipments of Portland and blended cement in the United States
and Puerto Rico were about 7.5Mt in March 2017, slightly less than
in March 2016, according to recent data from the United States Geologi-
its three-year, US$100m new kiln and cal Survey (USGS). In the first three months total shipments were around
modernisation project. The project has 19.0Mt, slightly up on the same period of 2016. The leading producing
boosted the plants capacity by 20%, states were, in descending order, Texas, California, Missouri, Florida and
raising its clinker capacity to 0.68Mt/ Alabama. These five produced 46% of all national shipments.
yr from 0.62Mt/yr. The upgrades allow Clinker production came to 6.2Mt in March 2017, a 3.1% rise com-
the plant to conform to the US National pared to March 2016. Clinker production for the year through March
Emissions Standards for Hazardous Air totaled 15.8 Mt, a 3.5% fall compared to the same period in 2016.
Pollutants (NESHAP) regulations. Masonry cement shipments of about 228,000t for March 2017 were
Mike Langan, Ada plant manager, down slightly from those in March 2016. The leading masonry-cement-
said, NESHAP is one performance consuming states were, in descending order, Florida, Texas, California,
standard thats fairly restrictive. New North Carolina and Georgia, which took about 60% of the months ship-
Source Performance Standards are the ments. Masonry cement shipments for the first three months of 2017
most restrictive environmental regu- were 587,000t, a 4.1% increase compared to the same period of 2016.
lations in our industry and this plant
meets that. It is much cleaner environ-
mentally (than before).
Brazil: Votorantims revenue falls by 14% in Q1
The upgrades make it possible for
the plant to increase its use of fuel
derived from scrap tyres, replacing at
V otorantims net revenue from its cement business fell by 14% year-
on-year to US$731m in first quarter of 2017 from US$848m in the
same period in 2016. The cement and steel producer blamed the con-
least 20% of the fossil fuel used in the tinuing decline on an 8% drop in cement consumption, which triggered
new kiln line. That change will make the lower sales volumes and prices. Negative currency exchange effects also
operation cleaner and more efficient, contributed to the situation as the country continued to suffer from the
supporting LafargeHolcims sustaina- on-going political crisis and the resulting negative effects on the local
ble-development goals. economy. The companys adjusted earnings before interest, taxation, de-
preciation and amortisation (EBITDA) for its cement division decreased
by 49% to US$60.9m from US$119m.
Outside of Brazil the group started up a 1.2Mt/yr expansion project
in Turkey in April 2017. In North America its good performance driven
by strong demand and cost optimisation helped to offset the groups
overall performance. In
China the group sold
non-core assets worth
Euro30m in May 2017.
Above: The Holcim US Ada upgrade is officially opened.
Mexico: Mexican housing chamber complains about cement prices in Baja California
A delegation of the Mexican housing development

and promotion chamber (Canadevi) in Baja California
has warned that construction companies are considering
LafargeHolcim and Cemex to stop rising prices, according
to the El Financiero newspaper. He added that the price of
cement rose by 32% year-on-year in 2016, by 15% in Janu-
increasing imports of cement due to the high price of the ary 2017 and by 12% in July 2017. Padilla also said that the
material in the local market. Jose Luis Padilla, president of chamber and building material firms had signed an agree-
Canadevi in the state, said that the chamber had asked ment to prevent prices rising above the level of inflation.
Peru: Production to pick up in 2H17 US: HeidelbergCement subsidiary to buy

Cemex assets
T he Association of Cement Producers (Asocem) has
forecast that cement production will grow by 1-1.5% in
2017. This is based on predicted growth in the second half C adman Materials Inc., a Lehigh Hanson company, itself
a HeidelbergCement subsidiary, has entered into an
of 2017 following a decline in production of 5.5% over the agreement to purchase the Pacific Northwest materials
last 12 months. Despite this, production continued to fall business of Cemex USA for US$150m. The deal comprises
in May 2017, by 6.4% year-on-year to 0.78Mt, although the seven quarries, five ready-mixed concrete plants and two
rate has slowed since April 2017. asphalt operations in Oregon and Washington.

Contents Subscribe Ad Index GLOBAL CEMENT: EVENT REVIEW
David Perilli, Global Cement Magazine
IEEE-IAS/PCA Conference 2017 - Reviewed
The 59th IEEE-IAS/PCA Cement Conference took place at the Telus Convention Centre in
Calgary, Alberta, Canada in May 2017. Global Cements David Perilli reports back on the
conferences most notable presentations and themes...
E d Sullivan, the Portland Cement Associations

(PCA) chief economist was in tub-thumping
mood at the 59th IEEE-IAS/PCA Cement Conference
the market. The crescendo of his presentation was a
prognostication of an extra requirement of 14Mt of
cement in 2021 and 2022. Sullivan concluded by say-
in Calgary, Canada that took place on 21-25 May ing that, We have the supply infrastructure in place
2017. The headline figures that the PCA put out in a right now.
press release was a forecast of a 3.5% rise in cement However, others were of the opinion that the
consumption for both 2018 and 2019. An eager audi- required cement could also come from vast excess
ence lapped it up. There was only one problem: little capacity in places like Vietnam, as well as from the
of this enthusiasm has yet translated into real sales. new McInnis Cement plant in Canada that will target
It was a tale of riches ahead. As Sullivan freely put it, exports to the US market.
Trump policies will impact cement But
we dont know what they are!
Sullivan broke down his forecast into
three sections that hinged around President
Trumps desired policy changes that will
each kick in from about the third quarter of
2019. At this point, owing to lack of informa-
tion about what the Trump administration
Left: The PCAs Chief Economist
actually wants to do, Sullivan freely broke Ed Sullivan wants the cement
open the assumptions. These covered issues sector to grab the infrastructure
such as a tax reform, infrastructure budget- opportunities that will come
ing, immigration reforms and more. He under the Trump Administration.
explained that all of these issues interact and
that reducing taxes could potentially push
up national debt, making infrastructure
spending harder.
Owing to the lack of specifics from the
current administration, Sullivan was forced
to resort to the more detailed plans of
Democratic presidential contenders Hillary
Clinton and even Bernie Saunders for nuggets of Elsewhere, the technical sessions at the conference
information of how a government might act. For contained a surprising amount of environmentally-
example, he used a breakdown of Saunders intended themed content given the recent change in leadership
infrastructure spend to try and predict how Mr at the US Environmental Protection Agency (EPA).
Trumps policies could play out. Increases in highway Through panel discussions on coping with National
building from the overall infrastructure spend in this Emission Standards for Hazardous Air Pollutants
context would be good news for the cement industry. (NESHAP), carbon tax schemes in Canada and Cali-
And as for Sullivans view on the impact of the Trump fornia and talks on practical carbon capture methods
border wall: overrated. at the plant level, a picture emerged of cement pro-
The new forecasts for 2018 and 2019 appear to be ducers actively engaging with climate change at their
a retrenchment given that the PCA was predicting own pace when not legally forced to do so.
growth of 4% for 2016 in the middle of that year. It For example, John Klines overview of CO2 capture
subsequently reduced its estimate to 2.7% for 2016 by technologies described different approaches emerg-
December 2016 after the presidential election. ing and trying to find their niche within various
However, its figures for 2017 and 2018 have by-product markets. Without the stick of legislation
increased since the December forecast. Sullivan pre- this may not be much more than the cement produc-
dicted that growth will start to surpass 5% in 2020 ers hedging the risk of government interference, but
once Trumps policies have time to fully impact upon it is happening, now.

GLOBAL CEMENT: EVENT REVIEW
The key here seems to be a piecemeal approach The technical papers covered a broad subject range
Above left: John Kline spoke
about the status of different CO2
across all the available options to cut CO2 emissions from general topics to automation, drives and more
capture technologies. from cement production. As Michael McSweeney on environmental advances. Highlights in the Gen-
the head of the Cement Association of Canada ex- eral Practices session included a paper on the Lehigh
plained, his country operates different carbon pricing Leeds cement plants increased use of synthetic gyp-
Above centre: Philippe Fonta of
the Cement Sustainability
systems in different Provinces and Territories, which sum and the resulting technical material handling
Initiative spoke at the IEEE-IAS/ points towards possible sub-national options in the challenges. Andy Edwards from Ash Grove Cements
PCA conference for the first time. US for climate-friendly states such as California. This presentation about retrofitting a separator provided a
is exactly the kind of talk that emerged in the general good story of coping with both a tight physical loca-
Above right: PCA President Jim
press once Donald Trump announced his intention tion and tight downtime timescales. Guillermo Etse
Toscas speaks at the Gala Dinner. to take the US out of the Paris agreement the week from Saxum took delegates off on an interesting tan-
after the conference. Companies, cities and states gent about how the mechanical properties of concrete
have resolved to meet their Paris obligations, even if affect the construction of concrete preheater towers,
the President doesnt think they need to. looking at aspects such as a horizontal displacement
The industrys suspicion of rules lingered from at differing operating temperatures. Also very inter-
PCA Chairman Allen Hamblens scepticism that the esting was the presentation of Stefan Thomas from
EPA would not change much even under its new Refratechnik, who spoke about refractory layout for
administration. Yet Klines comments about scale preheater vessels. He provided a succinct summary
summed up the general attitude of an industry often of steel corrosion with options on how to mitigate it.
attacked over its CO2 emissions but not necessarily Further on in the programme the Drives ses-
anti-environmental: Were not bad, were big. sion offered a link to the IEEEs roots in electrical
engineering. A previous speaker in a different
session set the scene perfectly with a comment
that although electricity comprises a small part
of a cement plants energy mix, it can become
its most expensive component. Presentations
such as that of Doug Phares from TMEIC
Corporation were thus music to the audiences
ears as he outlined how to reduce the power
demands of ID fans by using a low voltage slip
power recovery drive. Such was the improve-
Right: Delegates visit the ment that he promised savings of US$0.85m/
Lafarge Canada Exshaw plant as yr following the upgrade. Similarly, J George
part of the conference. Shown
Seggewiss from Rockwell Automations discus-
here is an FLSmidth OK vertical
roller mill for clinker grinding. sion about coping with high torque starts in
Credit: Xavier dHubert, new and retrofit applications carried promise.
combustion consultant. The IEEE/PCA Cement Conference will
next be held in Nashville, Tennessee, USA in
2018. It looks set to be a key event as more on
the US administrations infrastructure plans
become known and the new approach of the
EPA emerges. Will Mr Trump be the catalyst to
break the 5% growth barrier? Looks like well
have to wait until 2018 to find out.

Contents Subscribe Ad Index GLOBAL CEMENT NEWS: ASIA
Mongolia: MAK plant inaugurated

India: Cement plants to be built
next to power stations
P rime Minister J Erdenebat has attended the inauguration
ceremony of Mongolyn Alt Corporations (MAK) 1.1Mt/
A total of 15 companies have expressed inter-

est in building cement plants near to NTPCs
power stations. The electricity generation com-
yr cement plant at Dalanjargalan. The plant will create 900
jobs and replace cement imports worth up to US$75m/yr.
The unit will produce a range of different strength Ordinary
pany sought cement producers in early 2017 to Portland Cements, sulphate resistant cement and water-
submit expressions of interest for partnerships to resistant cement. Danish engineering contractor FLSmidth
build 1Mt/yr cement plants, according to the Mint won a Euro86m contract to build the 3000t/day plant in
newspaper. NTPC wants its partners to sign long- 2012. In conjunction with the project a 1.9km railway was
term agreements with it to exclusively use fly ash built from the Olon-Ovoot railway terminal and a 65km
and electricity from its power plants. The company power transmission line was set up from Choir.
has declined to name the companies that have ex-
pressed interest in the scheme. However, the power India: Puducherry proposes
plants it wants to set up cement plants near include subsidised cement scheme
Barh, Farakka, Bongaigaon, Dadri, Badarpur, Moda
and Aravali Power.
T he government of the Puducherry union territory has
proposed a subsidised cement scheme for low and
middle-income residents. The scheme will be named after
Bangladesh: Aman inaugurates plant former Congress President Sonia Gandhi, according to the
A man Group has opened its second cement grind-

ing plant at its Narayanganj complex, located 20km
south of the Bangladeshi capital Dhaka. The new plant
Press Trust of India. The project intends to emulate the
Amma Cement scheme currently running in Tamil Nadu.
Cement for the scheme will be procured outside of the re-
has a production capacity of 10,000t/day (~3.5Mt/yr). gion due to a lack of production plants.
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GLOBAL CEMENT NEWS: ASIA
Indonesia: Cement sales up Fiji: Production stops at Pacific Cement
T he Fitch credit rating agency says that

cement sales are starting to rise due to in-
creased investment in infrastructure projects
P acific Cement has stopped cement production due to a breakdown
at its plant. Acting Prime Minister, Attorney-General and Minister
for Economy Aiyaz Sayed-Khaiyum said that the cement producer
but that overcapacity will continue to limit im- stopped production in late May 2017, according to the Pacific News
provements in cement producers profitability. Agency Service. The government intends to allow people to import
The Indonesian Cement Associations (ASI) data cement duty free, as long as it meets the AS3972 standard, in order to
show that domestic cement sales volumes rose prevent a cement shortage.
by 7% year-on-year in May 2017 to 5.5Mt. Sales Pacific Cement supplies about 80% of the market in Fiji and it oper-
volumes for January to May 2017 increased by ates the only integrated plant in the country. The other local supplier
4% to 25.3Mt. in the market is Tengy Cement. Pacific Cement has also agreed to
Fitch has attributed this growth to a 13% sell 24,000t of surplus clinker to Tengy Cement following government
increase in sales of bulk cement, which is used intervention.
mainly for infrastructure-related developments.
By region, the main driver of the increase was
in central Java, where toll road projects are
Iran: Producers urged to target Russia
underway and where sales rose by 17%. De-
mand for bagged cement, which is generally
used for property developments, rose by 5% in
May 2017.
T he Iranian Chamber of Commerce, Industries, Mines and
Agriculture has urged cement producers to increase their ex-
ports to Russia to take advantage of rising demand there. Russian
Semen Indonesia increased its cement sales cement consumption is expected to reach 140Mt as it builds infra-
by 10% year-on-year to 11.5Mt in the first five structure for projects like the FIFA 2018 World Cup. Iran exported
months of 2017. The cement producer was 11.5Mt of cement in the 11 month period to 18 February 2017.
pleased with the result, despite competition Exports are hoped to nearly triple to 32Mt/yr by 2025, following
concerns and lower than expected government targets set by the governments Vision Plan.
infrastructure spending. Company commu-
nications chief Sigit Wahono added that the
company controls about 43% of the local mar-
ket and this has remained stable since 2012.
India: Cement sector to grow by 6-7%
Myanmar: Activists continue T he cement industry is expected to grow at 6-7% in the current
2017-2018 fiscal year, which runs from 1 April 2017 to 31 March
2018, according to HeidelbergCement India. The company said that,
resistance to cement plant
while infrastructure (including a focus on concrete roads), affordable
R esidents have signed a petition ask-

ing the Karen National Union (KNU)
to cancel the Min Lwin Mountain quarry
housing programmes and the prospect of a normal monsoon augur
well for the industry, oversupply may restrict the ability to pass on any
input cost increases.
and cement plant project. They say that
the plant could lead to environmental
concerns and land disputes. The Phyu Pakistan: Exports fall while domestic sales rise
Min Tun Company Limited started min-
eral tests at the site in 2014. However,
the KNU suspended the project in May
2016 in response to complaints lodged
C ement exports have continued to decline year-on-year for the fourth
consecutive month in May 2017, registering a fall of 44.6% according
to the All Pakistan Cement Manufacturers Association (APCMA). The decline
by the Min Lwin Area Natural Environ- follows a 45.7% year-on-year fall in exports in February 2017, a 60.4% year-
ment Protection Committee. Despite the on-year fall in March 2017 and a 50.8% year-on-year fall in April 2017.
cancellation, representatives of the KNU However domestic sales were up by 10.9% year-on-year for May 2017,
have continued to discuss the project reaching 3.4Mt, as compared to 3.1Mt in May 2016. Total dispatches during
with local residents leading to renewed May 2017 were 3.7Mt, as compared to 3.6Mt in May 2016, an increase of 2.4%.
opposition. So far in Pakistans fiscal year, which runs from 1 July to 30 June, domestic
cement consumption has increased by a healthy 10.8% to 37.6Mt against
35.5Mt for 1 July 2015 to 31 May 2016. Over the same period exports have
declined by 21.3% to 4.3Mt. A year earlier the figure was 5.5Mt. Exports to
Afghanistan more than halved from 206,000t in May 2016 to 97,000t in May
2017. Exports to India also declined, from 135,000t in May 2016 to 114,000t
in May 2017.
Industry experts have appealed to the government to take steps to boost
housing, as the sector is currently dependent on infrastructure projects. They
said that sustained growth in housing construction is essential to absorb the
additional capacities that will come online in the next two years.

Contents GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
South Africa: PPC blames poor financial year on credit rating downgrade
P PC has blamed its poor performance

in its financial year to 31 March 2017
on a poor credit rating from S&P Global
in May 2017 and sales are expected to
rise as the plant ramps up production.
Meanwhile, the company says that it
Ratings. Its chief executive officer Dar- has substantially agreed the structure
ryll Castle complained about a liquidity and how it intends to implement a new
crisis caused by the downgrading of broad-based black economic empow-
PPCs credit ratings to junk status by erment (BBBEE) transaction. However,
S&P Global Ratings in May 2016. He also it is waiting for the release of the new
attributed the result to falling cement mining charter before proceeding, ac-
prices in South Africa and poor weather cording to the Star newspaper. Castle
in early 2017. has said that the cement producers
The cement producers earnings proposed merger with Afrisam is going
before interest, taxation, depreciation and amortisa- on in the background and that it would have to assess
tion (EBITDA) fell by 13% year-on-year to US$160m for the impact of the Afrisam transaction on the companys
its financial year that ended on 31 March 2017, from new BBBEE transaction.
US$184m in the same period in 2016. Despite this its
sales revenue rose by 5% to US$745m from US$711m
and its sales volumes rose by 1.6% to 5.54Mt from 5.45Mt. Saudi Arabia: Al Safwa agrees ash use
PPC reported that its 1Mt/yr production line at PPC deal with Saudi Electricity Company
Slurry is on schedule for commissioning in the first half of
2018. Its 1.4Mt/yr plant in Ethiopia started selling cement
S audi Electricity Company (SEC) has signed a co-op-
eration agreement with Al Safwa Cement Company
to reuse carbon ash and oil residue byproducts that
result from the burning of heavy fuel in power genera-
Iraq: Chinese firm to build new plant
tion plants. They will be used as an alternative source of
C hina North Industries Corporation (Norinco) has signed a

US$445m deal with Jabal Bazian Co for General Trading to
build a cement plant. The contract includes the plants pro-
energy at the cement plant, instead of being landfilled.
Khalid Bin Abdulrahman Al Tuaimi, the executive vice
president for the generation at SEC, pointed out that
duction line design, purchasing, construction management, SEC was the first company to adopt this policy. This will
operational work as well as assorted administration build- reduce the dependence of the cement plant on heavy
ings, dormitories, dining halls and other facilities. The plant is fuel, thereby reducing dependence on oil, which is a key
scheduled for completion in the second half of 2019. element of the Kingdom Vision 2030 to restructure the
national economy, he said.
Congo: Dangote plant to produce in July
N igerias Dangote says it will deliver the first batch of 42.5

R grade cement from its new 1.5Mt/yr US$350m cement
plant at Mfila near Brazzaville in July 2017. The plant was com-
Mozambique: Cement imports to
become subject to quality controls
pleted in May 2017 and it is currently undergoing testing.
A lfredo Sitoe, the general director of the National
Norms and Quality Institute (INNOQ), has said that
all cement imports must be tested for quality. The new
Ghana: Ghacem starts academy and app
legislation was set up in July 2016 but took effect in Jan-
G hacem has launched its first ever cement academy and

a mobile app that is designed to equip block makers to
expand their knowledge regarding cement usage. Accord-
uary 2017, according to the Mozambique News Agency.
Cement importers are required to provide origin details
to the INNOQ, which will then check certification with
ing to the company, the latest innovation stems from three the relevant organisation in the exporting country.
principles; Developing a premium brand, professionalism and
facilitating easy transactions among its stakeholders.
Cameroon: Mira project moves forward
Guinea: Diamond Cement awarded loan
M iras plans to build a 1Mt/yr cement plant have taken
a step forward with an investment of US$55m. The
D iamond Cement Guinea has been awarded a US$22.5m

loan from the African Development Bank (AFDB) to build
a 0.5Mt/yr cement grinding plant at Souguta. Overall the
investment is a continuation of an agreement signed
with the government in late 2015, according to the
African Press Agency. The project intends to use a 2013
AFDB has pledged around US$37.5m for the project to the ce- private investment incentives law granting tax exemp-
ment producers owner Wacem. tions over a 5-10 year period to set up the plant.

GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Egypt: Egyptian Cement angling for Egypt: EMG to build US$300m plant
US$221m plant loan
E gyptian Cement has started negotiations to secure a

US$221m loan to finance the construction of its first cement
Islam Solaiman, the vice chairman of the Electro-
Mechanical Design Group (EMG), says that the group
plans to build a US$300m cement plant in Foukah,
plant in Sohag province. The cement division of Egyptian Group Marsa Matrouh. The plan follows the group securing ce-
is dealing with a consortium comprising the National Bank of ment licence prospectus documents and it has started
Egypt, Banque Misr, CIB and Arab African International Bank, ac- preliminary studies, according to the Daily News Egypt
cording to the Al Mal newspaper. The total cost of the new 2Mt/ newspaper. The plant will supply cement to the north-
yr plant is estimated at US$276m. Egyptian Groups chief execu- west Matrouh governate and it may export cement to
tive officer Ahmed Abu Hashima set up Egyptian Steel in 2010. Libya and other countries.
Israel: Commission investigates dumping claims
D anny Tal, the Trade Levies Commissioner at the Ministry

of Economy and Industry, is investigating a claim that
cement from Turkey and Greece is being dumped in the
processes, physical attributes, marketing channels, the use
and the treatment by consumers, said Tal.
The countrys biggest cement producer Nesher sup-
local market. The Melet Har Tuv Company originally made ported the claim in April 2017 and this helped initiate the
the claim to the ministry, according to the Globes business investigation. Data provided by Har Tuv to the Trade Levies
newspaper. In its claim Melet Har Tuv alleged that cement Commissioner suggest that the market share of the local
normally sold in Greece was being sold for about 85% of cement companies has fallen following the increase of
the value in Israel. imports. Neshers market share fell to 65% from 75% and
The complainant has reasonably proved that it manu- Melet Har Tuvs share fell to 5.8% from 10%. It is alleged
factures in Israel goods that are similar to the imported that LafargeHolcim is the main company flooding the
goods regarding the raw materials, manufacturing local market.
Somaliland: Berbera plant to be renovated
T he government of Somaliland, an autonomous region

of Somalia, has given ownership of the Berbera Ce-
ment Plant to Red Sea Cement, a new company formed by
Dahabshiil Group, Berbera Group and the Kuwaiti Kipco.
The joint venture plans to renovate the abandoned plant,
according to the Somaliland Press news website.
The 0.2Mt/yr integrated cement plant was originally built
by French and North Korean concerns in the late 1970s.
However, production ceased at the site during the civil war
in the 1990s.
Above: Nesher Cement is Israels largest cement supplier.
Namibia: Solar plant construction starts

Ohorongo Cement has signed a 15-year power pur-
O horongo Cement has held a ground breaking cer-

emony for a 5MW solar plant at its Sargberg cement
plant in North Otavi. The site is being developed and
chase agreement with SunEQ. Construction of the plant
will start once SunEQ has obtained a generation license
from the Electricity Control Board.
built by Germanys SunEQ and its local partner Hungileni.
The US$7.8m project is scheduled to start operation by
the end of 2017.
Electricity is of paramount importance to our
operations and constitutes 25% of our production re-
quirements. We are aware of the countrys precarious
energy situation and hence took the decision to tap
into the renewable energy resource which our country
is endowed with, said Hans-Wilhelm Schtte, Ohorongo
Cements managing director.

GLOBAL CEMENT: COAL
Osama Aly Ahmed, Independent Consultant & Khaled Ramadan Osman, Process Expert
The rise of coal mills in the Egyptian cement sector
Egypts cement industry is a crucial pillar of growth for the countrys economy but its
growth has been hampered by a complicated energy picture in the past few years. Natural
gas supplies have been reduced by the authorities, forcing the hand of cement producers
towards other fuels, mainly coal. For the first time, we have quantified the existing coal mills
in Egypt and identify the current and future projects.
T he Egyptian cement sector has traditionally

relied on natural gas, diesel oil and heavy oil.
However, a change of government policy since 2013
Build-ups and clinker temperatures will rise;
5. The refractory and castings will have to be changed

to promote exports of oil has left domestic industries, in most cases and the lifetime of castings is re-
the cement sector included, with significantly lower duced. The change to coal or petcoke will also
allocations of these fuels. change the coating profile inside the kiln;
In response, many cement plants have switched
to using imported coal for their operations, as well 6. Coal is significantly more dangerous to handle
as petcoke. This has not been without considerable than the other fuels, even petcoke, due to its low
expense, due to the need to purchase coal mills and ignition temperature and its auto-ignition poten-
make other alterations to the process. The choice of tial when stored. Comprehensive steps should be
coal mill supplier has often been based on price, avail- taken to protect the plant and its workers.
ability and the ease with which it can be incorporated
into the existing plant infrastructure. The changes by Heating values differences between fuels
the government have also prompted some producers It is really quite amazing that fuels are priced in terms
to look into the use of alternative fuels for the first of gross heat when only the net heat is employed.
time. Important factors that need to be considered Entrained water is lost as vapour. These two values
when any cement company switches to using coal or are far closer for coal than they are for the fuels that
petcoke are: the Egyptian cement industry has historically used,
as shown in Table 1.
1. The fundamental ability of the kiln to switch. In With coal, you get more of what you pay for. Also
many cases this includes changes to the burner notice that kiln production can rise by 3-5% when
configuration (or a new one) and steps to increase you replace oil or gas with coal. The amount of com-
the amount of primary air, possibly by upgrading bustion and exhaust gas also falls (See Table 2).
the primary air fan. The burner position may have
to be changed to take cooling zones into account;
Gross heat Net heat Difference
Left - Table 1: Comparison of
2. Changes may be needed to increase the clinker Coal (kCal/kg) 5500 - 7100 5400 -7000 2% gross and net heating values for
different fossil fuels.
cooler efficiency and total air flow, possibly by Oil (kCal/kg) 10,200 9700 5%
adding new fans or removing the Material Flow Natural gas (Nm3) 6200 5600 10%
Regulator (MFR);
3.There will be increased mechanical wear on cooler Egypt has installed 21 new
grates and cross bars when switching to solid fuels
due to increased snowman formation. The amount coal mills, four have been
of dusty clinker is also increased; converted from other use and
nine more are on the horizon...
4. The specification of the raw material will be
affected as:
Flame Combustion gas Total exhaust gas
The targets for lime saturation factor (LSF), Temp (C) (Nm3/million Cal) (Nm3/t clinker) Left - Table 2: Comparison of
SM and AM have changed due to the increased
Coal 2250 1.23 1360 characteristics of different fossil
amount of fuel used and its ash content; fuel flame in cement burners.
Oil 2350 1.31 1420
Some plants may have to add extra alkalines to Gas 2400 1.45 1550
combat the higher amount of sulphate in coal;

GLOBAL CEMENT: COAL
Company / plant name Mill supplier Mill type No. of Feeder Burner Designed Mill Actual Mill
Mills Supplier Supplier Throughput (t/hr) Throughput (t/hr)
Misr Cement Qena FLSmidth ATOX 25 1 FLS Pfister FLSmidth 47 53
Wadi El Nile Cement FLSmidth ATOX 25 1 FLS Pfister FLSmidth 50 50
Arabian Cement FLSmidth ATOX 25 2* FLS Pfister FLSmidth 50 70
Sewedy Cement FLSmidth ATOX 25 1 FLS Pfister FLSmidth 45 55
Sinai Cement (Vicat) FLSmidth ATOX 25 2 FLS Pfister FLSmidth 46 50
Nahda Cement HCRDI Sinoma ZGM 133 N 1 FLS Pfister Fives Pillard 48 50
Sinai White Cement HCRDI Sinoma ZGM 133 N 2 FLS Pfister Fives Pillard 20 22
Royal El Minya Cement HCRDI Sinoma ZGM 133 N 1 FLS Pfister Fives Pillard Not publicised
Arish Cement Sector A HCRDI Sinoma ZGM 133 N 2 FLS Pfister Fives Pillard 45 Not publicised
Medcom Cement HCRDI Sinoma ZGM 133 N 1 FLS Pfister Fives Pillard 45 Not publicised
Beni Suef Cement (Titan) Gebr. Pfeiffer MPS 2800 BK 1 FLS Pfister Unitherm 50 50
Gebr. Pfeiffer MPS 225 BK 1 FLS Pfister Unitherm Not publicised
Alexandria Portland Cement (Titan) Gebr. Pfeiffer Not publicised 1 FLS Pfister Unitherm 50 52
El Minya Cement Gebr. Pfeiffer MPS2800 BK 1 FLS Pfister Fives Pillard 50 55
BMIC Cement Gebr. Pfeiffer MPS2800 BK 1 Not publicised
Helwan Cement (HeidelbergCement) Gebr. Pfeiffer MPS 3350 BK 1 FLS Pfister FLSmidth Not publicised
Misr Beni Suef Cement thyssenkrupp CR1.TM01 (B) 2 Schenck Fives Pillard 45 Delayed by funding issues
Amreyah Cement (Intercement) Christian Pfeiffer M.A.S/7/KO.EG (B) 1 Schenck Unitherm Not publicised
M.A.S/8/KO.EG (B) 1 Schenck Unitherm
Suez Cement (HeidelbergCement) Other Conversion (B) 1 Schenck Unitherm Completed
Qatamia Cement (HeidelbergCement) Other Conversion (B) 1 Schenck
Lafarge Cement Egypt (LafargeHolcim) Fives FCB Conversion (B) 1 Schenck Fives Pillard Not publicised
Assiut Cement (Cemex) Other Conversion (B) 1 FLS Pfister Unitherm Completed
Arish Cement Sector B Loesche LM 21.2D 6 Order announced in May 2017 - Delivery scheduled during 2017
National Cement Tendering at present
South Valley Cement Tendering at present
Tourah Cement (HeidelbergCement) Has not acted over environmental concerns
Helwan White (HeidelbergCement) Has not acted, possibly due to concerns over white cement quality
Above - Table 3: Details of coal Coal mills in Egypt Fives

and petcoke mills installed in 1
Egypt as at June 2017, with Others
The most acute years of the energy crisis and cuts mill
dosing and burner suppliers and 3 mills
FLSmidth
mill throughputs. were 2014 and 2015 but the country continues to
7 mills
Details of planned mill struggle with obtaining hard currency due to the
installations also shown. variations between the Egyptian Pound and interna- Loesche Conversions
(B) = Ball mill. All others 6 mills
tional currencies. Despite the headwinds, Egyptian
vertical roller mills.
* = One mill remains cement producers have now installed 21 new coal
under construction. mills, four have been converted from other uses and
a further nine are on the horizon (See Table 3). There Christian Pfeiffer HCRDI
are at least two more in the tendering stage. 2 mills Sinoma
Right - Figure 1: Market share 7 mills
of different suppliers of coal The mill suppliers are presented in order of
thyssenkrupp
mills in Egypt, once all tendered descending market share by total mills currently in-
2 mills
projects have been completed. stalled. The relative market positions by installed and Gebr. Pfeiffer
commissioned projects, effectively the positions held 6 mills
by the main players at the end of 2017, are shown in
Figure 1.
The Danish cement plant manufacturer time as other equipment, particularly burners opti-
FLSmidth is currently the leader in terms of coal mill mised for coal.
supply in Egypt, often reinforced by its preference Chinas HCRDI Sinoma is second in terms of total
to install mills through turnkey projects at the same equipment installed, but has the same number of

GLOBAL CEMENT: COAL
mills as FLSmidth. The company

Left: Bagged cement
has introduced medium-level awaiting dispatch from
technology that appropriately Arabian Cement Company. The
matches the needs of the cement company uses two ATOX 25 coal
sector in Egypt at its current level mills from FLSmidth, a system
that is very popular across Egypt.
of development. Source: Arabian Cement
Germanys vertical roller mill Company website.
specialist Gebr. Pfeiffer is in third
place, helped by its reputation for
advanced technology. A number
of other suppliers, including
renowned ball mill producers
Christian Pfeiffer and thyssen-
krupp / Polysius then follow, as
well as instances in which legacy mills have been Left - Figure 2: Vertical
79% 21% roller mills dominate Egyptian
converted from other uses in the plant. LafargeHol-
coal grinding to the tune of
cim and HeidelbergCement have made inroads into nearly four fifths.
Vertical roller mills Ball mills
this approach using internal know-how.
Loesche has been a relatively late entrant to the
Egyptian coal grinding market as it only secured its Summary
first contract for coal grinding in Egypt in May 2017. The fast pace of coal mill building in Egypt is begin-
The order from Arish Cement is for six identical mills ning to slow down following a couple of years of
as part of an incredible 18 mill order for a new six line intensive adaptation. The sectors reliance on Egyp-
plant in Beni Suef. tian oil and gas has fallen significantly and coal use
Once these mills have been supplied, Loesche has risen just as fast. The massive six coal mill order
will jump to joint-third place alongside its local rival from Arish Cement clearly points to coal now being
Gebr. Pfeiffer. It has numerous other references in accepted as the base fuel for the industry.
cement and raw meal grinding in Egypt and will en- The most advanced producers are now also
hance its position further when the Beni Suef plant is looking towards the use of alternative fuels as sup-
completed. This is due to be by the end of 2017. plementary solid fuels now that their kilns have been
adapted to run using solid fuels. Refuse-derived fuel
Mill type breakdown (RDF) is highest on the list of targets. Renewable
The proportions of different types of mill are shown energy projects like photovoltaic solar systems and
in Figure 2. There are 26 vertical roller mills and eight wind energy investment may remain tricky due to
ball mills, including four that have been converted ongoing economic and political headwinds, but the
from cement grinding to use for coal. The dominance sector will continue to grow strongly, supporting the
of vertical roller mills lies in their higher efficiency, development of one of the continents most populous
saving 7-10kWh/t of coal ground compared to an and cement-hungry countries.
equivalent capacity ball mill, despite their higher ini-
tial start-up costs. Ongoing savings are found in the
lower operating costs, which are around 30% lower
than the equivalent ball mill.
Left: Qatamia Cement plant,

now part of HeidelbergCement.
Source: Italcementi website.

GLOBAL CEMENT: PRICES Contents Subscribe Ad Index
Here Global Cement Magazine presents its monthly review of global ce-
ment prices, in US$ for easy comparison. Much more price information
Do you have your finger on the cement (including the latest information on prices and market trends through-
price pulse where you are? out the global cement industry from our price correspondents) is only
If so, Global Cement Magazine needs you! available to subscribers of Global Cement Magazine.
To get the latest prices, you should subscribe - See page 17. In
Send cement prices to this issue subscribers receive further information from several other
peter.edwards@propubs.com. countries not shown here.
Regular contributors receive a free

subscription to Global Cement Magazine!
India: All-india cement prices in the South African Province of Guateng. In
prices saw a decline of Botswana selling prices fell by 9% year-on-year
US$0.09/bag (50kg) month- due to increased imports from South Africa. PPCs
on-month in June 2017 to Zimbabwean operations saw selling prices fall by
US$5.31/bag, eroding some of 10% in US Dollar terms. This was not offset by the
the increases seen in the preceding introduction of a US$100/t import tax for cement
two months. While the west of the coun- introduced on 1 October 2016, suggesting that the
try saw prices increase marginally and most areas local market is significantly oversupplied with ce-
maintain their previous price increases, north and ment.
central regions have seen cement prices fall since
the start of the second quarter of 2017. Israel: As part of a complaint that foreign cement
Cement prices in the north and central regions producers are dumping cement in the Israeli
of the country decreased by US$0.16/bag month- market, the Melet Har Tuv company has stated
on-month to US$4.95/bag, retracing most of the that cement from Greece and Turkey is selling
gains due to the price increase in April 2017. Ce- for US$80/t and US$69.80/t respectively, causing
ment prices in the west increased by just US$0.03/ damage to domestic producers. It claims that the
bag month-on-month to stand at an average of same tonne of Greek cement would be sold for as
US$5.19/bag. In Gujarat they rose by as much as much as US$94.30/t in Greece.
US$0.45/bag.
Cement prices in the south have declined by Philippines: Eagle Cement Corporation has said
US$0.19/bag compared to May 2017, leaving that it intends to compete with cheap imports
prices at around US$5.70/bag. The decline in prices from China and Vietnam by bringing down its ce-
was led by Andhra Pradesh, Telangana and Kerala. ment prices in the Philippines. We hope to bring
Cement prices in the east saw a very small price down cement prices to make it more affordable to
increase of US$0.05/bag. In West Bengal prices the consumer, said the company in a statement.
were up to a local all-time high of US$5.73.bag. In
Hyderabad cement costs US$4.19-5.12/bag. Vietnam: The imposition of a 5% export tax on
Meanwhile, petcoke prices continued to cement is reported to be weighing down the in-
increase in the month of April 2017, reaching dustry, which has been facing a severe surplus of
US$94/t, up from US$88/t in March 2017. supply over demand in the local market.
Under the Decree No 122/2016/ND-CP, which
Southern Africa: In its Annual Report, PPC said took effect on 1 September 2016, if spending on
that prices across its southern African operations natural resources and energy for production
fell in 2016. It noticed a particularly large fall in bulk accounts for 51% or more of a given prod-
ucts price or higher, the 5% export tax
applies. The decree was raised with
Prices are for cement in metric tonnes, unless stated otherwise. Where a source has given a range, an aim to limit the export of natural
the published price is the minimum value. resources and minerals.
FOB {+ the named port of origin} = Free On Board: The delivery of goods on board the vessel at the According to Nguyen Quang
named port of origin (loading), at sellers expense. Buyer is responsible for the main carriage/freight, Cung, president of the Vietnam
cargo insurance and other costs and risks. Cement Association, there is
CIF {+ the named port of destination} = Cost, Insurance and Freight: The cargo insurance and delivery currently no basis to verify the
of goods to the named port of destination (discharge) at the sellers expense. Buyer is responsible for content of natural resources and
the import customs clearance and other costs and risks. energy costs. He said that they still
ASWP = Any safe world port. rely on the declarations of producers,
a potential loophole through which
Conversions to US$ from local currencies are as at the time of original publication.
unscrupulous firms could avoid tax.

GLOBAL CEMENT: THE LAST WORD
Spam holds up a mirror to us... and to our society. Its not pretty.
Robert McCaffrey Editorial Director, Global Cement Magazine (rob@propubs.com)
A s editorial director of Global Cement, I need my

email address to be out there so that anyone that
wants to contact me can easily do so. Lots of interesting
fungus; gadget; games; get hard; get it up; gift; gift card;
glasses; God; golf; Google; hack; hair; HDR; health;
healthcare; hearing; heart; herb; Hilary; Hillary; hips;
cement industry people do contact me, from all over the hired; Home Depot; home security; homeowners; hot
world, asking questions, sending the latest information, body; hot product; hottest; humanity; hummingbird;
proposing an article or presentation or asking about identity; inches; ingenious; insomnia; insurance; invest;
forthcoming events. Thats fine - I welcome these seri- investors; ip voice; islamic; Jesus; Karyab; Kelly; kidney;
ous emails. However, Ive recently realised that I was killer; Kohls; last longer; Latin girl; Latin ladies; Latins;
spending too much time dealing with spam. I might re- lbs; lease; limbs; limitless; limp; liver; loan; lock-down;
ceive 10,000 emails each week, and my junk filters were Lori; lottery; lotto; love making; Macys; make money;
set at a level that I had no false-positives. I might have to manhood; Mark Cuban; marriage; match.com; medical
wade through 400 emails each day to find the good stuff. alert; medicare; medicine; Megyn; Melissa; memory;
Finally, however, I realised that I was using a set of metabolism; Metformin; Mieoko; militants; military;
spam trigger words to decide what was spam: If an miracle; Mitsubishi; mobile; moles; mortgage; movies;
email had one of these words in its subject line, then it multi-tool; muscle; music theory; my wife; nails; naive;
was definitely not legitimate. I compiled a list of words Nasa; naughty; Navajo; Navy Seal; negative; Netflix;
that would automatically mean that a message was neuropathy; new car; new vehicle; NHS; notification;
junked. The number of spam emails that gets through NRA; numbers in nature; numerology; obesity; omg;
is now very low (perhaps 50 per day). I decided to share Oprah; orgasm; overnight; pain; pancreas; panic;
the list with you, since it reflects what society is think- parasite; pc game; pedicure; peeing; penney; perfume;
ing about (or at least what the spammers think society pharma; piano; pig; pizza; platinum; plywood; points;
is thinking about). Perhaps youll recognise some of the Pope; poplamp; portfolio; posture; pounds; power bill;
terms from the spam that you receive yourself? Ive taken prescription; prestige; prime video; printer ink; promo-
the very rudest words out of the list, but here are the rest: tion; prostate; protein; psoriasis; Putin; ransomware;
#1; %; $50; 20/20; 6-pack; addiction; ADT; adult; razor; read music; realistic; regrow; reiki; Reilly; rem-
aircraft carrier; alcohol; alibaba; Alzheimers; amazing; edies; reward; ripped; romance; roof; roofing; Russian
amazon code; angel; Angelina; angry; Aniston; anxiety; bride; Sams Club; scandal; scientific; secret; senior liv-
apartments; arousal; arrears; Asian women; attacker; ing; sesame street; Seuss; sex; shame; Shark Tank; shed;
available coverage; awesome; background; bald; Bal- shock; shoot; simulator; single parent; singles; skin tag;
timore; batteries; beach; beautiful; belly; beneficiary; skinny; skyrocket; slash; sleep; slimming; smart money;
Bible; biblical; Bill Gates; billionaire; blackout; blinds; smartphone; snoring; solar panels; solution; stamina;
blood; blood pressure; blue pill; blueprint; boiler; boner; staycation; STD; step program; stiff; stock price; stomach;
bored; botox; brain; Brazilian girls; breaking news; stream; strength; strike pen; student; sucks; super hard;
breakthrough; Bunnings; business register; calories; superfood; surgery; surprising; survival; tactical; Tesla;
camera; candida; cannabis; cardio; cats; CDC; celeb- testosterone; timeshare; tinnitus; toenail; toner; tongue;
rity; cellulite; cherries; chiseled; cholesterol; Clinton; too late; towel; toxic; trick; true love; Trump; Uber; un-
CNN; cockpit; coconut; concealed carry; constipation; thinkable; urgent message; urine; vacation; veggie; video
container home; coolest; Costco; coupons; crazy; credit game; virility; virus outbreak; vitiligo; voucher; vulgar;
card; criminal; cruise; CVS; dating; deals from Amazon; Walgreens; wallet; Walmart; warning; warranty; wealthy;
debt; Degeneres; dementia; dentist; depression; diabetes; website; weight; weird; whitening; window; woodwork-
diet; disabled; discount; disease; Disney; disturbing; dog; ing; workout; wrinkle; Xerox; yeast; yoga; young woman;
dollar; Donald; dream; drink; DVD; Dyson; eharmony; youth; and finally, Zuckerberg.
electric; electricity; elixir; Ellen; Elllen; Elon Musk; em- Its a veritable A-Z of spam and it suggests that we are
barrassment; energy; enrolment; erect; erectile; erection; all vain, out-of-shape, weak and shallow, obsessed with
erotic; euro millions; exercise; exotic; Experian; expire; health, celebrity, status and sex. Were not, are we?
extra space; eyesight; Facebook; Fallon; family; fat; fiesta; Anyway, if you want to get an email through to me,
flashlight; flexor; flirting; floaters; flubber; flying; food; whatever else you put in, do not put any of the above
forget; Fox News; free gear; freshmen; frozen; fungal; terms in the subject line... itll go straight in the junk!

GLOBAL CEMENT: ADVERTISER INDEX Contents Subscribe
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July-August 2017
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EVOLVE THE TM
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Cover July 2017.indd 1 28/06/2017 15:19
Advertisers: July - August 2017

aixergee Aixprocess 21 Mersmann@aixergee.de www.aixergee.de
Aliapur OBC jmichels@aliapur.fr www.aliapur.fr
Alt Vellern 40 www.alt-vellern.de
Coal Mill Safety Pte Ltd 43 info@coalmillsafety.com www.coalmillsafety.com
DALOG Diagnosesysteme GmbH IFC, 3 info@dalog.net www.dalog.net
Elin Motoren 31 contact@elinmotoren.at www.elinmotoren.at
ENOTEC GmbH IBC juan.quintero@enotec.de www.enotec.de
Global CemFuels Conference 2018 31 rob@propubs.com www.CemFuels.com
Hardtop Gieereitechnologie GmbH 39 info@hardtop-gmbh.de www.hardtop-gmbh.de
HEKO Ketten GmbH 15 info@heko.com www.heko.com
Howden Group Ltd 27 cement@howden.com www.howden.com
KettenWulf 4 service@kettenwulf.com www.kettenwulf.com
Kima Echtzeitsysteme GmbH 47 contact@kimaE.de www.kimaE.de
Loesche GmbH FC Karin.Boeker-Mahr@loesche.de www.loesche.com
POWTECH 2017 42 visitorservice@nuernbergmesse.de www.powtech.de
robecco GmbH 8 robert.becker@robecco.de www.robecco.de
Scheuch GmbH 41 g.lechner@scheuch.com www.scheuch.com
Sika AG 9 leuppi.jeannine@ch.sika.com www.sika.com
TMB Conference Antalya 37 info@tcma.org.tr www.tcma.org.tr/ENG/
Testing Bluhm & Feuerherdt GmbH 53 info@testing.de www.testing.de
Total Lubricants 57 william.duchatelle@total.com www.lubricants.total.com
VDZ Congress 43 info@vdz-congress.org www.vdz-congress.org
Ventilatorenfabrik Oelde GmbH 23 info@venti-oelde.de www.venti-oelde.com
WTW & MHC Group 52 gramling@mhc-engineering.de www.mhc-engineering.de
info@wtwamericas.com www.wtwamericas.com
Xavier dHubert 21 xavier.dhubert@earthlink.net
Next issue: September 2017 Following issue: October 2017

Advertising deadline: 25 August 2017 Advertising deadline: 22 September 2017
Country report: Germany Country report: Russia, Turkey
Alternative fuels, Additives, Valves, Pneumatic Conveying Environmental protection, Coal for cement, Process Control,
Bulk dispatch, Rail distribution, Metal detectors Marine Transport, Loading
Distribution: Powtech, VDZ Cement Conference, RWM Event Distribution: TCMB, AUCBM
Event Reviews: Powtech, VDZ Cement Conference, RWM
To advertise: Paul Brown - paul.brown@propubs.com +44 (0) 776 74 75 998

Sren Rothfahl - soeren.rothfahl@propubs.com +44 (0) 7850 669169
Editorial contributions: editorial@propubs.com +44 (0) 1372 743 837
66 Global Cement Magazine July - August 2017 www.GlobalCement.com

REAL TIME FLUE GAS ANALYSIS
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Probe tube wall thickness of 5,4 mm
Yearly maintenance cycle only
Availability of Measurement
ENOTEC GmbH
Hher Birken 6, 51709 Marienheide, Germany | info@enotec.com
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Global Cement news Global Top 10 Bags Fans Bearings Slag Brexit Ecocem

Contents Subscribe Ad Index

JULY-AUGUST 2017 MAGAZINE

DALOG March 2017.indd 1 29/06/2017 13:01

DALOG March 2017.indd 2 29/06/2017 13:01

NEW HIGH SPEED CONVEYING

KettenWulf Betriebs GmbH T + 49.(0)2973.801-0 service@kettenwulf.com

Loesche: Since 1906, LOESCHE GmbH, has been constructing

Global Cement news

Loesche GmbH Hansaallee 243 D-40549 Duesseldorf

www.GlobalCement.com Global Cement Magazine July-August 2017 5

Global Cement articles

10 Top 10 cement producer profiles

18 Packaging cement the sustainable way

24 Fan and stack noise control - Stealth

28 Spherical roller bearings in tougher

32 In discussion: Chris Stern, Carbicrete CEO

34 Global Slag Conference 2017 - Reviewed

38 Product and contract news

An update on France; UK CPA frustrated at

44 In discussion: Michel McKittrick, Ecocem

48 Brexit: Not about uncertainty, but priorities

50 interpack 2017 in pictures

Cement in the Americas

52 American cement news

Middle East and African cement

61 The rise of coal mills in the 55

Regulars and comment 57

64 Global Cement prices

65 The Last Word

66 Advertiser Index & Forthcoming issue features

VDZ Annual Cement Conference 2017

14th TMB International Technical Seminar

17th Global Gypsum Conference

22nd Arab-International Cement Conference

TECHNOLOGICAL INNOVATIVE SYSTEMS

RGS robecco gas analysis system  2th Global CemFuels Conference

RDC robecco dust control

robecco GmbH Industriepark 17 D - 56593 Horhausen

Peter Edwards, Global Cement Magzine

Top 10 cement producer profiles

A lot has changed in the global cement industry

Figure 1 shows the Top 10 global cement produc-

10 Global Cement Magazine July-August 2017 www.GlobalCement.com

A nhui Conch is the largest cement company in

www.GlobalCement.com Global Cement Magazine July-August 2017 11

L afargeHolcim traces its history back to the found-

12 Global Cement Magazine July-August 2017 www.GlobalCement.com

F ollowing what CEO Bernd Scheifele described as

www.GlobalCement.com Global Cement Magazine July-August 2017 13

C hina National Building Materials (CNBM) is

T he modern-day Cementos Mexicanos (Cemex)

14 Global Cement Magazine July-August 2017 www.GlobalCement.com

HEKO Ketten GmbH

6. China Resources Cement 7. Taiwan Cement

S tate-owned China Resources Cement runs 44

I ndias largest cement producer is one of

10. Votorantim Cimentos

B razils Votorantim Cimentos saw its cement sales volumes fall by

16 Global Cement Magazine July-August 2017 www.GlobalCement.com

Independent thinking and analysis

JULY-AUGUST 2017 MAGAZINE

Global cement news

17th Global Gypsum Conference

RGS robecco gas analysis system 2th Global CemFuels Conference

First name:_Family name:____

Use phase of sacks Also includes sack breakage

Analytical & Advisory Services: Market

Business development: Technical articles