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Ximang Tap Chi Xi Mang Toan Cau Thang 11 2017
Ximang Tap Chi Xi Mang Toan Cau Thang 11 2017
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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
widely-read cement magazine! Looking through the global cement news in this issue, peter.edwards@propubs.com
we can see that the consolidation of the industry continues apace. HeidelbergCement (+44) (0) 1372 840967
has purchased Cementir Italia, leaving Cementir Group in the strange position of being
Italian but not having any Italian cement assets. In the October 2017 issue we rushed to
Web Editor
print the news that Ireland’s CRH had bought Ash Grove Cement in the US - the deal David Perilli
had been presented as a fait accompli. However, that particular picture has now been david.perilli@propubs.com
complicated by Summit Materials throwing its hat in the ring. It has offered US$500m (+44) (0) 1372 840952
more than CRH for the same assets. We go to press as Ash Grove’s new two-week shop
window closes and await the conclusion of these negotiations with interest. Commercial Director
Paul Brown
Elsewhere, the shenanigans surrounding the Afrisam / PPC merger continue, with paul.brown@propubs.com
some ‘sources’ now suggesting that CRH is looking to snap up PPC following its Mobile: (+44) (0) 7767 475998
disappointment over Ash Grove. A cynic might suggest that the ‘sources’ are just talking
up PPC. Dangote Cement was earlier linked with PPC but has since formally withdrawn
Business Development Executive
from discussions. Finally, our interest was piqued when we read the news that Saudi Sören Rothfahl
Arabia only ‘needs’ four major cement producers. According to Jihad Al Rashid, the soeren.rothfahl@propubs.com
head of the Saudi National Committee for Cement Companies, there is no need for Mobile: (+44) (0) 7850 669169
17 different producers in the market, where cement sales fell by 11% in the first seven
months of the year. Saudi policies on cement imports and exports have led to great Company manager
fluctuations in supply and demand in the past few years and it will be interesting to see Sally Hope
whether this new suggestion is followed through. sally.hope@propubs.com
This issue’s features include a look at the increasingly popular use of operation and
maintenance contracts by cement plant owners. Joe Harder highlights how they can save Subscriptions
Amanda Crow
money based on his company’s new report (Page 10). There are technical contributions amanda.crow@propubs.com
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
jane.coley@propubs.com
of the cement industries of selected AUCBM countries (Page 58), to coincide with
the 22nd Arab-International Cement Conference in Sharm-El- The views expressed in feature articles are those of the named
Sheikh, Egypt. author or authors. For full details on article submission, please
see: www.GlobalCement.com
We hope you enjoy this issue of Global Cement Magazine - the
world’s most widely-read cement magazine! Peter Edwards
Editor ISSN: 1753-6812
Published by Pro Global Media Ltd
First Floor, Adelphi Court 1 East Street,
Cement Printed on Forest Stewardship Council Epsom, Surrey, UK KT17 1BB
Industry (FSC®) certified papers by Pensord, Tel: +44 (0)1372 743837 (switchboard)
Suppliers’ a company with ISO 14001:2004 Fax: +44 (0)1372 743838
Forum environmental certification.
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.
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.
26
production and plans, as well as issues affecting the wider
Indian cement market.
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.
54
Use this form to subscribe to Global Cement Magazine,
or subscribe online at www.GlobalCement.com.
58
www.GlobalCement.com Global Cement Magazine November 2017 7
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GLOBAL CEMENT: OPERATION & MAINTENANCE
Interview by Peter Edwards, Global Cement Magazine
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
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!
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
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...
• 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.
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…
Designed with the same proven technology and modular design as our standard
OK™ cement mill, FLSmidth's OK™ 54-6 raw mill has successfully been installed at
Semen Padang, Indarung 6, in Indonesia. With a capacity of 750 tph and an 8,700
kW MAAG® WPV 5000 three-stage gear, it is the largest raw mill in the world.
For more information, contact us on: info@flsmidth.com
WE DISCOVER POTENTIAL
GLOBAL CEMENT: ALTERNATIVE FUELS
Reference
1. Lanner, C.: ‘Tackling alternative fuel production fires,’ in Global
Cement Magazine, October 2015.
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Zambia: Dangote rail deal Germany: Schenck Process launches new weighfeeders
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and troubleshooting
CONFERENCE & EXHIBITION
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The second Global CemProcess conference and exhibition will
look in depth at process optimisation, at de-bottlenecking, Global CemProcess
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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
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• 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
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If you are responsible for process optimisation or production • Meet old friends
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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
www.cemwise.com
GLOBAL CEMENT NEWS: EUROPE
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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...
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
7 8 7: Irina Ißleib-Lubojanski
and Armin Ißleib savouring
the celebrations.
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.
15
15: The Frank Sinatra Big
Band from Berlin in full swing.
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.
Grinding Optimisation
PACKAGE
·· increased production
improved product finess
· energy savings
Canada: Opposition backs tyre burning US: CRH makes a move on Suwannee
ban in Nova Scotia American Cement
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nt ers
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%.
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.
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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GLOBAL CEMENT NEWS: ASIA
Kazakhstan: Chinese firm invites Thailand Siam Cement signs US coal import deal
investors for US$200m project
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
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?
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In this article, Howden describes a recent rotor installation at UltraTech Cement’s Shambapura
works in India...
ASEC AUTOMATION
YOUR PARTNER AROUND THE WORLD
ASEC AUTOMATION
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PROCUREMENT AUDIT
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PROCUREMENT
CONSTRUCTION AUDIT
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Leader of Electrical & Automation Works in Cement Industry
ENGINEERING
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CONSTRUCTION MAINTENANCE
Leader of Electrical & Automation Works in Cement Industry
contact@asecautomation.com
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
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.
e: cement@howden.com www.howden.com
GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
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
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
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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.
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.
If necessary, we provide you with upgrades and revamps and care of all
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Mail: a.abdelbaky@tlt-turbo.com
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.
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
Organised by:
gl bal
cement
TM
MAGAZINE
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.
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.
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
Organised by:
gl bal
cement
TM
MAGAZINE
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.
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
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
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
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 re- construction 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
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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$125.
Anyone can enter and each individual may enter
up to five cement-related photographs.
PHOTOGRAPHY COMPETITION 2018
Every entry to the Global Cement Photography Entry is simple and free: Please send your entry (digital only, JPG,
Competition 2018 must be accompanied by a sepa- RAW or Tiff format) by email to rob@propubs.com. The subject line
rate MS Word document stating: Photographer’s must be as follows: ‘Global Cement Photo Competition.’ Files must
name, company, email and postal address; Location be above 500kb but must be below 5Mb in compressed size.
of the subject.
2017 Entrant: Seyed Mohamad Ali Alavi, Sabzevar Cement Company, Iran
Gulf Cement 2.7 9.2 aucbm.org/Members.aspx. 3. ‘Population, total,’ World Bank Data
Right - Table 3: Cement
Indicators website, https://data.worldbank.org/indicator/SP.POP.
producers in The UAE.1 Star Cement (Aditya Birla) 2.4 8.2
TOTL. 4. ‘GDP/capita (current US$),’ 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
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GLOBAL CEMENT: THE LAST WORD
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