APRIL 2015

Responsible business
boosts performance at
Ramliya
Smashing the costs with
EnviroTex ™

Financing
paves the way in DR Congo
2 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 3

LETTER FROM THE PRESIDENT SCAN TO VIEW PER

MEJNERT KRISTENSEN CONTENT 8
INTRODUCE THIS EDITION cement.flsmidth.com
OF eHIGHLIGHTS gives you more details and

Leading the market

additional articles

A dynamic market needs a dynamic organisation. It is crucial for

us to have the right team that can help us navigate the cyclical
nature of our industry. And as the cement market enters a cyclical Editor-in-chief Letter from the President 2 FEATURES
upturn, we have adjusted our organisation to ensure we can best Nadia Haagen Pedersen
Managing editor Responsible business boosts
respond to customer needs.
Charlotte Lærke Backmann NEW ORDERS performance 8
Content editor
This edition of Highlights tells everyday stories that demonstrate New greenfield plant, Financing paves the way 28
Hanne Flyger
how FLSmidth continues to lead the market in supplying the
Associate editors CEMEX, Colombia 4
cement industry’s complete array of products, projects and Brenda Kaplan,
services based on premium technology and know-how. New line at CEMEX´s Odessa plant 4 SITE REPORTS
Bharathkumaar Soundararajan
Editorial board Two mills for MCC Qena 5 From wet to dry in a cold climate 16
Better products Mark Brugan, Palle Erik Grydgaard,
New HRP at Kanodia Cement 37 Pyro system and cement mills for
We are seeing increasing demand for products that deliver greater Sten Stoltze, Martin Strouhal, Hari TR
productivity, lower costs and higher energy efficiency as well as Copywriting: Eye for Image Manikgarh cement 23
lower harmful substance emissions. We are focusing on creating Layout: Anne Grethe Helmark INNOVATION
timely, innovative and competitive offerings, and I am particularly
Innovative TRIBOMAX wear solution 6 PRODUCTS & SOLUTIONS
proud of the special partnership with Haldor Topsoe (page 20).
© 2015 FLSmidth. All rights reserved. Revival of a MAAG Gear classic 14 Pumping up the power 24
Together, we have developed an innovative filter bag that can
Reproduction permitted quoting
remove dust, volatile organic compounds and NOx in one Smashing the costs with EnviroTex 20 New Hydraulic Roller Press concept 34
‘Highlights’ as source.
integrated process. This is innovation in partnership at its best.
Significant reduction in power
All product names used herein are
Other examples of our product development focus are the consumption 26 News in brief 38
trademarks of their respective owners.
Tribomax™ wear solution (page 6), our new hydraulic roller press New version of QCX automation
concept (page 34), the double-suction HAF fan (page 24), and the Editorial office:
software 33 Upcoming events 40
latest release of our software automation platform (page 33). FLSmidth
Vigerslev Allé 77
Industry challenges DK-2500 Valby, Copenhagen, Denmark 34 Highlights Cement subscription 40
Tel: +45 36 18 10 00
FLSmidth’s know-how extends far beyond the practical aspects of
Fax: +45 35 45 44 27
technology and processes. For new cement plants to see the light
Email: highlights@flsmidth.com Highlights Cement Reader survey 40
of day, financing is key, especially in developing countries such as
www.cement.flsmidth.com
DR Congo. On page 28 you can read about the complexities of
obtaining project financing that meets all parties’ interests.

A responsible approach to business, the environment and society

is central to our very existence, and with our Design-Build-Operate
concept, FLSmidth is focusing on the complete lifecycle of cement
20
plant operations. Read about a ground-breaking study that reveals SCAN HERE FOR
the total impact of the construction and operations of the ACC PDF VERSION OF
Ramliya Cement Plant in Egypt (page 8). THE HIGHLIGHTS
MAGAZINE

I hope the stories in this magazine provide some inspiration for

USE THESE QR CODES AS A QUICK WAY TO GET
how you, too, can achieve greater efficiencies and more return MORE INFORMATION VIA YOUR SMARTPHONE
on your business investments. OR TABLET. DOWNLOAD THE SCANNER AT
GETSCANLIFE.COM

FRONT COVER: AHMED SAYED NASER,

Per Mejnert Kristensen MECHANICAL TECHNICIAN AT EGYPT´S ACC
President, Cement Division RAMLIYA CEMENT PLANT. (SEE PAGE 8)
2 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 3

LETTER FROM THE PRESIDENT SCAN TO VIEW PER

MEJNERT KRISTENSEN CONTENT 8
INTRODUCE THIS EDITION cement.flsmidth.com
OF eHIGHLIGHTS gives you more details and

Leading the market

additional articles

A dynamic market needs a dynamic organisation. It is crucial for

us to have the right team that can help us navigate the cyclical
nature of our industry. And as the cement market enters a cyclical Editor-in-chief Letter from the President 2 FEATURES
upturn, we have adjusted our organisation to ensure we can best Nadia Haagen Pedersen
Managing editor Responsible business boosts
respond to customer needs.
Charlotte Lærke Backmann NEW ORDERS performance 8
Content editor
This edition of Highlights tells everyday stories that demonstrate New greenfield plant, Financing paves the way 28
Hanne Flyger
how FLSmidth continues to lead the market in supplying the
Associate editors CEMEX, Colombia 4
cement industry’s complete array of products, projects and Brenda Kaplan,
services based on premium technology and know-how. New line at CEMEX´s Odessa plant 4 SITE REPORTS
Bharathkumaar Soundararajan
Editorial board Two mills for MCC Qena 5 From wet to dry in a cold climate 16
Better products Mark Brugan, Palle Erik Grydgaard,
New HRP at Kanodia Cement 37 Pyro system and cement mills for
We are seeing increasing demand for products that deliver greater Sten Stoltze, Martin Strouhal, Hari TR
productivity, lower costs and higher energy efficiency as well as Copywriting: Eye for Image Manikgarh cement 23
lower harmful substance emissions. We are focusing on creating Layout: Anne Grethe Helmark INNOVATION
timely, innovative and competitive offerings, and I am particularly
Innovative TRIBOMAX wear solution 6 PRODUCTS & SOLUTIONS
proud of the special partnership with Haldor Topsoe (page 20).
© 2015 FLSmidth. All rights reserved. Revival of a MAAG Gear classic 14 Pumping up the power 24
Together, we have developed an innovative filter bag that can
Reproduction permitted quoting
remove dust, volatile organic compounds and NOx in one Smashing the costs with EnviroTex 20 New Hydraulic Roller Press concept 34
‘Highlights’ as source.
integrated process. This is innovation in partnership at its best.
Significant reduction in power
All product names used herein are
Other examples of our product development focus are the consumption 26 News in brief 38
trademarks of their respective owners.
Tribomax™ wear solution (page 6), our new hydraulic roller press New version of QCX automation
concept (page 34), the double-suction HAF fan (page 24), and the Editorial office:
software 33 Upcoming events 40
latest release of our software automation platform (page 33). FLSmidth
Vigerslev Allé 77
Industry challenges DK-2500 Valby, Copenhagen, Denmark 34 Highlights Cement subscription 40
Tel: +45 36 18 10 00
FLSmidth’s know-how extends far beyond the practical aspects of
Fax: +45 35 45 44 27
technology and processes. For new cement plants to see the light
Email: highlights@flsmidth.com Highlights Cement Reader survey 40
of day, financing is key, especially in developing countries such as
www.cement.flsmidth.com
DR Congo. On page 28 you can read about the complexities of
obtaining project financing that meets all parties’ interests.

A responsible approach to business, the environment and society

is central to our very existence, and with our Design-Build-Operate
concept, FLSmidth is focusing on the complete lifecycle of cement
20
plant operations. Read about a ground-breaking study that reveals SCAN HERE FOR
the total impact of the construction and operations of the ACC PDF VERSION OF
Ramliya Cement Plant in Egypt (page 8). THE HIGHLIGHTS
MAGAZINE

I hope the stories in this magazine provide some inspiration for

USE THESE QR CODES AS A QUICK WAY TO GET
how you, too, can achieve greater efficiencies and more return MORE INFORMATION VIA YOUR SMARTPHONE
on your business investments. OR TABLET. DOWNLOAD THE SCANNER AT
GETSCANLIFE.COM

FRONT COVER: AHMED SAYED NASER,

Per Mejnert Kristensen MECHANICAL TECHNICIAN AT EGYPT´S ACC
President, Cement Division RAMLIYA CEMENT PLANT. (SEE PAGE 8)
4 HIGHLIGHTS CEMENT – APRIL 2015
NEW ORDERS
CONTACT FELIPE ARANGO
FELIPE.ARANGO@FLSMIDTH.COM
New greenfield plant for
CEMEX,
Colombia
New greenfield plant for CEMEX
plant in Colombia
FLSmidth has been awarded a contract
from the Mexican cement producer
CEMEX for the supply of a 2,800 tpd
cement production line to be installed at
its new Cementera del Magdalena Medio
S.A.S. cement plant.
The plant is located approximately 135 km
from the capital of Antioquia, Medellin in
the department of Antioquia. The line will
use the latest production technologies and
achieve high environmental and quality
standards. The department of Antioquia is
a region in Colombia that is expected to
see an increase in cement demand
resulting from continued economic growth
as well as planned investments in
infrastructure.
In addition to engineering services, project
management, and commissioning, all
major processing machines are included.
The pyro processing line consists of an
FRM™ mill for raw grinding, an ATOX® coal
mill, 5-stage ILC preheater with a Low NOx
calciner, a FLSmidth® Cross-Bar® cooler,
and a two-pier kiln. Pfister® weighing and
dosing systems, MAAG® gear reducers,
gas analysers as well as all Airtech process
filters are also included.
CONTACT SCOTT ZOLOTSKY
SCOTT.ZOLOTSKY@FLSMIDTH.COM
Read more about new
orders on www.flsmidth.com/
announcements
New line
for CEMEX's
Odessa plant
FLSmidth has been selected to supply a new
cement production line to be installed at
CEMEX’s Odessa cement plant located in
western Texas, USA. The new 2,540 tpd
production line will help CEMEX keep pace
with the rapidly growing cement demand
from the oil and gas industry in the West
Texas market.
The expansion will utilise state-of-the-art
production technology resulting in higher
fuel efficiency and improved productivity.
The equipment scope includes a 5-stage ILC
preheater with a Low NOx calciner, 3-pier
kiln, FLSmidth® Cross-Bar® cooler, Duoflex®
burner, Pfister® weighing and dosing
systems, gas analysers and three Fuller-
Kinyon® pumps. Furthermore, an FLSmidth
control system will ensure the highest level
of operational efficiencies. The project will
be supplied on an EPC (Engineering,
Procurement, and Construction) basis.
NEW ORDERS
Two mills
for Misr Cement Company
FLSmidth is to deliver an ATOX vertical coal mill and an OK
vertical cement mill to Egypt’s Misr Cement Company (MCC
Qena), which will improve the plant's production stability and
ensure high energy efficiency.
MCC Qena has signed two contracts with
FLSmidth for the supply of an ATOX®
vertical coal mill, an OK™ vertical cement
mill, Pfister® weighing and dosing systems,
Maag® gear reducers and Airtech filters.
The plant is located in the Valley Sondos,
approximately 45 km from Luxor in Egypt.
FLSmidth supplied the equipment for MCC
Qena’s original 1.4 million tpy cement
plant in 1999. But in 2014, the plant had
an actual production of 1.8 million tpy of
clinker, without any modifications of the
line.
Key to the decision to choose FLSmidth's
equipment was the ability to meet MCC
Qena's high demands for performance and
reliability.
Alaa Abdel Hamed, Plant Manager, at
MCC Qena says: “We asked FLSmidth to
specify a set of production levels for the
equipment we required and as they were
able to do that, it confirmed for us their
reliability in delivering to our needs.
Besides, our existing line, which is based
on FLSmidth equipment, has performed
above expectations. Therefore, we trust
FLSmidth equipment and are convinced
the new equipment is the best choice for
our operations."
Stable production
Cement plants in Egypt face a unique
challenge in that the gas supply is quite
unstable. This can significantly affect
production, leading to clinker production
being at a standstill for weeks at a time.
HIGHLIGHTS CEMENT – APRIL 2015 5
Consequently, many plants have begun to
install coal mills in order to improve
production stability. This is a key reason for
MCC Qena choosing the ATOX 25 vertical
coal mill. The energy-efficient ATOX coal
mill grinds and dries all types of coal and
can be installed at a relatively low cost.
MCC Qena will also take delivery of an OK
42/4 vertical cement mill. FLSmidth’s OK
mill is one of the most reputable roller mills
for finish grinding of Portland cement, slag
and blended cements. In fact, it is the only
vertical roller mill specifically designed for
cement grinding and has been consistently
shown to use 15-20 percent (3-5 KWh/MT)
less power than other cement vertical roller
mills and 25-40 percent less power than
ball mills. The OK mill’s high energy
efficiency is expected to contribute
significantly to MCC Qena’s profitability
and competitiveness.
Anders Josefsen, General Manager, at
FLSmidth comments: “This contract with
MCC Qena reflects what we see as an
increasing demand for full-service solutions
based on standalone products. FLSmidth is
ideally positioned to meet this demand
thanks to our complete range of cement
plant equipment and services covering the
entire cement plant lifecycle – from the
initial plant project to maintenance and
upgrades.”
CONTACT ANDERS JOSEFSEN,
ANJO@FLSMIDTH.COM
Read more about new
OK™ Vertical Roller Mill at
www.flsmidth.com/okmill
Qena Cement
Misr Cement Company (MCC Qena)
was established in 1997, at which time
FLSmidth was contracted to construct
the cement plant. Production started
up in 2002 with an annual production
of 1.8 million tpy of clinker. MCC Qena
today employs around 420 people.
4 HIGHLIGHTS CEMENT – APRIL 2015
NEW ORDERS
CONTACT FELIPE ARANGO
FELIPE.ARANGO@FLSMIDTH.COM
New greenfield plant for
CEMEX,
Colombia
New greenfield plant for CEMEX
plant in Colombia
FLSmidth has been awarded a contract
from the Mexican cement producer
CEMEX for the supply of a 2,800 tpd
cement production line to be installed at
its new Cementera del Magdalena Medio
S.A.S. cement plant.
The plant is located approximately 135 km
from the capital of Antioquia, Medellin in
the department of Antioquia. The line will
use the latest production technologies and
achieve high environmental and quality
standards. The department of Antioquia is
a region in Colombia that is expected to
see an increase in cement demand
resulting from continued economic growth
as well as planned investments in
infrastructure.
In addition to engineering services, project
management, and commissioning, all
major processing machines are included.
The pyro processing line consists of an
FRM™ mill for raw grinding, an ATOX® coal
mill, 5-stage ILC preheater with a Low NOx
calciner, a FLSmidth® Cross-Bar® cooler,
and a two-pier kiln. Pfister® weighing and
dosing systems, MAAG® gear reducers,
gas analysers as well as all Airtech process
filters are also included.
CONTACT SCOTT ZOLOTSKY
SCOTT.ZOLOTSKY@FLSMIDTH.COM
Read more about new
orders on www.flsmidth.com/
announcements
New line
for CEMEX's
Odessa plant
FLSmidth has been selected to supply a new
cement production line to be installed at
CEMEX’s Odessa cement plant located in
western Texas, USA. The new 2,540 tpd
production line will help CEMEX keep pace
with the rapidly growing cement demand
from the oil and gas industry in the West
Texas market.
The expansion will utilise state-of-the-art
production technology resulting in higher
fuel efficiency and improved productivity.
The equipment scope includes a 5-stage ILC
preheater with a Low NOx calciner, 3-pier
kiln, FLSmidth® Cross-Bar® cooler, Duoflex®
burner, Pfister® weighing and dosing
systems, gas analysers and three Fuller-
Kinyon® pumps. Furthermore, an FLSmidth
control system will ensure the highest level
of operational efficiencies. The project will
be supplied on an EPC (Engineering,
Procurement, and Construction) basis.
NEW ORDERS
Two mills
for Misr Cement Company
FLSmidth is to deliver an ATOX vertical coal mill and an OK
vertical cement mill to Egypt’s Misr Cement Company (MCC
Qena), which will improve the plant's production stability and
ensure high energy efficiency.
MCC Qena has signed two contracts with
FLSmidth for the supply of an ATOX®
vertical coal mill, an OK™ vertical cement
mill, Pfister® weighing and dosing systems,
Maag® gear reducers and Airtech filters.
The plant is located in the Valley Sondos,
approximately 45 km from Luxor in Egypt.
FLSmidth supplied the equipment for MCC
Qena’s original 1.4 million tpy cement
plant in 1999. But in 2014, the plant had
an actual production of 1.8 million tpy of
clinker, without any modifications of the
line.
Key to the decision to choose FLSmidth's
equipment was the ability to meet MCC
Qena's high demands for performance and
reliability.
Alaa Abdel Hamed, Plant Manager, at
MCC Qena says: “We asked FLSmidth to
specify a set of production levels for the
equipment we required and as they were
able to do that, it confirmed for us their
reliability in delivering to our needs.
Besides, our existing line, which is based
on FLSmidth equipment, has performed
above expectations. Therefore, we trust
FLSmidth equipment and are convinced
the new equipment is the best choice for
our operations."
Stable production
Cement plants in Egypt face a unique
challenge in that the gas supply is quite
unstable. This can significantly affect
production, leading to clinker production
being at a standstill for weeks at a time.
HIGHLIGHTS CEMENT – APRIL 2015 5
Consequently, many plants have begun to
install coal mills in order to improve
production stability. This is a key reason for
MCC Qena choosing the ATOX 25 vertical
coal mill. The energy-efficient ATOX coal
mill grinds and dries all types of coal and
can be installed at a relatively low cost.
MCC Qena will also take delivery of an OK
42/4 vertical cement mill. FLSmidth’s OK
mill is one of the most reputable roller mills
for finish grinding of Portland cement, slag
and blended cements. In fact, it is the only
vertical roller mill specifically designed for
cement grinding and has been consistently
shown to use 15-20 percent (3-5 KWh/MT)
less power than other cement vertical roller
mills and 25-40 percent less power than
ball mills. The OK mill’s high energy
efficiency is expected to contribute
significantly to MCC Qena’s profitability
and competitiveness.
Anders Josefsen, General Manager, at
FLSmidth comments: “This contract with
MCC Qena reflects what we see as an
increasing demand for full-service solutions
based on standalone products. FLSmidth is
ideally positioned to meet this demand
thanks to our complete range of cement
plant equipment and services covering the
entire cement plant lifecycle – from the
initial plant project to maintenance and
upgrades.”
CONTACT ANDERS JOSEFSEN,
ANJO@FLSMIDTH.COM
Read more about new
OK™ Vertical Roller Mill at
www.flsmidth.com/okmill
Qena Cement
Misr Cement Company (MCC Qena)
was established in 1997, at which time
FLSmidth was contracted to construct
the cement plant. Production started
up in 2002 with an annual production
of 1.8 million tpy of clinker. MCC Qena
today employs around 420 people.
6 HIGHLIGHTS CEMENT – APRIL 2015
INNOVATION
Keeping the
rollers turning
Innovative TRIBOMAX wear solution for
hydraulic roller presses boosts performance
and prolongs roller lifetime.
FLSmidth’s TRIBOMAX® wear solution is a new roller press wear
surface designed specifically to withstand the demanding condi-
tions of grinding clinker, slag and raw mix. Its high resistance to
wear and surface overloading prolongs roller lifetime significantly,
making it a highly cost-effective solution for roller presses.
HIGHLIGHTS CEMENT – APRIL 2015 7
CONTACT DAVID DAM OLSSON Compared with traditional hardfacing solutions, which require
DDO@FLSMIDTH.COM frequent repairs resulting in downtime, the TRIBOMAX surface
requires limited or no repair. In the unlikely event that it becomes
damaged, it can be spot repaired in-situ and rollers and sleeves
can be refurbished as necessary.
Whereas some solutions are limited in rollersize due to complex
manufacturing requirements, our TRIBOMAX surfaces are suitable
“THE DURABILITY, for all aftermarket applications and can be applied to any rollersize
™
FLEXIBILITY AND EASE
at a short lead time. Rollers having applied TRIBOMAX surfaces
can be supplied either as solid rollers or as shrink-fitted solutions
that reuse the main shaft, which is an ideal way to reduce the
OF MAINTENANCE OF overall cost.
THE TRIBOMAX
SURFACE MAKE IT A What is TRIBOMAX?
HIGHLY COST-EFFECTIVE Tribology is the science and engineering of interacting surfaces
in relative motion. It includes the study and application of the
Normal hardfacing rollers are susceptible to premature failure when
SOLUTION WITH A LOW principles of friction and wear. The name TRIBOMAX is derived
the hard surface is overloaded by tramp metal or oversized materi-
als. A key property of the TRIBOMAX surface is its extreme tough-
TOTAL COST OF from this science.
ness, which makes it more durable and significantly less susceptible OWNERSHIP.” The TRIBOMAX wear solution is based on unique plasma
transfer arc welding deposit technology. This results in a pure
to damage compared with traditional hardfacing surfaces.
metallurgical composition with fewer impurities, such as cracks
and porosities, compared with conventional hardfacing.
The TRIBOMAX surface’s microstructure formulations give it a
special ability to achieve a high surface friction and an
Unique properties
autogenous wear layer.
The TRIBOMAX surface is based on known welding technology,
but its formulation and constituent components have been
TRIBOMAX surface highlights:
especially adapted by FLSmidth to yield outstanding
performance. FLSmidth selected the TRIBOMAX wear surface for • Longer wear life than traditional hardfacing solutions – more
its rollers after several years of careful research and testing, than 25,000 hours
including the evaluation of 20 different technologies. Not only • One wear solution for cement, slag and raw mix
has it shown outstanding wear properties, but also superior • Higher resistance towards tramp material than existing
toughness and unprecedented resilience towards hard particles hardfacing solutions
and tramp material. • Low maintenance and cost-effective
• Reduced risk of failure
Reduced total costs
• Low total cost of ownership
The TRIBOMAX™ surface is expected to give FLSmidth’s roller press
rollers a minimum life of 25,000 hours extending up to 40,000
hours. (read more on pages 34-37) As TRIBOMAX is an advanced
welding technology utilising high-end material formulations, the
purchase cost is higher than traditional hardfacing solutions.
However, the TRIBOMAX solution is lower priced than most
similar high-end solutions.
The durability, flexibility and ease of maintenance of the
TRIBOMAX surface make it a highly cost-effective solution with a
low total cost of ownership. Due to the flexibility of the welding
technology and FLSmidth process knowledge, the surface
thickness can be tailored to accommodate specific needs to
achieve a specified lifetime.
6 HIGHLIGHTS CEMENT – APRIL 2015
INNOVATION
Keeping the
rollers turning
Innovative TRIBOMAX wear solution for
hydraulic roller presses boosts performance
and prolongs roller lifetime.
FLSmidth’s TRIBOMAX® wear solution is a new roller press wear
surface designed specifically to withstand the demanding condi-
tions of grinding clinker, slag and raw mix. Its high resistance to
wear and surface overloading prolongs roller lifetime significantly,
making it a highly cost-effective solution for roller presses.
HIGHLIGHTS CEMENT – APRIL 2015 7
CONTACT DAVID DAM OLSSON Compared with traditional hardfacing solutions, which require
DDO@FLSMIDTH.COM frequent repairs resulting in downtime, the TRIBOMAX surface
requires limited or no repair. In the unlikely event that it becomes
damaged, it can be spot repaired in-situ and rollers and sleeves
can be refurbished as necessary.
Whereas some solutions are limited in rollersize due to complex
manufacturing requirements, our TRIBOMAX surfaces are suitable
“THE DURABILITY, for all aftermarket applications and can be applied to any rollersize
™
FLEXIBILITY AND EASE
at a short lead time. Rollers having applied TRIBOMAX surfaces
can be supplied either as solid rollers or as shrink-fitted solutions
that reuse the main shaft, which is an ideal way to reduce the
OF MAINTENANCE OF overall cost.
THE TRIBOMAX
SURFACE MAKE IT A What is TRIBOMAX?
HIGHLY COST-EFFECTIVE Tribology is the science and engineering of interacting surfaces
in relative motion. It includes the study and application of the
Normal hardfacing rollers are susceptible to premature failure when
SOLUTION WITH A LOW principles of friction and wear. The name TRIBOMAX is derived
the hard surface is overloaded by tramp metal or oversized materi-
als. A key property of the TRIBOMAX surface is its extreme tough-
TOTAL COST OF from this science.
ness, which makes it more durable and significantly less susceptible OWNERSHIP.” The TRIBOMAX wear solution is based on unique plasma
transfer arc welding deposit technology. This results in a pure
to damage compared with traditional hardfacing surfaces.
metallurgical composition with fewer impurities, such as cracks
and porosities, compared with conventional hardfacing.
The TRIBOMAX surface’s microstructure formulations give it a
special ability to achieve a high surface friction and an
Unique properties
autogenous wear layer.
The TRIBOMAX surface is based on known welding technology,
but its formulation and constituent components have been
TRIBOMAX surface highlights:
especially adapted by FLSmidth to yield outstanding
performance. FLSmidth selected the TRIBOMAX wear surface for • Longer wear life than traditional hardfacing solutions – more
its rollers after several years of careful research and testing, than 25,000 hours
including the evaluation of 20 different technologies. Not only • One wear solution for cement, slag and raw mix
has it shown outstanding wear properties, but also superior • Higher resistance towards tramp material than existing
toughness and unprecedented resilience towards hard particles hardfacing solutions
and tramp material. • Low maintenance and cost-effective
• Reduced risk of failure
Reduced total costs
• Low total cost of ownership
The TRIBOMAX™ surface is expected to give FLSmidth’s roller press
rollers a minimum life of 25,000 hours extending up to 40,000
hours. (read more on pages 34-37) As TRIBOMAX is an advanced
welding technology utilising high-end material formulations, the
purchase cost is higher than traditional hardfacing solutions.
However, the TRIBOMAX solution is lower priced than most
similar high-end solutions.
The durability, flexibility and ease of maintenance of the
TRIBOMAX surface make it a highly cost-effective solution with a
low total cost of ownership. Due to the flexibility of the welding
technology and FLSmidth process knowledge, the surface
thickness can be tailored to accommodate specific needs to
achieve a specified lifetime.
8 HIGHLIGHTS CEMENT – APRIL 2015
FEATURES
Responsible
business boosts
performance
"We believe strongly there
is a co-relation between
the big picture of corporate
social responsibility and the
bottom line performance
of our customer"
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
CONTACT MORTEN JESS NIELSEN
MJN@FLSMIDTH.COM
Egypt’s ACC Ramliya
cement plant doesn’t
just deliver a
utilisation rate 10
percent higher than
the industry average,
it beats industry
norms in energy
consumption and
emission reductions.
Cement plant operations have a significant
impact on the local environment and the
economy. But although this has long been
recognised, exactly what that impact is has
been the subject of much debate. With
cement production predicted to increase
by at least 50 percent towards 2050, the
challenge for the cement industry is how
to balance the world's requirements for
cement and the need to reduce CO2,
waste and other gaseous emissions.
In a bid to gain a comprehensive
understanding of a cement plant’s impact,
FLSmidth commissioned a ground-breaking
impact assessment of the Arabian Cement
Company (ACC Ramliya) Cement Plant in
Egypt. The assessment was performed by
the consultancy firms Deloitte and Qbis,
who have considerable experience in
assessing a business’s impact on society.
Morten Jess Nielsen, CSR Advisor at
FLSmidth, explains why the assessment
was initiated: “Responsibility to the
environment and society is central to
FLSmidth’s strategy, and we wanted to
understand the impact of our offering and
specifically how we create value.”
ACC Ramliya Cement Plant
Built by FLSmidth, the Ramliya plant
consists of two production lines, which
together have a production capacity of 4.2
million tpy.
Following its construction, Arabian Cement
Company chose to outsource ACC
Ramliya’s clinker production to FLSmidth
through a comprehensive operations and
maintenance (O&M) contract. In addition
to managing the plant’s daily operations,
FLSmidth recruits and employs the plant’s
entire operational staff. This 360-degree
knowledge of the ACC Ramliya plant
meant FLSmidth was ideally placed to
conduct a study of the plant’s impact on its
surroundings and stakeholders.
Shared value benefits all
The study identifies and describes four
essential aspects of the plant’s total
impact. In addition to economic,
environmental and social impacts, it
defines the business value proposition
delivered to the plant’s owners.
Thomas Westergaard-Kabelmann, partner
at Qbis, was responsible for the impact
assessment in collaboration with Deloitte.
He explains the importance of
understanding the entire perspective of a
cement plant’s operations and not just the
economic value delivered to the owners:
“The customer is only one part of the
puzzle; it’s important to see the complete
picture. Cement plants have a large impact
HIGHLIGHTS CEMENT – APRIL 2015 9
on the local environment and society, and
if you do good in one aspect of the plant’s
impact, it is likely to have a positive impact
on all the other aspects.”
He continues: “Delivering profits and
socio-economic benefits results in shared
value, and if ACC Ramliya can optimise its
social and environmental impacts, not only
will the customer benefit, but it will have a
positive impact on economic activity in the
region.”
Per Mejnert Kristensen, Group Executive
Vice President at FLSmidth sees the
performance of the ACC Ramliya plant as
the result of a long-term focus on
responsible business. He says, “We believe
strongly there is a co-relation between the
big picture of corporate social responsibility
and the bottom line performance of our
customer, and we are pleased to see that
the impact assessment from ACC Ramliya
demonstrates this co-relation.”
Outstanding utilisation
Not surprisingly, the study revealed that for
ACC Ramliya to make a positive
contribution to its surroundings, it needs
to perform well commercially. And ACC
Ramliya’s commercial performance tells an
outstanding success story. In the period
2010 to 2013, during which Egypt’s
cement production capacity expanded by
40 percent, ACC outstripped its
competition, increasing market share from
2.9 to 7.8 percent. Notably, Egyptian
cement consumption in this period
increased by only two percent.
Several factors contribute to ACC
Ramliya's excellent performance. >>
8 HIGHLIGHTS CEMENT – APRIL 2015
FEATURES
Responsible
business boosts
performance
"We believe strongly there
is a co-relation between
the big picture of corporate
social responsibility and the
bottom line performance
of our customer"
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
CONTACT MORTEN JESS NIELSEN
MJN@FLSMIDTH.COM
Egypt’s ACC Ramliya
cement plant doesn’t
just deliver a
utilisation rate 10
percent higher than
the industry average,
it beats industry
norms in energy
consumption and
emission reductions.
Cement plant operations have a significant
impact on the local environment and the
economy. But although this has long been
recognised, exactly what that impact is has
been the subject of much debate. With
cement production predicted to increase
by at least 50 percent towards 2050, the
challenge for the cement industry is how
to balance the world's requirements for
cement and the need to reduce CO2,
waste and other gaseous emissions.
In a bid to gain a comprehensive
understanding of a cement plant’s impact,
FLSmidth commissioned a ground-breaking
impact assessment of the Arabian Cement
Company (ACC Ramliya) Cement Plant in
Egypt. The assessment was performed by
the consultancy firms Deloitte and Qbis,
who have considerable experience in
assessing a business’s impact on society.
Morten Jess Nielsen, CSR Advisor at
FLSmidth, explains why the assessment
was initiated: “Responsibility to the
environment and society is central to
FLSmidth’s strategy, and we wanted to
understand the impact of our offering and
specifically how we create value.”
ACC Ramliya Cement Plant
Built by FLSmidth, the Ramliya plant
consists of two production lines, which
together have a production capacity of 4.2
million tpy.
Following its construction, Arabian Cement
Company chose to outsource ACC
Ramliya’s clinker production to FLSmidth
through a comprehensive operations and
maintenance (O&M) contract. In addition
to managing the plant’s daily operations,
FLSmidth recruits and employs the plant’s
entire operational staff. This 360-degree
knowledge of the ACC Ramliya plant
meant FLSmidth was ideally placed to
conduct a study of the plant’s impact on its
surroundings and stakeholders.
Shared value benefits all
The study identifies and describes four
essential aspects of the plant’s total
impact. In addition to economic,
environmental and social impacts, it
defines the business value proposition
delivered to the plant’s owners.
Thomas Westergaard-Kabelmann, partner
at Qbis, was responsible for the impact
assessment in collaboration with Deloitte.
He explains the importance of
understanding the entire perspective of a
cement plant’s operations and not just the
economic value delivered to the owners:
“The customer is only one part of the
puzzle; it’s important to see the complete
picture. Cement plants have a large impact
HIGHLIGHTS CEMENT – APRIL 2015 9
on the local environment and society, and
if you do good in one aspect of the plant’s
impact, it is likely to have a positive impact
on all the other aspects.”
He continues: “Delivering profits and
socio-economic benefits results in shared
value, and if ACC Ramliya can optimise its
social and environmental impacts, not only
will the customer benefit, but it will have a
positive impact on economic activity in the
region.”
Per Mejnert Kristensen, Group Executive
Vice President at FLSmidth sees the
performance of the ACC Ramliya plant as
the result of a long-term focus on
responsible business. He says, “We believe
strongly there is a co-relation between the
big picture of corporate social responsibility
and the bottom line performance of our
customer, and we are pleased to see that
the impact assessment from ACC Ramliya
demonstrates this co-relation.”
Outstanding utilisation
Not surprisingly, the study revealed that for
ACC Ramliya to make a positive
contribution to its surroundings, it needs
to perform well commercially. And ACC
Ramliya’s commercial performance tells an
outstanding success story. In the period
2010 to 2013, during which Egypt’s
cement production capacity expanded by
40 percent, ACC outstripped its
competition, increasing market share from
2.9 to 7.8 percent. Notably, Egyptian
cement consumption in this period
increased by only two percent.
Several factors contribute to ACC
Ramliya's excellent performance. >>
10 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 11

RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE

The plant operates at a significantly higher

utilisation rate than its industry peers.
Measured over 2012 and 2013, it operated
at 83 percent utilisation, significantly
higher than the industry standard of 73
percent (Auerbach & Greyson, EFG
Hermes, 2014). Most of its cement is then
sold to areas of high demand, such as
Greater Cairo and the Nile Delta.
At ACC Ramliya, production manager
Mahmoud Abdel Ghany explains his
production philosophy: "We work to keep
our customers satisfied and to sustain the
plant performance. High production is not
a challenge, but it is not that simple. We
can easily produce 7,000 tonnes of clinker
a day, but if the machines break down the
next day due to overproduction, we cannot
meet our customers' demand for cement."
He continues: "The challenge is finding the
optimum point of production where
everything is in balance, and the machines
keep on running. At this point we have
sustained performance, the lowest energy
usage, lowest heat consumption, optimal
production and lowest cost."
It is the combination of high utilisation and
a highly effective sales strategy that has
boosted ACC Ramliya's market share and
profitability. And indeed, the success of
high utilisation rate can be attributed to
FLSmidth, who is responsible for the clinker
production enabling ACC Ramliya to
deliver high quality cement. “THE CHALLENGE IS
Egypt Country Manager at FLSmidth Salem
FINDING THE OPTIMUM
Sousou says, "The cooperation between POINT OF PRODUCTION
FLSmidth and ACC Ramliya is essentially a
partnership, because what benefits one WHERE EVERYTHING IS IN
part benefits the other. As operator of the
plant, FLSmidth is able to act on behalf of
BALANCE, AND THE
our customer and we see that as having an MACHINES KEEP ON
intimate relationship with our customer."
RUNNING.“
Environmental impact
Mahmoud Abdel Ghany
Sine Bøgh Skaarup, Process Manager at
Production Manager, ACC Ramliya
FLSmidth, identifies emissions as one of the
key areas that the cement production
industry needs to address.

“Carbon emissions from cement operations resulting in low utilisation and

production currently represent about five
percent of global emissions. With global
cement production still on the rise, we
have to maintain focus on reducing these
emissions, which we can do by closely
monitoring cement plant operations and
always trying to do better,” she says.
Measurements at ACC Ramliya from 2011
showed that NOx emissions are not always
under the required limit, while SO2 and
CO2 emissions have been well under the
limit. And despite Ramliya in 2011
delivered six percent of Egypt’s total
cement production, it was only responsible
for two percent of total suspended
particles (TSP), which was unrivalled in the
industry.
Coal – the sustainable choice?
A particular challenge for not just the ACC
Ramliya plant, but also most cement
producers in Egypt is the gas supply, which
is too unreliable to support stable
production rates.
So in 2013, FLSmidth and Ramliya’s
owners made the bold move of switching
from a gas supply to coal. This has in effect
increased Ramliya’s CO2 emissions by 10
percent. And even though more cement
plants are likely to make this switch,
leading to an estimated 15 percent
increase in CO2 emissions nationwide, the FLSmidth's operations
use of coal provides greater socio- at ACC Ramliya have
economic benefits. resulted in:
• A 10 percent higher utilisation rate
“The impact assessment estimates that a
than the industry average
30 percent switch from domestic cement
• Very low SO2 and CO2 emissions
production to imports will cost nearly
• 14 percent lower energy usage than
19,000 jobs and a loss in gross value
than the Egyptian industry in general.
added (GVA) of EGP 16.5 billion,” explains
Thomas Westergaard-Kabelmann, • A high proportion of local staff
continuing, “Importing clinker and cement • Only 1 percent of the local staff are
emits at least six times more CO2 than the expats
amount emitted by coal-based cement • An employee turnover of only 1.5
production.” >> percent
10 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 11

RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE

The plant operates at a significantly higher

utilisation rate than its industry peers.
Measured over 2012 and 2013, it operated
at 83 percent utilisation, significantly
higher than the industry standard of 73
percent (Auerbach & Greyson, EFG
Hermes, 2014). Most of its cement is then
sold to areas of high demand, such as
Greater Cairo and the Nile Delta.
At ACC Ramliya, production manager
Mahmoud Abdel Ghany explains his
production philosophy: "We work to keep
our customers satisfied and to sustain the
plant performance. High production is not
a challenge, but it is not that simple. We
can easily produce 7,000 tonnes of clinker
a day, but if the machines break down the
next day due to overproduction, we cannot
meet our customers' demand for cement."
He continues: "The challenge is finding the
optimum point of production where
everything is in balance, and the machines
keep on running. At this point we have
sustained performance, the lowest energy
usage, lowest heat consumption, optimal
production and lowest cost."
It is the combination of high utilisation and
a highly effective sales strategy that has
boosted ACC Ramliya's market share and
profitability. And indeed, the success of
high utilisation rate can be attributed to
FLSmidth, who is responsible for the clinker
production enabling ACC Ramliya to
deliver high quality cement. “THE CHALLENGE IS
Egypt Country Manager at FLSmidth Salem
FINDING THE OPTIMUM
Sousou says, "The cooperation between POINT OF PRODUCTION
FLSmidth and ACC Ramliya is essentially a
partnership, because what benefits one WHERE EVERYTHING IS IN
part benefits the other. As operator of the
plant, FLSmidth is able to act on behalf of
BALANCE, AND THE
our customer and we see that as having an MACHINES KEEP ON
intimate relationship with our customer."
RUNNING.“
Environmental impact
Mahmoud Abdel Ghany
Sine Bøgh Skaarup, Process Manager at
Production Manager, ACC Ramliya
FLSmidth, identifies emissions as one of the
key areas that the cement production
industry needs to address.

“Carbon emissions from cement operations resulting in low utilisation and

production currently represent about five
percent of global emissions. With global
cement production still on the rise, we
have to maintain focus on reducing these
emissions, which we can do by closely
monitoring cement plant operations and
always trying to do better,” she says.
Measurements at ACC Ramliya from 2011
showed that NOx emissions are not always
under the required limit, while SO2 and
CO2 emissions have been well under the
limit. And despite Ramliya in 2011
delivered six percent of Egypt’s total
cement production, it was only responsible
for two percent of total suspended
particles (TSP), which was unrivalled in the
industry.
Coal – the sustainable choice?
A particular challenge for not just the ACC
Ramliya plant, but also most cement
producers in Egypt is the gas supply, which
is too unreliable to support stable
production rates.
So in 2013, FLSmidth and Ramliya’s
owners made the bold move of switching
from a gas supply to coal. This has in effect
increased Ramliya’s CO2 emissions by 10
percent. And even though more cement
plants are likely to make this switch,
leading to an estimated 15 percent
increase in CO2 emissions nationwide, the FLSmidth's operations
use of coal provides greater socio- at ACC Ramliya have
economic benefits. resulted in:
• A 10 percent higher utilisation rate
“The impact assessment estimates that a
than the industry average
30 percent switch from domestic cement
• Very low SO2 and CO2 emissions
production to imports will cost nearly
• 14 percent lower energy usage than
19,000 jobs and a loss in gross value
than the Egyptian industry in general.
added (GVA) of EGP 16.5 billion,” explains
Thomas Westergaard-Kabelmann, • A high proportion of local staff
continuing, “Importing clinker and cement • Only 1 percent of the local staff are
emits at least six times more CO2 than the expats
amount emitted by coal-based cement • An employee turnover of only 1.5
production.” >> percent
12 HIGHLIGHTS CEMENT – APRIL 2015
RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE
Better skilled workforce
A key driver of ACC Ramliya’s social impact
is its contribution to employment.
FLSmidth’s ability to operate the plant
efficiently depends on the presence of a
qualified labour force. But this was not
always a given as there is a shortage of
workers with the experience and skills
needed for the cement industry.
So in 2009, FLSmidth established a cement
training and recruitment centre in Egypt
aimed at enhancing plant workers’
professional and technical skills in all
aspects of operations and maintenance.
At least 85 percent of plant staff has
passed through the training centre since its
opening. This means that FLSmidth can
confidently employ local technicians and
engineers, rather than importing foreign
labour.
To help develop competencies at an even
broader level, FLSmidth has partnered
with the Helwan University in Egypt in
establishing the world’s first Postgraduate
Cement Plant Engineering Degree. It is
initiatives such as these that have been
instrumental in building the skills and
know-how that have become the
backbone of the plant’s high utilisation
rate.
Salem Sousou elaborates, “The
development plans we have developed for
all employees at the plant increase their
skill level and ultimately their employability
over time. We’ve seen this result in an
employee turnover rate of 1.5 percent,
which is very low. That means we’re
retaining our valuable competencies,
which boosts the plant’s performance
further.”
"WE ARE HIGHLY SATISFIED
THAT THIS STUDY SHOWS
THAT ACC RAMLIYA IS
DELIVERING VALUE TO ITS
OWNER AS WELL AS THE
SOCIETY IN WHICH IT
OPERATES. THIS IS, AFTER ALL,
WHY WE ARE IN BUSINESS."
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
ACC Ramliya’s Production Manager,
Mahmoud Abdel Ghanry, explains how
people are central to maintaining stable
production: "The key to finding the
optimum point of production is having the
right people operating equipment. That is
why we have development plans for all our
employees and why we put tremendous
effort into training them. They will
determine how it will run and that takes
the right knowledge and experience.”
Thomas Westergaard-Kabelmann points
out that contributing to the development
of local skills also has other impacts
beyond just cement plant operations.
“Improving a person's competencies gives
them more opportunities for employment
and career development. As their income
is increased, their standard of life
improves,” he says.
THE ILLUSTRATION SHOWS ACC
RAMLIYA'S IMPACT ON THE LOCAL
ENVIRONMENT AND SOCIETY AND
HOW THE DELIVERY OF PROFITS AND
SOCIO-ECONOMIC BENEFITS RESULT
IN SHARED VALUE.
Perfect partnership
According to Per Mejnert Kristensen,
Group Executive Vice President at FLSmidth
the study has great significance for
FLSmidth, acknowledging FLSmidth’s
partnership with Arabian Cement
Company and long-term presence in
Egypt.
He says: “We are highly satisfied that this
study shows that ACC Ramliya is delivering
value to its owner as well as the society in
which it operates. This is, after all, why we
are in business. However, the study also
shows that we and our industry peers
must be vigilant in improving the way we
do things to reduce our environmental
footprint and remain economically viable.
We are equally driven by this quest.”
CUSTOMER
IMPACTS
MARKET SHARE
ACC’s market share has increased
from 2.9% to 7.9% due to
• High utilisation rate
• High demand/high price 2014 improved
segment
• Extended customer reach
REVENUE
• 10 percentage point higher
utilisation rate with an estimated
increase in revenue of EGP 493m
in 2012-2013.
EBITDA
• 10 percentage point higher
utilisation rate is estimated
to have increased EBITDA
by EGP 178m in 2012-2013
Positive impact
Negative impact
About Arabian Cement Company
Arabian Cement Company (ACC) was established in 1997 by a group of Egyptian
entrepreneurs, who aspired to establish a leading Egyptian cement company.
The cement factory is located in the Suez Governorate. It produces five million
tonnes of first quality cement, approximately 10 percent of Egypt's production.
The company is a joint venture between Cememtos La Union, a Spanish investor
holding the majority of shares, and a group of Egyptian investors. The company
was listed on the Egyptian stock exchange in May 2014.
HIGHLIGHTS CEMENT – APRIL 2015 13
ECONOMIC
IMPACTS
Job creation
Ramliya/FLSmidth Egypt
• Direct jobs: 272/937 jobs
• Indirect jobs: 695/2,335 jobs
• Induced jobs: 264/887 jobs
SUPPLY OF DOMESTIC
CEMENT
• Use of coal will secure domestic
cement production
• If 30% of domestic cement
production is replaced by import,
it is expected to result in the loss
of nearly 19,000 jobs and EGP
16.5bn in Gross Value Added
GROSS VALUE ADDED
from cement industry
• Direct: EGP 24bn SOCIAL
• Indirect: EGP 23bn
IMPACTS
• Induced: EGP 8bn
• Total GVA: EGP 55bn
HEALTH and SAFETY
• Lost Time Injury Frequency (LTIFR)
2012-13 too high
• Lost Time Injury Frequency (LTIFR)
LOCAL JOBS
• 99% of employees are Egyptians
TRAINING
• Own training; FLS-Institute
• 85% of all employees trained
• 35-65% jump in knowledge
• Change in job behaviour after
training rated as satisfactory or
very satisfactory
ENVIRONMENTAL EDUCATION
• Together with Helwan University,
IMPACTS FLSmidth established a post-
graduate diploma degree in
CO2 EMISSIONS
cement engineering
• When using gas, Ramliya’s CO2
emissions are below industry
average
• Shift to coal has increased
Ramliya‘s CO2 emissions by
around 10%
ENERGY
• 14% lower Gj/t cement than
Egyptian industry
• Consistently lower over last
three years
SO2, CO and TSP EMISSIONS
• Low SO2, CO and TSP emissions
• In 2011, ACC Ramliya emitted
2% of total TSP, but accounted
for 6% of the total cement
production in Egypt.
NOx EMISSIONS
• 2011-2013 too high compared to
the legal limit (600mg/m)
• Health impact uncertain due to
desert location
Impact assessment
Deloitte and Qbiz conducted a socio-
economic impact assessment of the
operations and maintenance of the ACC
Ramliya cement plant in Egypt. The overall
objective was to determine the total
impact of FLSmidth’s products and
services, including the impact on a cement
plant’s competitiveness and financial
performance, on the supply and value
chain, and on society as a whole.
12 HIGHLIGHTS CEMENT – APRIL 2015
RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE
Better skilled workforce
A key driver of ACC Ramliya’s social impact
is its contribution to employment.
FLSmidth’s ability to operate the plant
efficiently depends on the presence of a
qualified labour force. But this was not
always a given as there is a shortage of
workers with the experience and skills
needed for the cement industry.
So in 2009, FLSmidth established a cement
training and recruitment centre in Egypt
aimed at enhancing plant workers’
professional and technical skills in all
aspects of operations and maintenance.
At least 85 percent of plant staff has
passed through the training centre since its
opening. This means that FLSmidth can
confidently employ local technicians and
engineers, rather than importing foreign
labour.
To help develop competencies at an even
broader level, FLSmidth has partnered
with the Helwan University in Egypt in
establishing the world’s first Postgraduate
Cement Plant Engineering Degree. It is
initiatives such as these that have been
instrumental in building the skills and
know-how that have become the
backbone of the plant’s high utilisation
rate.
Salem Sousou elaborates, “The
development plans we have developed for
all employees at the plant increase their
skill level and ultimately their employability
over time. We’ve seen this result in an
employee turnover rate of 1.5 percent,
which is very low. That means we’re
retaining our valuable competencies,
which boosts the plant’s performance
further.”
"WE ARE HIGHLY SATISFIED
THAT THIS STUDY SHOWS
THAT ACC RAMLIYA IS
DELIVERING VALUE TO ITS
OWNER AS WELL AS THE
SOCIETY IN WHICH IT
OPERATES. THIS IS, AFTER ALL,
WHY WE ARE IN BUSINESS."
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
ACC Ramliya’s Production Manager,
Mahmoud Abdel Ghanry, explains how
people are central to maintaining stable
production: "The key to finding the
optimum point of production is having the
right people operating equipment. That is
why we have development plans for all our
employees and why we put tremendous
effort into training them. They will
determine how it will run and that takes
the right knowledge and experience.”
Thomas Westergaard-Kabelmann points
out that contributing to the development
of local skills also has other impacts
beyond just cement plant operations.
“Improving a person's competencies gives
them more opportunities for employment
and career development. As their income
is increased, their standard of life
improves,” he says.
THE ILLUSTRATION SHOWS ACC
RAMLIYA'S IMPACT ON THE LOCAL
ENVIRONMENT AND SOCIETY AND
HOW THE DELIVERY OF PROFITS AND
SOCIO-ECONOMIC BENEFITS RESULT
IN SHARED VALUE.
Perfect partnership
According to Per Mejnert Kristensen,
Group Executive Vice President at FLSmidth
the study has great significance for
FLSmidth, acknowledging FLSmidth’s
partnership with Arabian Cement
Company and long-term presence in
Egypt.
He says: “We are highly satisfied that this
study shows that ACC Ramliya is delivering
value to its owner as well as the society in
which it operates. This is, after all, why we
are in business. However, the study also
shows that we and our industry peers
must be vigilant in improving the way we
do things to reduce our environmental
footprint and remain economically viable.
We are equally driven by this quest.”
CUSTOMER
IMPACTS
MARKET SHARE
ACC’s market share has increased
from 2.9% to 7.9% due to
• High utilisation rate
• High demand/high price 2014 improved
segment
• Extended customer reach
REVENUE
• 10 percentage point higher
utilisation rate with an estimated
increase in revenue of EGP 493m
in 2012-2013.
EBITDA
• 10 percentage point higher
utilisation rate is estimated
to have increased EBITDA
by EGP 178m in 2012-2013
Positive impact
Negative impact
About Arabian Cement Company
Arabian Cement Company (ACC) was established in 1997 by a group of Egyptian
entrepreneurs, who aspired to establish a leading Egyptian cement company.
The cement factory is located in the Suez Governorate. It produces five million
tonnes of first quality cement, approximately 10 percent of Egypt's production.
The company is a joint venture between Cememtos La Union, a Spanish investor
holding the majority of shares, and a group of Egyptian investors. The company
was listed on the Egyptian stock exchange in May 2014.
HIGHLIGHTS CEMENT – APRIL 2015 13
ECONOMIC
IMPACTS
Job creation
Ramliya/FLSmidth Egypt
• Direct jobs: 272/937 jobs
• Indirect jobs: 695/2,335 jobs
• Induced jobs: 264/887 jobs
SUPPLY OF DOMESTIC
CEMENT
• Use of coal will secure domestic
cement production
• If 30% of domestic cement
production is replaced by import,
it is expected to result in the loss
of nearly 19,000 jobs and EGP
16.5bn in Gross Value Added
GROSS VALUE ADDED
from cement industry
• Direct: EGP 24bn SOCIAL
• Indirect: EGP 23bn
IMPACTS
• Induced: EGP 8bn
• Total GVA: EGP 55bn
HEALTH and SAFETY
• Lost Time Injury Frequency (LTIFR)
2012-13 too high
• Lost Time Injury Frequency (LTIFR)
LOCAL JOBS
• 99% of employees are Egyptians
TRAINING
• Own training; FLS-Institute
• 85% of all employees trained
• 35-65% jump in knowledge
• Change in job behaviour after
training rated as satisfactory or
very satisfactory
ENVIRONMENTAL EDUCATION
• Together with Helwan University,
IMPACTS FLSmidth established a post-
graduate diploma degree in
CO2 EMISSIONS
cement engineering
• When using gas, Ramliya’s CO2
emissions are below industry
average
• Shift to coal has increased
Ramliya‘s CO2 emissions by
around 10%
ENERGY
• 14% lower Gj/t cement than
Egyptian industry
• Consistently lower over last
three years
SO2, CO and TSP EMISSIONS
• Low SO2, CO and TSP emissions
• In 2011, ACC Ramliya emitted
2% of total TSP, but accounted
for 6% of the total cement
production in Egypt.
NOx EMISSIONS
• 2011-2013 too high compared to
the legal limit (600mg/m)
• Health impact uncertain due to
desert location
Impact assessment
Deloitte and Qbiz conducted a socio-
economic impact assessment of the
operations and maintenance of the ACC
Ramliya cement plant in Egypt. The overall
objective was to determine the total
impact of FLSmidth’s products and
services, including the impact on a cement
plant’s competitiveness and financial
performance, on the supply and value
chain, and on society as a whole.
14 HIGHLIGHTS CEMENT – APRIL 2015
INNOVATION
MAAG Gear
Revival of a classic
25 years down the line and FLSmidth MAAG
Gear has revamped a classic and created a
state-of-the-art gearbox: the PPU gearbox for
roller presses and other applications.
Roller presses in cement plants are used for
the primary reduction of the grinding
stock. For this application, FLSmidth
MAAG Gear offers a special series of
gearboxes for roller presses (read more
about FLSmidth's new roller press concept
on pages 34-37).
The gearboxes are always used in pairs for
the drive of the two grinding rollers. They
can be used in both directions of rotation.
The gearboxes for roller presses have been
designed as two-stage planetary reducers
with spur pre-stages. This ensures optimal
design of the planetary stages with good
load distribution and adaptation to the
required gearbox ratio.
The new version
Experience gained over the last 25 years
was analysed in order to fully redesign the
PPU gearbox. The following objectives
were met:
• Weight reduction of 25%
• 15% smaller outer diameter
• Diversity of parts reduced by 20%
The main focus of the redesign was in the
toothing and the bearing system of the
individual components. The choice of an
PPU IN ASSEMBLY
optimum bearing system and good sizing
has resulted in a high level of reliability.
With a bearing lifetime in excess of
100.000 hours, the PPU is like a marathon
runner who leaves the competition way
behind. Compared with other gearboxes in
the same application class, the new PPU
uses just five different types of antifriction
bearings instead of up to eight, which
simplifies the management of spare parts.
Operating costs are reduced thanks to
efficiency and optimised maintenance
intervals. Lubrication oil consumption has
been optimised. The ideal oil level reduces
churning losses and improves efficiency.
The dimensions and configuration of the
gearbox were aligned to the application
and other components in the drive train,
such as shrink disk, overload coupling and
cardan shaft. 
Top gearing quality
The tooth geometry was designed
following the well-proven MAAG®
standard and recalculated according to the
latest ISO and AGMA standards. This
guarantees optimum load distribution
across the teeth and therefore maximum
power transmission.
INSTALLATION OF PPU
HIGHLIGHTS CEMENT – APRIL 2015 15
CONTACT RUDOLF WARTENWEILER
RUDOLF.WARTENWEILER@FLSMIDTH.COM
WITH A BEARING LIFETIME
IN EXCESS OF 100,000
HOURS, THE PPU IS LIKE A
MARATHON RUNNER WHO
LEAVES THE COMPETITION
WAY BEHIND.
The toothed components are
manufactured in-house to the strictest Applications
quality standards and are made from case- Alongside classic roller press
hardened and heat-treated steel. In-house applications, the PPU is flexible enough
heat treatment gives complete control over for other uses:
the hardening processes and material • Central drive for small ball mills
properties. After assembly, each gearbox is • Furnace drives
tested on the internal test bed. • Industrial drives (sugar)
Installation
Through the use of a wide range of
The first gearbox of the latest PPU
options and components, the modular
generation was installed in India.
gearbox design allows the adaption of
Machine ............. FLSmidth Roller Press
the drive train precisely to the
(HRP R-3.00)
customer's needs. The drive train for a
Drive power ....................... 2 x 1600kW
ball mill application is being supplied as
Gearbox type ....................... 2 x PPU-44
a complete system by FLSmidth MAAG
Gearbox weight ........................6.300kg
Gear for a customer in the Far East:
Ratio ............................................. 50.23
• PPU gearbox unit with limited end
float
The other parts of the drive train, such as
the torque arm, overload coupling, • Gearbox foot for transferring load
driving shafts, shrink disks and oil supply into the foundation
systems, were also supplied by FLSmidth • Oil supply system
MAAG Gear. The customer benefitted • Low speed ZCF gear coupling with
from FLSmidth's ability to deliver a full intermediate flange for ball mill
range of products from one source.
• Water injection unit via the coupling
A local team of technicians installed the • Torsionally flexible high speed
gearbox under the supervision of a coupling
MAAG service engineer. The crew was • Auxiliary drive for maintenance work
well-trained and the individual drive train • Main drive motor
components were assembled quickly.
14 HIGHLIGHTS CEMENT – APRIL 2015
INNOVATION
MAAG Gear
Revival of a classic
25 years down the line and FLSmidth MAAG
Gear has revamped a classic and created a
state-of-the-art gearbox: the PPU gearbox for
roller presses and other applications.
Roller presses in cement plants are used for
the primary reduction of the grinding
stock. For this application, FLSmidth
MAAG Gear offers a special series of
gearboxes for roller presses (read more
about FLSmidth's new roller press concept
on pages 34-37).
The gearboxes are always used in pairs for
the drive of the two grinding rollers. They
can be used in both directions of rotation.
The gearboxes for roller presses have been
designed as two-stage planetary reducers
with spur pre-stages. This ensures optimal
design of the planetary stages with good
load distribution and adaptation to the
required gearbox ratio.
The new version
Experience gained over the last 25 years
was analysed in order to fully redesign the
PPU gearbox. The following objectives
were met:
• Weight reduction of 25%
• 15% smaller outer diameter
• Diversity of parts reduced by 20%
The main focus of the redesign was in the
toothing and the bearing system of the
individual components. The choice of an
PPU IN ASSEMBLY
optimum bearing system and good sizing
has resulted in a high level of reliability.
With a bearing lifetime in excess of
100.000 hours, the PPU is like a marathon
runner who leaves the competition way
behind. Compared with other gearboxes in
the same application class, the new PPU
uses just five different types of antifriction
bearings instead of up to eight, which
simplifies the management of spare parts.
Operating costs are reduced thanks to
efficiency and optimised maintenance
intervals. Lubrication oil consumption has
been optimised. The ideal oil level reduces
churning losses and improves efficiency.
The dimensions and configuration of the
gearbox were aligned to the application
and other components in the drive train,
such as shrink disk, overload coupling and
cardan shaft. 
Top gearing quality
The tooth geometry was designed
following the well-proven MAAG®
standard and recalculated according to the
latest ISO and AGMA standards. This
guarantees optimum load distribution
across the teeth and therefore maximum
power transmission.
INSTALLATION OF PPU
HIGHLIGHTS CEMENT – APRIL 2015 15
CONTACT RUDOLF WARTENWEILER
RUDOLF.WARTENWEILER@FLSMIDTH.COM
WITH A BEARING LIFETIME
IN EXCESS OF 100,000
HOURS, THE PPU IS LIKE A
MARATHON RUNNER WHO
LEAVES THE COMPETITION
WAY BEHIND.
The toothed components are
manufactured in-house to the strictest Applications
quality standards and are made from case- Alongside classic roller press
hardened and heat-treated steel. In-house applications, the PPU is flexible enough
heat treatment gives complete control over for other uses:
the hardening processes and material • Central drive for small ball mills
properties. After assembly, each gearbox is • Furnace drives
tested on the internal test bed. • Industrial drives (sugar)
Installation
Through the use of a wide range of
The first gearbox of the latest PPU
options and components, the modular
generation was installed in India.
gearbox design allows the adaption of
Machine ............. FLSmidth Roller Press
the drive train precisely to the
(HRP R-3.00)
customer's needs. The drive train for a
Drive power ....................... 2 x 1600kW
ball mill application is being supplied as
Gearbox type ....................... 2 x PPU-44
a complete system by FLSmidth MAAG
Gearbox weight ........................6.300kg
Gear for a customer in the Far East:
Ratio ............................................. 50.23
• PPU gearbox unit with limited end
float
The other parts of the drive train, such as
the torque arm, overload coupling, • Gearbox foot for transferring load
driving shafts, shrink disks and oil supply into the foundation
systems, were also supplied by FLSmidth • Oil supply system
MAAG Gear. The customer benefitted • Low speed ZCF gear coupling with
from FLSmidth's ability to deliver a full intermediate flange for ball mill
range of products from one source.
• Water injection unit via the coupling
A local team of technicians installed the • Torsionally flexible high speed
gearbox under the supervision of a coupling
MAAG service engineer. The crew was • Auxiliary drive for maintenance work
well-trained and the individual drive train • Main drive motor
components were assembled quickly.
16 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 17

SITE REPORT

CONTACT CLAUS HAGEN JENSEN

CHJ@FLSMIDTH.COM

CONTACT PALLE E. GRYDGAARD

PEG@FLSMIDTH.COM FIRST DIRECT FEED
KILN SYSTEM IN
THE WORLD

The ‘dreamline’ vision Lower fuel consumption

The idea of a dry line at JSC Sebryakovcement is in fact not new.
The plant’s first director and his colleagues had wanted to
transform the plant into a dry line. It was their common dream.
That's why today, more than sixty years later, the line is
affectionately known as the ‘dreamline’. But achieving the dream
needed to be based on real business objectives, explains Sergey P.
Rogachev: “Our objectives included upgrading the plant
infrastructure to achieve a steep reduction of fuel consumption
and, consequently, production costs at the same time as
maintaining the quality of clinker production. The clinker burning
equipment had become inefficient, obsolete and worn-out, and
we also saw the opportunity for taking it out of service.
JSC Sebryakovcement needed to find an equally visionary partner
who could meet the requirements of a demanding environment.
The company had worked with FLSmidth on various projects since
Where the new dry line sets itself apart is in the concept of direct
feeding to the kiln. The plant owners worked closely with the
team at FLSmidth to design a solution that did not require the use
of a raw meal storage silo, such as a CF-silo. This was one of the
key reasons JSC Sebryakovcement chose FLSmidth, partly because
of FLSmidth’s experience and reputation, but also because of its
proven track record in producing innovative solutions to meet
specific requirements.
The concept involved feeding the raw materials with their natural
moisture content directly into the kiln system without grinding
them to slurry. Since no further water is added as before, the overall
heat consumption was reduced from the expected 1450-1500
kcal/kg clinker to less than 900 kcal/kg, which is the equivalent of
more than 40 percent in fuel consumption savings. >>

From wet to dry in a 2005, and it was a natural decision to continue the partnership.

cold climate Filter
FLOW SHEET OF THE NEW DRY
CEMENT PLANT AT JSC

Additive
Additive
SEBRYAKOVCEMENT

Chalk

Clay
Filter dust silo

One of the biggest challenges facing cement plant owners in
Russia lies in the type and quality of the raw material extracted
from quarries. It is no different for JSC Sebryakovcement, whose
raw material has a moisture content of approximately 20 percent.
Traditionally, the raw materials (chalk and clay) need to be ground
clinker-producing capacity of 3,575 tpd: “The plant is located
between two large cement markets in the European part of
Russia. In order to sell a significant amount of cement on the Crusher Crusher
PGNAA
markets, even competing with wet plants, it is essential for us to Kiln feed silo
ensure the lowest production cost, since the transportation cost

Reclaimer

Reclaimer
Seperator
with water to produce a slurry with a 36 percent moisture content makes up a large part of the cement price.

making it easy to pump into the kilns.
But this is an energy-consuming process. An economically viable
solution was needed to replace two of JSC Sebryakovcement’s
wet-process kiln lines that dated back to 1953. Sergey P.
Rogachev, General Director at JSC Sebryakovcement explains the
reasons behind the construction of a new dry process line with a
Stacker
New dry cement plants have emerged recently on the same
markets, so it is vital our plant is as competitive as possible.
Therefore, as part of the plant upgrade programme and Cooler
reconstruction of all departments, the best means to bring down Dryer crusher Kiln Klinker
the fuel cost in the plant’s production cost structure was to
convert the pyro-section from a wet to dry process.”
16 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 17

SITE REPORT

CONTACT CLAUS HAGEN JENSEN

CHJ@FLSMIDTH.COM

CONTACT PALLE E. GRYDGAARD

PEG@FLSMIDTH.COM FIRST DIRECT FEED
KILN SYSTEM IN
THE WORLD

The ‘dreamline’ vision Lower fuel consumption

The idea of a dry line at JSC Sebryakovcement is in fact not new.
The plant’s first director and his colleagues had wanted to
transform the plant into a dry line. It was their common dream.
That's why today, more than sixty years later, the line is
affectionately known as the ‘dreamline’. But achieving the dream
needed to be based on real business objectives, explains Sergey P.
Rogachev: “Our objectives included upgrading the plant
infrastructure to achieve a steep reduction of fuel consumption
and, consequently, production costs at the same time as
maintaining the quality of clinker production. The clinker burning
equipment had become inefficient, obsolete and worn-out, and
we also saw the opportunity for taking it out of service.
JSC Sebryakovcement needed to find an equally visionary partner
who could meet the requirements of a demanding environment.
The company had worked with FLSmidth on various projects since
Where the new dry line sets itself apart is in the concept of direct
feeding to the kiln. The plant owners worked closely with the
team at FLSmidth to design a solution that did not require the use
of a raw meal storage silo, such as a CF-silo. This was one of the
key reasons JSC Sebryakovcement chose FLSmidth, partly because
of FLSmidth’s experience and reputation, but also because of its
proven track record in producing innovative solutions to meet
specific requirements.
The concept involved feeding the raw materials with their natural
moisture content directly into the kiln system without grinding
them to slurry. Since no further water is added as before, the overall
heat consumption was reduced from the expected 1450-1500
kcal/kg clinker to less than 900 kcal/kg, which is the equivalent of
more than 40 percent in fuel consumption savings. >>

From wet to dry in a 2005, and it was a natural decision to continue the partnership.

cold climate Filter
FLOW SHEET OF THE NEW DRY
CEMENT PLANT AT JSC

Additive
Additive
SEBRYAKOVCEMENT

Chalk

Clay
Filter dust silo

One of the biggest challenges facing cement plant owners in
Russia lies in the type and quality of the raw material extracted
from quarries. It is no different for JSC Sebryakovcement, whose
raw material has a moisture content of approximately 20 percent.
Traditionally, the raw materials (chalk and clay) need to be ground
clinker-producing capacity of 3,575 tpd: “The plant is located
between two large cement markets in the European part of
Russia. In order to sell a significant amount of cement on the Crusher Crusher
PGNAA
markets, even competing with wet plants, it is essential for us to Kiln feed silo
ensure the lowest production cost, since the transportation cost

Reclaimer

Reclaimer
Seperator
with water to produce a slurry with a 36 percent moisture content makes up a large part of the cement price.

making it easy to pump into the kilns.
But this is an energy-consuming process. An economically viable
solution was needed to replace two of JSC Sebryakovcement’s
wet-process kiln lines that dated back to 1953. Sergey P.
Rogachev, General Director at JSC Sebryakovcement explains the
reasons behind the construction of a new dry process line with a
Stacker
New dry cement plants have emerged recently on the same
markets, so it is vital our plant is as competitive as possible.
Therefore, as part of the plant upgrade programme and Cooler
reconstruction of all departments, the best means to bring down Dryer crusher Kiln Klinker
the fuel cost in the plant’s production cost structure was to
convert the pyro-section from a wet to dry process.”
18 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 19

FROM WET TO DRY

IN A COLD CLIMATE

“ALL PARTIES TOOK TIME DURING THE

DESIGN PHASE TO ENSURE THAT LESSONS
FROM OTHER COLD CLIMATE SITES WERE
TAKEN ON BOARD. EVERYTHING WAS
THOUGHT THROUGH VERY CAREFULLY TO
MINIMISE ANY AREAS OF DOUBT.“
Claus Hagen Jensen
Project Manager, FLSmidth

A world first FLSmidth, reveals why the issue of a cold climate is not actually a
A special feature of the raw materials, chalk and clay, is that they problem for the line’s performance: “All parties took time during
are relatively homogeneous, regardless of where they are the design phase to ensure that lessons from other cold climate
extracted in the quarry. It was this feature that led to the idea of sites were taken on board. Everything was thought through very
producing the final mixture in storage. The chemical composition carefully to minimise any areas of doubt. The team at JSC
of the mixture is controlled by measuring the weight and Sebryakovcement took an extremely professional approach to all
analysing the bulk on the conveyor belt before storage. aspects of the project. They went to great lengths to look ahead
in order to foresee potential issues. This plant means a lot to the
The intended chemical composition needs to be met before people who work there, and to the local community, which is why Operations have outperformed Main equipment
completion of a pile because no further chemical correction the plant’s management adopted a mindset of wanting to prevent performance guarantees of JSC Sebryakovcement line 5
is possible. problems before they occur.”
Crushers Guaranteed Achieved Equipment Type
In storage, the materials are stacked according to the windrow All performance guarantees achieved Chalk crusher 600 tph (dry) 620t/h (dry) Chalk crusher EH Double Roller - 150x200
method made up of 10 layers split into some 20 rows. Cutting Sergey P. Rogachev is pleased that his colleagues at JSC
Clay crusher 250 tph (dry) 261tph (dry) Clay crusher MHC Twin Shaft Breaker 630 x 2,1
across these approximately 200 rows produces a high Sebryakovcement have quickly developed the necessary skills to
homogenising effect. Not only does this unique concept eliminate operate the new dry cement line. And he is equally satisfied that Kiln Guaranteed Achieved Mix storage –
the need for a costly raw meal blending silo, but this combination all performance guarantees have been achieved. He puts this Kiln production 3575 tph (dry) 3618 t/d Stacker Windrow stacking
of direct kiln feed with blending of all raw materials in storage has down to the experience and helpfulness of FLSmidth’s experts
not been seen before. during the design, construction and commissioning of the plant: Heat consumption 949 tph (dry) 807 kcal/kg clinke Reclaimers 2 Bucket excavators
“FLSmidth believed in our experience and jointly developed a Power consumption 36.31 34.56 kWg/t "Raw Mill" ET Drier Crusher 450 x 330
First clinker was achieved in September 2013, less than three unique production flow sheet enabling a significant reduction of
Clinker temperature 82 °C + ambient 29 °C + ambient Preheater Single string 3 cyclone stages
years after the contract was signed with FLSmidth. By December the construction costs. The first year’s operation has proved that
2013, the performance guarantees were confirmed for the entire the flow sheet not only delivers the required clinker quality and a Free lime < 1% 0.3% Calciner Low NOx In-Line
upgraded clinker line. The plant has now been running for more considerable reduction of the fuel consumption, but also lowers Dust emissions Guaranteed Achieved Kiln 2 Piers – 4.35 x 54m
than one year with very high reliability. electric power costs compared to the ‘classic’ dry and wet
processes.” Main EP filter 34 mg/Nm (dry)
3
25 mg/Nm (dry)
3
Cooler SF CrossBar 3 x 5
Local expertise Cooler bag filter 30 mg/Nm (dry)
3
19 mg/Nm (dry)
3

Satisfied that the plant can run at 3,700 tpd, above the 3,575 tpd
Bypass bag filter 30 mg/Nm3 (dry) 26 mg/Nm3 (dry)
target originally agreed, Claus Hagen Jensen, Project Manager at
18 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 19

FROM WET TO DRY

IN A COLD CLIMATE

“ALL PARTIES TOOK TIME DURING THE

DESIGN PHASE TO ENSURE THAT LESSONS
FROM OTHER COLD CLIMATE SITES WERE
TAKEN ON BOARD. EVERYTHING WAS
THOUGHT THROUGH VERY CAREFULLY TO
MINIMISE ANY AREAS OF DOUBT.“
Claus Hagen Jensen
Project Manager, FLSmidth

A world first FLSmidth, reveals why the issue of a cold climate is not actually a
A special feature of the raw materials, chalk and clay, is that they problem for the line’s performance: “All parties took time during
are relatively homogeneous, regardless of where they are the design phase to ensure that lessons from other cold climate
extracted in the quarry. It was this feature that led to the idea of sites were taken on board. Everything was thought through very
producing the final mixture in storage. The chemical composition carefully to minimise any areas of doubt. The team at JSC
of the mixture is controlled by measuring the weight and Sebryakovcement took an extremely professional approach to all
analysing the bulk on the conveyor belt before storage. aspects of the project. They went to great lengths to look ahead
in order to foresee potential issues. This plant means a lot to the
The intended chemical composition needs to be met before people who work there, and to the local community, which is why Operations have outperformed Main equipment
completion of a pile because no further chemical correction the plant’s management adopted a mindset of wanting to prevent performance guarantees of JSC Sebryakovcement line 5
is possible. problems before they occur.”
Crushers Guaranteed Achieved Equipment Type
In storage, the materials are stacked according to the windrow All performance guarantees achieved Chalk crusher 600 tph (dry) 620t/h (dry) Chalk crusher EH Double Roller - 150x200
method made up of 10 layers split into some 20 rows. Cutting Sergey P. Rogachev is pleased that his colleagues at JSC
Clay crusher 250 tph (dry) 261tph (dry) Clay crusher MHC Twin Shaft Breaker 630 x 2,1
across these approximately 200 rows produces a high Sebryakovcement have quickly developed the necessary skills to
homogenising effect. Not only does this unique concept eliminate operate the new dry cement line. And he is equally satisfied that Kiln Guaranteed Achieved Mix storage –
the need for a costly raw meal blending silo, but this combination all performance guarantees have been achieved. He puts this Kiln production 3575 tph (dry) 3618 t/d Stacker Windrow stacking
of direct kiln feed with blending of all raw materials in storage has down to the experience and helpfulness of FLSmidth’s experts
not been seen before. during the design, construction and commissioning of the plant: Heat consumption 949 tph (dry) 807 kcal/kg clinke Reclaimers 2 Bucket excavators
“FLSmidth believed in our experience and jointly developed a Power consumption 36.31 34.56 kWg/t "Raw Mill" ET Drier Crusher 450 x 330
First clinker was achieved in September 2013, less than three unique production flow sheet enabling a significant reduction of
Clinker temperature 82 °C + ambient 29 °C + ambient Preheater Single string 3 cyclone stages
years after the contract was signed with FLSmidth. By December the construction costs. The first year’s operation has proved that
2013, the performance guarantees were confirmed for the entire the flow sheet not only delivers the required clinker quality and a Free lime < 1% 0.3% Calciner Low NOx In-Line
upgraded clinker line. The plant has now been running for more considerable reduction of the fuel consumption, but also lowers Dust emissions Guaranteed Achieved Kiln 2 Piers – 4.35 x 54m
than one year with very high reliability. electric power costs compared to the ‘classic’ dry and wet
processes.” Main EP filter 34 mg/Nm (dry)
3
25 mg/Nm (dry)
3
Cooler SF CrossBar 3 x 5
Local expertise Cooler bag filter 30 mg/Nm (dry)
3
19 mg/Nm (dry)
3

Satisfied that the plant can run at 3,700 tpd, above the 3,575 tpd
Bypass bag filter 30 mg/Nm3 (dry) 26 mg/Nm3 (dry)
target originally agreed, Claus Hagen Jensen, Project Manager at
20 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 21

INNOVATION

CONTACT KARSTEN POULSEN

FLSMIDTH AND HALDOR TOPSØE KSP@FLSMIDTH.COM
REPRESENTATIVES GATHERED AT HALDOR
TOPSØE HEAD QUARTER IN LYNGBY,
DENMARK DURING THE SIGNING
CEREMONY, JANUARY 2015

“WE BELIEVE THE CATALYTIC FILTER BAG

WILL BE A GAME-CHANGER BECAUSE IT
ENABLES CEMENT PLANT OWNERS TO
CLEAN INDUSTRIAL OFF-GASES AND MEET
STRICTER LEGISLATION AT A FRACTION OF
THE COST COMPARED WITH BEST
AVAILABLE TECHNOLOGIES TODAY.”
Ole Boegh, CEO, FLSmidth Air Pollution Control

Fabric filters are used across a variety of different industries as they
are very efficient in securing emissions at extreme low dust levels.
In many applications, they are used as a final purification step to
remove particulate matter from the flue gas. FLSmidth is a market
leader in this field with extensive experience and in-house
knowledge on how to design, manufacture and operate fabric
filters.
Reduced CAPEX and OPEX
Capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one cost-effective process, EnviroTex
provides compelling opportunities for CAPEX savings (initial
investment needed) and OPEX savings (ongoing operating cost).
Over the past four years, FLSmidth and Haldor Topsoe have
worked closely together on developing the patent-pending
EnviroTex™ technology. The product has been thoroughly tested
and proven efficient for several industrial applications.
Key to the development of this unique product is the combination
of FLSmidth's expertise and market leadership in filters for
industrial processes as well as process integration and Haldor
Topsoe’s leadership in catalysis. >>

Smashing the costs

Since the filter bag requires less space than alternative solutions, it
also provides opportunities to reduce the physical footprint.

Ole Bøegh, CEO, FLSmidth Air Pollution Control says, “We believe

of removing gaseous
the catalytic filter bag will be a game-changer because it enables
cement plant owners to clean industrial off-gases and meet
stricter legislation at a fraction of the cost compared with best

emissions and dust

available technologies today.”

A game-changing filter bag based on
catalytic technology provides significant
CAPEX and OPEX reductions.
FLSmidth has teamed up with the Danish catalyst specialist Haldor
Topsoe to release a new type of filter bag. Called EnviroTex™, it is
capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one integrated and cost-effective process.
It has been designed for use at cement plants, but it can just as
easily be used in power production, biomass, waste incineration,
glass and metal production, and similar.
The key differentiating factor about the patent-pending catalytic
filter bag lies in its three layers of filter fabric. Each layer contains a
tailored catalyst optimised for the removal of specific kinds of
compounds from the off-gas that passes through it.
Ole Bøegh explains the bag’s uniqueness: “It doesn’t just provide
us with the flexibility to tailor different catalytic combinations for
different industries; it also makes it possible to handle the removal
of several critical compounds in one integrated process. This can
significantly reduce the cost of off-gas cleaning. Remember that
today’s standard is to use separate stand-alone systems to remove
specific compounds.”
Fast-tracking innovation potential
Denmark-based Haldor Topsoe is a highly successfully
manufacturer and researcher within catalysis and surface science.
20 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 21

INNOVATION

CONTACT KARSTEN POULSEN

FLSMIDTH AND HALDOR TOPSØE KSP@FLSMIDTH.COM
REPRESENTATIVES GATHERED AT HALDOR
TOPSØE HEAD QUARTER IN LYNGBY,
DENMARK DURING THE SIGNING
CEREMONY, JANUARY 2015

“WE BELIEVE THE CATALYTIC FILTER BAG

WILL BE A GAME-CHANGER BECAUSE IT
ENABLES CEMENT PLANT OWNERS TO
CLEAN INDUSTRIAL OFF-GASES AND MEET
STRICTER LEGISLATION AT A FRACTION OF
THE COST COMPARED WITH BEST
AVAILABLE TECHNOLOGIES TODAY.”
Ole Boegh, CEO, FLSmidth Air Pollution Control

Fabric filters are used across a variety of different industries as they
are very efficient in securing emissions at extreme low dust levels.
In many applications, they are used as a final purification step to
remove particulate matter from the flue gas. FLSmidth is a market
leader in this field with extensive experience and in-house
knowledge on how to design, manufacture and operate fabric
filters.
Reduced CAPEX and OPEX
Capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one cost-effective process, EnviroTex
provides compelling opportunities for CAPEX savings (initial
investment needed) and OPEX savings (ongoing operating cost).
Over the past four years, FLSmidth and Haldor Topsoe have
worked closely together on developing the patent-pending
EnviroTex™ technology. The product has been thoroughly tested
and proven efficient for several industrial applications.
Key to the development of this unique product is the combination
of FLSmidth's expertise and market leadership in filters for
industrial processes as well as process integration and Haldor
Topsoe’s leadership in catalysis. >>

Smashing the costs

Since the filter bag requires less space than alternative solutions, it
also provides opportunities to reduce the physical footprint.

Ole Bøegh, CEO, FLSmidth Air Pollution Control says, “We believe

of removing gaseous
the catalytic filter bag will be a game-changer because it enables
cement plant owners to clean industrial off-gases and meet
stricter legislation at a fraction of the cost compared with best

emissions and dust

available technologies today.”

A game-changing filter bag based on
catalytic technology provides significant
CAPEX and OPEX reductions.
FLSmidth has teamed up with the Danish catalyst specialist Haldor
Topsoe to release a new type of filter bag. Called EnviroTex™, it is
capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one integrated and cost-effective process.
It has been designed for use at cement plants, but it can just as
easily be used in power production, biomass, waste incineration,
glass and metal production, and similar.
The key differentiating factor about the patent-pending catalytic
filter bag lies in its three layers of filter fabric. Each layer contains a
tailored catalyst optimised for the removal of specific kinds of
compounds from the off-gas that passes through it.
Ole Bøegh explains the bag’s uniqueness: “It doesn’t just provide
us with the flexibility to tailor different catalytic combinations for
different industries; it also makes it possible to handle the removal
of several critical compounds in one integrated process. This can
significantly reduce the cost of off-gas cleaning. Remember that
today’s standard is to use separate stand-alone systems to remove
specific compounds.”
Fast-tracking innovation potential
Denmark-based Haldor Topsoe is a highly successfully
manufacturer and researcher within catalysis and surface science.
22 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 23

SITE REPORT

New
SMASHING THE COSTS CONTACT RAZAL ALI
OF REMOVING GASEOUS RAZAL.ALI@FLSMIDTH.COM
EMISSIONS AND DUST

pyro system and cement

“Developing this product has been a combination of the very best
that Topsoe and FLSmidth have to offer from an R&D perspective.
By combining FLSmidth's expertise in filtration in industrial
processes with Topsoe’s leadership in catalysis, we have created a
unique product that will allow customers to meet increasingly
stringent environmental legislation” says Bjerne S. Clausen, CEO
at Haldor Topsoe.
Thomas Schulz, CEO of FLSmidth says, “It is an imperative for
FLSmidth to retain technology leadership with innovative new
solutions increasing energy efficiency and lowering cement plants’
environmental impact at a competitive lifecycle cost.”
He adds, “The EnviroTex™ catalytic filter bags will enable cement
plants to upgrade their environmental equipment to fulfill
tightened legislation at low cost and with minimum influence on
existing production equipment.”
Efficient removal of gaseous emissions and
particulate matter
Whereas a normal filter bag is a one-layer filter of textile, EnviroTex
has a three-layer porous woven structure with various catalyst
formulas customised for each layer through which gases are sent,
leaving the dust on the outer surface and removing the gaseous
pollutants when passing through the layers. Typically, the filter
bags are six to ten meters long and have a diameter of 127 mm.
EMBEDDED CATALYST IN WOVEN FIBER GLASS BAG
mills for Manikgarh Cement
Manikgarh Cement Limited, owned by India’s BK Birla Group of
Companies, has successfully commissioned a three million tpy
cement plant.
The cement producer first announced its
plans to build a brownfield integrated
cement plant in 2010. Located in
Gadchandur, a town in the Chandrapur
District in the State of Maharashtra,
Manikgarh Cement is a division of
Century Textiles & Industries Ltd., owned
by the BK Birla Group, which operates
within a variety of industries, including
textiles, rayon, chemicals, paper & pulp,
and cement.
Following a lengthy series of technical
and commercial negotiations, during
which many different solutions were
It will easily remove dust below 5mg/Nm3. At the same time, it weighed up, Manikgarh Cement awarded
converts nitrogen oxides (NOx) and ammonia (NH3) into harmless the contract for supply of pyro processing
nitrogen (N2) and water (H2O). Organic hazardous air pollutants system and cement mills to FLSmidth. The
(O-HAP), including toluene, benzene and formaldehyde, are project kicked off immediately after the
converted into carbon dioxide (CO2) and water (H2O). Dioxin, signing of the contracts for both projects
furans and CO are also removed if it is present in the flue gas. in May 2010.
Immediate opportunities in the US Modern pyro processing system
“Initially we believe the US market will benefit from the product, The scope of the 8,000 tpd pyro
because cement producers here are faced with immediate processing system includes the design,
challenge in order to meet new regulatory requirements that engineering, manufacture and supply of
have been issued by the US Environmental Protection Agency the complete array of equipment.
and will take effect 1 September 2015,” says Thomas Schulz,
CEO at FLSmidth. It features a CF silo for homogenising and
storing raw meal with a capacity of
He points out that, in the longer term, China may hold an even 24,000 tonnes and bulk density of
greater market potential as the country is also imposing stricter 0.9 t/m3. With a six-stage twin string
emission legislation. Inline Calciner (ILC), its preheater was
designed to optimise fuel and power
As part of the agreement between FLSmidth and Topsoe, the consumption and minimise emissions.
new product will be manufactured at FLSmidth’s bag production
facilities in Georgia, USA. The high quality filter bags will then be The rotary kiln was lit up on 17 August
embedded with catalyst and assembled at Topsoe’s catalyst 2014 and was soon producing the desired
production site in Houston, Texas. clinker output of 8,000 tpd.
Scope of supply - Pyro process
• CF silo – 22.4m in diameter, 55m
in height
• Kiln feed system
• ILC preheater – 8m in diameter, 160m
in height
• 3-base rotary kiln – 5.5m in diameter,
87m in length
• SF Cross Bar® 5x7F clinker cooler, with
heavy-duty roller breaker MF 418
• Coal dozing and firing system
• Clinker transport to storage
Cement mill
The cement mill contract included the
complete design, engineering, PREHEATER VIEW
manufacturing and supply of equipment.
The UMS ball mills supplied as part of the
contract grind at the rate of 150 tph.
All three mills have been commissioned
and are currently running at the expected
production rate, while performance Project timeline
guarantee tests are currently in progress.
26 May 2010
Scope of supply - Cement grinding Contract signed
• UMS Ball mill - 4.6m dia x 15.5 m long
• Dynamic separator Sepax 500 M-22 May 2011
Completion of engineering
Razal Ali, Project Manager, was
responsible for the project delivery from November 2011
FLSmidth. He is very pleased that the Site mobilisation (mechanical)
project ran smoothly, saying, “There was
no delay in deliveries, which is one of the September 2012
most essential aspects of completing a Supply of major equipment
project on time and at the expected level
of perfection.” He adds that the 17 August 2014
cooperation between FLSmidth and Plant commissioning
Manikgarh’s cement execution teams was
highly efficient.
22 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 23

SITE REPORT

New
SMASHING THE COSTS CONTACT RAZAL ALI
OF REMOVING GASEOUS RAZAL.ALI@FLSMIDTH.COM
EMISSIONS AND DUST

pyro system and cement

“Developing this product has been a combination of the very best
that Topsoe and FLSmidth have to offer from an R&D perspective.
By combining FLSmidth's expertise in filtration in industrial
processes with Topsoe’s leadership in catalysis, we have created a
unique product that will allow customers to meet increasingly
stringent environmental legislation” says Bjerne S. Clausen, CEO
at Haldor Topsoe.
Thomas Schulz, CEO of FLSmidth says, “It is an imperative for
FLSmidth to retain technology leadership with innovative new
solutions increasing energy efficiency and lowering cement plants’
environmental impact at a competitive lifecycle cost.”
He adds, “The EnviroTex™ catalytic filter bags will enable cement
plants to upgrade their environmental equipment to fulfill
tightened legislation at low cost and with minimum influence on
existing production equipment.”
Efficient removal of gaseous emissions and
particulate matter
Whereas a normal filter bag is a one-layer filter of textile, EnviroTex
has a three-layer porous woven structure with various catalyst
formulas customised for each layer through which gases are sent,
leaving the dust on the outer surface and removing the gaseous
pollutants when passing through the layers. Typically, the filter
bags are six to ten meters long and have a diameter of 127 mm.
EMBEDDED CATALYST IN WOVEN FIBER GLASS BAG
mills for Manikgarh Cement
Manikgarh Cement Limited, owned by India’s BK Birla Group of
Companies, has successfully commissioned a three million tpy
cement plant.
The cement producer first announced its
plans to build a brownfield integrated
cement plant in 2010. Located in
Gadchandur, a town in the Chandrapur
District in the State of Maharashtra,
Manikgarh Cement is a division of
Century Textiles & Industries Ltd., owned
by the BK Birla Group, which operates
within a variety of industries, including
textiles, rayon, chemicals, paper & pulp,
and cement.
Following a lengthy series of technical
and commercial negotiations, during
which many different solutions were
It will easily remove dust below 5mg/Nm3. At the same time, it weighed up, Manikgarh Cement awarded
converts nitrogen oxides (NOx) and ammonia (NH3) into harmless the contract for supply of pyro processing
nitrogen (N2) and water (H2O). Organic hazardous air pollutants system and cement mills to FLSmidth. The
(O-HAP), including toluene, benzene and formaldehyde, are project kicked off immediately after the
converted into carbon dioxide (CO2) and water (H2O). Dioxin, signing of the contracts for both projects
furans and CO are also removed if it is present in the flue gas. in May 2010.
Immediate opportunities in the US Modern pyro processing system
“Initially we believe the US market will benefit from the product, The scope of the 8,000 tpd pyro
because cement producers here are faced with immediate processing system includes the design,
challenge in order to meet new regulatory requirements that engineering, manufacture and supply of
have been issued by the US Environmental Protection Agency the complete array of equipment.
and will take effect 1 September 2015,” says Thomas Schulz,
CEO at FLSmidth. It features a CF silo for homogenising and
storing raw meal with a capacity of
He points out that, in the longer term, China may hold an even 24,000 tonnes and bulk density of
greater market potential as the country is also imposing stricter 0.9 t/m3. With a six-stage twin string
emission legislation. Inline Calciner (ILC), its preheater was
designed to optimise fuel and power
As part of the agreement between FLSmidth and Topsoe, the consumption and minimise emissions.
new product will be manufactured at FLSmidth’s bag production
facilities in Georgia, USA. The high quality filter bags will then be The rotary kiln was lit up on 17 August
embedded with catalyst and assembled at Topsoe’s catalyst 2014 and was soon producing the desired
production site in Houston, Texas. clinker output of 8,000 tpd.
Scope of supply - Pyro process
• CF silo – 22.4m in diameter, 55m
in height
• Kiln feed system
• ILC preheater – 8m in diameter, 160m
in height
• 3-base rotary kiln – 5.5m in diameter,
87m in length
• SF Cross Bar® 5x7F clinker cooler, with
heavy-duty roller breaker MF 418
• Coal dozing and firing system
• Clinker transport to storage
Cement mill
The cement mill contract included the
complete design, engineering, PREHEATER VIEW
manufacturing and supply of equipment.
The UMS ball mills supplied as part of the
contract grind at the rate of 150 tph.
All three mills have been commissioned
and are currently running at the expected
production rate, while performance Project timeline
guarantee tests are currently in progress.
26 May 2010
Scope of supply - Cement grinding Contract signed
• UMS Ball mill - 4.6m dia x 15.5 m long
• Dynamic separator Sepax 500 M-22 May 2011
Completion of engineering
Razal Ali, Project Manager, was
responsible for the project delivery from November 2011
FLSmidth. He is very pleased that the Site mobilisation (mechanical)
project ran smoothly, saying, “There was
no delay in deliveries, which is one of the September 2012
most essential aspects of completing a Supply of major equipment
project on time and at the expected level
of perfection.” He adds that the 17 August 2014
cooperation between FLSmidth and Plant commissioning
Manikgarh’s cement execution teams was
highly efficient.
24 HIGHLIGHTS CEMENT – APRIL 2015
PRODUCTS & SOLUTIONS
CONTACT JENS HARMUNDAL PETERSEN
JHP@FLSMIDTH.COM
“SINCE THE FAN IS
CONTAINED IN A SINGLE
UNIT, THERE ARE FEWER
PARTS TO INSTALL.”
Jens Harmundal Petersen
Chief Product Engineer at FLSmidth
FLSmidth’s double-suction HAF (DHAF)
fan is a new-generation, highly efficient
fan designed specifically for cement
plants. The result of a two-year
development project, the DHAF fan is a
development of FLSmidth’s HAF fan,
which has been widely used in cement
plants since 1980. With a much higher
flow rate and efficiency level than
conventional HAF fans, the DHAF can be
put to use in kilns, dryer crushers, raw
mills, OK™ mills, coal mills, and other
high-capacity applications.
Technological advances
The launch of the DHAF fan marks a
significant expansion of FLSmidth’s fan
range, and it meets the growing demand
DHAF 250 FULL-SIZE AMCA TEST AT WORKSHOP for fans that can deliver high performance
and excellent efficiency. The latest three-
dimensional Computational Fluid
Dynamics (CFD) simulation technologies
 Pumping up the
were used in designing and optimising
the fan to meet market requirements.
Power
Jens Harmundal Petersen, Chief Product
Engineer at FLSmidth says the fan has
been designed specifically to withstand
the harsh conditions of cement plants.
“It is particularly suitable for use in the
pyro and grinding processes,”he says.
“The double-suction technology that we
have added to the HAF fan means that a
Based on proven technology, FLSmidth’s newly single installation can easily generate the
developed DHAF fan handles all the demands flows required by today’s modern cement
plant equipment. Standard HAF fans do
of today’s cement plants for durability, cost not have the necessary power to
efficiency and easier installation. generate these flows.”
Standardised installation
Not only will the highly efficient DHAF fan
help to reduce operational costs and
energy consumption, but it will also save
on installation costs.
“Since the fan is contained in a single
unit, there are fewer parts to install,”
explains Jens Harmundal Petersen.
“For example, the fan’s rotor part is
delivered assembled, including coupling,
bearings and cool disk, and the inlet cone
is supplied with an adjustment tool for
easy adjustment of the inlet cone
position,”he says, adding, “Combined
with its competitive pricing, this gives the
DHAF a lower total installation cost than
previous similar solutions.”
Model testing at FLSmidth´s Dania R&D
centre and full-size workshop testing have
shown impressive results, with efficiencies
consistently higher than conventional HAF
fans. And as the DHAF has been
developed by FLSmidth, customers can
have quick access to product
documentation and basic data, such as
outline and load drawings and motor
data. “This means manufacturing can
begin earlier and we can deliver the
product faster,”says Jens Harmundal
Petersen.
FLSmidth’s DHAF fans are available in 10
standard sizes with impeller diameters
ranging from 1.8 to 5.5 metres. The first
two DHAF fans have been commissioned
at a plant in Asia.
HIGHLIGHTS CEMENT – APRIL 2015 25
DHAF
fan key features
• Design range of 60 to 900 m3/s at
5,000 to 25,000 Pa
• The new shaft cone improves fan
performance and protects the shaft
against wear
• Equal inlet and outlet velocity
eliminates need for a diffuser
• All DHAF fans can be delivered with
different degrees of wear protection
for the impeller and fan casing
• Special hub wear protection protects
the hub and the hub bolts
• DHAF fans are prepared for the
active control balancing system
• The bearings have a calculated
lifetime of at least 100,000 hours
• The rotor is manufactured in Europe
to the highest quality standards
Fan design
OK Mill filter fan
Pressure total: 9475 Pa
Volume flow: 186 m3/s
Efficiency: 87.7%
Fans ordered
to date
3 ID fans
2 Raw Mill fans
1 Dryer crusher fan
10 OK Mill filter fans
24 HIGHLIGHTS CEMENT – APRIL 2015
PRODUCTS & SOLUTIONS
CONTACT JENS HARMUNDAL PETERSEN
JHP@FLSMIDTH.COM
“SINCE THE FAN IS
CONTAINED IN A SINGLE
UNIT, THERE ARE FEWER
PARTS TO INSTALL.”
Jens Harmundal Petersen
Chief Product Engineer at FLSmidth
FLSmidth’s double-suction HAF (DHAF)
fan is a new-generation, highly efficient
fan designed specifically for cement
plants. The result of a two-year
development project, the DHAF fan is a
development of FLSmidth’s HAF fan,
which has been widely used in cement
plants since 1980. With a much higher
flow rate and efficiency level than
conventional HAF fans, the DHAF can be
put to use in kilns, dryer crushers, raw
mills, OK™ mills, coal mills, and other
high-capacity applications.
Technological advances
The launch of the DHAF fan marks a
significant expansion of FLSmidth’s fan
range, and it meets the growing demand
DHAF 250 FULL-SIZE AMCA TEST AT WORKSHOP for fans that can deliver high performance
and excellent efficiency. The latest three-
dimensional Computational Fluid
Dynamics (CFD) simulation technologies
 Pumping up the
were used in designing and optimising
the fan to meet market requirements.
Power
Jens Harmundal Petersen, Chief Product
Engineer at FLSmidth says the fan has
been designed specifically to withstand
the harsh conditions of cement plants.
“It is particularly suitable for use in the
pyro and grinding processes,”he says.
“The double-suction technology that we
have added to the HAF fan means that a
Based on proven technology, FLSmidth’s newly single installation can easily generate the
developed DHAF fan handles all the demands flows required by today’s modern cement
plant equipment. Standard HAF fans do
of today’s cement plants for durability, cost not have the necessary power to
efficiency and easier installation. generate these flows.”
Standardised installation
Not only will the highly efficient DHAF fan
help to reduce operational costs and
energy consumption, but it will also save
on installation costs.
“Since the fan is contained in a single
unit, there are fewer parts to install,”
explains Jens Harmundal Petersen.
“For example, the fan’s rotor part is
delivered assembled, including coupling,
bearings and cool disk, and the inlet cone
is supplied with an adjustment tool for
easy adjustment of the inlet cone
position,”he says, adding, “Combined
with its competitive pricing, this gives the
DHAF a lower total installation cost than
previous similar solutions.”
Model testing at FLSmidth´s Dania R&D
centre and full-size workshop testing have
shown impressive results, with efficiencies
consistently higher than conventional HAF
fans. And as the DHAF has been
developed by FLSmidth, customers can
have quick access to product
documentation and basic data, such as
outline and load drawings and motor
data. “This means manufacturing can
begin earlier and we can deliver the
product faster,”says Jens Harmundal
Petersen.
FLSmidth’s DHAF fans are available in 10
standard sizes with impeller diameters
ranging from 1.8 to 5.5 metres. The first
two DHAF fans have been commissioned
at a plant in Asia.
HIGHLIGHTS CEMENT – APRIL 2015 25
DHAF
fan key features
• Design range of 60 to 900 m3/s at
5,000 to 25,000 Pa
• The new shaft cone improves fan
performance and protects the shaft
against wear
• Equal inlet and outlet velocity
eliminates need for a diffuser
• All DHAF fans can be delivered with
different degrees of wear protection
for the impeller and fan casing
• Special hub wear protection protects
the hub and the hub bolts
• DHAF fans are prepared for the
active control balancing system
• The bearings have a calculated
lifetime of at least 100,000 hours
• The rotor is manufactured in Europe
to the highest quality standards
Fan design
OK Mill filter fan
Pressure total: 9475 Pa
Volume flow: 186 m3/s
Efficiency: 87.7%
Fans ordered
to date
3 ID fans
2 Raw Mill fans
1 Dryer crusher fan
10 OK Mill filter fans
26 HIGHLIGHTS CEMENT – APRIL 2015
INNOVATION
CONTACT CARSTEN DAMSLUND JENSEN
CDJ@FLSMIDTH.COM
Significant
reduction
in power consumption for FLSmidth® Cross-Bar® cooler
Reducing the pressure drop for the
OPTIMISATION STUDY
RESULTS IN DESIGN UPDATES
FLSmidth® Cross-Bar® cooler, with an eye
toward lowering the power consumption
TO REDUCE PRESSURE DROP
IN THE COOLER FOR ALL NEW
of the undergrate fans, was targeted as
INSTALLATIONS.
part of FLSmidth’s continuous product
improvement initiatives. The project goal
– defined by an optimisation study based
on field experience and customer
feedback – was to reduce power
consumption by 20 percent. This
optimisation is made while having no
impact on the FLSmidth Cross-Bar cooler's
market leading efficiency and
performance.
Reducing pressure loss
The cooler fans – used for cooling and
heat recuperation – account for 85
percent of the total energy consumption.
Modifications were made to reduce fan
power consumption, including
modifications of the cooler casing duct
system.
The central focus of the study, however,
was on power consumption improvement
through reducing pressure loss, including
modifications to the grate plates (Air
Distribution Plates or ADP). Special
attention was given to flow patterns
within the grate plates, which were
known to cause a significant part of the
total pressure drop due to the design.
New design possibilities were studied and
a solution that reduced pressure drop was
implemented in a revised design, which
HIGHLIGHTS CEMENT – APRIL 2015 27
CFD MODELLING HELPS TO EVALUATE THE
IMPACT OF DESIGN MODIFICATIONS ON
PRESSURE DROP THE UPDATED DESIGN WILL
NOW BE INCLUDED WITH ALL
NEW FLSMIDTH CROSS-BAR
provided approximately 80 percent of the
COOLERS GOING FORWARD.
total power savings. THIS WILL PROVIDE END USERS
The solution has been tested and WITH A MORE ENERGY-
validated at the FLSmidth Dania research
facility, where a complete FLSmidth Cross-
EFFICIENT COOLER WITH THE
Bar cooler installation acts as a test rig for
continued product and process
BENEFIT OF REDUCED
improvements. In the end, the project UNDERGRATE FAN POWER
goal of reducing power consumption by
20 percent was achieved.
CONSUMPTION.
The graph shows how the pressure drop
has been reduced over the range of air
flows.
Going forward MEASURED PRESSURE DROP THROUGH GRATE PLATES
The updated design will now be included 100
with all new FLSmidth Cross-Bar coolers 90 Standard Grate Plate
Pressure Drop [kPa/%]
going forward. This will provide end users 80 New optimized Grate Plate
with a more energy-efficient cooler with 70
the benefit of reduced undergrate fan 60
power consumption. In addition to new
50
coolers, this updated design could also be
40
retrofitted to existing FLSmidth Cross-Bar
30
coolers as evaluated on a case-by-case
basis. 20
10
Since its inception in 1997, FLSmidth has
sold over 300 Cross-Bar coolers. 0 50 100
This latest project to reduce power Air Flow [kg/min/m2]
consumption is part of FLSmidth’s
continuous product development efforts
to improve and evolve the Cross-Bar
Read more about the
cooler design based on operating
FLSmidth® Cross-Bar® cooler
experience and feedback from our
on www.flsmidth.com/cooler
customers.
26 HIGHLIGHTS CEMENT – APRIL 2015
INNOVATION
CONTACT CARSTEN DAMSLUND JENSEN
CDJ@FLSMIDTH.COM
Significant
reduction
in power consumption for FLSmidth® Cross-Bar® cooler
Reducing the pressure drop for the
OPTIMISATION STUDY
RESULTS IN DESIGN UPDATES
FLSmidth® Cross-Bar® cooler, with an eye
toward lowering the power consumption
TO REDUCE PRESSURE DROP
IN THE COOLER FOR ALL NEW
of the undergrate fans, was targeted as
INSTALLATIONS.
part of FLSmidth’s continuous product
improvement initiatives. The project goal
– defined by an optimisation study based
on field experience and customer
feedback – was to reduce power
consumption by 20 percent. This
optimisation is made while having no
impact on the FLSmidth Cross-Bar cooler's
market leading efficiency and
performance.
Reducing pressure loss
The cooler fans – used for cooling and
heat recuperation – account for 85
percent of the total energy consumption.
Modifications were made to reduce fan
power consumption, including
modifications of the cooler casing duct
system.
The central focus of the study, however,
was on power consumption improvement
through reducing pressure loss, including
modifications to the grate plates (Air
Distribution Plates or ADP). Special
attention was given to flow patterns
within the grate plates, which were
known to cause a significant part of the
total pressure drop due to the design.
New design possibilities were studied and
a solution that reduced pressure drop was
implemented in a revised design, which
HIGHLIGHTS CEMENT – APRIL 2015 27
CFD MODELLING HELPS TO EVALUATE THE
IMPACT OF DESIGN MODIFICATIONS ON
PRESSURE DROP THE UPDATED DESIGN WILL
NOW BE INCLUDED WITH ALL
NEW FLSMIDTH CROSS-BAR
provided approximately 80 percent of the
COOLERS GOING FORWARD.
total power savings. THIS WILL PROVIDE END USERS
The solution has been tested and WITH A MORE ENERGY-
validated at the FLSmidth Dania research
facility, where a complete FLSmidth Cross-
EFFICIENT COOLER WITH THE
Bar cooler installation acts as a test rig for
continued product and process
BENEFIT OF REDUCED
improvements. In the end, the project UNDERGRATE FAN POWER
goal of reducing power consumption by
20 percent was achieved.
CONSUMPTION.
The graph shows how the pressure drop
has been reduced over the range of air
flows.
Going forward MEASURED PRESSURE DROP THROUGH GRATE PLATES
The updated design will now be included 100
with all new FLSmidth Cross-Bar coolers 90 Standard Grate Plate
Pressure Drop [kPa/%]
going forward. This will provide end users 80 New optimized Grate Plate
with a more energy-efficient cooler with 70
the benefit of reduced undergrate fan 60
power consumption. In addition to new
50
coolers, this updated design could also be
40
retrofitted to existing FLSmidth Cross-Bar
30
coolers as evaluated on a case-by-case
basis. 20
10
Since its inception in 1997, FLSmidth has
sold over 300 Cross-Bar coolers. 0 50 100
This latest project to reduce power Air Flow [kg/min/m2]
consumption is part of FLSmidth’s
continuous product development efforts
to improve and evolve the Cross-Bar
Read more about the
cooler design based on operating
FLSmidth® Cross-Bar® cooler
experience and feedback from our
on www.flsmidth.com/cooler
customers.
28 HIGHLIGHTS CEMENT – APRIL 2015
PRODUCTS & SOLUTIONS
Financing
paves the way in DR Congo
Thanks to FLSmidth’s
connections and experience
with financing major
development projects, DR
Congo will see its first new
cement plant in 40 years.
A major new cement plant will soon become a reality in the
Democratic Republic of the Congo, made possible by the patience
and determination of visionary partners and financiers. This is a
significant development for the country and is driven by a trend
towards higher cement prices and burgeoning urban and
industrial development.
The 1.18 mtpy greenfield plant, Nyumba Ya Akiba SA, is not only
the first cement plant to be built in the country in 40 years, but it
will also become the country’s largest cement producer. It is a
50/50 joint venture between Pakistan’s largest cement producer,
HIGHLIGHTS CEMENT – APRIL 2015 29
CONTACT TINE BREMHOLM KOKFELT
TBK@FLSMIDTH.COM
Lucky Cement Ltd and Group Rawji, one of DR Congo’s largest
conglomerates. The project involves the construction of a
greenfield cement manufacturing plant with its associated
facilities. “WE APPRECIATE THAT
But launching a project of this kind and magnitude requires much
FLSMIDTH HAS A LOT
more than acquiring the right equipment and building the right
plant. Financing is key. And with a massive USD 270 million
OF EXPERIENCE IN
needed for Nyumba Ya Akiba, it was imperative that all parties FACILITATING PROJECT
could agree on the financing terms.
FINANCING, SO WE
A powerful partnership
The joint venture between Lucky Cement and the Rawji Group,
WERE CONFIDENT
both supported by FLSmidth, is in many ways a perfect match. THEY WERE THE
Lucky Cement brings cement production expertise and a strong
heritage of business development in a developing economy, while
RIGHT PARTNER FOR
the Rawji Group contributes equally with its commercial expertise
founded strongly in the local DR Congo economy. However, the
THE PROJECT.“
project owners had limited experience in the size and type of Muhammad Faisal,
international financing required for this project. So with exactly CFO and Chief Investment Officer (CIO) at Lucky Cement
this experience and track record in facilitating financing for
customers, FLSmidth was perfectly positioned to provide the
necessary support.
Tine Bremholm Kokfelt, Department Manager of Global Project &
Export Finance at FLSmidth, has been heavily involved in several
financing agreements in recent years. She explains that FLSmidth’s
experience spans several development projects in emerging and
developing economies, which has led to the development of a
Boosting business activity
wide network within the international financing community. in DR Congo
The Nyumba Ya Akiba cement plant will have significant
Fifty percent of the project cost, USD 135 million, was put up in
economic impact on the local region. In addition to supplying
equity by the two joint venture partners while the remaining
to DR Congo’s internal cement market, it will also produce
financing was provided in loans from five different lenders: the
African Development Bank (AfDB), Danish Export Credit Agency
cement for export.
(EKF, Denmark’s Export Credit Agency), International Finance
Corporation (IFC), Emerging Africa Infrastructure Fund (EAIF), and
The local infrastructure will be expanded with storage facilities,
Habib Bank Limited (HBL).
power lines, employee housing, waste management facilities,
access roads, rail connections and other auxiliary facilities.
Perseverance and skill
In addition to creating upwards of 400 jobs – and an estimated
But with significant commitments required from these different
parties, the entire process required perseverance, intimate market
10,000 indirect jobs, the project will advance the domestic
market and hasten technological development in the region.
knowledge and some skilled negotiation to make it all come
together. >>
28 HIGHLIGHTS CEMENT – APRIL 2015
PRODUCTS & SOLUTIONS
Financing
paves the way in DR Congo
Thanks to FLSmidth’s
connections and experience
with financing major
development projects, DR
Congo will see its first new
cement plant in 40 years.
A major new cement plant will soon become a reality in the
Democratic Republic of the Congo, made possible by the patience
and determination of visionary partners and financiers. This is a
significant development for the country and is driven by a trend
towards higher cement prices and burgeoning urban and
industrial development.
The 1.18 mtpy greenfield plant, Nyumba Ya Akiba SA, is not only
the first cement plant to be built in the country in 40 years, but it
will also become the country’s largest cement producer. It is a
50/50 joint venture between Pakistan’s largest cement producer,
HIGHLIGHTS CEMENT – APRIL 2015 29
CONTACT TINE BREMHOLM KOKFELT
TBK@FLSMIDTH.COM
Lucky Cement Ltd and Group Rawji, one of DR Congo’s largest
conglomerates. The project involves the construction of a
greenfield cement manufacturing plant with its associated
facilities. “WE APPRECIATE THAT
But launching a project of this kind and magnitude requires much
FLSMIDTH HAS A LOT
more than acquiring the right equipment and building the right
plant. Financing is key. And with a massive USD 270 million
OF EXPERIENCE IN
needed for Nyumba Ya Akiba, it was imperative that all parties FACILITATING PROJECT
could agree on the financing terms.
FINANCING, SO WE
A powerful partnership
The joint venture between Lucky Cement and the Rawji Group,
WERE CONFIDENT
both supported by FLSmidth, is in many ways a perfect match. THEY WERE THE
Lucky Cement brings cement production expertise and a strong
heritage of business development in a developing economy, while
RIGHT PARTNER FOR
the Rawji Group contributes equally with its commercial expertise
founded strongly in the local DR Congo economy. However, the
THE PROJECT.“
project owners had limited experience in the size and type of Muhammad Faisal,
international financing required for this project. So with exactly CFO and Chief Investment Officer (CIO) at Lucky Cement
this experience and track record in facilitating financing for
customers, FLSmidth was perfectly positioned to provide the
necessary support.
Tine Bremholm Kokfelt, Department Manager of Global Project &
Export Finance at FLSmidth, has been heavily involved in several
financing agreements in recent years. She explains that FLSmidth’s
experience spans several development projects in emerging and
developing economies, which has led to the development of a
Boosting business activity
wide network within the international financing community. in DR Congo
The Nyumba Ya Akiba cement plant will have significant
Fifty percent of the project cost, USD 135 million, was put up in
economic impact on the local region. In addition to supplying
equity by the two joint venture partners while the remaining
to DR Congo’s internal cement market, it will also produce
financing was provided in loans from five different lenders: the
African Development Bank (AfDB), Danish Export Credit Agency
cement for export.
(EKF, Denmark’s Export Credit Agency), International Finance
Corporation (IFC), Emerging Africa Infrastructure Fund (EAIF), and
The local infrastructure will be expanded with storage facilities,
Habib Bank Limited (HBL).
power lines, employee housing, waste management facilities,
access roads, rail connections and other auxiliary facilities.
Perseverance and skill
In addition to creating upwards of 400 jobs – and an estimated
But with significant commitments required from these different
parties, the entire process required perseverance, intimate market
10,000 indirect jobs, the project will advance the domestic
market and hasten technological development in the region.
knowledge and some skilled negotiation to make it all come
together. >>
30 HIGHLIGHTS CEMENT – APRIL 2015
FINANCING PAVES THE WAY
IN DR CONGO
30m USD
EKF/African Development Bank
30m USD
African Development Bank
DEBT
30m USD
IFC
30m USD
Emerging Africa Infrastructure Fund
“Obtaining financing for projects in developing economies is
complex and often challenging,” says Tine Bremholm Kokfelt.
“The key is to understand the requirements and capabilities of all
parties, align expectations, and obtain assurances that everyone
will live up to their commitments.”
“The requirements for a project finance structure for a greenfield
project in a country such as DR Congo are comprehensive,” she
elaborates. “A thorough due diligence process, including
environmental and social assessment, was undertaken and
coordinated by the lenders, independent consultants and advisors.
This included producing extensive loan documentation and
agreements between the various parties, which is no easy task.”
Throughout the process, EKF, Denmark’s Export Credit Agency,
played an important role, not backing away from challenges that
arose. “Without the strong support by EKF and subsequent
involvement of the legal advisors of the lender group, we would
67.5m
USD
Lucky Cement
EQUITY
67.5m
Rawji Group
USD
15m USD
Habib Bank
not have reached the final agreement,” states Tine Bremholm
Kokfelt.
The partnership between EKF and the African Development Bank
(AfDB) was a vital piece of the financing puzzle, too, with the two
parties creating a new financial structure in 2014. For Nyumba Ya
Akiba, AfDB fronted two facilities of USD 30m, of which one was
fully guaranteed by EKF. “ DR-Congo is a challenging country and
EKF would not have been able to support the Project without the
participation of and close cooperation between the high quality
lending parties, sponsors and FLSmidth” says Senior Director
Morten Sørensen of EKF.
“This was the second time AfDB and EKF had worked closely
together, creating an excellent basis for a greater cooperation on
the African continent,” says Fernando Rodrigues, Senior
Investment Officer at AfDB. “It was the first time we had worked
with FLSmidth – a cooperation that could pave the way for new
opportunities of collaboration into common areas of intervention
in the mining sector,” he adds.
Paving the way
Muhammad Faisal, CFO and Chief Investment Officer (CIO) at
Lucky Cement admitted it was a big step to invest in DR Congo
operations, but he is confident in the partnerships with Rawji
Group and FLSmidth: “We have worked with FLSmidth in Pakistan
and we think that FLSmidth has the best technology supported by
highly competent advisors and engineers. We also appreciate that
FLSmidth has a lot of experience in facilitating project financing,
so we were confident they were the right partner for the project.”
Muhammad Faisal added that Lucky Cement would not have
been in DR Congo without Group Rawji and Group Rawji would
not have been in cement business without Lucky Cement. This is
considered to be an ideal combination of a leading cement player
from Pakistan with one of the largest business groups in DR
Congo to make this huge investment for building and developing
DR Congo.
For Lucky Cement, this was first of its kind and also a break-
through opportunity and important for its future growth. Not only
was it the company’s biggest foreign investment, but it was also
the first time the company had obtained financing from
multilateral and international financial institutions.
“This is a major step for Lucky Cement. In entering into the
agreements with various parties, we wanted to be absolutely sure
all the right foundations were in place to support our partnership
with Group Rawji and to secure our future in DR Congo,” says
Muhammad Faisal, CFO and CIO Lucky Cement, adding, “We
believe we have achieved that and have started construction of
the plant now.”
Indeed, the success of this financing could have long-term
ramifications, marking a different approach to large projects and
investments in developing countries such as DR Congo. >>
“AT FLSMIDTH, WE HAVE A GOOD TRACK
RECORD IN ESTABLISHING CEMENT
PLANTS IN DEVELOPING COUNTRIES, SO
WE USUALLY KNOW WHAT THE RISKS
ARE AND HOW TO MANAGE THEM.“
Tine Bremholm Kokfelt
Department Manager, Global Project & Export Finance, FLSmidth
HIGHLIGHTS CEMENT – APRIL 2015 31
Investor profiles
Lucky Cement
With a total production capacity of 7.75 million tpy and 19
percent overall market share, Lucky Cement is Pakistan's
largest cement manufacturer and exporter. The company is
part of one of Pakistan's largest conglomerates, the Yunus
Brothers Group and is listed on the London Stock Exchange
as well as Karachi, Lahore and Islamabad Stock Exchanges
in Pakistan.
Founded in 1993, the company has developed to be the
Pakistani cement industry's trendsetter in terms of business
excellence, innovation and environmental performance.
Other than Cement as its core business in Pakistan, the
Company diversified by way of acquiring majority shares of
ICI Pakistan Limited in 2012 and recently announced a 660
MW coal based power project in Karachi, Pakistan. The
proposed investment in coal based power project is to the tune
of more than US$ 1.0 billion. The company is highly
experienced in working within developing economies and aims
to expand its footprint to other developing countries. Almost a
year ago, it completed an 871,000 tpy, grinding facility in
Basrah, Iraq which is fully operational and contributing towards
to the development of Iraq.
Rawji Group
With over 100 years of history behind it, the Rawji Group is
one of the largest conglomerates in DR Congo. Its activities
span financial services, real estate, manufacturing and
distribution. With its extensive activities, the group has in-
depth knowledge of the country's social fabric and its
economy.
30 HIGHLIGHTS CEMENT – APRIL 2015
FINANCING PAVES THE WAY
IN DR CONGO
30m USD
EKF/African Development Bank
30m USD
African Development Bank
DEBT
30m USD
IFC
30m USD
Emerging Africa Infrastructure Fund
“Obtaining financing for projects in developing economies is
complex and often challenging,” says Tine Bremholm Kokfelt.
“The key is to understand the requirements and capabilities of all
parties, align expectations, and obtain assurances that everyone
will live up to their commitments.”
“The requirements for a project finance structure for a greenfield
project in a country such as DR Congo are comprehensive,” she
elaborates. “A thorough due diligence process, including
environmental and social assessment, was undertaken and
coordinated by the lenders, independent consultants and advisors.
This included producing extensive loan documentation and
agreements between the various parties, which is no easy task.”
Throughout the process, EKF, Denmark’s Export Credit Agency,
played an important role, not backing away from challenges that
arose. “Without the strong support by EKF and subsequent
involvement of the legal advisors of the lender group, we would
67.5m
USD
Lucky Cement
EQUITY
67.5m
Rawji Group
USD
15m USD
Habib Bank
not have reached the final agreement,” states Tine Bremholm
Kokfelt.
The partnership between EKF and the African Development Bank
(AfDB) was a vital piece of the financing puzzle, too, with the two
parties creating a new financial structure in 2014. For Nyumba Ya
Akiba, AfDB fronted two facilities of USD 30m, of which one was
fully guaranteed by EKF. “ DR-Congo is a challenging country and
EKF would not have been able to support the Project without the
participation of and close cooperation between the high quality
lending parties, sponsors and FLSmidth” says Senior Director
Morten Sørensen of EKF.
“This was the second time AfDB and EKF had worked closely
together, creating an excellent basis for a greater cooperation on
the African continent,” says Fernando Rodrigues, Senior
Investment Officer at AfDB. “It was the first time we had worked
with FLSmidth – a cooperation that could pave the way for new
opportunities of collaboration into common areas of intervention
in the mining sector,” he adds.
Paving the way
Muhammad Faisal, CFO and Chief Investment Officer (CIO) at
Lucky Cement admitted it was a big step to invest in DR Congo
operations, but he is confident in the partnerships with Rawji
Group and FLSmidth: “We have worked with FLSmidth in Pakistan
and we think that FLSmidth has the best technology supported by
highly competent advisors and engineers. We also appreciate that
FLSmidth has a lot of experience in facilitating project financing,
so we were confident they were the right partner for the project.”
Muhammad Faisal added that Lucky Cement would not have
been in DR Congo without Group Rawji and Group Rawji would
not have been in cement business without Lucky Cement. This is
considered to be an ideal combination of a leading cement player
from Pakistan with one of the largest business groups in DR
Congo to make this huge investment for building and developing
DR Congo.
For Lucky Cement, this was first of its kind and also a break-
through opportunity and important for its future growth. Not only
was it the company’s biggest foreign investment, but it was also
the first time the company had obtained financing from
multilateral and international financial institutions.
“This is a major step for Lucky Cement. In entering into the
agreements with various parties, we wanted to be absolutely sure
all the right foundations were in place to support our partnership
with Group Rawji and to secure our future in DR Congo,” says
Muhammad Faisal, CFO and CIO Lucky Cement, adding, “We
believe we have achieved that and have started construction of
the plant now.”
Indeed, the success of this financing could have long-term
ramifications, marking a different approach to large projects and
investments in developing countries such as DR Congo. >>
“AT FLSMIDTH, WE HAVE A GOOD TRACK
RECORD IN ESTABLISHING CEMENT
PLANTS IN DEVELOPING COUNTRIES, SO
WE USUALLY KNOW WHAT THE RISKS
ARE AND HOW TO MANAGE THEM.“
Tine Bremholm Kokfelt
Department Manager, Global Project & Export Finance, FLSmidth
HIGHLIGHTS CEMENT – APRIL 2015 31
Investor profiles
Lucky Cement
With a total production capacity of 7.75 million tpy and 19
percent overall market share, Lucky Cement is Pakistan's
largest cement manufacturer and exporter. The company is
part of one of Pakistan's largest conglomerates, the Yunus
Brothers Group and is listed on the London Stock Exchange
as well as Karachi, Lahore and Islamabad Stock Exchanges
in Pakistan.
Founded in 1993, the company has developed to be the
Pakistani cement industry's trendsetter in terms of business
excellence, innovation and environmental performance.
Other than Cement as its core business in Pakistan, the
Company diversified by way of acquiring majority shares of
ICI Pakistan Limited in 2012 and recently announced a 660
MW coal based power project in Karachi, Pakistan. The
proposed investment in coal based power project is to the tune
of more than US$ 1.0 billion. The company is highly
experienced in working within developing economies and aims
to expand its footprint to other developing countries. Almost a
year ago, it completed an 871,000 tpy, grinding facility in
Basrah, Iraq which is fully operational and contributing towards
to the development of Iraq.
Rawji Group
With over 100 years of history behind it, the Rawji Group is
one of the largest conglomerates in DR Congo. Its activities
span financial services, real estate, manufacturing and
distribution. With its extensive activities, the group has in-
depth knowledge of the country's social fabric and its
economy.
32 HIGHLIGHTS CEMENT – APRIL 2015
FINANCING PAVES THE WAY
IN DR CONGO
Lender profiles
EKF
EKF, Denmark’s Export Credit Agency, insures businesses
against extraordinary risks not covered by the private credit
insurance market. In this case, EKF is guaranteeing a USD 30
million loan provided by the African Development Bank.
African Development Bank
The African Development Bank (AfDB) supports the economic
development and social progress of African countries. It
promotes investments in and provides technical assistance to
relevant projects within its member countries. AfDB will
contribute to the development of Nyumba Ya Akiba with two
tranches of up to USD 30 million each, with one tranche being
fully guaranteed by EKF.
IFC
IFC, a member of the World Bank Group, is the largest global
development institution focused exclusively on the private
sector in developing countries. IFC plays an important role in
the project, providing a loan of USD 30 million. This project
aligned particularly well with IFC’s objectives as it is an example
of investment from one developing country, Pakistan, in
another. The project is seen as a good example for other
companies and institutions considering investing in DR Congo.
Emerging Africa Infrastructure Fund
The Emerging Africa Infrastructure Fund (EAIF) is a public
private partnership. It provides long-term denominated debt or
mezzanine finance on commercial terms to finance the
construction and development of private infrastructure in 47
countries across sub-Saharan Africa. EAIF is contributing to the
project with a USD 30 million loan.
Habib Bank
Habib Bank (HBL) is the largest and one of the oldest banks of
Pakistan. HBL’s expanding presence around the world is evident
from the fact that HBL acted as the lead arranger for this
transaction for arranging USD 135 million loan. HBL is also
supporting this foreign direct investment by a successful
Pakistani multinational with a loan of USD 15 million through
its offshore branch.
Normally, financial institutions only look at financing complete
engineering, procurement and construction (EPC) contracts, but in
this case, Lucky Cement insisted that the contract was split into
two elements. With extensive experience and intimate knowledge
of the components and processes required for constructing
cement plants, the Pakistani cement producer has become adept
at reducing overall project costs.
Commenting on the significance, Tine Bremholm Kokfelt says,
“It demonstrates that it is possible to get support for non-EPC
projects in Africa.”
FLSmidth’s supply
FLSmidth is supplying a complete package of equipment and
engineering for the 3,000 tpd cement plant, including all the
engineering, equipment and construction support. The equipment
includes crushers, pyro processing equipment and vertical mills for
raw meal, coal and cement grinding.
The impact of the cement plant on the environment and local
community was a key factor for the owners and lenders choosing
FLSmidth as equipment supplier. They demanded a technology
provider with a proven ability to deliver reliable products and high
level of service, particularly because of the challenging conditions
under which the plant will be installed and operated, pointing to
FLSmidth's proven ability to supply environmentally optimised and
energy-efficient equipment.
Mitigating risk
Along with the considerable upsides of developing Nyumba Ya
Akiba come considerable risks, too. DR Congo’s banking and legal
systems are relatively under-developed and there is perceived to
be some political uncertainty. It was therefore necessary to
structure the financing in such a way that mitigates risk for all
parties as best as possible.
This involves opening up dialogue and making connections, which
is a particular strength of FLSmidth. Tine Bremholm Kokfelt
explains: “At FLSmidth, we have a good track record in
establishing cement plants in developing countries, so we usually
know what the risks are and how to manage them. But it’s
understandable that it can make some parties uneasy. There has,
up to now, only been very limited large private industry projects in
DR Congo.”
With the final financing agreements in place at the end of 2014,
FLSmidth is mobilising the equipment. Cement production is
expected to start towards the end of 2016.
Reflecting on the many days of negotiations and discussions, Tine
Bremholm Kokfelt says that belief in the final outcome throughout
was vital: “This project goes to show that with the right approach
as well as a fair amount of determination and patience, it is
possible to achieve goals that seem unattainable.”
INNOVATION
Easy-to-use
laboratory automation solutions
The newest version of FLSmidth’s QCX® automation software is the
cement industry’s most operator-friendly sample preparation system.
FLSmidth has released a new version of its
QCX/AutoSamplingTM and QCX/RoboLab®
software, marking a major leap forward in
laboratory automation solutions. This
version 8 release offers significantly
improved usability for plant operators and
maintenance personnel.
A focused research and development
programme using feedback from
FLSmidth’s extensive installed base has
resulted in better integration of sampling
equipment, sample preparation equipment
and the software. This integration is
important as it provides better system
availability and minimises operational
costs.
Improved usability
Mette Dobel, Global Product Manager at
FLSmidth explains the objectives behind
the development of the new software:
“Our aim has been to create the most
operator and maintenance-friendly
sampling and sample preparation system
for the cement and minerals industries.”
Operators can configure the software as
necessary to suit their work processes, with
its intuitive user interfaces able to provide
a complete overview of the automated
laboratory, the sampling system and the
analysis results. Standard tasks, including
preparing sample preparation recipes and
tracking samples and results, can be
performed quickly and easily.
New software standards
According to Mette Dobel, the software is
developed based on the new QCXSYS V8
programming standard, which allows for
seamless integration with QCX equipment
and the QCX software.
“Consequently, all FLSmidth sampling,
sample transport and sample preparation
equipment is delivered with transparent,
uniform and comprehensive equipment
diagnostic tools combined with relevant
equipment performance indicators,” she
says. “This reduces the need for specialised
HIGHLIGHTS CEMENT – APRIL 2015 33
knowledge to operate and maintain the
equipment and enables maintenance
personnel to plan and conduct preventive
maintenance in a fast and direct manner
with the required wear part.”
The launch of this new software is the
result of six months of industrial testing at
four major production sites.
CONTACT METTE DOBEL
MDO@FLSMIDTH.COM
CONTACT CHRISTIAN RYTTER
CHRY@FLSMIDTH.COM
Read more about FLSmidth’s
QCX® automation software on
www.flsmidth.com/automation
About FLSmidth’s QCX®
software
QCX is a software system used by
cement plant operators to support their
quality control procedures. Its purpose
is to deliver reliable data from sampling,
sample preparation and analysis.
FLSmidth’s QCX system integrates all of
these key activities into an intuitive
system architecture that improves
laboratory automation and on-line
analysis.
32 HIGHLIGHTS CEMENT – APRIL 2015
FINANCING PAVES THE WAY
IN DR CONGO
Lender profiles
EKF
EKF, Denmark’s Export Credit Agency, insures businesses
against extraordinary risks not covered by the private credit
insurance market. In this case, EKF is guaranteeing a USD 30
million loan provided by the African Development Bank.
African Development Bank
The African Development Bank (AfDB) supports the economic
development and social progress of African countries. It
promotes investments in and provides technical assistance to
relevant projects within its member countries. AfDB will
contribute to the development of Nyumba Ya Akiba with two
tranches of up to USD 30 million each, with one tranche being
fully guaranteed by EKF.
IFC
IFC, a member of the World Bank Group, is the largest global
development institution focused exclusively on the private
sector in developing countries. IFC plays an important role in
the project, providing a loan of USD 30 million. This project
aligned particularly well with IFC’s objectives as it is an example
of investment from one developing country, Pakistan, in
another. The project is seen as a good example for other
companies and institutions considering investing in DR Congo.
Emerging Africa Infrastructure Fund
The Emerging Africa Infrastructure Fund (EAIF) is a public
private partnership. It provides long-term denominated debt or
mezzanine finance on commercial terms to finance the
construction and development of private infrastructure in 47
countries across sub-Saharan Africa. EAIF is contributing to the
project with a USD 30 million loan.
Habib Bank
Habib Bank (HBL) is the largest and one of the oldest banks of
Pakistan. HBL’s expanding presence around the world is evident
from the fact that HBL acted as the lead arranger for this
transaction for arranging USD 135 million loan. HBL is also
supporting this foreign direct investment by a successful
Pakistani multinational with a loan of USD 15 million through
its offshore branch.
Normally, financial institutions only look at financing complete
engineering, procurement and construction (EPC) contracts, but in
this case, Lucky Cement insisted that the contract was split into
two elements. With extensive experience and intimate knowledge
of the components and processes required for constructing
cement plants, the Pakistani cement producer has become adept
at reducing overall project costs.
Commenting on the significance, Tine Bremholm Kokfelt says,
“It demonstrates that it is possible to get support for non-EPC
projects in Africa.”
FLSmidth’s supply
FLSmidth is supplying a complete package of equipment and
engineering for the 3,000 tpd cement plant, including all the
engineering, equipment and construction support. The equipment
includes crushers, pyro processing equipment and vertical mills for
raw meal, coal and cement grinding.
The impact of the cement plant on the environment and local
community was a key factor for the owners and lenders choosing
FLSmidth as equipment supplier. They demanded a technology
provider with a proven ability to deliver reliable products and high
level of service, particularly because of the challenging conditions
under which the plant will be installed and operated, pointing to
FLSmidth's proven ability to supply environmentally optimised and
energy-efficient equipment.
Mitigating risk
Along with the considerable upsides of developing Nyumba Ya
Akiba come considerable risks, too. DR Congo’s banking and legal
systems are relatively under-developed and there is perceived to
be some political uncertainty. It was therefore necessary to
structure the financing in such a way that mitigates risk for all
parties as best as possible.
This involves opening up dialogue and making connections, which
is a particular strength of FLSmidth. Tine Bremholm Kokfelt
explains: “At FLSmidth, we have a good track record in
establishing cement plants in developing countries, so we usually
know what the risks are and how to manage them. But it’s
understandable that it can make some parties uneasy. There has,
up to now, only been very limited large private industry projects in
DR Congo.”
With the final financing agreements in place at the end of 2014,
FLSmidth is mobilising the equipment. Cement production is
expected to start towards the end of 2016.
Reflecting on the many days of negotiations and discussions, Tine
Bremholm Kokfelt says that belief in the final outcome throughout
was vital: “This project goes to show that with the right approach
as well as a fair amount of determination and patience, it is
possible to achieve goals that seem unattainable.”
INNOVATION
Easy-to-use
laboratory automation solutions
The newest version of FLSmidth’s QCX® automation software is the
cement industry’s most operator-friendly sample preparation system.
FLSmidth has released a new version of its
QCX/AutoSamplingTM and QCX/RoboLab®
software, marking a major leap forward in
laboratory automation solutions. This
version 8 release offers significantly
improved usability for plant operators and
maintenance personnel.
A focused research and development
programme using feedback from
FLSmidth’s extensive installed base has
resulted in better integration of sampling
equipment, sample preparation equipment
and the software. This integration is
important as it provides better system
availability and minimises operational
costs.
Improved usability
Mette Dobel, Global Product Manager at
FLSmidth explains the objectives behind
the development of the new software:
“Our aim has been to create the most
operator and maintenance-friendly
sampling and sample preparation system
for the cement and minerals industries.”
Operators can configure the software as
necessary to suit their work processes, with
its intuitive user interfaces able to provide
a complete overview of the automated
laboratory, the sampling system and the
analysis results. Standard tasks, including
preparing sample preparation recipes and
tracking samples and results, can be
performed quickly and easily.
New software standards
According to Mette Dobel, the software is
developed based on the new QCXSYS V8
programming standard, which allows for
seamless integration with QCX equipment
and the QCX software.
“Consequently, all FLSmidth sampling,
sample transport and sample preparation
equipment is delivered with transparent,
uniform and comprehensive equipment
diagnostic tools combined with relevant
equipment performance indicators,” she
says. “This reduces the need for specialised
HIGHLIGHTS CEMENT – APRIL 2015 33
knowledge to operate and maintain the
equipment and enables maintenance
personnel to plan and conduct preventive
maintenance in a fast and direct manner
with the required wear part.”
The launch of this new software is the
result of six months of industrial testing at
four major production sites.
CONTACT METTE DOBEL
MDO@FLSMIDTH.COM
CONTACT CHRISTIAN RYTTER
CHRY@FLSMIDTH.COM
Read more about FLSmidth’s
QCX® automation software on
www.flsmidth.com/automation
About FLSmidth’s QCX®
software
QCX is a software system used by
cement plant operators to support their
quality control procedures. Its purpose
is to deliver reliable data from sampling,
sample preparation and analysis.
FLSmidth’s QCX system integrates all of
these key activities into an intuitive
system architecture that improves
laboratory automation and on-line
analysis.
34 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 35

PRODUCTS & SOLUTIONS

CONTACT AVANISH KARRAHE

AK-IN@FLSMIDTH.COM

“THE HYDRAULIC ROLLER

FLSmidth launches new PRESS SYSTEM INCLUDES
concept for Hydraulic SEVERAL FEATURES THAT

Roller
DELIVER MUCH IMPROVED
EFFICIENCY.“
Designed to take the complexity
out of installation and maintenance,

Press
Avanish Karrahe
Product Manager, HRP, FLSmidth
FLSmidth’s new Hydraulic Roller
Press concept has the potential to
double capacity and significantly
reduce energy consumption.
FLSmidth has released a new hydraulic roller press (HRP) concept
designed to overcome some of the biggest challenges facing
cement plants today. It features a compact layout, which is Special features of FLSmidth’s new
important both at greenfield installations and at plant upgrades, hydraulic roller press concept
where limited space is an increasingly important design and
construction factor. • Latest generation, top-fed ROKS-H/RAR-M separator system
with best-in-class wear protection and efficiency
Whether for raw material or clinker, an HRP is commonly used in • Control gates to adjust power draw of the two roller motors
pre-grinding processes as well as semi-finish and finish grinding
• Shut-off gate on choke feed bin avoids idle running prior to
arrangements. The technology enables clinker and hard brittle
starting maintenance
materials to be ground at high pressure.
• Specially designed torque arm that reduces vibrations
FLSmidth’s new HRP achieves a grinding force of an impressive
• Easy roller removal for maintenance
6,500 kN/m2 for clinker and slag applications and up to 5,500 kN/
m2 for raw grinding. The system features a latest generation, • Isolated HRP foundation for reduced vibration
top-fed ROKS-H separator for clinker grinding or RAR-M for raw
• All heavy equipment placed on lower floor levels reduces
grinding. When used in semi-finish mode to an existing closed
civil costs
circuit ball mill system, it can deliver up to more than a 100
percent increase in grinding capacity while achieving an estimated • High-efficiency metal detector improves safety and
savings of 30 percent in energy consumption. consistency

• Feed bin can be moved for easy maintenance

Simplified concept for easier maintenance
FLSmidth’s newest HRP system concept offers a range of • Best-in-class wear resistant material for rollers - TRIBOMAX™
innovations designed to reduce civil costs, improve cement plant
• Spherical roller bearings to accommodate angular
efficiencies and ease maintenance. The heavy components, such
misalignment
as the roller press, separator cyclones, dedusting filters and
separators, are placed closer to the ground and towards the • Oil Lubrication for bearing lubrication and cooling
centre of the building, allowing easier access and reduced overall
civil costs. >>
34 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 35

PRODUCTS & SOLUTIONS

CONTACT AVANISH KARRAHE

AK-IN@FLSMIDTH.COM

“THE HYDRAULIC ROLLER

FLSmidth launches new PRESS SYSTEM INCLUDES
concept for Hydraulic SEVERAL FEATURES THAT

Roller
DELIVER MUCH IMPROVED
EFFICIENCY.“
Designed to take the complexity
out of installation and maintenance,

Press
Avanish Karrahe
Product Manager, HRP, FLSmidth
FLSmidth’s new Hydraulic Roller
Press concept has the potential to
double capacity and significantly
reduce energy consumption.
FLSmidth has released a new hydraulic roller press (HRP) concept
designed to overcome some of the biggest challenges facing
cement plants today. It features a compact layout, which is Special features of FLSmidth’s new
important both at greenfield installations and at plant upgrades, hydraulic roller press concept
where limited space is an increasingly important design and
construction factor. • Latest generation, top-fed ROKS-H/RAR-M separator system
with best-in-class wear protection and efficiency
Whether for raw material or clinker, an HRP is commonly used in • Control gates to adjust power draw of the two roller motors
pre-grinding processes as well as semi-finish and finish grinding
• Shut-off gate on choke feed bin avoids idle running prior to
arrangements. The technology enables clinker and hard brittle
starting maintenance
materials to be ground at high pressure.
• Specially designed torque arm that reduces vibrations
FLSmidth’s new HRP achieves a grinding force of an impressive
• Easy roller removal for maintenance
6,500 kN/m2 for clinker and slag applications and up to 5,500 kN/
m2 for raw grinding. The system features a latest generation, • Isolated HRP foundation for reduced vibration
top-fed ROKS-H separator for clinker grinding or RAR-M for raw
• All heavy equipment placed on lower floor levels reduces
grinding. When used in semi-finish mode to an existing closed
civil costs
circuit ball mill system, it can deliver up to more than a 100
percent increase in grinding capacity while achieving an estimated • High-efficiency metal detector improves safety and
savings of 30 percent in energy consumption. consistency

• Feed bin can be moved for easy maintenance

Simplified concept for easier maintenance
FLSmidth’s newest HRP system concept offers a range of • Best-in-class wear resistant material for rollers - TRIBOMAX™
innovations designed to reduce civil costs, improve cement plant
• Spherical roller bearings to accommodate angular
efficiencies and ease maintenance. The heavy components, such
misalignment
as the roller press, separator cyclones, dedusting filters and
separators, are placed closer to the ground and towards the • Oil Lubrication for bearing lubrication and cooling
centre of the building, allowing easier access and reduced overall
civil costs. >>
36 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 37

NEW ORDER

Kanodia
FLSMIDTH LAUNCHES SEE THE NEW MOVIE
NEW HYDRAULIC ON FLSMIDTH'S HRP
ROLLER PRESS CONCEPT

Cement
1 Hydraulic roller press chooses FLSmidth’s new
2
3
Static separator
Dynamic separator
hydraulic roller press system
8 4 Ball mill
9 CONTACT PRAVEEN SHENOY
6 5 Fresh feed PRAVEEN.SHENOY@FLSMIDTH.COM
6 Dust collector
6

7 Bucket elevator
3
8 Magnetic separator
9 Metal detector
10 Reject bin
2
7 10 11 Choke feed bin

11 Mill air flow 7

Separator air flow
5 Material flow
8
9
1

The HRP itself is also placed on an isolated foundation preventing
vibrations from being transferred to the rest of the building.
The feed bin can be moved relatively easily to one side for easier
maintenance access. And, its user-friendly design has resulted in
fewer components than previous designs, leading to greater
consistency in performance, higher output quality, and reduced
operation and maintenance costs.
High wear resistance
A critical feature of the roller press is the actual roller surface,
which needs to be highly resistant to wear from clinker, slag or
other material used for grinding, and should also have high
resistance to tramp metals. FLSmidth’s objective is to reduce the
wear rate, and for this, two types of surfaces are offered. The first
is a hard-faced surface that can be rebuilt in-situ as required.
The second is the extremely hard TRIBOMAX™ wear surface (read
more on pages 6-7). The wear life of the unique 'Fit n forget'
TRIBOMAX wear surface is expected to be minimum 25,000 hours
in clinker grinding, and is likely to achieve up to 40,000 hours.
TRIBOMAX also has an outstanding resistance to tramp metals
and oversized feed materials
Avanish Karrahe, Product Manager of Hydraulic Roller Press
Systems at FLSmidth, explains that an important aim in
developing the new HRP was to create a much more efficient
grinding system. “The HRP includes several features that deliver
much improved efficiency. We didn’t just want to achieve
noticeable electrical energy savings, but ultimately also more
consistent production levels, with less maintenance
requirements,”he explains.
Safer operations
Metal detection has also been improved with a reliable and
efficient metal detector. It detects all metal pieces down to 16 mm
spheres, which restricts damaging metal particles from entering the
system. This provides a safer working environment for the rollers,
better feed consistency and more stable operations.
Avanish Karrahe explains how the HRP’s new concept overcomes
an all-too-common problem: “Anyone who operates a hydraulic
roller press knows that angular misalignment can really lead to
severe inefficiencies and mechanical damage to roller press rollers.
So, we continue to use spherical roller bearings instead of cylindri-
cal bearings, and oil lubrication instead of grease lubrication to
address this problem directly. We have also improved the bearing
house assembly to prevent oil leaks. ”He adds, “It is developments
such as these that will significantly increase the expected lifetime
of the roller press and lead to much more consistent operations.”
TOP-FEED ROKS-H SEPARATOR
International success
During its relatively short history, roller press technology has un- Shortly after the release of FLSmidth’s new concept hydraulic roller
dergone significant development from a pre-grinding process to a press system, New Delhi-based Kanodia Cement has ordered two
range of applications including semi-finish grinding and 2.0m2 roller press systems for its clinker grinding plants in Bihar
finish grinding. State of India. The roller presses will be supplied with new top-fed
ROKS-H separators that will reduce building height by 5m,
To date, FLSmidth has supplied more than 100 HRPs to cement support levels for separator by 10m helping reduce sizeable civil
plants around the world. Of these, six HRP systems have been sold cost. The hydraulic roller press includes several features that
since 2013. One is already in operation and three more will be in deliver much improved efficiency.
operation before the end of 2015.
36 HIGHLIGHTS CEMENT – APRIL 2015 HIGHLIGHTS CEMENT – APRIL 2015 37

NEW ORDER

Kanodia
FLSMIDTH LAUNCHES SEE THE NEW MOVIE
NEW HYDRAULIC ON FLSMIDTH'S HRP
ROLLER PRESS CONCEPT

Cement
1 Hydraulic roller press chooses FLSmidth’s new
2
3
Static separator
Dynamic separator
hydraulic roller press system
8 4 Ball mill
9 CONTACT PRAVEEN SHENOY
6 5 Fresh feed PRAVEEN.SHENOY@FLSMIDTH.COM
6 Dust collector
6

7 Bucket elevator
3
8 Magnetic separator
9 Metal detector
10 Reject bin
2
7 10 11 Choke feed bin

11 Mill air flow 7

Separator air flow
5 Material flow
8
9
1

The HRP itself is also placed on an isolated foundation preventing
vibrations from being transferred to the rest of the building.
The feed bin can be moved relatively easily to one side for easier
maintenance access. And, its user-friendly design has resulted in
fewer components than previous designs, leading to greater
consistency in performance, higher output quality, and reduced
operation and maintenance costs.
High wear resistance
A critical feature of the roller press is the actual roller surface,
which needs to be highly resistant to wear from clinker, slag or
other material used for grinding, and should also have high
resistance to tramp metals. FLSmidth’s objective is to reduce the
wear rate, and for this, two types of surfaces are offered. The first
is a hard-faced surface that can be rebuilt in-situ as required.
The second is the extremely hard TRIBOMAX™ wear surface (read
more on pages 6-7). The wear life of the unique 'Fit n forget'
TRIBOMAX wear surface is expected to be minimum 25,000 hours
in clinker grinding, and is likely to achieve up to 40,000 hours.
TRIBOMAX also has an outstanding resistance to tramp metals
and oversized feed materials
Avanish Karrahe, Product Manager of Hydraulic Roller Press
Systems at FLSmidth, explains that an important aim in
developing the new HRP was to create a much more efficient
grinding system. “The HRP includes several features that deliver
much improved efficiency. We didn’t just want to achieve
noticeable electrical energy savings, but ultimately also more
consistent production levels, with less maintenance
requirements,”he explains.
Safer operations
Metal detection has also been improved with a reliable and
efficient metal detector. It detects all metal pieces down to 16 mm
spheres, which restricts damaging metal particles from entering the
system. This provides a safer working environment for the rollers,
better feed consistency and more stable operations.
Avanish Karrahe explains how the HRP’s new concept overcomes
an all-too-common problem: “Anyone who operates a hydraulic
roller press knows that angular misalignment can really lead to
severe inefficiencies and mechanical damage to roller press rollers.
So, we continue to use spherical roller bearings instead of cylindri-
cal bearings, and oil lubrication instead of grease lubrication to
address this problem directly. We have also improved the bearing
house assembly to prevent oil leaks. ”He adds, “It is developments
such as these that will significantly increase the expected lifetime
of the roller press and lead to much more consistent operations.”
TOP-FEED ROKS-H SEPARATOR
International success
During its relatively short history, roller press technology has un- Shortly after the release of FLSmidth’s new concept hydraulic roller
dergone significant development from a pre-grinding process to a press system, New Delhi-based Kanodia Cement has ordered two
range of applications including semi-finish grinding and 2.0m2 roller press systems for its clinker grinding plants in Bihar
finish grinding. State of India. The roller presses will be supplied with new top-fed
ROKS-H separators that will reduce building height by 5m,
To date, FLSmidth has supplied more than 100 HRPs to cement support levels for separator by 10m helping reduce sizeable civil
plants around the world. Of these, six HRP systems have been sold cost. The hydraulic roller press includes several features that
since 2013. One is already in operation and three more will be in deliver much improved efficiency.
operation before the end of 2015.
38 HIGHLIGHTS CEMENT – APRIL 2015
NEWS IN BRIEF
Fuller-Kinyon
pump achieves ATEX
Zone 20 certification
The original Fuller-Kinyon pump patent
filed by Alonzo G. Kinyon was granted on
June 23, 1925 for a method “by which
pulverized fuel or other material may be
conveyed cheaply and efficiently without
the production of dust and in quantities
which can be closely regulated in the same
manner that the flow of ordinary liquids is
controlled".
The original intent was to replace
mechanical and dilute phase pneumatic
conveying systems that allow dust to
escape, producing explosive atmospheres.
Since then, our Fuller-Kinyon (FK) pump
has conveyed dozens of abrasive and hard-
to-handle materials in over 19,000
installations.
Pumps now built to higher standard
The FK Pump has proven to be reliable;
many FK pumps remain in operation after
more than 60 years. Moreover, through
continuous innovation, it is one of the
ATEX STANDS FOR
“ATMOSPHERE EXPLOSIVE”
– A EUROPEAN DIRECTIVE
FOR EQUIPMENT
OPERATING IN
POTENTIALLY EXPLOSIVE
ATMOSPHERES.
3D VIEW OF FULLER-KINYON® M PUMP, DEMON-
STRATING THE EASE OF SCREW REPLACEMENT
USING THE 3-PIECE SCREW
® FLSmidth process
easiest to operate and most-preferred
convey line charging devices. A recent
example is achieving ATEX certification.
ATEX stands for “Atmosphere Explosive”
- a European directive for equipment
operating in potentially explosive
atmospheres. The pump’s previous design
was in accordance with the National Fire
Protection Agency (NFPA) which is widely
used for such purposes in the United
States. Consequently, European customers
can now use FK pumps for applications
related to ATEX Directive Zone 20 for
handling of pulverized coal and other
combustible fuel products. As ATEX is
widely recognised as a more stringent
standard, customers worldwide also have
an improved product.
Certification process
The four-year certification process included
a complete analysis of the FK pump
design, supplier sourcing and
CONTACT FRED WUERTELE
FRED.WUERTELE@FLSMIDTH.COM
manufacturing practices. All aspects were
reviewed and revised as needed to comply
with the ATEX standard. Some highlights
include:
• The pump can now withstand much
higher internal pressures to contain an
explosion
• The maximum surface temperature of
the pump must not exceed 135°C for
full load operation
• Suppliers must be continually monitored
and all critical casing castings must be
certified
• Our Manheim production facility has
additional procedures for tracking
materials, training manufacturing team,
and maintaining records on materials,
personnel training, inspections, etc.
• All details of the ATEX Pump application
and project execution must be
maintained for 10 years after the final
production of the pumps
Upon implementation of the updated
design and approach, rigorous testing of a
300 m Type M pump was completed
successfully and witnessed by Sira Test &
Certification Ltd. of the United Kingdom.
Final certification was received early in
September 2014.
inspections increase
mill lifetime
Wear on an ATOX® coal mill
reduced by half as a direct result
of a process inspection.
As one of its comprehensive Plant Service Maintenance packages,
FLSmidth offers extended process inspections for grinding
stations, including raw, coal and cement mills.
Root causes of high wear
The number one reason for higher-than-expected wear in a
vertical roller mill is raw material composition being different from
the composition for which the mill was designed.
A close second is the operation of the mill. This has a direct
influence on the condition and performance of the mill and
longevity of wear parts.
Optimised mill configuration, together with a thorough
understanding of important parameters for mill operation, will not
HIGHLIGHTS CEMENT – APRIL 2015 39
CONTACT RUNE HØGH JENSEN
RHJE@FLSMIDTH.COM
CONTACT JACOB JØRGENSEN
JACJ@FLSMIDTH.COM
only improve production, but can also significantly reduce costs of
wear and power consumption.
This was called for at a recent inspection of an ATOX® 25 coal mill
that appeared to be suffering from abnormal high wear. FLSmidth
was asked to evaluate the mill’s remaining lifetime.
It turned out that the segments on the mill’s rollers and table had
become worn. The recommendation by FLSmidth’s service
engineer was therefore to hard-face or replace the segments.
While on site, FLSmidth also investigated process parameters and
operational procedures to find what was behind the high wear.
It quickly became clear that the site’s operating procedures were
causing adverse effects.
To counter these effects, the mill’s set-up and operational
procedures were adjusted in accordance with FLSmidth
specifications. The adjustments resulted in a significant drop in the
total wear rate from 23.5 g/t to 11.8 g/t., in other words, wear
reduction of 50 percent - equivalent to doubling the segment’s
lifetime.
Fast payback
FLSmidth’s Plant Service Maintenance, which includes mechanical
inspections and services, has been expanded to include process
inspections. Mechanical inspections and services help maintain
plant equipment in good working condition and ensure a long-
term payback in terms of reliable equipment and stable
production.
A process inspection is likely to lead to instant savings in fuel and
power and increased production capacity. In addition, lower wear
rates will reduce maintenance and the need for new parts.
Benefits of an FLSmidth
process inspection
• Optimised operations
• Better product quality
• Improved performance of downstream equipment
• Increased efficiency, capacity and/or quality
• Recommendations by experienced service engineers
38 HIGHLIGHTS CEMENT – APRIL 2015
NEWS IN BRIEF
Fuller-Kinyon
pump achieves ATEX
Zone 20 certification
The original Fuller-Kinyon pump patent
filed by Alonzo G. Kinyon was granted on
June 23, 1925 for a method “by which
pulverized fuel or other material may be
conveyed cheaply and efficiently without
the production of dust and in quantities
which can be closely regulated in the same
manner that the flow of ordinary liquids is
controlled".
The original intent was to replace
mechanical and dilute phase pneumatic
conveying systems that allow dust to
escape, producing explosive atmospheres.
Since then, our Fuller-Kinyon (FK) pump
has conveyed dozens of abrasive and hard-
to-handle materials in over 19,000
installations.
Pumps now built to higher standard
The FK Pump has proven to be reliable;
many FK pumps remain in operation after
more than 60 years. Moreover, through
continuous innovation, it is one of the
ATEX STANDS FOR
“ATMOSPHERE EXPLOSIVE”
– A EUROPEAN DIRECTIVE
FOR EQUIPMENT
OPERATING IN
POTENTIALLY EXPLOSIVE
ATMOSPHERES.
3D VIEW OF FULLER-KINYON® M PUMP, DEMON-
STRATING THE EASE OF SCREW REPLACEMENT
USING THE 3-PIECE SCREW
® FLSmidth process
easiest to operate and most-preferred
convey line charging devices. A recent
example is achieving ATEX certification.
ATEX stands for “Atmosphere Explosive”
- a European directive for equipment
operating in potentially explosive
atmospheres. The pump’s previous design
was in accordance with the National Fire
Protection Agency (NFPA) which is widely
used for such purposes in the United
States. Consequently, European customers
can now use FK pumps for applications
related to ATEX Directive Zone 20 for
handling of pulverized coal and other
combustible fuel products. As ATEX is
widely recognised as a more stringent
standard, customers worldwide also have
an improved product.
Certification process
The four-year certification process included
a complete analysis of the FK pump
design, supplier sourcing and
CONTACT FRED WUERTELE
FRED.WUERTELE@FLSMIDTH.COM
manufacturing practices. All aspects were
reviewed and revised as needed to comply
with the ATEX standard. Some highlights
include:
• The pump can now withstand much
higher internal pressures to contain an
explosion
• The maximum surface temperature of
the pump must not exceed 135°C for
full load operation
• Suppliers must be continually monitored
and all critical casing castings must be
certified
• Our Manheim production facility has
additional procedures for tracking
materials, training manufacturing team,
and maintaining records on materials,
personnel training, inspections, etc.
• All details of the ATEX Pump application
and project execution must be
maintained for 10 years after the final
production of the pumps
Upon implementation of the updated
design and approach, rigorous testing of a
300 m Type M pump was completed
successfully and witnessed by Sira Test &
Certification Ltd. of the United Kingdom.
Final certification was received early in
September 2014.
inspections increase
mill lifetime
Wear on an ATOX® coal mill
reduced by half as a direct result
of a process inspection.
As one of its comprehensive Plant Service Maintenance packages,
FLSmidth offers extended process inspections for grinding
stations, including raw, coal and cement mills.
Root causes of high wear
The number one reason for higher-than-expected wear in a
vertical roller mill is raw material composition being different from
the composition for which the mill was designed.
A close second is the operation of the mill. This has a direct
influence on the condition and performance of the mill and
longevity of wear parts.
Optimised mill configuration, together with a thorough
understanding of important parameters for mill operation, will not
HIGHLIGHTS CEMENT – APRIL 2015 39
CONTACT RUNE HØGH JENSEN
RHJE@FLSMIDTH.COM
CONTACT JACOB JØRGENSEN
JACJ@FLSMIDTH.COM
only improve production, but can also significantly reduce costs of
wear and power consumption.
This was called for at a recent inspection of an ATOX® 25 coal mill
that appeared to be suffering from abnormal high wear. FLSmidth
was asked to evaluate the mill’s remaining lifetime.
It turned out that the segments on the mill’s rollers and table had
become worn. The recommendation by FLSmidth’s service
engineer was therefore to hard-face or replace the segments.
While on site, FLSmidth also investigated process parameters and
operational procedures to find what was behind the high wear.
It quickly became clear that the site’s operating procedures were
causing adverse effects.
To counter these effects, the mill’s set-up and operational
procedures were adjusted in accordance with FLSmidth
specifications. The adjustments resulted in a significant drop in the
total wear rate from 23.5 g/t to 11.8 g/t., in other words, wear
reduction of 50 percent - equivalent to doubling the segment’s
lifetime.
Fast payback
FLSmidth’s Plant Service Maintenance, which includes mechanical
inspections and services, has been expanded to include process
inspections. Mechanical inspections and services help maintain
plant equipment in good working condition and ensure a long-
term payback in terms of reliable equipment and stable
production.
A process inspection is likely to lead to instant savings in fuel and
power and increased production capacity. In addition, lower wear
rates will reduce maintenance and the need for new parts.
Benefits of an FLSmidth
process inspection
• Optimised operations
• Better product quality
• Improved performance of downstream equipment
• Increased efficiency, capacity and/or quality
• Recommendations by experienced service engineers
40 HIGHLIGHTS CEMENT – APRIL 2015

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DATE EVENT LOCATION
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September 2015 FICEM TBD
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