Ximang Tap Chi Xi Mang Toan Cau Thang 11 2017

News Fans Grinding Sanghi Cement Automation Hardtop Alternative fuels Sustainability Middle East Maintenance
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Contents Subscribe Ad Index
NOVEMBER 2017 MAGAZINE
ECOLOGICAL AND
PROFITABLE
Remote
Service
Diagnostics
DALOG March 2017.indd 1 29/06/2017 13:01

Plant Protection Concept
Online Condition Monitoring
Performance
Optimization
DALOG Process Monitoring System
Process Signals D-PMS
Proactive
Failure Prevention
DALOG Torque Monitoring System
Torque D-TMS
Predictive
Failure Detection
DALOG Condition Monitoring System
Vibration D-CMS
DALOG March 2017.indd 2 29/06/2017 13:01

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GLOBAL CEMENT MAGAZINE
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This issue’s front cover...
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Welcome to the November 2017 issue of Global Cement Magazine - the world’s most Editor
Peter Edwards
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This issue’s features include a look at the increasingly popular use of operation and
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on the topics of grinding (Pages 12 & 50) alternative fuel preparation (Page 14),
automation (Page 44), sustainability in the Egyptian cement sector (Page 54) and fans
(Page 42). We also carry a wide-ranging interview with Sanghi Cement Director Alok Office administration
Sanghi (Page 38) to coincide with the NCB Conference in New Delhi, India, and a review Jane Coley
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GLOBAL CEMENT CONTENTS
Subscribe Ad Index
Global Cement articles

10 Uncovering potential with O&M contracts
OneStone Consulting’s Joe Harder looks at how operating and
10 maintenance contracts can open up significant savings.
12 Grinding stations for flexibility

John Terembula from FLSmidth explains the opportunities
afforded by building a grinding station.
14 Alternative fuel preparation technology:

The latest safety considerations
12 UNTHA’s Peter Streinik looks at the criteria that should top the
list of cement producers buying waste shredders in 2018.
18 Special elastomer saves workspace and weight

Benjamin Müller introduces EFFBE’s Urelast components,
which have now been tried in vertical roller mills.
19 Product and contract news

14 Dalian saves with Mobilith SHC 100 synthetic grease; Dangote
rail deal; Schenck Process launches new weighfeeders.
European cement
21 European cement news
18
HeidelbergCement to buy Cementir Italia; Akmenes Cementas
strikes deal with creditors; New CFO for LafargeHolcim.
26 20 years of Hardtop
We report from the 20th anniversary celebrations of the
bi-metallic castings expert Hardtop Gießereitechnologie.
Cement in the Americas

19 30 American cement news

McInnis plant inaugurated; Summit makes counter-bid for Ash
Grove; Cementos Argos reports on positive first half.
Asian cement
21 34 Asian cement news
Regional picture mixed heading into 2018; Chinese firm
invites investment in US$200m Kazakh project; Bulacan
plant expansion approved.
38 In discussion: Alok Sanghi, Sanghi Cement

We talk with Alok Sanghi about Sanghi Cement’s history,
26
production and plans, as well as issues affecting the wider
Indian cement market.
6 Global Cement Magazine November 2017 www.GlobalCement.com

GLOBAL CEMENT CONTENTS
42 Howden rotor retrofit for UltraTech Cement

An account of a recent rotor installation at UltraTech Cement’s
Shambapura works in India. 34
44 Electrical and automation upgrades:
An effective solution in the Philippines
Lahcen Abellaoui from ASEC Automation describes the
company’s recent automation and electrical upgrades for
Republic Cement in the Philippines.
38
Middle East and African cement
48 Middle East and African cement news
Saudi Arabia only ‘needs four major cement producers’; Lafarge
‘paid Islamic State group’; Ciments de Bizerte doubles loss.
50 Major vertical roller mill breakdown... again?

Osama Aly Ahmed looks at the lessons learned from a ‘worst-
case’ vertical roller mill failure at an Egyptian cement plant.
42
54 A low carbon roadmap for the Egyptian
cement sector
Lesscoo’s Bruno Vanderborght outlines the opportunities and
steps that should be taken to improve the environmental
performance of the Egyptian cement sector.
58 Cement round-up: Middle East

44
We look at the producers, plants, trends and latest news from
selected AUCBM member countries, to coincide with the 22nd
Arab-International Cement Conference in Sharm-El-Sheikh.
Regulars and comment 50

63 Global Cement prices
Cement prices from around the world: Subscribers to Global
Cement Magazine receive additional information.
64 Subscription form for Global Cement Magazine
54
Use this form to subscribe to Global Cement Magazine,
or subscribe online at www.GlobalCement.com.
65 The Last Word

This issue: Future building materials...
66 Advertiser Index & Forthcoming issue features

A list of advertisers and editorial preview for next two issues.
58
GLOBAL CEMENT: DIARY
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GLOBAL CEMENT: OPERATION & MAINTENANCE
Interview by Peter Edwards, Global Cement Magazine
Uncovering potential with O&M contracts

Contents
Cement producers around the world are looking for measures on how to improve productivity
Subscribe
and lower operating and maintenance (O&M) costs, yet many are still resistant to external
consulting. However, good results have been achieved by providers of specialised services,
Ad Index including full O&M contracts. In this interview we hear about the findings of a recent market
report by Joe Harder, Managing Director of OneStone Consulting.
Global Cement (GC): Can you first briefly JH: First, we work closely with clients, so they trust us
introduce OneStone Consulting? and our market information and also supply us with
reference lists and achievement records. Much of our
Joe Harder (JH): OneStone Consulting was estab- information is based on reference lists of suppliers. If
lished 20 years ago in Hamburg in Germany. Five we need more information, we do an intensive pri-
years ago the company moved to Barcelona in Spain. mary and secondary research online and interview
The main focus is on market research for the cement the major players in the sector. The quality of the
industry and other process industries such as min- cross-checking of data in our primary research is, to
ing and energy. Our clients in the cement industry the best of our knowledge, unparalleled worldwide.
comprise cement majors as well as smaller cement
producers around the world but most of our clients GC: Your latest report is on O&M services. What
Above: Joe Harder, founder of are cement equipment suppliers and engineering are the main findings?
OneStone Consulting.
companies.
Before I founded OneStone 20 years ago, I was JH: Our report ‘Outsourcing O&M 2017’ is a brand
a process engineer, with 10 years as Research and new report and has just been released.1 It was a
Development Manager and Marketing Director particularly interesting project because there was
Below - Figure 1: Different within the UK-based Babcock International Group. I not much qualitative and quantitative information
types of O&M contract put founded OneStone because there was a lack in market available for O&M contracts in the cement sector up
different levels of emphasis on research analysis in the cement industry. Since that until now. This is astonishing because you can find
the parties involved.
time I have worked for more than 50 international this information fairly easily for the power and min-
Supplier clients on more than 500 projects. ing sectors. Secondly, you will also be astonished how
Owner
many contracts have already been established and
1. Online support. GC: Tell us about your multi-client market reports. how many are active.
2. Technical Assistance (TA).
3. Technical Management (TM).
4. Full O&M contract.
JH: Our market reports have always been on the GC: Can you tell us the numbers?
5. Build-operate-transfer (BOT) or forefront of topics in the cement industry. Our report
Build-own-operate-transfer (BOOT). ‘Cement Projects Focus 2010’ published in 2006 was JH: We found that since 1987, when the first contract
already our third edition, long was awarded, up to now, 102 service contracts have
before other providers entered been awarded. In the last five years, 43 contracts were
the market. We published ‘Ce- awarded, of which 23 are still active. The spectrum of
100
100
ment Substitutes Focus 2010,’ contracts mostly covers complete plant management,
Supplier
which is still a foundational however quarry operation, grinding plant or packing
80
80 Owner
report when it comes to un- plant operation are also covered in many of them.
in %
derstanding the importance If we look just at the past five years, 54% of the
1 Online
of support
the clinker ratio in cement. contracts were made with plants in Africa and 23%
Responsibility
60
60 In theAssistance
2 Technical past few years we pub- were made with plants in the Middle East. However,
Responsibility (%)
lished reports on grinding the share of plants in other world areas, including
3 Technical Management
equipment, cement pyro-pro- Europe, is growing. What is also interesting is that five
40
40 4 Fullcessing
O&M contract
systems and cement suppliers comprise almost 90% of the market when
automation
5 BOT-/BOOT model equipment, to we include O&M contracts, Technical Assistance
name a few. At the time of pub- (TA) and Technical Management (TM) contracts.
20
20
lishing, each is unique in its
respective field. GC: Can you please explain in a bit more detail?
00
GC: How do you get the JH: All these different contact types depend on the
1 2 3 4
1 2 3 4 55 information? level of involvement of the service supplier and how

GLOBAL CEMENT: OPERATION & MAINTENANCE
much responsibility the plant owner has. We identi- eral interviews with cement producers, some who are
fied five different models (See Figure 1). With the using such services and others who are not enthusias-
online support model, which is just an advisory sup- tic about it. We also spoke to the service providers. The
port by the supplier with measuring and adjustment biggest problem is the ‘not invented here’ syndrome.
of key performance indicators (KPIs), the owner still If the cement producer has long-term experience and
has 100% responsibility for its decisions. In the other adequate people then often there are objections to
models, the responsibility progressively changes to involving external expertise. Actions are only taken if
the supplier, so that in a full O&M contract the service the top management is not satisfied with the results,
supplier is responsible for the complete staffing, opera- for example with the achieved MTBF rates. On the
tion and maintenance of the plant including for spares other hand, we see a development mostly in large
and consumeables. groups and different country locations, that they
For cement producers, there are different tailor- prefer a local O&M strategy and not a central O&M
made options available. From our point of view, many strategy with the involvement of externals.
plants have only an average performance, which you
can fix by focusing on the mean time between failures GC: Can you prove that externals are able to achieve
(MTBF). In the benchmark figures we provide with these results?
our market report you will find a chart of a major
cement producer that has 11 kilns. In one year their JH: I think we can, there are enough examples, but
best kiln MTBF was 27 days, the worst was just four unfortunately not often published. I have examples
days. This has to be compared to best practices of 35 from some of the top service providers in the sector,
days. If you can improve the kiln MTBF, then lots of but I prefer not to go into details, because we have to
energy can be saved, because with each kiln stop a be neutral in the field. Anyhow, some service provid-
huge amount of energy is wasted. With a more stable ers state that, in their projects, they are able to reduce
kiln operation and fewer unplanned stoppages, sig- production costs by Euro2/t.
nificant savings are possible, over the year.
GC: What do the cement producers typically pay
GC: Can you give us an example? for these savings?
JH: Let use take a kiln line with 1.5Mt/yr capacity. JH: That depends on the contract. Normally for on-
The kiln line shall have 90% capacity utilisation, line services a fixed daily sum is paid, independent of
with 3500MJ of fuel needed for each tonne of clinker the achievements. In full O&M contracts guarantees
produced, 100kWh needed per tonne of cement are given on performance parameters such as fuel and
produced and a clinker factor of 75%. If the MTBF electricity demand and production rate. The payment
can be improved from 20 days to 30 days, it should in such cases is more by the negotiated price per ton
be possible to easily achieve 3% annual saving in (PPT) for the O&M services, with bonuses/penalties
electricity demand. If the cost is Euro0.08/kWh, the on production compared to the annual target and
saving is Euro0.32m/yr. It could also save 5% on its losses/savings in energy.
fuel demand. At Euro100/t for coal with 25,000MJ/t
this saves Euro0.71m/yr. The savings in this example GC: Thank you very much for the interview.
will result in Euro1.03/yr, or Euro0.54/t, which is
more than significant (See Figure 2). JH: You are very welcome. Thank you!
GC: Why is this potential not used by more plants? Reference

1. http://www.onestone.eu/downloads_docs/Flyer_O_M__2017.pdf
JH: That is the most interesting question. We did sev-
35
35
1.2
1.2
30
30
1.0
1.0
kiln MTBF in days
€m
(MillioninEuros)
25
25
Kiln MTBF (days)
0.8
0.8
20
20 Left - Figure 2: Increasing the
savings
0.6
0.6 kiln MTBF rate can save over
15
15 Euro1m/yr.
savings
After
After Electricty
Electrical
10
10 Before 0.4
0.4
Cost
Before Fuel
Fuel
Cost
55 0.2
0.2
00 0.0
0.0
KilnKiln improvement
improvement Cost savings
Costs savings

GLOBAL CEMENT: GRINDING
John Terembula, FLSmidth
Grinding stations for flexibility
In order to meet demand, cement producers can follow one of three routes to market:
import, invest in a complete cement plant, or build a grinding station. John Terembula from
FLSmidth explains the opportunities afforded by building a grinding station...
F or cement producers looking to break into new

markets, high fuel prices and import tariffs often
make importing cement an unattractive option.
Flexible grinding solutions
Typically, grinding stations are situated on a com-

Building a complete cement plant requires more pact plot and incorporate raw feed storage, a mill or
time and capital. Both of these options are mainly mills, product storage and packing or bulk load out
worthwhile only when both future demand and systems. They are usually located to serve clearly-
ongoing raw material supplies are certain and there defined and relatively small geographic markets.
is sufficient time and space in the market to take a However, small size does not mean the plants are less
significant share. However, in markets where there is flexible. FLSmidth’s OK™ mills can cater to different
a lack of locally-available raw materials for produc- cement types even at the smallest sizes and can still
ing clinker or where existing cement plants within be tailored to market demand.
the company have sufficient local clinker capacity The mill size selected doesn’t only come down
to meet demand, producers may choose to build to capacity requirements. For example, in markets
a grinding station. As a less expensive and quicker where demand is fragmented or transport infra-
solution, investing in a grinding station can often be structure is less well developed, grinding stations
the most economical choice. Moreover, given that it with small mills of around 800–1300kW are more
doesn’t require the extensive infrastructure that ac- appropriate. In markets where infrastructure isn’t an
companies clinker production facilities, it also suits issue and market demand justifies it, mill sizes up to
markets where the long-term demand scenario is less 11,600kW can be chosen in order to make the most
clear. Under these circumstances, the type and size of of local demand hotspots. The configuration of each
grinding station chosen depends on: grinding station will be decided based upon factors
such as:
• Capacity demand;
• Regional geography; • The speed with which the plant needs to be
• Local distribution channels. established to meet demand;
Right: FLSmidth’s OK™ mill is

widely recognised for its
exceptional performance in the
global cement grinding market.
With a complete range of mill
sizes available, FLSmidth can
cater to all levels of capacity
demand, from just 35t/hr up-
wards. In addition to installing
hundreds of OK™
mills as part of integrated
cement plant projects, FLSmidth
also supplies and builds grinding
stations across the world, each
of which is designed according
to the customer’s product
requirements.
12 Global CementMagazine November 2017 www.GlobalCement.com

• The range of cement types to be produced; entered a new market when an OK™ 40-4 mill was
• The number of raw feed components; ordered for a new grinding station being built in
• Expected changes in capacity. Musanze, Rwanda. This contract includes a complete
range of equipment, from storage to packing and ce-
Most commonly, the layout of a grinding station ment loading. The mill itself has an 1800kW drive
follows that of a typical grinding line within an inte- and a rated capacity of 100t/hr. In this instance, the
grated cement plant. FLSmidth advises on the best grinding station is intended as the first stage in a two-
plant configuration based on the owner’s product phase project. The second stage will see the company
requirement. build a clinker production line, creating a fully inte-
grated cement plant.
A range of projects Rwanda is a relatively small cement market, with
Over the last decade, FLSmidth has supplied 17 OK™ cement demand of just 450,000t/yr. The additional
mills for grinding stations across the world. These capacity provided when the new plant goes online
mills range in size from 675kW to 11,600kW and will support the country’s export industry and help
in production capacity from 35t/ht to 540t/hr. The bring down local cement prices. Beginning with the
most recent of these contracts, and the smallest, was grinding station is a good way for a new player to
to Shalimar Cements in Nepal, which ordered a 28-3 enter the market relatively quickly and establish their
OK™ mill for its Simara plant. Nepal’s total cement brand in a country that is currently served by just one
demand is relatively low, but environmental concerns other player. The sample of recent OK mills shown
are still paramount. in Table 1 reflects the range of possible sizes that
At an OPC production capacity of just 35t/hr, the FLSmidth can provide to meet any capacity need.
contract with Shalimar Cements shows that world-
class energy-efficient technology applies even for the Financial support
smallest capacity grinding units. The scope of the In addition to technology and process support,
contract included the OK™ 28-3 for cement grind- FLSmidth is also able to offer financial support by
ing, bag filters, weigh feeders, gear reducer, loading facilitating financing for clients that would have dif-
machine and plant control systems. ficulties arranging international financing on their
own or facilitate more attractive
The world’s biggest mill financing than available locally. In
Mill type Drive Capacity
Infrastructure projects are fuelling the past, FLSmidth has been able
(kWh) (t/hr)
cement demand in Bangladesh, to assist clients in obtaining inter-
where grinding stations are the OK™ 28-3 675 35 national financing for more than
norm due to the lack of locally OK™ 37-3 1390 70 US$100m in order to fund cement
available raw materials. Here, OK™ 61-4 5500 200 plant projects globally. This is made
FLSmidth has sold a range of OK™ possible by FLSmidth’s wide inter-
OK™ 61-4 5500 200
mills, up to the biggest, the OK™ national financing connections and
81-6 with an 11,600kW drive and a OK™ 61-4 5500 200 its strong links with the Danish Ex- Left - Table 1: Recent OK mills
OK™ 61-4 5500 200 provided by FLSmidth for cement
rated capacity of 540t/hr. This mill, port Credit Agency EKF.
grinding applications.
which is the largest in the world, OK™ 56-4 4600 220
was purchased by Shah Cement Conclusion
OK™ 56-4 5410 225
Industries for its Char Mershar Whether the decision is made to
plant. The contract included the OK™ 61-4 6500 250 install a grinding station because
supply of the main equipment, OK™ 71-6 9180 380 of a need to enter a booming mar-
process and layout engineering and OK™ 81-6 11 000 540 ket quickly, or because local raw
site advisory. This is a full-scope material supply wouldn’t support
project for FLSmidth, including a clinker production line, or even
FLSmidth Automation advanced process control just to make initial inroads into an uncertain market,
systems, FLSmidth Pfister weigh feeders, FLSmidth standalone grinding station suppliers like FLSmidth
Airtech process bag filters, as well as process fans are on hand to supply and install a full range of
and auxiliary equipment from raw material hop- grinding stations to suit every need. With the com-
per discharge to process bag filter discharge. Hafiz pany’s engineering, process and services knowledge,
Sikander, Director Operations, Cement Division at FLSmidth is best-placed to advise on suitable con-
Shah Cement Industries Ltd attributed the choice figurations to meet local demand and to provide
of mill to its ‘exceptional efficiency and reduced ongoing support. FLSmidth is of the opinion that the
power consumption’. OK™ mill is the highest-efficiency vertical roller mill
on the market and also that the energy efficiency of
Entering new markets the design surpasses ball mills by 30–50% and other
Grinding stations are not only popular choices in cement vertical roller mills by as much as 5–10%,
South Asia. Earlier this year, FLSmidth’s OK™ mill leading to significant operational cost savings.

GLOBAL CEMENT: ALTERNATIVE FUELS
Peter Streinik, UNTHA shredding technology
Alternative fuel preparation technology:

The latest safety considerations
The specifications for new alternative fuel preparation technologies are becoming
increasingly sophisticated as industry innovation continues apace. But when it comes to
investing in waste shredders that help manufacture alternative fuels, which criteria should
top the procurement wish-list in 2018? With more than 25 years’ experience in this sector,
Peter Streinik, head of UNTHA’s waste shredding division, offers his thoughts…
I nvesting in a new capital asset is never a straight-

forward exercise. There are, indisputably,
performance criteria to fulfil and, typically, such
ment period. Financial packages, often inclusive of
service and maintenance, have further opened up the
market.
factors are of primary importance when drawing up
a technological shortlist. The procured equipment The rising safety challenge
must be fit for purpose after all. When it comes to Thankfully, in the past five years, safety factors have
alternative fuel preparation technology such as a also risen to the forefront of operators’ minds. A pre-
shredder, these criteria typically include evidenced vious Global Cement article1 specifically highlighted
uptime statistics, throughput rates, particle sizing the need to adopt greater fire mitigation strategies
homogeneity and foreign object protection mecha- within feedstock preparation lines. Some shredder
nisms. All will influence the capacity of the resulting manufacturers were quick to respond, having already
plant and the quality of the cement fuel it is able engineered greater fire safety mechanisms into their
to produce. technology, by design. As a result, anti-explosive
There are then fiscal considerations to accommo- ATEX-specification motors, plus slow speed rotors
date. Only a few years ago, when the aftermath of the that generate far less dust than those with higher tip
global economic crisis was still extremely raw, a large speeds, are just two of the features that began to be
proportion of investments were cost driven. Now, on demanded by operators as standard.
the other hand, while commercial viability still needs Carefully positioned UV, infrared, heat and spark
to be carefully scrutinised, savvier alternative fuel detectors on inlet hoppers and discharge conveyors
manufacturers are looking beyond the initial price have also been increasingly sought. In the event of
tag of a machine in favour of assessing the whole a significant temperature increase, these sensors,
life costs of the asset. This involves the calculation which sit adjacent to strategically-located extinguish-
of slightly more complex, yet far more meaningful, ing nozzles, can automatically trigger a controlled
sums, which factor in the ongoing costs of mainte- amount of water spray onto the targeted area. This
nance, wear and power consumption, to name just means that, if the risk is within the shredder, the ma-
a few. Armed with these figures, it is then possible terials can be cooled and/or the fire doused, before
to truly understand the likely fiscal drain, or yield, any hot glowing fractions can propagate. Alarms can
of the machine and the anticipated return on invest- even be activated to alert the operator to commence
a manual extinguishing process, and/or auto-
matically notify the fire brigade.
2018 safety considerations

While these performance, finance and fire
safety considerations mean that a shredder
wish-list has become far more sophisticated
Right: Ear defenders. Such
hearing protection isn’t required than it was a few years ago, procurement
if the shredder operates below criteria should evolve further still if op-
the first action point for noise. erators are considering an investment in 2018
or beyond.
Noise will come to the forefront like never
before. Some alternative fuel manufacturers
have previously considered noise in respect of
the potential debilitating damage to employee

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GLOBAL CEMENT: ALTERNATIVE FUELS
wellbeing and this duty of care requirement

is only going to escalate. Admittedly in some
parts of the world, noise minimisation is less
of a priority. However, given most plants seek
long-lasting equipment, it seems prudent
to future-proof the investment. Certainly,
in Western Europe and North America, as
Right: UNTHA offers ergonomic
and easy servicing, aiding safety. legislation becomes increasingly stringent,
the need to protect operators’ hearing is
non-negotiable. Fuel manufacturers should
therefore seek to invest in shredding tech-
nology that runs below the first action point
at 80dB(A). Not only is this the right thing
to do ethically, but heightened wellbeing
strategies also typically reduce stress levels
and boost productivity too, as noisy distrac-
tions and the constant drone of equipment
is lessened. tory authorities will have to take greater action as
2018 unfolds. However, in facilities where dust does
The noise debate grows louder pose an issue, operators should welcome, rather than
However, the noise debate is growing louder still, dread, the push to improve the cleanliness of their
as suggested in a recent article in the UK Chartered sites. Reduced dust levels will inevitably help to pla-
Institution of Wastes Management (CIWM) journal.2 cate neighbours, while consequently bringing about
The Environment Agency spoke openly about the operational benefits too. The fire risk of the plant will
difficulties that can be encountered between ‘waste’ also immediately drop, and employees’ health will
plants and their neighbouring communities, if dis- improve if fewer dust particles are airborne.
gruntled members of the public object to excessive From a commercial perspective, steps to moder-
noise levels. ate dust can, perhaps inadvertently, result in a better
Operators therefore need to address the noise pol- quality fuel too, not to mention increased margins.
lution they create, particularly if planning permission Slower speed, higher torque shredders will, by their
is to be sought for the build of new production lines or design, produce less dust without compromising
extended/multi-shift operating hours. If noise obliga- throughputs.
tions continue to be ignored, permits will simply not Furthermore, such technology will create up to
be granted. Of course, noise considerations don’t just 80% less fines. Because fines are non-specification
encompass the shredding technology. Every piece of dust-like particles that cannot be mixed with ce-
equipment, even down to the in-feed kit, needs to be ment industry fuels, they are usually simply screened
assessed. Sometimes even simple improvements to off and sent to landfill. However, in high capacity
the door of a plant can aid soundproofing. plants this can result in disposal costs in excess of
Below: An UNTHA shredder Euro1m/yr, not to mention an adverse environmen-
can be controlled by a simple Dust pollution mitigation = benefits for all tal impact of a process that is supposed to support
touch screen panel – a modern,
ergonomic and simple way to In a similar vein, communities are quite rightly push- the world’s renewable energy strategy. Avoid the pro-
optimise the running condition ing back on alternative fuel production plants that duction of these fines in the first place, however, and
of the machine. create excess dust pollution, which means regula- disposal cost savings of Euro800,000/yr will soon ac-
celerate the return on investment from the shredder
and the break-even point of the wider plant.
In truth, many technological innovations can gen-
erate both safety and commercial benefits. So, while
the business case for improved safety considerations
should not need any further rationalisation, there
are, in truth, multiple advantages associated with
more considered shredder procurement.
Reference
1. Lanner, C.: ‘Tackling alternative fuel production fires,’ in Global
Cement Magazine, October 2015.
2. Kirkup, J.: ‘Everybody needs good neighbours’ in CIWM Journal,

September 2017.

2021 FEBRUARY 2018 BERLIN
gl bal
12th
cemfuels
CONFERENCE • EXHIBITION • AWARDS
“Better than
excellent”
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when it comes to ...
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Tel +44 1372 840950 Sourcing and trading
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or Mob: +44 776 7475 998
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Aixergee - CemFuels November 2017.indd 1 20/10/2017 13:15

GLOBAL CEMENT: PROCESS EFFICIENCY
Benjamin Müller, EFFBE
Special elastomer saves workspace and weight
Polyurethane is one of the most versatile materials: it can be as soft as rubber or extremely
hard. As an elastomer, it is useful for springs and damping elements that can provide
benefits to even the most modern manufacturing systems.
Elastomer-springs are state-of-the-art combined with CFK-material to lower the weight.

technology These elastomer springs have even proven them-
selves as an alternative to disc springs, steel springs,
EFFBE, a member of the globally-active Woco Group, compression spring or pneumatic springs.
provides springs made from its trademark-protected While the fracture of a single disc spring could
Polyurethane Urelast, which is available in 80 and 90 cause the loss of power of all springs, the Urelast
shore. Wherever springs are used as flexible compo- springs have an emergency operating feature that
nents or energy storages, Effbe-Elastomer springs prevents the total cancellation of the other springs.
can be used. EFFBE is able to customise its products This attribute leads to more safety for the machines
from a range of more than 2000 formulations due to and reduces potential maintenance costs.
cooperation within the Woco Group.
Monitoring by integrated sensors
Elastomer endures four times the pressure EFFBE has innovative, yet affordable sensors inte-
Urelast is a pourable elastomer with very good grated into its elastomer components that constantly
qualities relating to capacity, fatigue endurance and monitor the workload of the machine. While compo-
settlement. Due to these qualities, it is a very popu- nent ageing can obviously be detected very easily, the
lar material for producing customised components. physical aging, caused by the constant load, is hardly
Compared to conventional rubber-metal-elements, noticeable. The sensors capture all relevant informa-
Urelast is capable of enduring four times the pres- tion about the load on the elastomer element. With
sure. This means that Urelast components can be this data, it’s possible to calculate the attrition, work-
30-40% smaller. On top of this, the weight can be load and positional change.
reduced by more than 80%, because Urelast doesn’t EFFBE has honed its data collection and analysis
require material additions. with Urelast components in wind turbines in recent
years. It has now also completed trials in which
Products with emergency operating Urelast components were used in vertical roller
features mills for the cement sector. Components made from
To influence the characteristics of a spring, it’s usual Urelast have a wide range of potential applications in
to use the common state of technology, in which the the cement sector in any piece of equipment where
seating of the elastomer is connected to a rigid frame. enhanced spring or dampener longevity would be
Instead of using metal parts, EFFBE uses Urelast, of value.
Right: Urelast dampers

are capable of enduring four
times the workload of conven-
tional rubber-metal systems.

WE’VE RAISED THE BAR
Once again Pfeiffer has set the new

standard in grinding performance: MultiDrive®
Ultimate protection against total failure thanks to active mechanical and electrical
redundancy – only provided by the MultiDrive®, especially developed for the Pfeiffer
MVR mill. The grinding table of the mill is driven by a girth gear. The power of as much as
18,000 kW is delivered by up to six independent drive units, each consisting of gear unit
and electric motor. Due to this innovative design, no gear unit is directly located under
the mill and thus exposed to grinding forces. This makes the MultiDrive® so unique and
most reliable. The active redundancy enables the mill to continue in operation, even in the
unlikely event of failure of one of the drive units. The advantage: No unplanned downtime.
Maximum production capacity. Always.
Pfeiffer. Passion for grinding.
www.gebr-pfeiffer.com
Silo systems Conveying Dosing Alternative Fuels Processing
ODM-WeighTUBE® RWS-G2 — the innovative

dosing system from DI MATTEO
The gravimetric dosing weigh feeder ODM-Weigh • innovative weighing section allows precise control
TUBE® RWS-G2 allows alternative fuels, i.e. SRF, RDF, and secures a constant bulk material flow to the kiln
FLUFF, sewage sludge, biomass or animal meals, to • low space requirements allow retrofitting into
be weighed rapidly and precisely. Also it�s usable for existing plants
abrasive and other conventionally bulk materials. • automatic recalibration allows an interruption
Through the innovative weighing system of the free production operation
ODM-WeighTUBE® RWS-G2 severe fluctuations in • test the ODM-WeighTUBE® RWS-G2 with the
the kiln atmosphere are no longer a problem. bulk material of your choice in our testing facility
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DI MATTEO Group
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Tel: +49 2521 9344-0
Fax: +49 2521 9344-222
www.dimatteo.de
info@dimatteo.de
DIM_Anz_Dosing_210x297_GCM_E_11_2017.indd 1 02.05.17 10:29

GLOBAL CEMENT NEWS: PRODUCT & CONTRACT NEWS
China: Dalian Cement saves US$153,000/yr with Mobilith SHC 100 synthetic grease
Contents
A hammer crusher operated by Dalian Cement

Group was frequently overheating, resulting
in multiple bearing failures. After an on-site in-
Subscribe
vestigation, ExxonMobil engineers recommended Ad Index

that the company switch its conventional lu-
bricant to Mobilith SHC 100 synthetic grease.
This high-performance grease is formulated for
extreme environments and its advanced formula-
tion resists viscosity thinning and oxidation at
elevated temperatures.
After transitioning to Mobilith SHC 100, the
hammer crusher bearings no longer experienced
overheating problems, which significantly re-
duced bearing failures and related unscheduled
downtime. These benefits resulted in significant
cost savings and enhanced safety by reducing employee- Above: The kiln at Dalian Cement, China.
equipment interaction.
“High temperature applications can take a heavy toll SHC Advisor at ExxonMobil. “A simple changeover to
on industrial equipment, and in these demanding envi- Mobil SHC synthetic greases allowed Dalian Cement to
ronments, using the right lubricants is critical to ensuring immediately improve crusher bearing protection and re-
optimal reliability,” said Imtiaz Ahmed, Asia-Pacific Mobil duce unscheduled downtime.”
Zambia: Dangote rail deal Germany: Schenck Process launches new weighfeeders
D angote Cement Zambia has

contracted Zambia Railways to
transport 2000t/month of cement
S chenck Process has launched the Multidos VDP-C apron weighfeeder, a new
range of medium-sized and compact apron weighfeeders targeted at raw ma-
terial feeding, hot clinker feeding and similar applications.
and 500t/month of coal. The Multidos VDP-C uses an enclosed design to enable a cleaner installation
Zambia Railways is transporting environment with inspection access offered by removable covers. Alternatively, an
cement from Ndola to Lusaka and open design is possible for permanently visible material feed. The kit structure of
coal from Batoka to Ndola on behalf the Multidos VDP-C enables the installation of a total of 48 possible geometrical
of Dangote. The cement producer configurations to suit plant requirements. It can be installed on the ground or sus-
operates a 1.5Mt/yr integrated plant pended under a bin. The chain used on the Multidos VDP-C can tolerate a drive
in the country with 1200 employees torque four times higher than required. In addition, apron pans accept loads up
and a fleet of over 500 trucks. It also to six times the nominal load. Apron pans are available for fine grain material and
runs a 30MW coal power plant. alternative designs for sticky and coarse material. The coarse material apron pans
are made of Hardox steel for strength and service life.
Netherlands: Wessem Port Services buys third

Dino mobile bulk truck unloader from Van Beek
L ogistics service provider Wessem Port Services Group in Stein,

which transports, stores and trans-ships bulk goods, has bought
its third Dino mobile bulk truck loader from Van Beek. The system
replaces Wessem Port Services’ self-build, non-mobile equipment.
Wessem’s Commercial Director Peter van Gemert said, “The sys-
tem had to be mobile, because we have a variety of bulk goods
over several warehouses in our dock areas. This also meant that
we needed a system that was easy to clean, so that it could be
quickly deployed for a different product, without the risk of con-
tamination. Furthermore, the loading speed had to be at least
the same or greater than 50m3/hr, which is what most fixed sys-
tems can achieve. The Dino was the only system that met all of Above: The new Van Beek Dino in action at Wessem Port Services, Stein,
these requirements”. the Netherlands.

2324 MAY 2018 LONDON
gl bal Process optimisation,

2nd
PROCESS OPTIMISATION
de-bottlenecking,
cemprocess
IN CEMENT MANUFACTURE
production maximisation
and troubleshooting
CONFERENCE & EXHIBITION
www.CemProcess.com
#cemprocess
The second Global CemProcess conference and exhibition will
look in depth at process optimisation, at de-bottlenecking, Global CemProcess
at production maximisation and at troubleshooting. With Conference and Exhibition
over 2500 cement plants around the world, many of them
in sold-out or hyper-competitive markets, the drive for the will allow delegates to:
additional tonne of production and for process efficiency is • Learn from process optimisation experts
ever-more important.
• Discuss problems and find solutions
Global CemProcess will take place once again in London,
the easy-to-access world city with direct transport links to • Discover industry best-practice
over 300 cities via its six airports. A major exhibition will run • Make new cement contacts
alongside the conference.
• Find new suppliers
If you are responsible for process optimisation or production • Meet old friends
maximisation in the cement industry, then you must attend
Global CemProcess! • Do business!
Who should attend?

• Cement plant maintenance managers
• Cement plant general managers
• Cement company technicians
• Industry optimisation experts
• Academics & researchers
• Equipment suppliers
• Service providers
Exhibition and
Including sponsorship
confirmed visit enquiries
to the Hope Cement paul.brown@propubs.com
plant to see industry- Tel: +44 1372 840 950
best-practice case Mob: +44 7767 475 998
studies in action
Organised by:
gl bal
cement
TM
Photos courtesy Stephen Elliott,

Hope Cement
MAGAZINE
CemProcess 2018 FP.indd 1 20/10/2017 13:16

NEWS
Comment: HeidelbergCement to buy

Cementir Italia
W e said to expect more consolidation in Italy. Then,

on 20 September 2017 HeidelbergCement an-
nounced that it is going to buy Cementir Italia from
Cementir Holding for Euro315m.
Global Cement’s first reaction was that the deal
seemed cheap. The agreement covers five integrated ce-
ment plants and two cement grinding plants with a total
capacity of 5.5Mt/yr, as well as the network of terminals
and concrete plants. HeidelbergCement is buying all of
this for Euro57/t. This suggests a downward trend given
that Buzzi Unicem paid Euro80/t for some Cementizillo
units that it bought in mid-2017. However, Cementir
only paid Euro38/t when it purchased Sacci back in
mid-2016.
Cementir’s acquisition of Compagnie des Ciments Casting a
confident glance
Belges (CCB) boosted its sales revenue, volume and
operating profit in 2016 and in the first half of 2017.
However these figures suffered on a like-for-like basis
at the future!
due to falling revenue in Turkey and Malaysia. Overall
revenue rose in Italy for the company in 2016, due to
a growing ready mix concrete business. However, with
this removed, its sales revenue would have fallen by
14% year-on-year due to a 13.5% decrease in the sales
volumes of cement.
Cementir Holding chief executive officer (CEO)
Francesco Caltagirone has framed the sale of Cementir
Italia in terms of improved financial leverage. He’s
placed it at close to 0.5x by the end of 2018. This, he
says, will allow the group to “…take the opportunities
arising in the future, as it has happened during the last
12 months.” By this, he likely means the purchase of CCB.
Given the low cost for what Cementir picked up the
bankrupt Sacci, it makes one wonder whether its plan
all along was to leave Italy and they just happened to
pick up a bargain along the way. HARDTOP® Bimetal Castings provide
Meanwhile, HeidelbergCement has framed its
acquisition in terms of preparing its presence in the
high wear resistance
Italian market for the future when the recovery kicks in. increased durability
The usual talk about synergies is also there and Italian reduced overall costs
workers for both Italcementi and Cementir Italia will be
wondering what this means for their jobs. Given that
high efficiency
the group’s overall sales have struggled to grow so far reduced expense for maintenance
in 2017, the company may be telling the truth when it minimised downtime
says it’s banking on the medium to long term in Italy.
After all, in its half-year report for 2017, it described the
raised production
Italian economy as subdued and reported cement sales added profit
volumes as ‘stable.’
Once the deal completes, Cementir Holding will be
an Italian-based cement company without any produc-
tion facilities in Italy. Unless the group is planning to Reichelstrasse 23
re-enter its home market at a later date, it does sug- D-39124 Magdeburg
gest a certain lack of confidence at home. Let’s see if Germany
HeidelbergCement has the nerve to stick it out.
phone: +49 (0) 391 532969-0
fax: +49 (0) 391 532969-21
e-mail: sales@hardtop-gmbh.com
Global Cement Magazine November 2017 21 web: www.hardtop-gmbh.com
ENERGY INTENSIVE CEMENT NEWS: EUROPE
INDUSTRIES /
INNOVATIVE TECHNOLOGIES Lithuania: Akmenes Cementas strikes deal
Fuels, Combustion, & Air Pollution Control with creditors
• Analytical & Advisory Services: Market

A kmenes Cementas has
managed to strike a
deal with its creditors over
research, studies and intelligence gathering the extension of a loan it
took out in 2007. The ce-
ment producer has been
• Business development: Technical articles in talks with various banks
and webinar organization since mid-2016 to post-
pone the loan settlement
deadline by three years,
according to the Baltic
Business Daily. However,
Akmenes Cementas went
to court and asked for an
obligation for the banks to
comply with the loan pay-
ment schedule signed in Above: The KHD preheater with calciner and partial
view of the kiln at Akmenes Cementas.
May 2017. Legal action was
dropped in late September
2017 when the banks agreed to continue crediting the company
under a deal. The loan currently stands at Euro53m.
Lithuania: New terminal to help exports to

Scandinavia
A kmenes Cementas says that its new terminal at the port of

Klaipėda will increase its exports to Scandinavia. At present
the cement producer sends about 15% or 0.15Mt/yr of its output
to the region. Once completed in the spring of 2018, the terminal
will allow exports to be increased to 0.2Mt/yr.
Switzerland: New CFO for LafargeHolcim
G éraldine Picaud has been appointed as the Chief Financial Officer

(CFO) of LafargeHolcim and member of the Executive Committee
with effect from 1 February 2018. She succeeds Ron Wirahadiraksa,
who is described as leaving the company for ‘opportunities outside the
group.’ He leaves after less than two years in the role.
Picaud, a French national, joins the group from Essilor International,
Xavier d’Hubert • Senior Consultant an opthalmic optics company, where she has been Group CFO and
member of the Executive Committee since 2011. Prior to joining Essilor,
she spent four years working for the ED&F Man group in Winterthur,
Tel: +33 6 44 23 66 57 or +1 502 819 0614 Switzerland, following 13 years as CFO at international specialty chemi-
Email: xavier.dhubert@earthlink.net cals group Safic Alcan. She originally trained as an auditor.
Greece: Heracles launches online client platform
H eracles Group, part of LafargeHolcim, has launched Xtizoume Mazi

(Building Together), an online platform for marketing, product
information and training. Via a new website its customers can find
information about Heracles’ products and access training courses. The
site will also allow access to the company’s loyalty scheme.
22 Global Cement Magazine November 2017

Making decisions regarding the realisation of a Have your project supported by an
new coal grinding system, as part of a complete independent specialist, right from the beginning.
new clinker line, or as an independent job?
You will demand the best from your supplier. But
ensuring that your system will end up un-compromised Coal Mill Safety Pte Ltd
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GLOBAL CEMENT NEWS: EUROPE
France: Aalborg Portland inaugurates Italy: Cementir defends conduct in

terminal at Rochefort illegal waste investigation
D enmark’s Aalborg Portland has inaugurated its termi-

nal at Rochefort. The Atlantic port terminal is intended
C ementir has defended its conduct in an illegal waste
investigation. It expressed ‘full confidence’ in the
Prosecutor’s Office of Lecce, following the decision by a
to supply the west of France with white cement under judge to seize a power plant run by Enel, according to
the Aalborg White® brand. The terminal has a capacity of Reuters. The probe is exploring whether Cementir Italia’s
4900t and it has been operational since May 2017. Taranto plant purchased ‘illegal’ by-products from Enel
Aalborg Portland said that the plant will significantly and the ILVA steel plant to produce cement. Cementir
reduce delivery times to the west of France, which had confirmed that it had regularly purchased fly ash for its
previously been supplied by its Moerdijk plant in the Taranto plant but that this ended at the start of 2016. It
Netherlands. Instead of a delivery time of two or three added that its use of sludge in cement production was
days, the west of France can now be supplied within a covered by an Integrated Environmental Authorisation.
single day.
“With the new terminal in Rochefort we can cover
almost all of France,” said Henrik Hougaard, Aalborg Turkey: YD Madencilik orders three silos
Portland’s export sales director. “The establishment of from Claudius Peters
Rochfort also sends a very strong signal to the French
market about our strategic presence. It gives customers
security of delivery.” Y D Madencilik, a subsidiary of Agoaglu, has signed a
contract with Claudius Peters for the delivery of three
new silos. The silos will be operated by YD Madencilik in
Düzce, Turkey. Commissioning is scheduled for 2018.
The scope of supply comprises a multi storage tricell
silo MS-IC/EC for cement, a cement storage duocell silo
MS-IC/EC as well as a raw meal MC silo. Both cement silos
have a volume of nearly 16,800m³ with an inner diam-
eter of 24m and a filling height of 75m. The raw meal silo
has a volume of nearly 16,700m³ and an inner diameter
of 20m.
UK/Germany: Hosokawa Alpine and

Atritor start marketing partnership
G ermany’s Hosokawa Alpine and the UK’s Atritor have

started a global marketing partnership to promote
their processing equipment for ground calcium car-
bonate (GCC). The Hosokawa Alpine ANR vertical wet
grinding mill will combine with the Atritor Cell Mill slurry
drying and powder coating system to provide an offer-
ing for superfine GCC products.
Germany/Italy: New global sales

Above: A vessel being loaded with cement at Aalborg Portland Cement’s quay on the director for two FLSmidth firms
Limfjord in Denmark. The white cement making its way to the Rochefort terminal
ultimately starts here as clinker.
S tephan Oehme has been appointed as the Global
Sales Director of both FLSmidth Pfister and FLSmidth
Ventomatic. Oehme, aged 50 years, is an industry expert
France: Mill upgrade for Lafarge France’s with more than 20 years’ experience in the respective
Havre-Saint-Vigor plant business fields. He holds a degree in mechanical engi-
L afarge France plans to spend Euro14.5m towards up-

grading its Havre-Saint-Vigor cement plant. Euro8m
will be spent on upgrading the plant’s mill and modernis-
neering and has worked previously as a Director Sales
and Technology. In order to support the combined sales
force of both companies he will increase the coopera-
ing its dock. The remainder will be spent on changes to tion between both sales teams.
the quarry including a new crane and wharf. The quarry FLSmidth Pfister develops high-end gravimetric dos-
at the site will be used to process construction waste from ing systems for cement and minerals plants. FLSmidth
the Greater Paris area. Ventomatic specialises in packaging and delivering
solutions for the same sector. Both companies are sub-
sidiaries of Denmark’s FLSmidth.

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UNTHA - ELIN November 2017.indd 1 20/10/2017 13:17

GLOBAL CEMENT: EVENT REVIEW
Global Cement staff
In the right mould: 20 years of HARDTOP
Around 150 guests converged on Magdeburg for bi-metallic casting specialist HARDTOP
Giessereitechnologie GmbH’s 20th anniversary celebrations on 14 September 2017.
Global Cement was in attendance to hear the company’s success story...
HARDTOP celebrated its 20th company anniversary 2

at the Millennium Tower in the 100 hectare Elbau-
enpark, Magdeburg, Germany. In the company of
almost 150 guests from 13 countries encompassing
1: The Millennium Tower four continents, company founder Prof. Dr. Armin
offered the perfect Ißleib and managing director Irina Ißleib-Lubojanski
environment for international
guests to listen to Irina Ißleib- cast a glance back at HARDTOP’s impressive history
Lubojanski’s presentation. spanning two decades.
Two keynote speakers – both former colleagues
through Magdeburg’s Otto-Guericke-University -
2: State Secretary Dr.
Jürgen Ude flanked by the former Senior Mayor of Magdeburg, Dr. Wilhelm
hosts, managing director, Polte and Saxony-Anhalt State Secretary Dr. Jürgen
Irina Ißleib-Lubojanski and Ude, gave insights into Magdeburg’s strong industrial 3
founder, Armin Ißleib. engineering history and HARDTOP’s very early days
respectively. They expressed their pride in having a
3: A warm welcome company such as HARDTOP in their region – and,
accompanied by a flying stressed Dr. Polte, the city would be pleased to wel-
buffet: Guests arrive come more!
from HARDTOP Centrum
Odlewnictwa, Poland. Irina Ißleib-Lubojanski explained that the com-
pany had modest beginnings, securing a start-up
capital loan following a challenging multi-interview
4: A prelude of classical music process in Berlin. A young, highly motivated and
ranging from Bach to Mozart:
The charming string quartet interdisciplinary team of ten scientists from Otto-
Guericke-University was thus formed. They saw
‘quartetto tonale’ from Berlin. 4
themselves as providers of research and development
services for the foundry sector. Product prototypes
employing bi-metallic castings were manufactured in
cooperation with companies and scientific institutes,
for example brake discs in the automotive industry
and roll segments in the steel industry. To earn an
income, the focus was on the sale of sub-licences. Top
1
of the agenda in 1997 was to secure the HARDTOP
registered trademark for its innovative bi-metallic
casting technology.
The first major investment for the company was a
software product from the USA, the ProCAST cast-
ing process simulation software. This evolved into the
acquisition of exclusive sales rights for ProCAST in
Germany until 2001 when ProCAST sold its software
programme to a large German group which subse-
quently sold the software through its own network,
HARDTOP thus losing its sales rights.
In 2001 the company had to change its business
concept as the idea of wishing to sell sub-licences was

5 6 5: Guests on a discovery tour

in the Millennium Tower:
A vivid illustration
of vacuum power.
6: Dr. Wilhelm Polte, former

Senior Mayor of Magdeburg,
right, poses for the camera
with Irina Ißleib-Lubojanski.
7 8 7: Irina Ißleib-Lubojanski
and Armin Ißleib savouring
the celebrations.
8: Pankaj Jain, Hardtop’s

agent in India, director of
Wearresist Technologies,
being welcomed.
9
not achievable. This led to the company commencing 9: HARDTOP’s managing
development of its own sales for bi-metallic casting director, Irina Ißleib-
Lubojanski giving her
technologies and thus use its own know-how for its impressive presentation
own products. So the search was on to locate suitable on HARDTOP’s company
foundries which could manufacture their bi-metallic achievements.
castings for them, to develop sales references and ap-
proach the market.
10 industry representing a large part of this. Hammers

are cast employing two different materials, the shaft
being cast from impact-resistant steel, the head
being from a hard-chromium cast iron, cast together
employing specialist know-how so that a com-
pound layer of just a few micrometres specifically 10: A fitting adornment
holds it together. for HARDTOP’s 20th
Companies beyond Germany’s borders became anniversary celebrations.
aware of HARDTOP’s offerings and larger capacities
were required, since a partner foundry in Poland
which cast on HARDTOP’s behalf could no longer
meet customer needs. So during the period 2006-
Dr. Jürgen Ude, today State Secretary, once ran 11

the competence centre, CCC Harzgerode, specialis-
ing in powder metallurgy technology which, in turn,
gave HARDTOP composite material manufacturing 11: The spectacular
Millennium Tower in
capabilities through using its own forging press in- Magdeburg’s Elbauenpark
stallation on site to produce composites comprising - a fitting venue
for example chrome, copper, aluminium and tita- for the celebrations.
nium.
Based on market analysis it was decided to focus
on wear technologies in the extractive industries
where materials need to be crushed, the cement

12: An impressive overview of 12 13

guests enjoying the
atmospheric festive banquet.
13: Samba dancers added

colourful, lively entertainment
to the special celebrations,
and a managing director
received special permission
to join in!
2008 a new foundry was established, HARDTOP

Centrum Odlewnictwa near Krakow. The partner-
ship in a joint venture foundry in China which the
company established in 2007 ended in 2012. As
a result a joint venture, HARDTOP HUAHENG
14
wear-resisting castings, was established in 2015.
In connection with the Chinese operation, a sepa-
14: Guests from Aquarius
rate company HARDTOP Engineering GmbH was
Germany presenting Irina
Ißleib-Lubojanski and founded in Germany. HARDTOP also has a most
Armin Ißleib with a maritime successful strategic partner foundry in Turkey.
wheel as the evening drew HARDTOP lists 21 representatives worldwide, some
to a close.
of whom travelled considerable distances to attend,
e.g. USA, India, Egypt and Russia. A laboratory was
also built near Magdeburg in 2012.
HARDTOP can look back on several years of
steady growth, only knocked a little in 2009 by the
global financial crisis. 2016 was an excellent year for
the company, over 56,000 castings were sold, small
and large, of which 80% were bi-metallic castings.
16
Cement, energy and construction machinery make
up the three largest end-user sectors.
15
15: The Frank Sinatra Big
Band from Berlin in full swing.
16: International guests from

China and Russia enjoying the
After the official programme guests enjoyed a fes-
convivial festive banquet. tive banquet accompanied by a Frank Sinatra-style
big band, lively samba dancers and an impressive
firework display in the night sky of Magdeburg.
17 18 19
17: A stunning firework 18: Dennis and Cindy Todd from 19: A wide choice of whisky was on offer
display lit up the night sky Wear-Concepts, Inc., Liberty, Missouri, to round off the evening.
of Magdeburg. USA enjoying the firework display.

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GLOBAL CEMENT NEWS: THE AMERICAS
Canada: McInnis plant inaugurated Argentina: Loma Negra aims to raise

US$800m in initial public offering
M cInnis Cement has inaugurated its Port-Daniel–
Gascons plant in Quebec. Provincial Prime
Minister Philippe Couillard attended the ceremony. L oma Negra aims to generate up to US$800m in
an initial public offering in Argentina and the US.
First cement at the 2.2Mt/yr plant was produced in Around US$700m of the money raised will go to its
June 2017 and the unit has since started commer- parent company, Brazil’s InterCement, according to
cial production. Construction at the site started in Reuters. InterCement is selling a
mid-2014. However, cost overruns saw the govern- 32% stake in the company
ment-backed project delayed and then taken over by to pay its debts. Subse-
an investor. quently it will hold a 57%
stake in the Argentine
cement producer.
No schedule for the
transaction has been
disclosed.
Paraguay: INC on target for 2017
Industria Nacional del Cemento (INC) sold 9.85

million bags of cement in the first nine months of
2017, representing 74.6% of its total sales in 2016.
The aim is to achieve sales of at least 13.5 million
bags in 2017, up from 13.2 million bags sold in 2016.
Above: The view from the McInnis plant out to its marine terminal at its brand INC’s sales were boosted by a new mill and a new
new plant in Port-Daniel-Gascons, Quebec. dryer in Villeta. The firm will also be able to use alter-
native fuels in its kiln from late 2017. The plant will
increase its capacity by 45% and will shortly issue a
US$500,000 tender for a new cement packing plant
US: Summit Materials makes US$3.8bn at its plant in Villeta to achieve this.
counter bid for Ash Grove Cement
S ummit Materials has offered US$3.8bn to buy Ash Grove

Cement. The board of Ash Grove Cement has described
the proposal as ‘superior’ to the US$3.5bn bid made by
Argentina: Avellaneda to spend
US$230m at La Calera and Olavarría
Ireland’s CRH in September 2017. It extended its so-called
‘shop window’ consideration period with CRH to 20 October
2017, the day that this issue went to press.
C ementos Avellaneda plans to spend US$230m
towards upgrading its La Calera and Olavar-
ría cement plants. The company is a joint venture
between Spain’s Cementos Molins and Brazil’s
Votorantim. US$200m will be used to increase the
Brazil: Sales continue to tumble in 2017 production capacity of the La Calera plant in San
S ales of cement have fallen by 7.6% year-on-year to

40.5Mt in the first nine months of 2017 from 43.8Mt in
the same period of 2016. The data from the Brazilian ce-
Luis to 1.0Mt/yr from 0.7Mt/yr by the second half
of 2019. US$30m has been targeted to increase the
Olavarría plant’s capacity by 0.3Mt/yr. Commission-
ment association SNIC showed that cement sales had fallen ing is planned for the end of 2017.
in all regions of the country, with particular decreases in the
North and North-East areas. SNIC president Paulo Camillo
Penna commented that the rate Mexico: Cruz Azul confirms US$300m
of decline was slowing com- upgrade plan
pared to 2016 and that
further progress was
expected in 2018. He
added that further
C ruz Azul has confirmed that it plans to spend
US$300m on upgrades at two of its cement
plants over the next 28 months. Previously the
government infra- plan was announced in late 2016. Guillermo Álva-
structure investment rez Cuevas told the El Economista newspaper that
was necessary to en- the cement producer intends to carry out work to
courage this trend. increase production capacity at its Hildalgo and
Oaxaca plants.

Colombia: Cementos Argos reports on

Canada: New CEO for CTLGroup
first half of 2017
C TLGroup, a subsidiary of the Portland Cement
Association that operates as a consulting and test-
ing company for a variety of markets, including the C ementos Argos has announced strong results for
the first half of 2017 and presented a good macro-
cement sector, has appointed Brian Schudiske as its economic outlook in its most relevant markets. Cement
president and chief executive officer (CEO). He succeeds sales rose to 8Mt, a 15% year-on-year rise compared to
Timothy Tonyan. the same period of 2016. The company saw revenues of
Schudiske has held leadership roles over the last US$1.5bn and earnings before interest, tax, depreciation
20 years in areas such as manufacturing, supply and amortisation (EBITDA) of US$219m. Argos said that
chain, operations, and engineering management. He the second quarter was significantly more productive
holds a Bachelor of Science and Master of Science in than the first due to increased operating efficiencies and
Environmental & Public Health from the University a greater revenue from its US operations, which offset an
of Wisconsin-Eau Claire. Prior to joining CTLGroup, overall slight decline in the Colombian market.
Schudiske was General Manager, US Materials and Man-
ufacturing, for SGS North America where he provided
operational and sales leadership for the Metallurgical Mexico: Cemex sells remaining direct
Engineering and Testing business in the US and was GCC stake
credited for delivering new business as a result of inno-
vative growth and sales strategies.
Tonyan will remain as chief operating officer and
continue to focus his efforts on firm-wide business and
C emex has sold its remaining direct 9.47% stake in
Grupo Cementos de Chihuahua (GCC) for around
US$168m. Proceeds from the sale will be used for debt
client development, project management and leader- reduction and for ‘general’ corporate purposes. However,
ship promotion. the Mexican cement producer will continue to hold a 20%
indirect stake in GCC through its subsidiary Camcem.
Canada: Opposition backs tyre burning US: CRH makes a move on Suwannee
ban in Nova Scotia American Cement
T he New Democratic Party has called for a ban of burn-

ing tyres in Nova Scotia. The opposition political party
held a news conference with opponents of the govern-
I reland’s CRH is close to agreeing a purchase of
Suwannee American Cement from Votorantim
Cimentos and Anderson Columbia. The deal is valued
ment’s decision in July 2017 to approve a one-year pilot at US$750m, accord-
project allowing Lafarge Canada to burn tyres for energy ing to Bloomberg.
at the company’s Brookfield cement plant, according to the However, this is an
Canadian Press newspaper. No tyres have been burned at extremely high value
the plant so far as the cement producer waits for industrial for a single cement
approval of the project from the provincial government. plant sale in the US.
Mark Butler of the Ecology Action Centre said the gov- Suwannee American
ernment’s decision was based on a Dalhousie University Cement operates a
engineering study that was too narrow in its focus and 1Mt/yr plant at Bran-
wasn’t peer reviewed. However the government has said ford in Florida.
that it used several technical studies to inform its decision.
A group of local residents also started legal action in August
2017 on the grounds that the project violated the province’s
Environment Act. Canada: North American cement unions
meet in Toronto
R epresentatives of US and Canadian cement industry un-

ions have met in Toronto. International Brotherhood of
Teamsters from the US and Canada, the United Steelwork-
ers from Canada and the US, the International Brotherhood
of Boilermakers and the Fédération de l’Industrie Manu-
facturière from Canada attended the third meeting of
the North America Cement Network, according to the
IndustriAll Global Union. The participants exchanged ideas
Bolivia: Potosí cement plant build drained about collective bargaining issues, the current situation in
by issues with water supply the cement industry and the latest developments in deals
such as the attempted purchase of Ash Grove.
R amiro Heredia, the technology manager of Empresa

Publica Productiva Cementos de Bolivia (ECEBOL), says
that the company has an issue with the water supply to the Cuba: Cementos Cienfuegos restarts
new Potosí cement plant it is planning near Chuitara. The production following Hurricane Irma
cement producer has asked the local government for help,
according to the El Potosí newspaper. Once operational,
the plant will require 6.5L/s, although it will be able to cope
with 3.5L/s during the construction phase. ECEBOL is also
C ementos Cienfuegos has gradually restarted produc-
tion following Hurricane Irma hitting the island in
early September 2017. Electricity was restored to the site
due to sign a contract with Empresa Nacional de Electrici- on 14 September 2017, enabling the cement mills to be
dad (ENDE) to provide electivity to the unit. Construction operated. The kiln was ignited on 19 September 2017, ac-
at the site is scheduled to start in the first quarter of 2018. cording to the 5 de Septiembre newspaper. Components
damaged by the storm included the insulation covering
electrofilters on the plant’s tower, broken power cables
Brazil: Piauí governor seeks reopening of and a breach to a water dyke near the site.
Itapissuma cement plant
W ellington Dias, the governor of Piauí, is seeking the

reopening of the Itapissuma cement plant. Owners
João Santos Group closed the plant in March 2017 due to an
US: Kuraray to buy Calgon Carbon
80% drop in sales caused by the country’s poor economy.
Around 500 employees were laid off, according to the state
government. The cement producer planned to make a final
K uraray has entered into an agreement to buy Calgon
Carbon for more than US$1.3bn. Calgon Carbon pro-
duces filtration technologies and systems for a variety of
decision on the future of the plant by the end of Septem- industries, including cement. The deal will be subject to
ber 2017. However, the governor has intervened to try and shareholder and regulatory approval. It is expected to be
coordinate the purchase of the plant by a local business completed by the end of 2017. Kuraray, a Japanese chemi-
consortium. cal company, intends to run Calgon Carbon as a subsidiary.

22  23 JANUARY 2018 LONDON, UK
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GLOBAL CEMENT NEWS: ASIA
Asia: Regional picture mixed heading into 2018
Pakistan: Exports fall as domestic China: Production falling so far in 2017

situation improves
C ement sales rose by 15% year-on-year to 10.3Mt

in the first quarter of the local financial year that
C ement production has fallen by 0.5% year-on-year to
1.5Bnt in the first eight months of 2017. This compares
to a rise of 2.5% in the same period in 2016, according to
ended in September 2017, from 9Mt in the same pe- data from the National Development and Reform Commis-
riod of 2016. However, the export part of this figure sion (NDRC). The Xinhua News Agency has also reported
fell by 16.7% to 1.29Mt, according to the All Paki- that the property sector stagnated in major cities due to
stan Cement Manufacturers Association (APCMA). government moves to prevent speculation.
Exports fell faster in the
south of the country,
where the country’s Philippines:
ports are based, with Shortages to 2020
a significant drop in
seaborne trade.
“Robust construc-
tion activities within the
A gap between local pro-
duction and demand is
expected to lead to a deficit
country are supporting in cement for the next three
the cement sector, but to four years to 2020. Napo-
it is still sitting on some leon Co, president and owner
idle capacity that could of cement importer Cebu
be exported through Oversea Hardware, told the
government facilitations Manila Bulletin newspaper
like sharing the transport that imports from China
cost,” said the APCMA to and other countries in the
the Nation newspaper. It Association of Southeast
added that the govern- Asian Nations (ASEAN)
ment should cut duties should be able to address
on cement to encourage the shortfall until new pro-
the residential sector. duction capacity is built.
Co added that the country
India: ICRA downgrades cement demand growth estimate imported 6Mt of cement in
2016, mainly from China and
T he credit ratings agency ICRA has downgraded its forecast for cement demand
growth to 3.5 – 4% for the 2017 - 2018 financial year, due to a slow first half
of the year. It blamed the slow first half on a sand shortage in some regions, the
Vietnam. Similar or higher
volumes of imports are ex-
pected for the whole of 2017.
implementation of the Real Estate Regulatory Authority and slowed construc-
tion activity in the west, according to the Press Trust of India. The agency expects
demand to be subdued during the second quarter of the financial year due to
weather and the implementation of the Goods and Services Tax (GST). However, Pakistan: Pioneer to
it forecasts demand to rebound afterwards as housing demand and infrastructure buy Galadari
projects pick up. For July 2017 the agency had predicted a growth rate of 5%.
P ioneer Cement has

signed a memorandum
of understanding to buy
Sri Lanka: New Insee mill under construction Galadari Cement (Gulf ).
Insee Cement has started building a new 0.45Mt/yr cement grinding mill, supplied by
Loesche, at its Ruhunu plant in Galle. Deputy Minister of Port and Shipping Nishantha
Muthuhettigama and Residence Manager of Galle Sujeewa Wimalasiri attended the event,
Galadari Cement has been
building its plant at Hub
Choki in Balochistan since
according to the Daily Financial Times newspaper. The US$14m project is scheduled for 1998, according to the
completion in mid-2018. News International news-
Loesche is supplying a jumbo-sized compact paper. The unit is 50%
cement grinding (CSG) mill for the unit. The mill is complete. No amount for
capable of grinding clinker and granulated blast the sale has been disclosed
furnace slag into Portland Limestone Cement and but it is estimated to be
Portland Slag Cement (PSC) with a throughput of around US$66m.
up to 60t/hr.

India: Protests at Nepal: Vicious circle harming sector

UltraTech project
T he proposed UltraTech
Cement plant at Khamar-
R egular power cuts have reduced production
at the Udayapur Cement plant since mid-Sep-
tember 2017 leading to a loss of US$190,000 so
nuagaon in Cuttack District has far. Meanwhile, the Nepal Electricity Authority re-
witnessed protests by locals ports that new hydroelectric projects are stalling
after it obtained the required due to a lack of imported cement. This contributes
90 acres from the government to the kind of power failures being experienced
to start building the plant. by Udayapur Cement, leading to a ‘chicken and
Addressing a press confer- egg’ scenario. Without cement for the dam, there
ence, villagers of Gurudijhatia is not enough power and without more power the
and Khamarnuagaon said that country cannot achieve self-reliance in the sector.
they would lose almost all graz- In the medium term, the import shortage has
ing fields for cattle when the been caused by new standards set by the Nepal
land is given to the plant. They Bureau of Standards and Metrology (NBSM) for
also alleged that elephants imported cement, according to the Himalayan
from nearby jungles would be Times. The NBSM made Nepal Standard certifi-
forced into the villages and cation mandatory for imported cement in July
destroy crops after a fence 2017. Foreign producers supplying cement to
is erected around the plant. Nepal, principally from India, have to follow qual-
UltraTech responded that the ity, packaging and labelling criteria fixed by the
plant would be ‘people-friendly.’ NBSM. Five Indian producers have submitted bids
to supply cement to Nepal under the new rules.
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Kazakhstan: Chinese firm invites Thailand Siam Cement signs US coal import deal
investors for US$200m project
G ezhouba Shieli Cement Company LLC is

now inviting international banks and finan-
S iam Cement Group (SCG) has signed a deal to import 155,000t of
coal from the US for its cement plants in Thailand and elsewhere
in the Association of Southeast Asian Nations (ASEAN). Kalin Sarasin, a
cial institutions to support the construction of its senior SCG executive and chairman of the Thai Chamber of Commerce
planned cement production plant in Kyzylorda and Board of Trade, made the announcement following an official
region, Kazakhstan, according to Li Jinqing, the visit to the US by Prime Minister Prayut Chan-o-cha, according to the
company’s general manager. Gezhouba Shieli is Nation newspaper.
a three-party joint venture (JV) between China SCG will buy 100,000t of US coal in the first contract and a second
Gezhouba Group Corporation Limited (CGGC) contract will be for 55,000t to test the quality. Subsequently, the ce-
(50%), China Gezhouba Group Overseas Invest- ment producer may buy more coal. At present, SCG imports around
ment Co., Ltd (20%), a subsidiary of CGGC, and a 6Mt/yr coal from Indonesia and Australia. The US coal will be used to
local cement company (30%). substitute some of the Indonesian supply, which has been imported
The cement production line will require a due to a higher demand for coal from power stations.
total investment of around US$200m, of which
70% will be funded through bank loans. At pre-
sent, CGGC is actively in communication with
some Chinese banks and financial institutions,
including Export-Import Bank of China (EIBC)
and China Development Bank Corporation
(CDB). The plant is designed to have a produc-
tion capacity of 2500t/day. It is expected to be
operational by the end of 2018. Vietnam: Cement sales up in first nine months
China Triumph International Engineering
Co Ltd (CTIEC) won the engineering, procure-
ment and construction (EPC) contract in April
2017, while its subsidiary Beijing Triumph
V ietnam sold 59.3Mt of cement in the first nine months of 2017,
a rise of 6% compared to the same period of 2016. The coun-
try has now fulfilled 74.1% of its whole-year plan, according to the
International Engineering Co., Ltd will take re- Ministry of Construction. 45.3Mt of cement was sold domestically,
sponsibility for design work, according to Qian a 4% rise year-on-year, while 14.0Mt of cement was exported.
Yingchun, the project leader at CTIEC. In September 2017, the country’s cement sales rose by 9.4%
compared to August 2017 to 6.7Mt, comprising 5.2Mt of domestic
sales and 1.5Mt of exports. As of September 2017, Vietnam had
India: Ambuja wins limestone 3.0Mt of cement and clinker inventory, most of which is clinker.
block after delay At present, Vietnam’s cement capacity is 86Mt/yr, but domestic
demand is estimated at 60Mt/yr, a surplus of 26Mt/yr, according to
A mbuja Cement has won an auction for

Nagaur’s Harima Peethasar limestone block
in Rajasthan following a procedural objection.
the Vietnam National Cement Association (VCNA).
JSW Group claimed that it was unable to place

a counter bid in the online auction due to prob- Malaysia: Negeri Sembilan to invest in WHR
lems with the computer servers of Metals and
Minerals Trading Corporation (MMTC), the state
company running the sale, according to the
DNA newspaper. After examination the claim
T enaga Nasional Bhd (TNB) is investing US$50m in two waste
heat recovery (WHR) plants to generate electricity through the
recovery of exhaust waste heat from two cement plants operated
was dismissed. by Negeri Sembilan Cement Industries. TNB’s
wholly-owned subsidiary TNB Repair and Main-
Philippines: Board of Investments clears Eagle tenance Sdn Bhd will develop and operate the
Cement for expansion of Bulacan plant plants and raise the necessary financing.
Negeri Sembilan Cement owns two cement
T he Board of Investments (BOI) has approved Eagle Cement’s appli-

cation to build a third production line at its Bulacan cement plant.
The cement producer plans to increase the site’s clinker production
plants in Bukit Keteri, Perlis and Bahau, Negeri
Sembilan with a total production capacity of
7.2Mt/yr. TNB said that the WHR plants will have
capacity to 4.2Mt/yr from 2.8Mt/yr and its cement production capacity a combined power generation capability of
to 7.1Mt/yr from 5.1Mt/yr, according to the Philippine Star newspaper. 23MW, giving Negeri Sembilan a 9-12% saving
The upgrade has a cost of around US$138m. on its electricity cost. The group said its venture
The BOI, part of the attached agency of Department of Trade and into the waste heat recovery development will
Industry, has also approved an application by Eagle Cement’s sub- provide a new business opportunity in promot-
sidiary South Western Cement Corp. (SWCC) to become a new cement ing energy efficiency, green technology and a
producer on a non-pioneer status but with pioneer incentives. sustainable long-term energy solution.

GLOBAL CEMENT: ASIA
India: Rohri deaths rise to seven
T he number of fatalities from an explosion at

the Rohri Cement Plant in mid-September
2017 has risen to seven, following the death of
„
The Blaine - Master“
journalist Lal Bux Kandhro. Four people died in the
initial blast whilst defusing explosives, according
The only producer of six
to the Dawn newspaper. Seven other people were different Blaine apparatus
severely injured in the incident, of which three
have subsequently died, including Kandhro.
Including demo film:
India: Orient pays compensation How to use the Blaine apparatus
over plant deaths
O rient Cement has paid US$46,000 in com-

pensation to the families of two workers who
were electrocuted at the Chittapur cement plant.
The move follows tension in the local community, Blaine, manual
according to the New Indian Express newspaper.
and Blaine,
The cement producer has also agreed to offer em-
ployment to the members of both families and to
semiautomatic
grant pensions to the widows of the workers.
Australia: Birkenshead plant under fire

over dust emissions
A delaide Brighton’s Birkenhead cement plant has

been criticised by a local environmental group
for its dust emissions ahead of a review of its licence. Blaine,
The Port Adelaide Residents’ Environmental Protection PC operated,
Group has asked the plant to pay towards cleaning fully automatic
up dust emissions near to the plant, as well as stricter
controls of dust and noise, according to the Westside
Weekly newspaper. The local Environmental Protection
Authority (EPA) is reviewing the cement producer’s cur-
rent licence, which expires at the end of October 2017.
The EPA has released a draft licence, including condi-
tions that require the cement company to produce
management plans to address dust and noise levels.
Blaine Dyckerhoff,
semiautomatic,
Indonesia: New President for
Semen Indonesia
H endi Prio Santoso has been appointed as the

president director of Semen Indonesia following
his approval at a shareholders meeting. He succeeds
Rizkan Chandra, who died in July 2017. Santoso is the
former president director of state-owned gas company
Perusahaan Gas Negara (PGN). Blaine Dyckerhoff,
PC operated,
India: KEC International wins orders fully automatic,
1 or 2 cells
K EC International has secured various orders with a
value of up to US$10.7m for structural and civil work
on cement plants. The orders have been announced as
part of a wider group of orders worth US$156m, mainly
in the power transmission, cable and railway industries.
TESTING Bluhm & Feuerherdt GmbH
Motzener Straße 26b • 12277 Berlin / Germany
Global Cement Magazine November 2017 37 Phone: +49 30 710 96 45-0
www.testing.de • info@testing.de
GLOBAL CEMENT: SANGHI CEMENT
Interview by Peter Edwards, Global Cement Magazine
In discussion: Alok Sanghi, Sanghi Cement
Here Sanghi Cement Director Alok Sanghi describes how the company is doubling its
capacity by 2020, making large investments in its distribution network as well as investing
in alternative fuels and waste heat recovery to maintain its position as the price and quality
leader in western India.
Global Cement (GC): Can you briefly introduce Plant and production process
Sanghi Industries? GC: How has the capacity of the plant changed over
the years?
Alok Sanghi (AS): Sanghi Industries Limited has
emerged as a major cement player in western India AS: Our original installed capacity in 2003 was
over the past few years. The company’s 4.1Mt/yr ca- 2.6Mt/yr. Then, through debottlenecking of some of
pacity plant, located at Sanghipuram, Abdasa Taluka, the preheater sections, we upgraded it to 3.1Mt/yr. In
Gujarat, is ranked as one of the largest cement plants the 2016 fiscal year, we further raised our capacity to
at a single location in India. This fully integrated 4.1Mt/yr by adding a 1Mt/yr grinding unit next to
plant includes a 63MW captive thermal power plant, the existing production line.
all-weather captive port and two sea terminals, one in
Above: Alok Sanghi, Director of Gujarat and one near Mumbai. It also has some of the GC: Where / who are the plant’s main customers?
Sanghi Industries Limited. largest limestone reserves in the country. It is one of
the top three players in Gujarat and is now increasing AS: Our customers vary from individual house build-
its presence in Maharashtra and Rajasthan. ers to real estate developers to mega infrastructure
I would say that we are the price and quality leader companies and, of course, government infrastructure
in the growing market in western India, with a strong agencies.
distribution network. Our two sea terminals enable
us to undertake coastal distribution at a cost that is GC: What is the distribution method to customers?
significantly lower than that of transporting cement
by road or rail. We are close to the international mar- AS: We have focused on changing our distribution
kets and our own captive port is well placed to cater method from road to marine as it is cost effective
to the export demand. The company has a vision to and helps us to target coastal markets. Our current
be a large scale, top quality cement manufacturer share of sales via marine routes is around 10%. We
with low costs and efficient distribution. plan to further increase it to 18-20% in the next
Right: The Sanghi Cement plant

in Gujarat was commissioned
in 2003. It has an FLSmidth kiln
and Loesche mills.

two years. For this, we have developed bulk cement Existing line production process
receiving sea terminals at Dharmatar near Mumbai
and Navlakhi in the Saurashtra area to service these 1. Mining: Limestone and additives like silica sand and laterite are mined
markets more efficiently. We have also procured from identified lease through mechanised mining and transported to
two low draft bulk carrier ships to further boost our plant using haul trucks as well as long belt conveyor for limestone. The
marine logistics. raw materials are stockpiled through stackers and reclaimed for raw grind-
ing section in a sequential manner.
GC: Does the plant use alternative fuels or have
plans to do so? 2. Raw grinding and homogenisation: Raw materials are dosed and
ground in a vertical roller mill to reduce size from 100mm to 50% residue on
AS: We have installed an automated alternative fuel 212μm. The entire process is automatic and real time corrections are made.
and raw material (AFR) system in the clinker plant The ground raw meal is fed to a silo that has the capability to simultaneously
to use waste material like municipal solid waste, used be fed, extracted from and homogenised.
oil, coal tar, plastics, oily cotton waste, sewage sludge,
paint sludge and others generated by other industries 3. Pyro-processing: The ground raw meal is fed to the kiln through a three
as alternative fuels in the kiln. We have started ex- stage preheater. After the kiln, hot clinker is fed to clinker cooler for quench-
perimenting with these materials. Though currently ing and cooled clinker is stored in silos.
the percentage of alternative fuel substitution rate is
around 2%, we want this to increase manyfold in 4. Cement grinding: Clinker is fed to dedicated hoppers to three FLSmidth
the future. cement ball mills. There are separate parallel hoppers for gypsum as well
as pozzolonic material. The ground cement is conveyed to cement silos for
GC: What are the plans for the plant going forward storage and dispatch.
in the near term?
AS: We have chalked out a comprehensive ex-

pansion plan divided into well defined phases. Plant Profile: Sanghi Cement
Phase 1 of the expansion was completed by
the expansion of the grinding capacity to
4.1Mt/yr, the establishment of the bulk terminals, Location: S anghipuram, Abdasa Taluka,
procurement of the low draft bulk carriers and Gujarat, India
the establishment of three ready-mix concrete
plants. The commissioning of a 13MW waste Founded: 2003 RAJASTHAN
heat recovery system is in the final stage and will Kilns: 1 - FLSmidth •
be completed by December 2017. Capacity: 4.1Mt/yr Navlakhi • JARAT
GU
Phase 2 of the capital expenditure plan in-
TRA
cludes the addition of an additional 4.1Mt/yr of Mumbai • ARASH
MAH
Above: Map of Sanghi Cement’s

missioned in the 2020 operations in western India.
fiscal year.
Left: One of Sanghi Cement’s

GC: Do you have plans two new low draft bulk
to make any further carrier ships.
changes to the first pro-
duction line in the next
few years?
grinding capacity fed by a new 3.3Mt/yr clinker line
from FLSmidth. This will take our total grinding ca- AS: The new capacity will be added at the same lo-
pacity to 8.2Mt/yr and clinker capacity to 6.6Mt/yr. cation but there are no planned expansions on the
A further 63MW power project will take our electri- existing line.
cal generation capacity to 169MW, including WHR.
All these expansion projects are likely to be com-

cement ratio in Gujarat has nearly

doubled from around 9% bulk sales
in the 2013 fiscal year to about 17%
in the 2017 fiscal year. It is expected
to rise to around 20% in the current
2018 fiscal year.
GC: How is the over-capacity situ-

ation playing out in India at the
moment? What is your capacity
utilisation rate?
AS: India has faced an over-capacity

situation over the past five years and
there seems to be no respite from
this situation in the near future.
However, some states and regions,
like where we operate, do not face
Above: Cement grinding mills Pan-Indian issues this issue and have adequate de-
were supplied by FLSmidth.
GC: What were the effects of demonetisation on mand to absorb excess capacity of adjoining states
Sanghi Cement and its customers? and regions. Due to over-capacity, the price realisa-
tion has been low and has impacted on the margins
AS: Demonetisation impacted real estate sales in the of cement players. Therefore, the only way for the
final quarter of the 2017 fiscal year. Due to subdued players to sustain in this industry is to control costs,
demand from real estate, cement prices were lower. which would at least maintain their margins. The
However, since the first quarter of the 2018 fiscal capacity utilisation rate for most cement companies
year, there has been significant improvement in de- has been below 70% for the past couple of years due
mand and price realisation across India. We believe to this situation. During the 2017 fiscal year, we oper-
effects of demonetisation are broadly over. ated at around 73% capacity utilisation, better than
the industry average of around 69%.
GC: What are your comments with respect to
the Indian tax regime for cement producers at GC: What are Sanghi Cement’s targets for the rest
this time, especially with respect to the Goods & of 2017 and 2018?
Services Tax (GST)?
AS: In the 2017 fiscal year, the sale of both clinker and
AS: Cement previously attracted a tax of 30%. The cement was around 2.9Mt. Going into the 2018 fiscal
GST Council has now placed it under a 28% tax rate year, we expect overall cement demand to improve.
slab, which is lower than the earlier tax rate. With higher capacity utilisation of around 75%, we
We had expected cement to be included in the expect clinker and cement sales to touch 3.1Mt.
capital goods list and taxed at 18%. However, even at
28%, the industry stands to gain. GST implementa- GC: Mr Sanghi, Thank you for your time.
tion is likely to be beneficial for the overall economy,
though we believe paperwork will increase signifi- AS: You are very welcome indeed.
cantly to start. We believe margins
are likely to expand for the cement
industry with implementation of
GST. Implementation of GST is
definitely a good step towards the
future and a digital India.
GC: Can you comment on

the changing bulk / bag ratio
Right: The plant’s stacker- in Gujarat?
reclaimer for raw materials.
AS: With increasing share of the

large scale real estate projects
and government infrastructure
projects, the share of bulk cement
sales is increasing. The bulk / bag

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HEKO November 2017.indd 1 20/10/2017 13:19

GLOBAL CEMENT: FANS
T Ananthakumar & Samuel Jeyaseelan, Howden India
Howden rotor retrofit for UltraTech Cement
In this article, Howden describes a recent rotor installation at UltraTech Cement’s Shambapura
works in India...
U ltraTech Cement Limited is India’s big-

gest cement manufacturing group, with
93Mt/yr of cement procuction capacity. The
company, part of Aditya Birla Group and a divi-
Right: Retrofitted Impeller L5N
sion of Grasim Industries, exports 2.5Mt/yr of
2729.00.77 DBL6T. cement, around 30% of India’s cement exports.
UltraTech Cement’s Shambapura works in
Rajasthan invited Howden to improve its Line 1
raw mill fan efficiency by retrofitting a new rotor
that was suitable for the existing casing. The de-
sign parameters of the existing fan are shown in
Table 1.
Parameter (unit) Value Parameter (unit) Design Operating

Right - Table 1: Operating Flow (m3/hr) 712,800 Flow (m3/h) 712,800 662,400
parameters of pre-existing raw
mill impeller. Inlet Static Pressure (mmWC) -1000 Static pressure rise (mmWC) 1000 955
Outlet Static Pressure (mmWC) 0 Dust load (g/m3) 40 40
Rotational speed (rpm) 980 Shaft power with dust (kW) 2310 2047
Far right - Table 2: Design and
operating parameters for the Dust loading (g/m3) 40 Efficiency (%) 84 % 84 %
retrofitted impeller. Shaft Power (kW) 2329
Efficiency (%) 83
Parameter (unit) Value
Flow (m3/h) 748,800
The Shambapura plant team gave the responsibility of Static pressure developed (mmWC) 918
this fan retrofit to Howden, as its experts conducted Rotational speed (rpm) 990
Right - Table 3: Test results of performance tests for various operating conditions
retrofitted impeller. Motor efficiency (%) 95.9
and proved the high performance of their solutions.
It allowed the maximum energy to be saved by Ul- Fan shaft power (kW) 2190
traTech. Fan static efficiency (%) 85.4
After conducting performance tests at site,
UltraTech asked Howden’s retrofit specialists in India
to design the fan considering the design and operat- the choice of Howden as supplier of this advanced
ing parameters described in Table 2. retrofit solution.
For the above parameters, Howden offered retrofit Howden has supplied the new rotor and sup-
rotor ‘Model: L5N 2729.00.77 DBL6T,’ which would ported UltraTech during all installation works. After
fit into the existing casing without modification. This erection, a site performance test was conducted on
proposal also considered the higher efficiency at op- the new fan. The results in Table 3 were obtained
erating parameters, new design parameters and the during tests in the presence of UltraTech representa-
guaranteed new retrofit rotor efficiency of 84%. tives. UltraTech was very satisfied by the solution,
This solution provided the advantage of mini- especially as the obtained efficiency level was more
mising the cost of the operation, which therefore than Howden’s initial commitment. Indeed, even
maximised the payback for UltraTech due to the though the flow has been increased by 5% between
re-use of the existing casing and reduction of the the new operating conditions (748,800m3/hr) and
lead-time. Moreover there is a significant improve- the previous conditions (712,800m3/hr), UltraTech
ment noticed in the wear pattern of the impeller and can still save 139kW/hr with the new fan. Following
a considerable reduction in the repair time. Based the project, Howden has supplied several other retro-
on the above parameters, UltraTech confirmed fit solutions to UltraTech group companies.

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ASEC November 2017.indd 1 20/10/2017 13:21

GLOBAL CEMENT: AUTOMATION
Lahcen Abellaoui, ASEC Automation
Electrical and automation upgrades:

An effective solution in the Philippines
In 2012 Republic Cement, now part of CRH-Aboitiz Company, decided to undertake

electrical and automation upgrades at its five plants in the Philippines. At the same time,
the decision was taken to install two new cement grinding plants based on the FCB
Horomill technology at its Teresa and Norzagaray plants. Republic Cement awarded the
project to ASEC Automation, an Engineering, Procuring and Construction (EPC) contractor
that had already provided services to the cement industry for more than 20 years.
E lectrical and automation upgrades or revamp-

ings are known to be difficult. However, specific
conditions, including a tight turnaround time, pre-
systems (PCSs) would be new and the motor con-
trol centres (MCCs) would be renewed or at least
refurbished to comply with the standards. A specific
cise budgets and a requirement to deliver a turnkey shutdown schedule was drawn up for all steps, along
product may further complicate the situation. The with associated timings for pre-shutdown, shutdown,
turnkey requirement necessitates a full plant survey start up and post-start-up.
during the bidding phase, often for weeks in col- Price and commercial conditions were another
laboration with engineers specialised in cement plant challenge. Although only a few companies with
maintenance, electrical systems, instrumentation, strong references in the automation and electrical
automation and erection. These conditions applied upgrade sector can meet the above conditions, the
during ASEC’s work with Republic Cement. competition is still tough.
The other challenge here was to comply with The installation of a new PCS means that a new
Republic Cement’s minimal business disruption re- technology would have to be transferred under the
quirements, with three days shutdown for a crusher, best conditions to the plants’ process engineers, op-
7-10 days for a cement mill and 21 days for the py- erators and automation engineers based on specific
roprocessing line (including raw meal transport, raw and dedicated training. To do this, a training centre
mill, kiln, cooler and utilities). The process control was developed, installed and commissioned.
Right: Central control room at

the Batangas plant, prior to the
upgrade.

The use of a new PCS also means new levels of operation. On top of this, the POLCID-DC system
connectivity between all communicating devices. had not been supported since June 2004. It is there-
This ranges from Level 1 devices, such as local pro- fore easy to understand the plant’s urgent need for a
grammable logic controllers (PLCs), proprietary PCS upgrade and its demand to no longer depend on
PLCs, proprietary cubicles and electrical devices, up a proprietary system.
to the availability of the resultant ‘big data’ for Level 3 The new PCS had to be compliant with the
systems such as process optimisation systems, quality company’s standards, which limits the choice to
control systems and record-keeping systems. four PCS manufacturers: ABB, Siemens, Schneider
and Nexeya. Finally the plant engineer chose to
Teresa and Batangas upgrades use the Siemens PCS7 System. All the local PLCs
Although this investment process has continued were also upgraded to the latest Siemens equivalent
under CRH-Aboitiz with the work in Norzagaray and PLCs such as the REPOL Cooler Grates and the
Iligan progressing, this article presents case-studies of PILLARD main burner. Along with the PCS, a new
the upgrades at CRH-Aboitiz’s Teresa and Batangas control room was designed with new automation and
plants. Prior to the upgrade, the Teresa plant had a networks panels as well as new I/O panels. All cables
very old proprietary PCS and electricals systems and (optical and copper) for all the necessary communi-
the Batangas plant had outdated electrical systems cation protocols (Ethernet, Profibus, Modbus, etc)
with no automated process control system at all. were also supplied.
Concerning the communication with Level 3
Teresa plant systems, the open platform communications (OPC)
CRH-Aboitiz’s Teresa Plant, located in Rizal province, server was programmed and tested based on prede-
30km east of the capital Manila, was the first plant to fined data tables of all kind of process variable. Final
be upgraded by ASEC Automation in 2014. factory acceptance tests were carried out with each of
The plant’s PCS was based on the proprietary these systems.
POLCID-DC system from Polysius with Vax sta- For the electrical part, all MCCs were retrofitted
tions, Real Time Computers (rt Vax) and Schmitz or renewed according to the company’s standards.
remote Inputs/Outputs (I/Os). Aside from the com- Newly-supplied MCCs were ASEC Automation’s
mon POLCID-DC programming control language MCC30 fixed type Plug-In Design. These MCCs
(STL-type programming), the system used Fortran- allow for highly-reliable operation, high flexibility
based programming for special programs used in and reduced maintenance. This type of MCC is con-
the system. One of these was the cement roller press sidered by many to offer the best price / performance
(Polycom control system), which controls the grind- ratio for the cement industry. The control voltage
ing pressure, roller parallel and power for efficient was also changed from 48V to 24V DC. Some of the
Left: Central control room at the

Teresa plant, following
the upgrade.

instrumentation devices were also changed, based on have a PCS at all. Each stage of production was
the audits made in the plant and the list that had been driven individually by a local mimic control panel
agreed with the plant engineers. without any kind of interaction with other areas
Last but not least, and in order to compensate for of the plants. For this plant, the arrival of the new
a prior lack of automation and electrical drawings PCS also necessitated the first ever central control
and documentation of the plant, a complete set of room. As for all of the other plants in this project, the
new engineering drawings was generated based on Siemens PCS7 System was selected.
the company’s standards. The whole plant process was thoroughly reviewed
Plant engineer and operator training is always an by plant process engineers and operators. The com-
important issue when a new brand of PCS is used. plete automation documentation, complying with
ASEC Automation has always offered its solution, the company’s standards, was generated in this plant
which consists of extensive ‘on job training.’ Plant for the first time. The existing mimic control panels
engineers are invited to participate with ASEC were removed, along with their associated cables.
Automation engineers in all the phases of the pro- This constituted a painstaking effort, but it was nec-
ject – engineering, programming, factory acceptance essary to simplify for the future plant maintenance
tests (FATs), commissioning, start up and post-start works.
up - a process that can last for several months. Special The majority of the MCCs were renewed based
training is also provided to operators during the ‘on on ASEC Automation’s MCC30 fixed type Plug-In
job training’ and the commissioning phase. design and the rest were refurbished in order to com-
Further to this training, plant engineers now ply with the company’s standards. The control voltage
handle the new system without any external help. was also changed from 48V to 24V DC.
An Automation Center training facility has been All power cables were tested and some were
installed in the Teresa Plant that serves all the CRH- renewed. The majority of the local panels were
Aboitiz plants. completely redesigned due to being outdated and
an associated lack of documentation. Some of the
Batangas plant instrumentation devices were changed based on
The Batangas Plant, located in the Taysan Municipal- the earlier plant audits and the list agreed with the
ity, 110km south of Manila, was the third plant to be plant’s engineers.
upgraded by ASEC Automation, in 2015. The critical issue of electrical safety was settled for
This plant had never been upgraded and didn’t all the plant by fulfilling all the company’s standards.
Complete electrical documentation was issued for
the whole plant.
All the site activities, pre-shutdown, erection,
site acceptance tests (SATs), commissioning, train-
ing, start up and post-start up, were conducted
successfully and on time. They required, during the
pyroprocessing line phase, the presence in the plant
of 65 people from ASEC’s local erection company
and 45 people, engineers, supervisors, technicians
and foremen, from ASEC Automation.
It is also noteworthy that the critical issue of
the Batangas plant engineer and operator training
was easily overcome thanks to the Training Center
at Teresa.
Images: Typical MCCs before (above) and after (below) an upgrade.
Conclusion
Electrical and automation upgrades in the cement
industry represent a complicated process at the best
of times. Such tasks become far more complicated
when they have to accommodate a tight schedule, a
limited budget and delivery on turnkey conditions.
A thorough knowledge of the plant during the bid-
ding phase and during the execution is mandatory.
This cannot be achieved without a team of engineers,
including those dealing with maintenance, electricity
(medium voltage and low voltage), instrumentation,
automation and erection and... crucially... with a
strong background in the cement industry.

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GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Contents Libya: LCC inspects Benghazi plants

Saudi Arabia: Kingdom ‘only needs
Subscribe four large cement producers’ B ritish consultants on behalf of the Libyan Cement
Company (LCC) have met with the Benghazi Mayor
Ad Index J ihad Al Rashid, the head of the Saudi National Com-

mittee for Cement Companies, has said that the
local market only needs four large cement producers.
Abdelrahman Al-Abaar in order to help restart two cement
plants in Benghazi and Hawari. Work is due to commence
on removing land mines from the sites, as well as an assess-
He added that the industry does not need the 17 cement of damage caused to the units from fighting that took
ment companies it has at present, according to the Al place in 2016, according to the Libya Herald newspaper.
Eqtisadiah newspaper. The owners and shareholders LCC announced that it was going to reopen the plants in
of these companies are ‘seriously’ considering merger May 2017.
options. Al Rashid said that the government and con-
sumers would benefit from a consolidated industry. South Africa: Dangote retracts PPC offer
as Investec investigates Fairfax plan
D angote Cement has formerly withdrawn from the bid-

ding process for PPC. The Nigerian cement producer
confirmed it had been in talks with PPC in mid-September
2017, following an offer by Fairfax Financial Holdings.
In early October 2017, PPC hired Investec bank to review
the offer from Fairfax. No duration for the review has been
specified but the cement producer said it would take ‘some
time.’ The Takeover Regulation Panel had granted Fairfax
In related news, the Saudi Industrial Exports an extension until November 2017 to distribute its offer
Company (SIEC) has signed a memorandum of under- to shareholders, PPC said, allowing Investec more time to
standing with Al Jouf Cement Company to export its complete its report into the proposal.
products internationally. The Saudi government lifted
a ban on exporting cement in 2016. Oman: Duqm signs deal with Al Wusta
Syria: Lafarge ‘paid Islamic State group’ T he Special Economic Zone Authority of Duqm (SEZAD)
has signed a usufruct agreement with the Al Wusta
Cement Company to establish a cement plant in Duqm. As
L afarge Cement Syria allegedly paid up to US$100,000/

month to armed groups, including US$20,000 to the
Islamic State (IS) terrorist group. Former plant manager
per the terms of the deal the Al Wusta Cement has received
a 500,000m2 plot in the zone for a duration of 50 years,
according to the Oman News Agency. The new cement
Bruno Pescheux told investigators that the money went via producer is a joint venture between Oman Cement and
local businessman Firas Tlass, who was a former minority Raysut Cement.
shareholder in the cement plant, according to the Agence Al Wusta Cement plans to start building the plant in
France Presse. Witnesses in the French judicial inquiry have 2018 with production scheduled for 2020. The unit will
also described false accounting methods used to disguise start with a production capacity of 5000t/day before raising
oil purchases from IS, travel documents allowing Lafarge this to 10,000t/day, subject to market demand.
trucks to move in the region and a planned meeting be-
tween IS and a Lafarge Cement Syria security official. The
Ethiopia: Capacity to hit 27Mt/yr by 2020
enquiry continues.
Morocco: Hakan Gürdal appointed E thiopia earned US$17.3m from exports of 0.2Mt of ce-
ment exports in its latest financial year, which ended on
7 July 2017. The Chemical and Construction Input Industry
Managing Director of Ciments du Maroc
Development Institute added that the country’s cement
H akan Gürdal has been appointed as the managing

director of Ciments du Maroc, a subsidiary of Heidel-
bergCement. He succeeds Nabil Francis, according to the
industry is planning to reach a production capacity of
27Mt/yr by the end of the Second Growth and Transforma-
tion Plan in the 2019 – 2020 year.
Telquel newspaper.
Hakan Gürdal graduated from the Technical University Ivory Coast: New association head
of Yildiz in Istanbul in Mechanical Engineering and from
the University of Istanbul with an MBA in International
Management. He then joined Çanakkale Çimento in
1992. He became a member of the board of directors of
X avier Saint-Martin-Tillet, the CEO of LafargeHolcim Côte
d’Ivoire has been appointed as the head of the Associa-
tion of Cement Producers of Cote d’Ivoire (APCCI). His term
HeidelbergCement in 2016 and has been in charge of the will last two years. Soro Nagolo, deputy general manager of
Africa-Eastern Mediterranean region since then. He has the Société des Ciments d’Abidjan (SCA), will serve as the
been responsible for purchasing since the start of 2017. vice-president of the association.

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GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Algeria: Cement imports Zambia: LafargeHolcim

‘will stop’ in 2018 deal boosts Zambia
Railways
M ohamed Benmeradi, the min-
ister of commerce, says that
Algeria will stop importing cement A contract with LafageHolcim has
boosted Zambia Railways freight
in 2018. He stated on national rate by 28% year-on-year to 318,000t
radio that the country is producing in the first half of 2017 from 247,000t
enough cement and is now consider- in the same period of 2016. The rail-
ing exports, according to the Liberté way company attributed the increase
Algerie newspaper. The government to a new contract with LafargeHolcim.
is amending the import licence sys- It also cited rising coal imports from
tem to encourage local growth. Zimbabwe for ‘booming’ cement pro-
duction in Zambia, as well as in the
Left: The Algerian government wants cement Democratic Republic of Congo.
imports to become a thing of the past.
Tunisia: Ciments de Bizerte doubles loss
C iments de Bizerte has nearly doubled its loss to Euro5.7m in the first half
of 2017 compared to Euro3m in the same period of 2016. The cement
producer’s revenue fell by 8.4% year-on-year and its operating income fell to
a loss of Euro2.5m from Euro1.9m, according to the L’Économiste Maghrébin
magazine. The company operates a single cement plant at Bizerte that has a
clinker production capacity of 0.9Mt/yr.

Osama Aly Ahmed, Technical Consultant
Major vertical roller mill breakdown...again?
One of the most common problems in vertical roller mills (VRMs) around the world is a
failure of the main gear unit. In this article, Osama Aly Ahmed looks at a case-study in
which a 400t/hr VRM was fixed at an Egyptian cement plant after an unexpected shutdown.
O n 15 February 2015 engineers detected a tem-

perature rise in one of the roller bearings of a
400t/hr VRM at an Egyptian cement plant. At this
For mills with a rated power >2000kW, the rec-
ommendation is to have safety factor of 2.0. The
reducers should be equipped with three stages,
point the decision was taken to change the two roll- reducers should be equipped with friction type bear-
ers, A and B, with the rising temperature observed in ings, mill control system and tripping conditions.
roller B. Before the VRM was stopped on 20 February
2015, there was no alarm to indicate that the situa- Recommendation of the fault analysis
tion was critical. The mill was vibrating normally, The fault was traced to ingress of foreign material
the oil temperature and gearbox were observed to be into the gearbox casing. However, other factors also
normal and there was no clogging of the filter. hindered the plant’s response to the unplanned out-
However, upon opening the roller bearing with age. Some recommendations are outlined below.
the elevated temperature, metallic particles were
found in the oil. When the inspection door of the Vibration monitoring: It is recommended that all of
gearbox was opened, it became clear that there had the reducers are monitored to detect failures early on
been, unfortunately, a big failure. to give sufficient time to anticipate imminent failures.
By pulling out the gearbox under the mill, it could Visual inspections, oil analysis, vibration measure-
be seen that the axial thrust bearing and the cover ment and frequency analysis should be employed in
had been damaged, dismantling the planetary gear all reducers via a continuous condition monitoring
and damaging the bearing. The decision was taken system to be supplied by Dalog. Five sensors inside
to change seven bearings as a preventive procedure. the VRM’s gearbox were found to not actually be
One was not changed due to an anticipated 20 linked to the central control room.
month delivery time and the fact that the bearing It was also recommended that transmitters be in-
was observed to be in good condition. The thrust stalled, which will become operational in June 2018.
bearing and cover were machined in the plant’s These should be integrated with the other sensors to
local workshop. afford complete monitoring. Dalog will complete the
set-up during the next kiln shutdown. There should
Maintenance time also be special on-the-job training for inspectors
Unfortunately a lot of time was spent on the repair and operator training, preventive maintenance and
because the stoppage was unplanned. There was no reducer instrumentation.
crane at the plant to remove the rollers, meaning a Standard velocity probes (Schenck or similar)
wait of two days and no established procedure to should be used to measure root mean square (RMS)
open the gearbox, which led to one day lost. As the values of the vibration between 10Hz and 1000Hz
dismantling was taking place, special tools had to at the base plate in the vertical direction. The most
be prepared as the situation demanded (1 day lost). pronounced mill vibration (natural frequencies) are
There were no bearings at the plant (2 days lost). 7-9Hz and therefore are filtered out with a standard
There were also delays to the machining of the cover, probe. Important vibrations are in radial (horizontal)
which eventually had to be repeated (7 days in total). direction and not picked up in vertical mounting. Vi-
In total the elongated repair time led to a total kiln brations are more pronounced on the top of the table
stoppage of 36 days. than on the base plate.
By using Equation 1, the safety factor of the Pabs
= motor shaft power (kW), i = number of rollers, μ
n (Eq. 1)
= friction factor (0.09 for raw material), k = Specific Pabs.  i    k  DR  WR  DM   
grinding pressure (kN/m2), DR = Roller diameter 60
(m), WR = Roller width (m), DM = Grinding table
diameter (centre of track) (m) and n = Table speed Optimise: The VRM currently works at a very high
(rpm). specific grinding force of 800kN/m2. It is recom-
mended that the hydraulic pressure be reduced to

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120bar in steps by June 2018. In order

to prevent a reduction of the output of
the raw mill when decreasing the hy-
draulic pressure, the air flow (quantity,
Right: Inside the gear unit. speed), nozzle ring area, recirculation
material parameters and separator reject
chute and other parameters must be ad-
dressed. A complete study of both the
maintenance and process operation of
the VRM, to be completed during June
2018, will look at the speed of the noz-
zle ring, recirculation rate, gas velocity
profile and pressure drop.
Contingency planning: There is a need

for a far better and more developed
contingency plan in the event of future
failures. The specific resources to remove
Right: Dismantling the the reducers and potential repair shops
gear unit.
have been identified. The sets of imme-
diately-available spare parts available has
been reviewed.
Conclusion
It is no secret that VRMs are very often
capacity bottlenecks in cement plants.
Careful attention should be given to
keeping them in good condition, as they
are crucial to the smooth running of the
plant. As this ‘worst-practice’ example
demonstrates, the lessons are not dif-
Right: Table pads. ficult to learn. Cement producers can
easily avoid the cost of lost production
due to VRM main drive failures.
Left and below: Bearing failure due to contamination.

2425 APRIL 2018 PRAGUE
gl bal globalslag.com
13th
CONFERENCE
slag
#globalslag
EXHIBITION
AWARDS 2018 Slag for profit
The 13th Global Slag Conference will visit the popular city of Prague for the Improving slag
first time in 2018 - and is expected to attract a strong audience from within performance
Europe and from around the rest of the world. The conference will allow all
attendees to maximise their profits from slag, will keep them up-to-date New applications
with the industry state-of-the-art and will provide extensive networking and for slag
business opportunities.
Global slag markets
If your business is slag, make it your business to attend and trading
the 13th Global Slag Conference in Prague!
Who should attend?
• Slag producers
Call for Papers - Global Slag 2018 • Slag users
The conference convenors are interested to hear from • Cement producers
prospective presenters for the 13th Global Slag Conference • Cement users
in Prague in April 2018. • Equipment vendors
Papers should fit in with the main themes of the conference: • Traders and shippers
• Academics
Slag and sustainability • Adding value to slag
Growing market share • Non-ferrous slags • Researchers
Interested authors should send a proposed presentation title Previous events:
and the name of the author to the conference convenor, Düsseldorf 2005
Dr Robert McCaffrey, rob@propubs.com, as soon as possible.
Bangkok 2006
Istanbul 2007
Including Strasbourg 2008
Global Slag What the delegates say: Brussels 2009
Awards “Good organisation” Registration Sydney 2010
Gala Dinner “Quality very good” discounts for Helsinki 2011
“Strong focus on GGBFS” Las Vegas 2012
EuroSlag
Dubai 2013
“Good to see so many
Members Aachen 2014
potential clients from outside
London 2016
the iron and steel industry” Düsseldorf 2017
“Excellent venue, well
organised event”
Exhibition and
“Gave good overall picture of sponsorship enquiries
handling, grinding, paul.brown@propubs.com
processing and testing” Tel: +44 1372 840950
Mob: +44 7767475998
International Slag Association sponsors Event partner
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MAGAZINE
Global Slag 2018 FP.indd 1 20/10/2017 13:45

GLOBAL CEMENT: SUSTAINABILITY
Bruno Vanderborght, Lesscoo GmbH
A low-carbon roadmap for the Egyptian

cement industry
Up until 2014, the Egyptian cement industry principally used state-subsidised natural gas
and heavy fuel oil to fire their kilns. Due to the gradual phasing out of the subsidies, using
natural gas and heavy fuel is no longer economically viable.
Key findings
T he enactment of amendments to the environ-
mental law in April 2015 now allows Egyptian
cement companies to use coal and petcoke. Such fuel
Industry performance: Although the clinker kilns
in Egypt are of the Best Available Technology (BAT),
switch will, however, increase CO2 emissions. There- their operational performance indicators compare
fore this new regulation requires that the operating unfavourably with Best Available Practice (BAP) and
permit of companies using solid fuels should include industry in most other world regions:
a plan of action on how they will limit the increase of
CO2 emissions. • Due to the high chlorine content of Egyptian
The technologies that can reduce CO2 emissions limestone deposits, as much as 5% of clinker
in the cement industry are well known, but their volume is discarded and landfilled as by-pass
deployment will not necessarily happen simply be- and cement kiln dust, resulting in energy losses
cause of an amendment to a law. Mitigation actions and CO2 emissions;
such as using alternative fuels (AF), energy efficiency
improvement, clinker content reduction and by- • Whereas about half of the Egyptian clinker
pass dust (BPD) recycling must be technically and kilns operate close to BAT thermal energy ef-
economically attractive to be implemented. This will ficiency (taking into account dust disposal),
require supporting policies and decisive and col- the others consume on average about 14% too
laborative action by several stakeholders, including much energy;
authorities and cement producers, as well as up-
stream and downstream companies. • In Egypt, waste and biomass derived fuels
Recognising the need to objectively assess the contribute less than 5% to thermal energy,
possibilities and necessary actions, a ‘Low-Carbon compared to 16% global average and 40% good
Roadmap for the Egyptian Cement Industry’ was de- available practice;
veloped in 2016 by South Pole Group and Cementis
in Zürich, for the European Bank for Reconstruction • The 89% clinker content in cement is 15% more
and Development (EBRD), the Egyptian Environ- than the global average and by far the highest
mental Affairs Agency, the Chamber of Building worldwide;
Materials Industries / Cement Industry Division and
in collaboration with the Ministry of Trade and In- • Electric power consumption is slightly above the
dustry and the Cement Sustainability Initiative. global average, but 15% above BAT.
Right: Qatamia Cement plant,

now part of HeidelbergCement.
Source: Italcementi website.

1. Lowering the clinker

content in cement;
Left: Bagged cement
2. Increasing the use of AF; awaiting dispatch from
Arabian Cement Company.
3. Energy efficiency Source: Arabian Cement
Company website.
improvements;
4. Increasing the capacity

utilisation of kilns.
The switch from natural gas and fuel oil to solid

fuels will increase CO2 emissions by 15%, from
710kg of CO2 per tonne of cement on average in “The switch from natural
2013 to 820kg of CO2 per tonne of cement and to
around 76Mt of CO2 in total in 2030. Consequently, gas and fuel oil to solid
the Egyptian cement production will be within the fuels will increase CO2
highest 2% globally by CO2 intensity. emissions by 15%...”
Furthermore, the Egyptian cement sector’s eco-
nomic performance and competitiveness are not
ideal. For the last five years the Egyptian cement
industry has operated at only about 70% capacity uti-
lisation. Such low capacity utilisation is economically Key policy actions in the next 5-10 years
unsustainable in the long term and hampers the af- For the cement companies to effectively implement
fordability of CO2 mitigation measures. In particular, the mitigation actions suggested in the Low-Carbon
installed clinker production capacity is expected to Roadmap and improve their energy and CO2 perfor-
be significantly higher than market demand for sev- mance, these actions must be economically attractive.
eral years in the future. This is, however, currently not the case in the pre-
sent economic and policy context in Egypt. Hence
Potential for emission reduction and energy decisive action by several governmental, public and
performance improvement business stakeholders is indispensable for creat-
The new coal regulation and the Low-Carbon Road- ing the necessary conditions for improvement. The
map seek to set the pathway for the Egyptian cement Roadmap describes the necessary policy actions,
industry to reduce its CO2 emissions, so that the 15% some of which can be summarised as follows:
CO2 emission increase resulting from the fuel switch
can be compensated. Although several options for Good data: Good data is key for good decision-
CO2 mitigation exist, achieving the objective could making. A cement sector monitoring, reporting and
become technically feasible in Egypt through mainly verification (MRV) system and database, compat-
four levers: ible with the CSI international standard, should be
Left: The efficient processing of

wastes into alternative fuels will
be important for the Egyptian
cement sector.

installed, collecting reliable information on all key disposal complies with the ‘waste hierarchy’ and the
performance indicators defining the industry’s CO2 ‘polluter pays principle.’
emissions; While this currently does not exist yet in Egypt,
adequate waste management legislation, regulation
Slow down capacity addition: The pace of licens- and law enforcement should be developed to gen-
ing new clinker and cement installations should be erate market demand for environmental and legal
adapted with the purpose of balancing installed pro- waste treatment. This will lead to the development
duction capacity with long-term domestic cement of proper waste management infrastructure and a
market demand and taking into account a lower con- market price for waste treatment and disposal. This
tent of clinker in cement. No additional new clinker will help to create a business case for waste-derived
capacity needs to be built before 2025. Until 2020, alternative fuels in the cement industry.
increasing market demand can be met by increasing
existing capacity utilisation and, until 2025, by lower- Using more BPD: While discarding BPD from the
ing the clinker content in cement; kiln cannot be avoided, techniques to recycle it do
exist. If the applicability and costs of these tech-
Change standards: Egyptian standards currently niques could be improved, by lowering their water
prohibit using most composite cements for rein- and energy consumption and recycling the recovered
forced concrete applications because of insufficient salts, then significant further CO2 savings could
quality control and assurance at the construction become possible.
sites. For the same reason Egyptian construction
standards require heavier design specifications to Steering Committee for the Roadmap’s
ensure structural integrity. implementation
Training of architects and engineers should The implementation of the policy and technology
be improved. A quality assurance certification recommendations described in the Roadmap will
system for ready-mix concrete installations and enable, by 2030, a complete reversal in the projected
construction companies should be developed that CO2 emission increase from the fuel switch. By 2030,
would enable them to use composite cement and 2.2Mt of coal will no longer have to be imported.
leaner construction while ensuring the structural A more ambitious scenario would further decrease
integrity of the buildings. Coal fly ash, currently specific CO2 emissions to about 2% below the his-
classified as hazardous waste, should be declassified toric level prior to the fuel switch. The Roadmap is
and import of fly ash, slag and pozzolana for clinker ambitious but realistically achievable in the Egyptian
substitution authorised. context.
A Steering Committee, chaired by the Ministry of
Polluter pays: The key success factor for waste-to- Trade and Industry and supported by the EBRD and
energy and alternative fuels is market demand for consultants from South Pole Group and Cementis,
environmentally sound waste disposal. has been installed in 2017. It will bring together on
It is essential that waste producers have a legal a regular basis all stakeholders that are necessary to
obligation to dispose of their waste in a safe, envi- bring the Low-Carbon Roadmap into action and to
ronmental and legal way and ensure that their waste improve the CO2 emission and profitability of the
Egyptian cement industry.
Right: The future of the

Egyptian cement sector will
be explored at the 22nd Arab-
International Cement Conference
in Sharm El Sheikh, Egypt on 14-
16 November 2017, along with
the cement industries of other
Middle Eastern and North
African countries.

2021 FEBRUARY 2018 BERLIN, GERMANY
gl bal
12th Alternative fuels for cement and lime
Global CemFuels Awards
cemfuels
Gala Dinner
Major exhibition
www.cemfuels.com
CONFERENCE • EXHIBITION • AWARDS
What’s at CemFuels?
Global CemFuels Conference and Exhibition has established itself as the largest
specialised annual alternative fuels event in the world, attracting 150-200 Alternative fuel trends
international delegates and many exhibitors each year. Pricing factors
The 12th Global CemFuels event in Berlin will showcase the best alternative fuels Sourcing and trading
projects and equipment from the cement industry in Europe and from around
Storage and handling
the world. Delegates are expected to attend from more than 40 countries, to
learn from experts how to start to use - or to increase their use of - alternative Processing and dosing
fuels. If your business is in alternative fuels for the cement and lime industry,
then you must attend! Combustion optimisation
Business opportunities
NETWORKING!
“Better than
excellent”
CemFuels 12th CemFuels Exhibition
delegate Please contact Paul Brown with all
exhibition enquiries:
paul.brown@propubs.com,
Tel +44 1372 840950
or Mob: +44 776 7475 998
Who should attend?
Cement and lime producers

who want to reduce their
fuel bills
Legislators and regulators
Alternative fuels equipment

manufacturers & service
providers
Fuels producers, agents,

traders & shippers
Those with an interest in fuel

project financing
Energy and fuel analysts
Academics & researchers
Organised by:
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MAGAZINE
cemfuels2018 fullpage.indd 1 24/10/2017 12:32

GLOBAL CEMENT: MIDDLE EAST
Peter Edwards, Global Cement Magazine
Cement round-up: Middle East
Here Global Cement turns its attention to the larger cement markets of the Arab Union of
Cement and Building Materials (AUCBM), to coincide with the 22nd Arab-International
Cement Conference in Sharm-El-Sheikh, Egypt on 14-16 November 2017.
T he economies and cement industries of the Egypt - Cement sector

19 countries that comprise the Arab Union of The Egyptian cement sector is the largest in the
Cement and Building Materials (AUCBM) are var- AUCBM, with 23 integrated plants,1 three grinding
ied in terms of size and their levels of development. plants1 and 67.3Mt/yr of cement production capacity
Table 1 provides information for all AUCBM mem- in 2016, according to the AUCBM.2 Production in
ber countries: Number of integrated and grinding 2016 came to 48.0Mt, with sales of 49.0Mt, indicating
cement plants,1 available cement capacity, produc- imports of around 1.0Mt/yr.
tion and sales data for 2016,2 and general population3 The Global Cement Directory 2017 lists 17 different
and GDP/capita figures.4 cement producers, with all of the major international
GDP/capita rates in the group range from groups represented.1 Between them, foreign firms
US$990/capita in Yemen, which is in the midst of a operate 42.1Mt/yr of cement capacity, around 62% of
humanitarian crisis, to US$59,330/capita in oil-rich the country’s total. The integrated cement producers
Qatar.4 Their cement industries range in size from are listed in Table 2 on Page 60.
zero in Palestine, to Egypt’s 67.3Mt/yr cement ca- The largest producer in Egypt is Germany’s
pacity.2 Their populations range from 1.5 million in HeidelbergCement, which recently acquired former
Bahrain to 95.7 million in Egypt.3 This article will Italcementi assets in the country. It has six integrated
focus on the five largest cement sectors by capacity. cement plants that share 14.2% of Egyptian capacity.
Country Number of plants Cement statistics (2016) Other data (2016)

Integrated Grinding Capacity Production Sales GDP/ Population Capacity/
(Mt/yr) (Mt) (Mt) capita (millions) Population
(US$) (kg/cap/yr)
Egypt 23 3 67.3 48.0 49.0 3514 95.7 703
Saudi Arabia 20 1 56.0 54.4 54.8 20,028 32.3 1734
Iraq 19 2 37.9 16.2 16.2 4609 37.2 1019
UAE 13 8 29.5 - - 37,622 9.3 3172
Morocco 13 2 28.3 15.2 - 2832 35.3 802
Algeria 17 6 22.2 17.0 19.0 3843 40.6 547
Tunisia 10 - 12.9 - - 3688 11.4 1132
Right - Table 1: Number of Jordan 6 - 10.7 9.0 20.0 4087 9.5 1126
integrated and grinding cement
Yemen 8 1 10.6 - - 990 27.6 384
plants1, cement statistics for
2016,2 population,3 GDP/capita4 Syria 10 2 10.5 - - 2058 18.4 571
and capacity / population (cal-
Libya 8 - 9.7 - - 5602 6.3 1540
cluated) for AUCBM countries.
Oman 4 - 8.8 - - 14,982 4.5 1956
Kuwait 3 - 7.0 - - 28,975 4.1 1707
Sudan 6 2 6.8 - - 2415 39.6 172
Lebanon 3 - 6.5 - 5.2 7914 6.0 1083
Qatar 6 1 4.5 3.6 3.7 59,330 2.6 1731
Bahrain 2 1 1.0 9.0 2.0 22,354 1.5 667
Mauritania 0 2 0.9 - - 1077 4.3 209
Palestine 0 0 0.0 0.0 2.7 - 4.6 0
AUCBM (Totals / Median) 171 31 331.1 4348 390.8

TUNISIA SYRIA
LEBANON
PALESTINE IRAQ
MOROCCO KUWAIT
ALGERIA JORDAN BAHRAIN
LIBYA EGYPT QATAR
SAUDI UAE Left - Figure 1: Cement
production capacity in
ARABIA 2016 across AUCBM
member countries.2
MAURITANIA
SUDAN OMAN
YEMEN
OMt/yr <5Mt/yr 5-10Mt/yr 10-20Mt/yr 20-30Mt/yr 30-50Mt/yr >50Mt/yr
TUNISIA SYRIA
LEBANON
PALESTINE IRAQ
MOROCCO KUWAIT
ALGERIA JORDAN BAHRAIN Left - Figure 2: Populations
LIBYA EGYPT QATAR
SAUDI UAE of AUCBM member
countries in 2016.3
ARABIA
MAURITANIA
SUDAN OMAN
YEMEN
0-5m 5-10m 10-20m 20-30m 30-50m >50m
TUNISIA SYRIA
LEBANON
PALESTINE IRAQ
MOROCCO KUWAIT
ALGERIA JORDAN BAHRAIN
LIBYA EGYPT QATAR
SAUDI UAE
ARABIA Left - Figure 3: Cement
production capacity2 divided
MAURITANIA by population3 for AUCBM
SUDAN OMAN member countries in 2016.
YEMEN
0kg/cap/yr <500kg/cap/yr 500-100kg/cap/yr 1000-1500kg/cap/yr 1500-2000kg/cap/yr >2000kg/cap/yr

The second, third, fourth and plant1 and 56.0Mt/yr of cement production capacity
Company Capacity Share
fifth-largest players are also foreign- in 2016, according to the AUCBM.2 Production in
(Mt/yr) (%)
owned. LafargeHolcim operates 2016 came to 54.4Mt in 2016, with sales of 44.8Mt.
HeidelbergCement (Germany) 14.2 20.9
the mammoth 10.6Mt/yr Lafarge The Global Cement Directory 2017 lists 17 differ-
LafargeHolcim (Switzerland) 10.6 15.6 Cement Egypt plant at El Ain Al ent cement producers, all of which are Saudi-based.
Cemex (Mexico) 5.7 8.4 Sokhna, near to Cairo, giving it Foreign firms have almost no involvement in the sec-
Intercement (Brazil) 5.5 8.1 15.6% of national capacity. Cemex tor, with the exception of LafargeHolcim’s 25% stake
operates Assiut Cement, another in the proposed Al Safwa Cement. The integrated
Titan Cement (Greece) 5.2 7.6
large single-location local subsidiary. producers are shown in Table 3.
Arabian Cement 5.0 7.3 Intercement is close behind with its The most prominent cement producer in Saudi
National Cement 3.8 5.6 5.5Mt/yr plant in the Nile Delta city Arabia is Southern Province Cement, which has
Misr Beni Suef 3.5 5.1 of Alexandria, while Titan Cement three integrated plants, one of which has 9.3Mt/yr of
also operates at Alexandria (2.0Mt/ capacity. Along with its two more modest facilities,
VICAT (France) 3.5 5.1
yr) and at Beni Suef (3.2Mt/yr). this gives Southern Province 15.7Mt/yr of cement
Misr Cement Qena 2.0 2.9 Egyptian-owned cement plants production capacity, enough to corner it nearly a
Wadi El Nile Cement 2.0 2.9 make up a significant minority quarter of national capacity. All other producers
Nahda Cement 1.7 2.5 of overall capacity. The largest is in Saudi Arabia operate one integrated plant each.
Arabian Cement (5.0Mt/yr). None Many of these are fairly large operations, with the
BMIC 1.5 2.2
of the domestically-owned produc- majority 3.0Mt/yr or larger.
South Valley Cement 1.5 2.2
ers operates more than one plant.
Misr Qena Cement 1.4 2.1 Saudi Arabia - Recent trends
Medcom Cement 0.8 1.2 Egypt - Recent trends Clinker production fell by 10.9% year-on-year
Royal El Minya Cement 0.2 0.3 Much has been written previously to 29.3Mt in Saudi Arabia during the first seven
in these pages about the switch months of 2017. The Saudi Economic Review by the
from subsidised oil and natural National Commercial Bank attributed the slowdown
Above - Table 2: Cement gas towards coal in the Egyptian cement sector.5 in production to weak domestic demand, which fell
producers in Egypt.1 This change, coupled to the lack of impetus to use by 9.8% in 2016, and ‘record high’ clinker inventory
alternative fuels by the authorities and devaluation levels of 32.5Mt in July 2017. The local cement indus-
of the Egyptian Pound has adversely affected input try has also suffered from rising input costs due to
costs, and hence profitability, in the sector. In August higher energy and fuel prices following government
2017, Vicat stated that its results had been adversely policy changes. Sales for July 2017 itself, however,
affected due to its Egyptian operations in the first half were higher year-on-year than in July 2016. This was
of 2017, where it noted a ‘difficult macro-economic due in part to an earlier Ramadan, which had delayed
Below - Table 3: Cement and industrial environment.’ In Cimpor’s first half reconstruction activities during June 2017.
producers in Saudi Arabia.1 sults it noted continued ‘issues’ in the country. Misr With the apparent aim of improving the poor
Beni Suef, one of the local producers showing between January and July 2017, Jihad Al
Company Capacity Share to issue results, saw its net profit fall Rashid, the head of the Saudi National Committee for
(Mt/yr) (%) by 41% year-on-year to US$3.1m. Cement Companies, has said that the local market only
Southern Province Cement 15.7 23.9 However, new players seem needs four large cement producers. He added that the
Yamama Cement 6.3 9.6 undaunted by such results. industry does not need the 17 cement companies it
Electro-Mechanical Design Group has at present. The owners and shareholders of these
Yanbu Cement 5.9 9.0
announced in June 2017 that it companies are apparently ‘seriously’ considering
Najran Cement 4.3 6.6 wants to build a US$300m plant merger options. Al Rashid also said that the govern-
Arabian Cement 4.2 6.4 in Foukag, Marsa Matrouh. Mean- ment and consumers would benefit from a more
Qassim Cement 4.2 6.4 while, Egyptian Cement is planning consolidated industry.
a US$221m plant in Sohag Province.
City Cement 3.6 5.5 Iraq - Cement sector
It announced the order of three ver-
Eastern Province Cement 3.5 5.3 tical roller mills from Loesche in According to the AUCBM, Iraq has the third-largest
Al Jouf Cement 3.5 5.3 October 2017. Finally, South Valley cement sector in the AUCBM, with 19 integrated
Saudi Cement 3.2 4.9 Cement, one of Egypt’s smallest ce- plants,1 two grinding plants1 and 37.9Mt/yr of ce-
ment producers, could stand to gain ment production capacity in 2016.2 However, due
Northern Region Cement 3.2 4.9
a significant investment from Saudi to the ongoing political situation in the country,
United Cement 1.9 2.9 Arabia’s Al Sharbatly Group, with a production and sales are nowhere near such levels.
Al Ahsa Cement 1.8 2.7 second production line on the cards. Production in 2016 came to just 16.2Mt, as did sales,2
Tabuk Cement 1.6 2.4 indicating a capacity utilisation rate of just 43%. This
Saudi Arabia - Cement sector is not surprising given that many industrial facilities
Hail Cement 1.6 2.4
Saudi Arabia has the second-largest have been under the control of armed groups or even
Al Gharibah Cement 0.7 1.1
cement sector in the AUCBM, with destroyed as the result of fighting.
Saudi White Cement 0.4 0.6 20 integrated plants,1 one grinding

Global Cement Magazine invites entries for the
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Global Cement Photography Competition 2018.
The winning photos will be showcased in Global TM
Cement Magazine in the New Year. The winner
of the competition will also receive US$250 as a
cash prize and the runners up will receive US$125.
Anyone can enter and each individual may enter
up to five cement-related photographs.
PHOTOGRAPHY COMPETITION 2018
Every entry to the Global Cement Photography Entry is simple and free: Please send your entry (digital only, JPG,
Competition 2018 must be accompanied by a sepa- RAW or Tiff format) by email to rob@propubs.com. The subject line
rate MS Word document stating: Photographer’s must be as follows: ‘Global Cement Photo Competition.’ Files must
name, company, email and postal address; Location be above 500kb but must be below 5Mb in compressed size.
of the subject.
DEADLINE: 15 December 2017 - GOOD LUCK!
2017 Entrant: Seyed Mohamad Ali Alavi, Sabzevar Cement Company, Iran
PhotoComp 2018 November 2017.indd 1 20/10/2017 13:57

Company Capacity Share

Due to the complex at Qarachog. The plant is also a 6000t/day facility and
(Mt/yr) (%)
nature of the ongoing is expected to be online by August 2018.
Lafarge 6.6 22.7 conflicts, the information
MASS Group 6.0 20.6 in the Global Cement Di- United Arab Emirates - Cement sector
Southern Cement 5.3 18.2 rectory 2017 is now likely The UAE has the fourth-largest cement sector in the
to be incomplete and/or AUCBM region, with 13 integrated plants,1 eight
Al Rawi Group 3.3 11.3
out of date. It lists 29.1Mt/ grinding plants1 and 29.5Mt/yr of capacity.2 As it has
Northern Cement 3.3* 11.3 yr of cement capacity, a relatively small population for a country with such
Iraqi Cement 2.6 8.9 of which 2.0Mt/yr was a large capacity, the UAE has by far the largest cement
Family Group 2.0 6.9 known to be destroyed.6 capacity per capita in the AUCBM group, with more
There are seven producers than 3100kg/capita/yr. This has resulted in significant
listed, as shown in Table 3. exports, with the UAE turning into a net exporter of
The largest producer by installed capacity is cement in 2010. Local producers exported 3.0Mt of
Above - Table 3: Cement LafargeHolcim, via its three plants at Tasluja cement in 2012, aided by high energy cost subsidies.
producers in Iraq.1 (2.3Mt/yr), Karbala (1.8Mt/yr) and Bazian (2.5Mt/ Prior to this the nation had been importing large
* = Northern Cement’s yr). Close behind is MASS Group, with a single amounts of cement and building up its local produc-
2.0Mt/yr Badoosh plant 6.0Mt/yr plant in Sulamaniyah, Kurdistan. Southern tion capacity to meet its voracious real estate market.
was reportedly destroyed by Cement is third-largest with seven integrated plants
Islamic State in March 2017. and 5.3Mt/yr of installed integrated cement capacity. United Arab Emirates - Recent trends
It is included in the figures for
completeness.6 The largest producer in the UAE is Arkan Group,
Iraq - Recent trends which opened its 5.7Mt/yr plant in Al Ain in 2014.
Announcements of new cement plant projects The producer was even larger, before it shut down
continue apace in Iraq in the light of the recent an older 1.0Mt/yr plant in 2017. Prior to the closure,
destruction of some facilities. In June 2017, China Arkan’s cement business saw its revenue fall by 9%
North Industries Corporation signed a US$445m year-on-year to US$220m in 2016 from US$239m
deal with Jabal Bazian Company for General Trad- in 2015. Net profit fell more sharply, by 25% to
ing to build a cement plant. The contract includes US$20.6m.
the plant’s production line design, purchasing, con- Other local producers have had similar experi-
struction management, operational work as well ences. Fujairah Cement reported that its revenue
as assorted administration buildings, dormitories, fell by 2.5% to US$162m from US$167m although it
dining halls and other facilities and is scheduled for did manage to grow its profit by 12% to US$15.4m.
completion in the second half of 2019. Earlier in the year it attributed the rise in profits to
Back in November 2016, FLSmidth announced higher prices and cost control on the production
a contract of US$200m with Iraq Cement to build a side. Meanwhile, Union Cement’s revenue fell by 10%
6000t/day production line in the Al Muthana region to US$153m from US$170m and its profit fell by 19%
on an engineering, procurement and construction to US$22.9m from US$28.2m.
basis. Around the same time, China Machinery The Dubai Chamber reported that the potential
Engineering signed a US$250m deal to build a plant value of construction projects awarded in 2016 was
US$36.5bn. Overall in the Gulf Cooperation Council
Company Capacity Share region the value of contracts fell by 17% year-on-
(Mt/yr) (%) year. A report by the Chamber has recently called for
Arkan Group 5.7 19.5 cement producers to improve their competitiveness,
save on production costs, use more alternative fuels
Union Cement 4.8 16.4
and push exports.
(Norcem < HeidelbergCement)
Lafarge Emirates 3.2 11.0 References
(50% LafargeHolcim) 1. ‘Global Cement Directory 2017,’ Pro Global Media Ltd, Epsom,
Fujairah Cement 2.9 9.9 UK, 2016. 2. ‘AUCBM Countries,’ AUCBM website, http://www.
Gulf Cement 2.7 9.2 aucbm.org/Members.aspx. 3. ‘Population, total,’ World Bank Data
Right - Table 3: Cement
Indicators website, https://data.worldbank.org/indicator/SP.POP.
producers in The UAE.1 Star Cement (Aditya Birla) 2.4 8.2
TOTL. 4. ‘GDP/capita (current US$),’ World Bank Data Indica-
Sharjah Cement 2 6.8 tors website, https://data.worldbank.org/indicator/NY.GDP.PCAP.
Pioneer Industries 1.7 5.8 CD?view=chart. 5. ‘The rise of coal mills in the Egyptian cement
(Raysut Cement) sector,’ Ahmed, O. A. & Osman, K. R. in Global Cement Magazine
National Cement 1.5 5.1 - July-August 2017, Pro Global Media Ltd. 6. ‘Islamic State sets
Badoosh cement plant on fire,’ Global Cement website, 20 March
RAK Cement 1.0 3.4
2017: http://www.globalcement.com/news/item/5933-islamic-state-
Nael Cement 0.7 2.4
sets-badoosh-cement-plant-on-fire.
RAK White Cement 0.6 2.1

GLOBAL CEMENT: PRICES
Here Global Cement Magazine presents its monthly review of global

cement prices, in US$ for easy comparison. Much more price informa-
tion (including the latest information on prices and market trends Do you have your finger on the cement
throughout the global cement industry from our price correspondents) price pulse where you are?
is only available to subscribers of Global Cement Magazine. If so, Global Cement Magazine needs you!
To get additional prices, you should subscribe - See page 64. In this
issue subscribers receive information from 12 more countries, including Send cement prices to
Malaysia, South Africa, Pakistan, Philippines, Indonesia and Sudan. peter.edwards@propubs.com.
Regular contributors receive a free

subscription to Global Cement Magazine!
India: According to Equity Bulls, all-India cement El Menya Cement

prices declined by US$0.12/bag (50kg) month- - Super Royal =
on-month in October 2017, falling to an average US$97.63/t; Menya Hel-
of US$4.98/bag. Prices were down compared to wan Cement = US$97.63/t.
September 2017 in all areas except the west of the Blended cement prices as
country, which had earlier seen a larger decline of 12 October 2017: Sinai Cement -
than elsewhere in September 2017. Alnakheel = US$37.07/t; National Cement
Prices declined sharply in the East by - Altawfir = US$37.07/t; Helwan Cement - Alwaha
US$0.28/bag to US$5.01/bag and by US$0.24/ = US$36.50/t.
bag in the south to US$5.35/bag. The west saw a Sulphate-resistant cement prices as of 12
small increase of US$0.02/bag, while the prices in October 2017: Cemex Albukawem = US$45.87/t;
the north and central areas fell by US$0.05/bag to ASEC Cement (Asic Sea Water) = US$44.44/t;
US$4.69/bag. Suez Cement (Alsuez Sea Water) = US$44.16/t;
In the central northern state of Himachal Lafarge (Kaher Albehar) = US$45.70/t; Suez
Pradesh, Ambuja and ACC agreed to reduce their Cement (Al Suez Sea Water) = US$44.67/t; El
ex-factory prices by US$0.08/bag on 12 Octo- Sewedy Cement = US$44.56/t.
ber 2017. The move followed an intervention by
Chief Minister Virbhadra Singh and takes rates to Angola: Users of cement in Angola are concerned
US$5.53/bag. UltraTech Cement and CCI, which that the sector is creeping towards a monopoly as
also operate plants in the state, were instructed not higher input prices increasingly marginalise smaller
to increase their prices. suppliers of material. Ex-factory prices have report-
edly risen by more than 70% since 2013 to reach
Egypt: Ordinary Portland Cement prices as of US$15.68/bag (50kg) in late September 2017.
12 October 2017: Arabian Cement (Al Mosalah)
= US$43.88/t; Arabian Cement (Al Nasr) = China: Sunsirs Commodity Data Group reports
US$41.44/t; Cemex (Al Muhandis) = US$45.87/t; All-Chinese cement prices: 6-9 October 2017 =
Building Materials Industries = US$41.44/t; ASEC US$48.57/t; 10-11 October 2017 = US$48.69/t.
Cement = US$41.72-42.29/t; El Nahda Cement =
US$41.44/t; Wadi El Nile Cement = US$41.72/t; Ethiopia: Cement prices are currently US$78.30-
Lafarge (Al Makhsous) = US$42.29/t; Arish Ce- 79.40/t on average.
ment = US$41.72/t; Sinai Cement = US$41.04/t;
National Cement = US$41.89/t; Suez Cement
= US$41.61/t; Tourah Portland Cement
= US$41.61/t; Helwan Cement =
US$41.61/t; Misr Beni Suef Cement
= US$42.24/t; El Sewedy Ce- Prices are for cement in metric tonnes, unless stated otherwise. Where a source has given a range,
ment = US$3.59/t; South Valley the published price is the minimum value.
Cement = US$41.61/t; Misr Ce- FOB {+ the named port of origin} = Free On Board: The delivery of goods on board the vessel at the
ment Qena = US$41.44/t. named port of origin (loading), at seller’s expense. Buyer is responsible for the main carriage/freight,
White cement prices as cargo insurance and other costs and risks.
of 12 October 2017: Sinai CIF {+ the named port of destination} = Cost, Insurance and Freight: The cargo insurance and delivery
White Cement (Alabid Elada) of goods to the named port of destination (discharge) at the seller’s expense. Buyer is responsible for
= US$101.04/t; Sinai White Ce- the import customs clearance and other costs and risks.
ment (Super Sinai) = US$98.20/t; ASWP = Any safe world port.
Conversions to US$ from local currencies are as at the time of original publication.

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GLOBAL CEMENT: THE LAST WORD
Future building materials
Robert McCaffrey Editorial Director, Global Cement Magazine (rob@propubs.com)
I recently enjoyed the film Bladerunner 2049, where

in an early scene, one replicant (synthetic human),
smashes another through a wall apparently made of
may give you an indication of two major trends: that
building materials will have less embodied energy (they
will be more energy-efficient to produce) and that they
gypsum wallboard. A bit later on, the surviving repli- will also have less embodied CO2. Despite the fact that
cant takes off in a flying car. While some things change, many climate modelling programmes have now been
some things stay the same. acknowledged to ‘run hot’ and to over-estimate the
We at Global Cement have our eyes on a number of degree of future global warming (probably due to an
different industries, primarily in the building materials over-sensitivity of the models to the global warming
sector. We get to see all the latest innovations in cement potential of CO2), there is no doubt that CO2 is firmly
and concrete, of course, but also those in the insulation, in society’s sights as the main culprit of global warming.
cement-board and gypsum wallboard industries. We are We have seen some consumers shying-away from mate-
‘materials agnostic,’ since some materials can substitute rials with high embodied CO2 (for example requesting
for each other quite well (for example different types the use of lower-clinker cement for concrete founda-
of insulation provide the same level of performance), tions) and this is a trend we expect to continue.
whereas it seems that at other times one material offers When the cost of energy is high, those building
clear advantages over another in a specific application products that can reduce energy consumption can gain
(for example the use of slag-based concrete as gravity a premium in the market. Concrete justly claims to have
dam foundations, due to the low heat of hydration of a high heat capacity and can provide thermal stability
the cement). to buildings, while insulation can of course slow the
We also get to see some incipient trends, and how transmission of heat from one area to another. Phase
they eventually transpire. For example, alternative fuels change materials (such as wax globules) incorporated
are a maturing trend in some parts of the industry, but into building materials - such as concrete - absorb heat
are still ‘the new thing’ in other areas: As shown on page during the day and let it out at night and can emulate
54 of this issue, Egypt uses less than 5% of biomass- the effects of insulation, but there’s a long way to go
based fuels, compared to a 16% global average (and before the technology becomes widespread.
40% best practice). We have also seen a strong trend Gypsum wallboard offers a cheap, lightweight,
in the last few years towards reducing the clinker fac- perfectly flat, fire-resistant wall (and ceiling) surface
tor. After all, when you can replace costly clinker with that can be installed with relatively low skill and at
cheaper and more environmentally-benign substitutes high speed. Its main weakness is in its poor response
(and make better concrete), why wouldn’t you? If your to moisture (it can grow mouldy and can also sag).
local regulations allow it, of course. Cement-based boards are inherently and permanently
So, what other trends are coming down the line, moisture- and mould-resistant, but we’d like to see ce-
and what can we see for the future of building materi- ment-based boards add insulating properties, improved
als? Well, a quick glance at my favourite graph, below, acoustic attenuation, active moisture management and
greater control and improvement of indoor
air quality (as do other boards). There is a lot
of potential for adding value to cement-based
boards, and this will be discussed in depth at
the 3rd Global Boards Conference in London
on 22-23 January 2018.
In the future, we might see a modified
tilt-up or prefabrication approach to build-
ing construction, where a low-or-no clinker,
recycled and recyclable ‘concrete’ with added
insulation and phase change materials offers
all-round performance at low cost. Since
glow-in-the-dark and translucent concrete
already exist, this is actually not such a leap.
Global Cement 2049 here we come!

Contents Subscribe
GLOBAL CEMENT: ADVERTISER INDEX
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Aixergee Aixprocess 17 Mersmann@aixergee.de • www.aixergee.de
ASEC Automation 43 contact@asecautomation.com • www.asecautomation.com
CemWise 23 info@cemwise.com • www.cemwise.com
Christian Pfeiffer Maschinenfabrik GmbH 4 office.de@christianpfeiffer.com • www.christianpfeiffer.com
Coal Mill Safety Pte Ltd 23 info@coalmillsafety.com • www.coalmillsafety.com
DALOG Diagnosesysteme GmbH IFC, 3 info@dalog.net • www.dalog.net
Di Matteo Förderanlagen GmbH Ins. 18/19 info@dimatteo.de • www.dimatteo.de
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FLSmidth 15, OBC info@flsmidth.com • www.flsmidth.com
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Howden Group Ltd 47 cement@howden.com • www.howden.com
KettenWulf IBC service@kettenwulf.com • www.kettenwulf.com
Keith Mfg. Co. 31 sales@keithwalkingfloor.com • www.keithwalkingfloor.com
Kima Echtzeitsysteme GmbH 29 contact@kimaE.de • www.kimaE.de
Loesche GmbH FC Karin.Boeker-Mahr@loesche.de • www.loesche.com
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Scantech Pty Ltd 49 geoscan@scantech.com.au • www.scantech.com.au
Testing Bluhm & Feuerherdt GmbH 37 info@testing.de • www.testing.de
TLT-Turbo 51 service@tlt-turbo.com • www.tlt-turbo.com
Total Lubricants 35 william.duchatelle@total.com • www.lubricants.total.com
UNTHA shredding technology GmbH 25 info@untha.com • www.untha.com
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Next issue: December 2017 Advertising deadline: 24 November 2017

Special reports: Top 100 cement producers & 2017 in Cement Future cements, Fans, Alternative fuels, Gears, Electronics, Drives
Event Reviews: AUCBM, Egypt, VDZ Cement Conference, Germany Smart buildings, Euroslag, North Africa, Cement boards
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WE DISCOVER POTENTIAL
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News Fans Grinding Sanghi Cement Automation Hardtop Alternative fuels Sustainability Middle East Maintenance

Contents Subscribe Ad Index

NOVEMBER 2017 MAGAZINE

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

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

Complete Grinding Plants in Record Time.

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NOVEMBER 2017 MAGAZINE

Loesche: Since 1906, LOESCHE GmbH, has been constructing

Loesche GmbH • Hansaallee 243 • D-40549 Duesseldorf 1701274_Titel_Global_Cement_216x250mm.indd 2 13.10.17 15:15

Tel: +49-211-5353-0 • Fax: +49-211-5353-500

www.GlobalCement.com Global Cement Magazine November 2017 5

Global Cement articles

10 maintenance contracts can open up significant savings.

12 Grinding stations for flexibility

14 Alternative fuel preparation technology:

18 Special elastomer saves workspace and weight

19 Product and contract news

Cement in the Americas

19 30 American cement news

38 In discussion: Alok Sanghi, Sanghi Cement

6 Global Cement Magazine November 2017 www.GlobalCement.com

42 Howden rotor retrofit for UltraTech Cement

50 Major vertical roller mill breakdown... again?

58 Cement round-up: Middle East

Regulars and comment 50

64 Subscription form for Global Cement Magazine

65 The Last Word

66 Advertiser Index & Forthcoming issue features

Contents Subscribe Ad Index

22nd Arab-International Cement Conference

15th NCB International Seminar of Cement,

Let´s play it safe!

 2th Global CemFuels Conference

✓ 25th AFCM Technical Symposium & Exhibition

systems – made in Germany

Uncovering potential with O&M contracts

10 Global Cement Magazine November 2017 www.GlobalCement.com

GC: Why is this potential not used by more plants? Reference

www.GlobalCement.com Global Cement Magazine November 2017 11

John Terembula, FLSmidth

Grinding stations for flexibility

F or cement producers looking to break into new

Typically, grinding stations are situated on a com-

Right: FLSmidth’s OK™ mill is

12 Global CementMagazine November 2017 www.GlobalCement.com

www.GlobalCement.com Global Cement Magazine November 2017 13

Peter Streinik, UNTHA shredding technology

Alternative fuel preparation technology:

I nvesting in a new capital asset is never a straight-

2018 safety considerations

14 Global CementMagazine November 2017 www.GlobalCement.com

wellbeing and this duty of care requirement

2. Kirkup, J.: ‘Everybody needs good neighbours’ in CIWM Journal,

16 Global CementMagazine November 2017 www.GlobalCement.com

when it comes to ...

www.cemfuels.com don’t just

+ 49 241 4134492-50 www.aixergee.de

Aixergee - CemFuels November 2017.indd 1 20/10/2017 13:15

Benjamin Müller, EFFBE

Special elastomer saves workspace and weight

Elastomer-springs are state-of-the-art combined with CFK-material to lower the weight.

Right: Urelast dampers

18 Global CementMagazine November 2017 www.GlobalCement.com

2th Global CemFuels Conference

• Analytical & Advisory Services: Market

KIMA Echtzeitsysteme GmbH