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GCL
MAY 2005

Contents Ad index

Subscribe
GLOBAL CEMENT AND LIME MAGAZINE

• Global cement and lime news

• Lafarge’s Sugar Creek plant
• American Conference 2005 - Cancun
• IEEE-IAS/PCA: Kansas City
• Hillhead previewed
• 2005 Reader’s Survey
 GCL Reader Survey 2005
Return by fax to (+44) (0) 1372 743838,
or mail (to arrive no later than 31 July 2005) to
PRo Publications, 6B East Street,
✃

G LOBAL C EMENT & L IME M AGAZINE

Epsom, Surrey, KT17 1HH, UK.
Introduction May 2005
In GCL: Global Cement and Lime Magazine’s Reader Survey 2005, we aim to find out exactly what our
readers think about GCL magazine and its associated conferences, so that we can continue to improve
both the magazine and the conferences in the future and bring our readers and delegates
exactly what they want: it’s as simple as that!

In order to encourage you to spend a few minutes of your valuable time in filling out this
questionnaire, every respondent will be entered into the free prize draw to win a cash
prize of US$200 or a new iPod Shuffle MP3 music player.

As they say, ‘If you’re not in, you can’t win’....Thank you for your time and input!

Tell us about yourself!

Given name_________________________________Family name_____________________________________________
Position_____________________________________Company________________________________________________

o x t o d o w n load a
b
Click on this d e r Survey
b l e R e a
printa
❏

d f a x i t t o u s....
n
About ...fill it out a
THANKS!
❏
❏
❏
Interviews ❏ ❏ ❏ ❏ ❏
Plant reports ❏ ❏ ❏ ❏ ❏
Conference previews (before event) ❏ ❏ ❏ ❏ ❏
Conference reviews (after event) ❏ ❏ ❏ ❏ ❏
Cement industry country reports ❏ ❏ ❏ ❏ ❏
CEMBUREAU’S View from Brussels ❏ ❏ ❏ ❏ ❏
European cement news ❏ ❏ ❏ ❏ ❏
N&S American cement news ❏ ❏ ❏ ❏ ❏
Asian cement news ❏ ❏ ❏ ❏ ❏
Middle Eastern cement news ❏ ❏ ❏ ❏ ❏
Global lime news ❏ ❏ ❏ ❏ ❏
Global lime technical articles ❏ ❏ ❏ ❏ ❏
Robert McCaffrey has the last word ❏ ❏ ❏ ❏ ❏
GCL Magazine overall ❏ ❏ ❏ ❏

Do you like the design of GCL Magazine? ❏ Yes ❏ No ❏ No opinion

What do you like best about GCL Magazine?__________________________________________________________
What do you like least about GCL Magazine?__________________________________________________________
What would you change about GCL Magazine?_________________________________________________________
______________________________________________________________________________________________________
✃
 ✃
About GCL Magazine, continued....
When you read GCL Magazine, how do you read it?
❏ Start at the front ❏ Start at the back
❏ Start at contents page ❏ Dip into it at random ❏ Other_______________________________
If there is a loose insert in GCL Magazine, what do you do with it?
❏ Throw it away without reading it ❏ Keep it with the magazine, but don’t read it
❏ Read it and then throw it away ❏ Read it and keep it.
Do you read the advertisements? ❏ All ❏ Most ❏ Some ❏ None
Do you respond to advertisements ❏ Frequently ❏ Sometimes ❏ Seldom ❏ Never
What makes you respond to an advertisement? _____________________________________________________
Which was the most effective advertisement in this issue?____________________________Page_____________
What advice would you give to advertisers?____________________________________________________________
Do you plan to advertise in GCL Magazine? ❏ Yes ❏ No ❏ Perhaps
When do you plan your advertising budget?___________________________________________________________
If you respond to an advertiser, do you send GCL Magazine a copy or your query? ❏ Yes ❏ No

Subscribing to GCL Magazine

❏
t o d o w n l o a da
box
❏
Click on this d e r S u rvey
e R e a
About eGCL printabl

a n d f a x i t t o us....
...fill it out
❏ THANKS!
Never

How does GCL Magazine compare? Other

Which of the following magazines do you read? ❏ GCL ❏ WC ❏ ZKG ❏ ICR ❏ __________
Which is best for news? ❏ ❏ ❏ ❏ ❏
Which is best for technical articles? ❏ ❏ ❏ ❏ ❏
Which is best for country reports? ❏ ❏ ❏ ❏ ❏
Which is best for industry interviews? ❏ ❏ ❏ ❏ ❏
Which is best for industry trends and analysis? ❏ ❏ ❏ ❏ ❏
Comments____________________________________________________________________________________________

Cement industry conferences

Please rate the following conferences 1, 2, 3 etc, in terms of overall quality:
❏ European Cement ❏ N&S American Cement ❏ Asian Cement ❏ AUCBM
❏ Intercem ❏ Cemtech ❏ IEEE-IAS/PCA ❏ Other___________________
What makes you decide to attend a cement industry conference (tick all that apply)
❏ Price ❏ Location ❏ Topics ❏ Presenters ❏ Delegates ❏ Organiser
❏ Other features (please specify)_______________________________________________________________________
What is a fair price for a good two-day cement conference (excluding hotel room, but including all
lunches, gala dinner, proceedings, briefcase, attendance at exhibition etc)? US$______________
What would you change about cement industry conferences in the future?
______________________________________________________________________________________________________

Thank you!
We appreciate your time and effort in filling out this reader survey. Please check that you have filled in
all fields, and send it back via fax or by post, to the address on the other side. You will automatically be
entered for the free prize draw. Your survey must reach our offices by 31 July to be entered for the FREE
PRIZE DRAW - see www.propubs.com/draw for full rules. Thanks again for your help!
✃
 GCL
This month’s front cover...
WTW Americas material handling products
are used for non-free flowing bulk materi-
als and applications. These machines are
used in the cement industry for handling
synthetic- and rock gypsum, marl, shale,
clay, bauxite, wet bottom ash, etc. The
chain conveyors are designed for special
applications. Very hot, abrasive or sticky
material can be transported with these
conveyors. The chain conveyors can even
G LOBAL C EMENT & L IME M AGAZINE
be designed in an explosion proof version.
May 2005
WTW Americas
Tel. +1 705-749-3544
Fax +1-705-740-1775
Exclusive Official Magazine for
info@wtwamericas.com N&S American CEMENT Conference,
www.wtwamericas.com European CEMENT Conference,
Asian CEMENT Conference, ICCC

First of all, I would like to apologise for the larger size of this month’s issue - there was so
much happening that we could not fit the magazine into its usual reader-friendly 68-page format, and we have had
to ‘Go Large’. We hope that you still have time to read every gem-like word, and to visit all of our advertisers.
I found out - after my column last month on religious intolerance in the cement industry - that there are instances
of bigotry in Australia too (it turns out that where you worship can mean the difference between getting the contract
and going hungry). If it happens in a place as laid-back as Oz, then we are all in trouble. Guys, just Chill, OK?
As you will see scattered through out news pages this month, the multinational cement companies have been
reporting their results for 2004, and it turns out that there has been moderately good to very good year for nearly
all of them (with the exception of some in China....). Following the unfortunate postponement of the Asian Cement
Conference, we take a good look at prospects for the Chinese cement industry on page 77, and find that the jitters
in the cement community are probably justified. We will just have to wait and see if it is a hard or a soft landing.
If you are reading this and you have not yet registered for the free digital version of GCL, then you should point
your browser at www.GCLMagazine.com, and register to receive the next issues. Nigh on 1500 companies around
the world have already signed-up, including all the multinationals and almost all of your com-
petitors, I expect. Shouldn’t you join them?
If you are reading this in Kansas City, then I hope that you have a good conference (come
and see GCL at booth 15). I wish I could be there, but as you will see from the tale on page 81,
Dr Robert McCaffrey
I have a good reason to be absent this year. Don’t laugh. It might be you next time.... Editorial Director

GCL R EADER’S SURVEY 2005

3 Your chance to have your say!
GCL’s 2005 Reader’s Survey gives you the chance to have your say on GCL Magazine and on its associ-
ated cement conferences. It will take less than 10 minutes to fill in, and in return, you will be included in
a draw for a new iPod shuffle, or US$200 in cash....yours to keep!

Extra distribution of this issue of GCL: Global Cement and Lime Magazine The Editor welcomes editorial
contributions (letters, articles etc).
In addition to its normal mailed and digital distribution, this issue of GCL: Global Cement For full details on article submission,
and Lime Magazine will be distributed to delegates at the IEEE-IAS/PCA Cement Industry please see
Conference in Kansas City, VDMA Symp./Moscow and Hillhead Quarrying Show, UK. www.propubs.com/GCL/gclauthor.html

Contacts Tel:+44 (0) 1372 743837 Fax: +44 (0) 1372 743838

----------------------------------------------------------------------------------- GCL
GLOBAL CEMENT & LIME MAGAZINE
Editorial director Dr Robert McCaffrey rob@GCLmagazine.com ISSN 1473-1940
Published by PRo Publications International Limited
Tel:+44 (0) 1372 743837 Fax: +44 (0) 1372 743838

Commercial director Paul Brown paul@GCLmagazine.com

www.GCL magazine.com

Mobile: (+44) (0) 776 7475998 Elise House, 6b East Street, Epsom, Surrey,
KT17 1HH, UK
World Business
Administration/subscriptions admin@propubs.com Council for
Sustainable Cement Industry
Development Suppliers Forum
 Subscribe Ad index

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Hillhead 2005 Previewed

GCL previews the world’s largest active display of quarrying, mining and recycling equipment, staged
every two years in Derbyshire, UK. See GCL on Pavilion Stand P130.

European
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79 Asian Cement Conference Vietnam - 2006

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ROBERT MCCAFFREY HAS THE LAST WORD...

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 Contents Subscribe Ad index Cement TECHNOLOGY
CORROSION & ABRASION

CORROSION AND ABRASION: THE FINAL FRONTIER

NEW SOLUTIONS FOR CORROSION AND ABRASION IN CEMENT PLANTS
BY LINAS MAZEIKA, PRESIDENT, 3L&T INC.

Corrosion protection experts 3L&T have identified a number of areas in the cement
industry where even advanced technologies have been found wanting: high temperature
areas, under-refractory areas, electrostatic precipitator walls and plates and some struc-
tural steelwork. Using a combination of technologies including inorganic nano-particles
and organic resins, the company has had a number of successful applications in all of
these situations.

C
orrosion is the destructive
attack of a metal by reaction
with its environment. The
serious consequences of the corro-
sion process have become a signifi-
cant problem in many cement plants.
Corrosion causes plant shutdowns,
waste of valuable resources, loss or
contamination of product, reduction
in efficiency, costly maintenance and
can also jeopardise safety. Corrosion
can also be combined with abra-
sion in a vicious cycle that destroys
metal at an accelerated rate. Many
methods have been developed in an
attempt to prevent and stop metal
losses. This article will focus on some
major issues regarding corrosion and
abrasion in cement plants and some
new technologies for prevention and
control.
viously. There has been no corrosion.
In many of those cement plants,
the maintenance manager has iden-
tified additional corrosion issues
that need a different solution and
some abrasion problems that have
not been solved satisfactorily. We at
3L&T looked closely at the following
situations:
• Some sections of the plant operate
part of the time at very high tem-
peratures, beyond the scope of the
FlueGard-225;
• With the increase of use of alterna-
tive fuels, the kiln shell has corro-
sion under the refractory;
• The fans, cyclones and screw con-
veyors experience a difficult combi-
nation of abrasion and corrosion;
Fig 1. Baghouse wall coated with FlueGard-225SLB, two years previously.
• In electrostatic precipitators not
only the walls but also the collect-
ing plates have corrosion;
• The structural steel in many cases
starts corroding soon after the
application of a new coating.
This article details new material
technologies recently introduced to
prevent those corrosion and abrasion
problems in a cement plant.
High temperature corrosion
When the operating temperature
of the gases in a baghouse filter
exceed 225°C, it is difficult to find an
organic coating that can survive very
long. The use of refractory materi-
als is prohibitive because of weight
and cost issues. The best solution

Corrosion and protection

The type of corrosion and abrasion
mechanism and its rate of attack
depend on the nature of the atmo-
sphere in which the process takes
place. The first step in preventing
corrosion and/or abrasion is under-
standing its specific mechanism. The
second and often more difficult step is
designing a type of protection mecha-
nism.
Three years ago, 3L&T Inc. intro-
duced a new corrosion protection
technology called FlueGard-225, with
a focus on baghouse filter corrosion.
Today, after four upgrades, this coat-
ing material is being used around the
world. Figure 1 shows the condition of
a baghouse inspected after the appli-
cation of FlueGard-225 two years pre-

May 2005 8 GCL: GLOBAL Cement TECHNOLOGY

GLOBAL CEMENT AND LIME MAGAZINE CORROSION AND ABRASION: THE FINAL FRONTIER

Abrasion-Corrosion
There are many good refractory
materials for very high temperature
abrasion, but they are heavy, expen-
sive and need routine maintenance.
Also there are many elastomeric
materials for abrasion resistance at
room temperature. There seems to be
a gap in the range of 100 to 200°C,
where elastomers do not survive and
refractories are too heavy.
The recently introduced WearGard-
200 is intended to fill that gap. The
first application was in the housing
of a fan in Oregon, while subsequent
installations will be in the housing
of a screw conveyor in Texas and
the static separator of a raw mill in
Spain. Figure 4 shows the applica-
tion in a housing fan that operates
at 160°C, to protect it from abra-
sion–corrosion damage.
Figure 2. Application of FlueGard-325S on an economiser.

is a new inorganic binder combined steel that come off the shell is
with a very high loading of active that it is strongly magnetic, this
fillers, some of them in the range of indicates that the material has a
nano-particle materials. These nano- high content of Fe3O4.
size fillers have a unique impact For this situation we devel-
on performance: their surface area oped another inorganic, nano-
increases by a factor of one million particle composite designated
as the particles decrease in size from as KilnGard-600. This material
2µm to 13 nanometers. The effective will resist corrosion and abra-
dispersion of these small particles is sion up to 600°C of continuous
difficult, but once it is achieved, the operation. The first successful
results are impressive. applications were in Mexico and
This new coating material - called in Italy. This year we will be
Figure 4: Coating of a fan housing to protect
FlueGard-325 - can sustain con- making two more applications it from abrasion–corrosion.
tinuous operating temperatures of in Italy. Figure 3 shows typical
325°C and short peaks up to 500°C. corrosion damage in the shell
So far, it has been used on two heat of a kiln, under the refractory: the Electrostatic filter corrosion
economisers in power plants and corrosion slabs are up to 8 mm in Many electrostatic precipitators have
will be installed in two cement plant thickness. been coated with FlueGard-225SLB
baghouse filters, one in the UK and already, most recently a new,
one in Mexico. The Figure 2 shows a Figure 3: Kiln shell corrosion under the large ESP in Mexico for Cemex and
recent application on the exterior of refractory, up to 8mm in thickness. another in Spain for Holcim. For a
a finned tube economiser that oper- rehabilitation project in Italy for
ates at 290°C. BuzziUnicem, under completion
in May 2005, the customer speci-
Under-refractory corrosion fied the use of FlueGard-225SLB
The outside shell temperature of for the walls and the ducts but
a cement kiln is usually around the contractor also asked about a
250°C. In some cases, especially in product for the plates. This is a
plants that use a large proportion tough request because the coating
of alternative fuels, there is severe needs to be electrically conductive.
corrosion of the inside shell under After extensive development
the refractory. One unusual charac- work, including investigation of
teristic of the thick slabs of corroded the use of carbon nano-tubes, we

May 2005 9 GCL: GLOBAL Cement TECHNOLOGY

GLOBAL CEMENT AND LIME MAGAZINE
Figure 5. Severe corrosion in an electrostatic precipitator.
introduced the Electro-Gard-225.
This material has corrosion protec-
tion, abrasion resistance, strong
bonding to steel and conductivity of
200 Ohm-mt up to 225°C. We will fol-
low up closely the performance of this
filter to confirm the potential improve-
ment of the plate efficiency due to the
smooth surface of the coating.
The Figure 5 shows the effects of
corrosion on a stainless steel electro-
static separator: this is typically due
to the presence of chlorides in the gas
stream.
Structural steel corrosion
The structural steel in many indus-
trial plants is exposed to moisture
and corrosive airborne dust. After
sandblasting the steel, before the
application of a conventional coat-
ing, some of this dust settles on the
surface of the clean metal. Once the
coating is done, these contaminated
spots are areas for future problems.
Pretty soon some small rust spots
appear, followed by blisters, delami-
nation and corrosion. Usually the
maintenance cost is high due to the
repetitive coatings and additionally
the image of the plant suffers, since it
just looks ugly.
Our most recent development in
corrosion control for structural steel in
May 2005
CORROSION
industrial and marine environments
is SteelGard-50. This new technology
is also the result of nano-particle fill-
ers combined with an organic resin
that withstands chemical attack and
UV damage. The lab testing involved
the immersion of sandblasted plates
in sea water, coating them after dry-
ing and acid solution spray for six
months on a scratched surface.
Figure 6: Severe corrosion of structural steel.
10
AND ABRASION: THE FINAL FRONTIER
The results were better than any
of the benchmarks coatings used for
comparison. The first application in
an aggregate plant in California looks
very good after several months in
service. Figure 6 shows the type of
corrosion damage that is common in
structural steel exposed to marine or
industrial environment.
Conclusions
There is a lot of corrosion and abra-
sion out there! Fortunately, there are
also many available solutions includ-
ing a few more in the pipeline.
Usually the best way to solve a
specific problem involves the iden-
tification of the issues by a current
‘victim’ and the involvement of an
outsider with the technology tools to
address the root causes.
The new technologies presented
here are good examples of this combi-
nation. In each and every case there
was an engineer with a problem and
a scientist with resources and ideas
on how to solve it.
A maintenance engineer in Cemex
Venezuela, who pointed at the severe
corrosion problems in his baghouse,
got 3L&T started in this direction,
and for that we sincerely thank him.
We have already come a long way on
the road to the elimination of corro-
sion as a recurring problem. GCL
GCL: GLOBAL Cement TECHNOLOGY
Corrosion / Wear Damage
in your Cement Plant?
3L&T has the solution!
New polymeric alloy materials
for corrosion and abrasion
resistance in harsh conditions

www.3L-T.com
• FlueGard-225SLB
• FlueGard-325S
• KilnGard-600S
• ElectroGard-225SEC
• WearGard-200S
• SteelGard-50S

Find out more:

Phone : (650) 625-0177
Fax: (650) 625-0105
E-mail: Linas@3L-T.com
 Contents Subscribe Ad index
CementTECHNOLOGY
GEARS AND LUBRICATION

THE KEY TO LONG GEAR SERVICE LIFE

LATE RETIREMENT FOR OPEN GEAR DRIVES?
KLAUS HOLZ, PRODUCT MANAGER FUCHS LUBRITECH GMBH

Open gears are among the most process-crucial pieces of equipment in a cement plant,
and when treated with respect, they can give long and trouble-free service. The keys to
long service life are correct installation, correct running-in (often with reduced load and
using special lubricant), correct application of the correct lubricant in the correct quan-
tity, and a clean environment for operation and lubrication. If these steps are followed,
gears should qualify for ‘late retirement.’

O
pen gears are most often used as drive units in tects the gear from initial damage (pitting) during the first
the raw materials industry. Among their uses are movements. It is important to never rotate an open gear
tube mills and rotary kilns in cement and gypsum without sufficient lubricant on the teeth surfaces!
production. Production equipment using open gear drive
units usually occupies a key position in the production Running-in of new open gears
process, so that failure is not an option. Even when the newly installed open gear has been care-
Beside the importance for the manufacturing process, fully aligned, the initial load distribution is often not more
these drives are usually among the most expensive spare than 50 to 60% of the entire tooth flank. The reasons for
parts in these industries. It is never a good day for the this insufficient load distribution are relatively high sur-
producer when a gear drive fails. face roughness and deviation of the tooth flanks due to
In this article some tips will be given to achieve the their shape and mounting tolerances. This low load car-
best operational safety and the highest possible lifetime rying capacity can lead
of open gears. to initial damage as
a result of local over-
Installation load. It is therefore of
The lifetime of a newly installed open gear is, of course, great importance that
highly influenced by accurate mounting. During erection, the running-in of -for
the radial and axial run-out, backlash, root clearance and example an open gear
meshing tolerance have to be adjusted. If the open gear of a ball mill - does not
was mounted by an established company like the gear take place under full Table 1: Running-in programme
manufacturer, equipment manufacturer or an authorised load (Table 1). for a ball mill.
company, a report about all these measurements will be Furthermore, a special running-in lubricant has to be
provided to the customer. used for approximately 350 running hours after start-
During the first movements with the auxiliary drive, up of the gear drive. A proper running-in lubricant will
the load carrying pattern has to be checked. This can be reduce the surface roughness, smoothen the surface and
done by using a priming lubricant which gives you a ‘print’ compensate slight mounting and material deviations. The
of the load distribution. This priming lubricant also pro- running-in lubricant is sprayed onto the gear pinion with
Figure 1: Load distribution using running-in lubricant Ceplattyn RN. suitable spray equipment. The running-
in process is finished if at least 80% of
A: Load carrying pattern before B: Load carrying pattern after
running-in, around 80%.
load distribution over the tooth flank is
running-in, around 50%.
achieved (Figure 1). It is important to note
that the condition of the tooth flanks has
to be checked throughout the running-
in process, since a re-alignment might
become necessary during this process.

A: Surface roughness profile

before running-in.
B: Surface roughness
profile after running-in with
Ceplattyn RN.
Open gears in daily operation
Since every moving part - including open
gears - has to be lubricated properly dur-
ing operation, the quality of the lubri-
cant is of importance, as is the correct
application method. The lubricant has to

May 2005 12 GCL: GLOBAL Cement TECHNOLOGY

GLOBAL CEMENT AND LIME MAGAZINE THE KEY TO LONG GEAR SERVICE LIFE

Figure 2a, left: Optimum overlap for sprayed lubricants.

Figure 2b, above: The following points should be observed before commencing
operation of machinery lubricated with Ceplattyn RN: Functional test, spray
pattern, spray angle, nozzle distance and lubricant quantity. The increased
throughput of lubricant is necessary in order to wash away the metallic par-
ticles caused by wearing down the peaks of the rough surface. The lubricant
consumed must be allowed to flow - without restriction - out of the girth gear’s
protective housing, and dredging in the lubricant sump must be avoided.

be applied onto the pinion over the
entire tooth flank. The optimum solu-
tion provides spray systems with oval
nozzles which allow an overlapping
spray pattern. Figure 2 shows the
correct mounting of the lubrication
nozzles.
To secure the running condition of
open gears, the following measure-
ments should be undertaken:
• FOR THE LUBE SYSTEM, check the
spray system frequently, taking a
spray pattern on a piece of card-
board, as shown in Figure 3;
• Clean filter/sieves;
• Check Air pressure (4-6 bar);
• Check lube pump (leakage/lube
pressure);
• Store the lube drums in a clean
environment and cover it to prevent
dust ingress;
• Adjust lubrication amounts and
lubrication intervals properly;
• Remove old lubricant from the gear
sump frequently.
Figure 4, below: Gear tooth wear
due to abrasion.
• FOR THE DRIVE SYSTEM, take tempera-
ture readings with an infra red tem-
perature gun over the tooth flank.
Measure 2-5 points over the tooth
width. The difference should not
exceed 5°C;
• Take measurements of axial, hori-
zontal and vertical vibrations on the
pinion bearings. The upper value for
vibrations is 10mm/s;
• Tighten the gear housing as well as
possible. Check the seals, cover and
seal inspection flap and spray panel
to prevent dust ingress.
In cement plants one of the most
crucial points with respect
to lubrication is maintain-
ing a clean environment.
Once dust and lubricant
come together, it will cre-
ate an abrasive paste which
leads to increased wear
(Figure 4).

Gear repair
Once a gear has damage
due to poor operation or
environmental conditions,
or if fatigue damage like
pitting occurs, there are
still some possibilities to
Figure 3, above: Checking the spray improve the situation.
pattern, simply using a piece of
cardboard.
• Wear steps (Figure 5) can
be removed by hand grind-
ing of the gear. The surface
can be re-shaped and wear
steps can be removed.

May 2005 13 GCL: GLOBAL Cement TECHNOLOGY

GLOBAL CEMENT AND LIME MAGAZINE THE KEY TO LONG GEAR SERVICE LIFE

• Fatigue damage (pitting) must be

Figure 5: Wear steps.
1: Hair cracks on the tooth surface.
3: Development of the crack.
2: Oil is pressed into the cracks.
4: Forced rupture of the crack.
removed by finger grinding. This
is the only way to stop the devel-
opment of this ‘tooth disease.’
By removing the pitting and the
cracked surroundings, this process
can be stopped. The development of
pitting can be seen in Figure 6.
• In case of misalignment (Figure 7)
a re-alignment should be done. It is
once again important to note that a
re-alignment of the pinion is often
not sufficient. The alignment of the
entire driveline up to the back gear
has to be checked.
• In case of unequal load distribu-
tion which cannot be influenced by
re-alignment, reconditioning can be
undertaken.
Re-conditioning is done with a very
abrasive lubricant which is sprayed
onto the higher load spots of the run-
ning gear by hand. Since this is a very
critical procedure it is only under-
taken by authorised Lubritech Service
Engineers.
• Some companies offer welding of
cracks and of broken teeth. This
might be a solution for some heavily
damaged gears until the new spare
part is manufactured;
• Cracks in the concrete foundation
can be repaired by high pressure
plastic fillings in some cases;
• Turning the pinion/gear rim can
help if only one side is worn off or
damaged.

Summary
Figure 6: Gear tooth pitting development mechanism. Open gear drives can reach lifetimes
of up to 30 years if they are treated
Figure 7: An uneven wear distribution caused due to misalignment. with ‘respect’ from the very begin-
ning. It is proven that a correct
mounting and running-in procedure
can extend the lifetime of an open
gear by up to 20%.
However, proper running condi-
tions under a clean environment,
together with a modern lubricant
and an effective lubrication system,
are additionally the main keys for
long gear life.
Once a gear is damaged there are,
in most cases, possibilities to help
the gear to survive for another couple
of years.
We believe that late retirement for
open gear drives is possible!
GCL

May 2005 14 GCL: GLOBAL Cement TECHNOLOGY

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 Contents Subscribe Ad index CementTECHNOLOGY
FILTER INNOVATION

FILTER INNOVATION AT SOLNHOFER CEMENT

CHRISTIAN PUCHER OF SCHEUCH INTERVIEWS HERRN DIPL.-ING. SAUTER OF SOLNHOFER PORTLAND ZEMENTWERK, BAVARIA
CHRISTIAN PUCHER VON SCHEUCH IM GESPRÄCH MIT HERRN DIPL.-ING. SAUTER, SOLNHOFER PORTLAND ZEMENTWERK, BAYERN

Solnhofer Portland Zementwerke in Bavaria took the decision a few years ago to put more
emphasis on new technologies. Since then it has introduced not only selective catalytic
reduction and a Polysius Polytrack cooler, but also Scheuch’s Energy Minimising Concept
(EMC) for dedusting classifiers. Solnhofer’s Gerd Sauter says that the company would
immediately make the same decision again today.

S I
olnhofer Portland Zementwerk was founded in n Solnhofen/Bayern wurde 1933 das Solnhofer
1933 in Solnhofen, Bavaria and is today a mid- Portland Zementwerk gegründet – heute ein mittel-
sized cement company with some 150 employees. ständisches Unternehmen mit ca. 150 Mitarbeitern.
Dipl.-Ing. Gerd Sauter, the plant’s technical director, is Mit Dipl.-Ing. Gerd Sauter, Technischer Werksleiter, trifft
an innovative decision-maker responsible for new invest- ein innovationsfreudiger Techniker die Entscheidungen
ments and renovation of the cement plant’s technical über Neuinvestitionen und Sanierungen am technisch-
equipment. During the past few years, more emphasis has en Equipment des Zementwerkes. In den vergangenen
been placed on the use of new technologies at the plant. Jahren legte man verstärkt Wert auf den Einsatz von
Practical results subsequently verified the correctness neuen Technologien und konnte anschließend in der
of his decision. Christian Pucher of Austrian filtration Praxis die Richtigkeit erfolgreich unter Beweis stellen.
company Scheuch recently spoke with Gerd Sauter about Christian Pucher der österreichischen Firma Scheuch
the implementation of new technology - particularly with führte in diesen Tagen mit Herrn Sauter ein Gespräch
regard to air filtration - at the plant. über Einsatz neuer Technologien im Werk - insbeson-
dere Hinsichtlich Luftfiltration:
Christian Pucher: “In 2002, you were the first German
company to use EMC technology for dedusting classifiers. Christian Pucher: “Im Jahr 2002 haben Sie
How do you see this decision today?” als erstes Unternehmen in Deutschland die EMC-
Technologie zur Sichterentstaubung eingesetzt. Wie
Gerd Sauter: “We would immediately make the same beurteilen Sie heute Ihre damalige Entscheidung?”
decision today. We now have up to date measurements
[Figures 3 and 4] which document the
actual levels of consumption. They show
average compressed air consumption of Figure 1: Interior view of the filtration unit.
3 Bild 1: Innenblick auf die Filtrationsanlage.
10-18 Nm /h for a variety of cement
types. The cleaning pressure was uni-
formly set at 1.0 bar (overpressure),
resulting in a flange/flange differential
filter pressure of 900–1100 Pa. I would
like to say on principle that the mainte-
nance time of about 2 hours per month
for this filter plant is extremely low and
that the filter bags are still in perfect
condition in our third year of operation.
We have achieved residual dust levels far
below 5 mg/Nm3.”

Christian Pucher: “In 1999, you

converted an existing electrostatic pre-
cipitator used for kiln dedusting to a bag
filtration plant. In 2002, you added EMC
technology. Did these conversions fulfil
your expectations?”

May 2005 16 GCL: GLOBAL Cement TECHNOLOGY

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Flexibles and Coating – we are able to provide the right packaging solution
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more than happy to meet the challenge. www.mondipackaging.com SOLUTIONS FOR YOUR SUCCESS.
GLOBAL CEMENT AND LIME MAGAZINE FILTER INNOVATION AT SOLNHOFER CEMENT

Figure 2: External filter at Solnhofer Cement. Gerd Sauter: “Diese Entscheidung

Bild 2: Externer Filter bei Solnhofer Zement.

durchschnittlichen Druckluftverbrauch

Zementsorten. Der Abreinigungsdruck

Gerd Sauter: “To begin with, yes - completely and in Christian Pucher: “1999 haben Sie das beste-
every respect. We had to convert because of consider- hende Elektrofilter zur Ofenentstaubung auf eine
ations with respect to emissions, investment costs and Schlauchfilteranlage umbauen lassen. 2002 folgte
space requirements, since bag filtration plants generally dann die Umrüstung auf die EMC-Technologie. Haben
achieve lower clean gas dust content and because we diese Umbauten Ihre Erwartungen erfüllt?”
were able to use the existing electrostatic precipitator
casing.” Gerd Sauter: “Vorab gesagt, ja – im vollen und
“The positive results achieved using EMC technol- ganzen Umfang. Diese Entscheidung für den Umbau
ogy for classifier dedusting tipped the scales in favour mussten wir aus Emissions-, Investitions- und
of converting the IMPULS-filter to this technology in Platzgründen treffen, da Schlauchfilteranlagen gener-
October 2002. Our goal was a reduction in compressed ell geringere Reingasstaubgehalte erzielen und das
air consumption from 320 Nm3/h at 6 bar (overpres- bestehende Elektrofiltergehäuse weiter benutzt werden
sure) to 80 Nm3/h and a cleaning pressure of circa 1.5 konnte.”
bar (overpressure). We also wanted to reduce the filter “Die positiven Ergebnisse mit der EMC-Technologie
differential pressure of the entire filter by 300-400 Pa in der Sichterentstaubung gaben den Ausschlag, im
and then subsequently move an increased volume of air Oktober 2002 das Impulsfilter auf diese Technologie
through the filter using the savings in differential pres- umzurüsten. Zielsetzung war es, den Druckluftverbrauch
sure. We were able to achieve all these goals through von 320 Nm³/h bei 6 bar (Ü) auf 80 Nm³/h bei einem
Abreinigungsdruck von ca. 1,5
bar (Ü) zu reduzieren. Gleichfalls
Figure 3: Operating data for the classifier filter at Solnhofen, 8-12 May 2004.
Bild 3: Betriebsdaten der Sichterentstaubung in Solnhofen, 8-12. Mai 2004. sollte der Filterdifferenzdruck
um ca. 300 - 400 Pa des gesa-
mten Filters reduziert werden,
um danach mit dem ersparten
Differenzdruck eine erhöhte
Luftmenge durch das Filter zu
ziehen. Dies alles wurde durch
die Umrüstung auf die EMC-
Technologie und durch die
Optimierung der Reingasleitung
erreicht.”
“Allein die Optimierung des
Druckluftverbrauches hat eine
Kostenersparnis von ca. 9.500
EUR pro Jahr ergeben, so dass
wir heute sagen können, die
Umrüstung hat sich aus unserer
Sicht gelohnt.“

May 2005 18 GCL: GLOBAL Cement TECHNOLOGY

The XPERT breakthrough
Combining XRF and XRD analysis
for a total cement solution

The XPERT Solution: analysis with Rietveld PANalytical B.V.

precision and microscopy accuracy. P.O. Box 13
7600 AA Almelo
PANalytical combines all aspects of X-ray fluo-
rescence and X-ray diffraction into an ultimate The Netherlands
and optimized tool for cement production con- Tel: +31 (0) 546 534 444
trol. Both the PANalytical XRF spectrometer Fax: +31 (0) 546 534 598
and the CubiX FAST diffractometer easily meet e-mail: info@panalytical.com
the analysis requirements, operating seamlessly
under the control of the Supervisor software.

All parts of the XPERT Solution are automa-

tion-ready, and the robust hardware ensures reli-
www.panalytical.com
able performances among the heat, dust, and
vibrations of industrial environments.

Contact PANalytical for more information on

our total cement solution.
GLOBAL CEMENT AND LIME MAGAZINE
the conversion to EMC technology and optimisation of the
clean gas pipe system.”
“Optimisation of compressed air consumption alone
has resulted in an annual savings of about Euro9500.
From our point of view, we can say today that the conver-
sion was definitely worth it.”
Christian Pucher: “You recently commissioned
Scheuch to convert your existing rapping filter to IMPULS
cleaning. What do you hope to achieve with this move?”
Gerd Sauter: “One of the problems with these out-
dated rapping filters was the high maintenance cost for
replacement of the filter bags, as well as the increased
differential pressures in the existing filter plants. By con-
verting to an IMPULS-filter, we would like to more than
double the service life of the filter bags, while also reduc-
ing the compressed air requirements of the existing filter
plant by about 50%. In this way, the cost of converting
to IMPULS-filter technology should be
paid back relatively quickly.”
“The investment costs for this under-
taking are relatively low, since only the
filter heads must be changed on the
three existing rapping filters when the
casing is re-used.”
Figure 3: Operating data for the classifier
filter at Solnhofen, 8-12 May 2004.
Bild 3: Betriebsdaten der
Sichterentstaubung in Solnhofen, 8-12.
Mai 2004.
Christian Pucher: “One last question, if you please:
Innovation is inherently risky. How do you handle this
fact? In addition, how do you evaluate your working rela-
tionship with Scheuch?”
Gerd Sauter: “The cement industry in general is very
conservative and it sometimes takes a while before new
technologies are reliably and profitably implemented in
the cement sector. We’ve made it our goal to be open for
innovation and to widely implement innovative technolo-
gies with a view to optimising our return on such inno-
vations, for example, SCR (selective catalytic reduction)
plants, Polytrack (cooler from Polysius) and Scheuch’s
EMC (Energy Minimising Concept) technology.”
“Our working relationship with Scheuch is outstand-
ing. We had a well organised, satisfactory planning phase,
excellent implementation, and a very promising assembly
deadline that was actually met on time. We experienced
nothing negative whatsoever. From the project planning
phase, and awarding of the contract to commissioning
and the latest measurement results, everything was out-
standing.” GCL
May 2005 20
FILTER INNOVATION AT SOLNHOFER CEMENT
Christian Pucher: “Vor kurzem haben Sie
Scheuch beauftragt, bestehende Klopffilter auf die
Impulsabreinigung umzurüsten. Was versprechen Sie
sich davon?
Gerd Sauter: “Ein Problem bei den veralteten
Klopffiltern waren die hohen Wartungskosten für
den Austausch der Filtertaschen sowie die erhöhten
Differenzdrücke der vorhandenen Filteranlagen.
Durch den Umbau auf Impulsfilter möchten wir die
Standzeiten des Filtermaterials mehr als verdop-
peln sowie den Druckluftbedarf der vorhandenen
Filteranlagen um ca. 50 % reduzieren, so dass sich
durch die Umrüstung auf Impulsfilter die Kosten rela-
tiv schnell amortisieren lassen.”
“Die Investitionskosten hierfür sind relativ gering,
da bei den 3 bestehenden Klopffiltern lediglich die
Filterköpfe bei Wiederverwendung der Gehäuse getaus-
cht werden müssen.“
Christian Pucher: “Eine letzte Frage bitte, Herr
Sauter: Innovationsfreude birgt Risiko in sich, wie
gehen Sie damit um? – Und wie beurteilen Sie die
Zusammenarbeit mit Scheuch?
Gerd Sauter: “Die Zementindustrie ist allgemein
sehr konservativ und es dauert manchmal lange, bis
eine neue Technologie in der Zementbranche zuverläs-
sig und gewinnbringend eingesetzt wird. Wir haben
uns zum Ziel gesetzt, dass wir uns Innovationen nicht
verschließen und so weit wie möglich einsetzen, um so
dadurch aus unserer Sicht das Optimale heraus zu
holen, wie z.B. mit SCR (Selective Catalytic Reduction),
Polytrack (Kühler von Polysius) und EMC (Energy
Minimising Concept).”
“Die Zusammenarbeit mit Scheuch war aus-
gezeichnet. Ordentliches und zufriedenstellendes
Planungsstadium, der Ablauf war hervorragend, die
Montage war vielversprechend und wurde auch einge-
halten. Nichts Nachteiliges. Von der Projektphase, der
Vergabe bis hin zur Inbetriebnahme und auch jetzt mit
den Messergebnissen war alles ausgezeichnet.” GCL
GCL: GLOBAL Cement TECHNOLOGY
Ein neuer Meilenstein in der
Schlauchfilter-Technologie
A new milestone in
bagfilter-technology

www.scheuch.com
 Contents Subscribe Ad index Cement TECHNOLOGY
CONVEYING INNOVATION

PIPE CONVEYORS FOR ALTERNATIVE FUELS

INNOVATIVE SOLUTION FOR THE CEMENT INDUSTRY:

TRANSPORT OF DIFFERENT WASTE DERIVED FUELS IN ONE CONVEYING LINE

Koch details its pipe conveyor solution for the secure transport of problematic alternative
fuels (and cement, clinker and coal) - a solution which can handle inclines up to 30° and
curve radii of less than 45m, and bulk density of up to 2.5t/m3.

T
he combustion of production feeder are frequency controlled. In inclines up to 30° and curve radii of
residues or residual materials addition, the weigh feeder automati- less than 45 metres, and can thus be
is increasingly gaining impor- cally adjusts the capacity, depending optimally integrated in existing plants
tance in the cement industry. The on the product weight and consis- – without transfer stations. Material
most diverse substances can be used, tency. Thus, the weigh feeder is the spillage is excluded, thus ensuring a
starting with wastes from paper recy- ‘timing generator’ of the plant. The clean conveying line over the entire
cling right up to industrial sludge. PLC-unit automatically adjusts the route. In addition, the Koch pipe con-
For the most part, problems arise speed of the discharging- and feeding veyor can be equipped with a spillage
if several material types with differ- components to the bulk density and scraper chain conveyor if exceptional-
ent consistencies are used and have heating value of the various fractions, ly tough or sticky sludge is conveyed.
to be transported in one conveying thus ensuring that adequate amounts This way, optimum cleanliness is also
line. Koch has developed an innova- of a particular combustible substance guaranteed at the discharge point.
tive solution for this challenging task, are fed to the system. From the Koch pipe conveyor, the
which conveys materials from light, A Koch pipe conveyor handles the waste-derived fuels are discharged
dry paper rejects to tough and moist transport of the waste-derived fuels over a rotary valve into the bulk fuel
industrial sludge with a weight of up from the storage hall to the kiln. In its spreader. This innovative Koch-com-
to 2.5t/m³, in one conveying line. fully enclosed pipe, the system trans- ponent ensures that the substitute
The process starts with an ATG-S- ports dry as well as moist substances fuels are distributed evenly in a thin
Rotor, which activates the respective to the furnace, securely protected and layer, into the kiln. This component
substance in the feeding hopper and without any impact on the environ- is also variable speed-controlled in
discharges it into an extracting screw ment. The system can do the same for order to adjust the spreading range
conveyor. The ATG-S option works cement, clinker and coal, and if nec- and width, depending on the product
with a rigid arm, making the system essary for simultaneous transport of consistency for an optimum distribu-
particularly flexible. The rotor offers a different material types, in opposing tion. The bulk fuel spreader and the
number of advantages over conven- directions as well. Due to its compact rotary valve are of wear- and heat
tional discharging systems, especially design, the Koch pipe conveyor allows resistant design. A water-cooled slide
if materials with different gate has been integrated as an
consistencies are used, as A Koch pipe
additional heat protection.
material compaction is mostly conveyor at
eliminated. In the pilot plant, work at Ciment Conclusion
an ATG-S-Rotor with an elec- de Sibline, in The use of substitute fuels
Lebanon.
tric drive has been installed; a opens up interesting possi-
hydraulic drive is available as bilities for cutting costs in the
an alternative option. cement industry. These pos-
The rotor in the pilot plant sibilities can be exploited best
can be activated either in with adaptable transport- and
continuous or interval mode, feeding systems, for materials
depending on the consistency with different consistencies. A
of the material. As a result solution from one source, as
and if the material permits, applied by Koch and realised
energy is saved, wear and tear on the basis of time-proven
reduced. The material reaches components, ensures optimum
a weigh feeder via the extract- adaptability of the plant to the
ing screw conveyor. Rotor, specified requirements and
screw conveyor and weigh demands. GCL

May 2005 22 GCL: GLOBAL Cement TECHNOLOGY

 Contents Subscribe Ad index CementTECHNOLOGY
HILLHEAD 2005 PREVIEW

HILLHEAD 2005 PREVIEW

BY GCL STAFF

Hillhead 2005 Quarrying & Recycling Show, near Buxton in the UK and 50km south-west
of Manchester, will take place June 21st for three days when an estimated 16,000 visitors
will converge on Tarmac Central’s Pennine Hills region quarrying facility. Around 10%
or so of the visitors will be coming from outside the UK. The show covers 10 hectares of
exhibition area encompassing 500 companies. This article is a guide to the most relevant
companies for the cement, lime and gypsum industries. Visit GCL at stand P130. Click
on www.hillhead.com for full details.

If you have never experienced this show, which is a blend of static and live-demonstration exhibits in a real working
quarry, you really have missed out. GCL looks forward to welcoming you to its exhibition stand in the Main Pavilion,
Stand P130. As usual, GCL is the only cement/lime/gypsum sector publisher represented at Hillhead. See you there!

ABB
P-104
Tel: 0161 438 3204
Fax: 0161 448 1066
enquiries@gb.abb.com
www.abb.co.uk/energy
ABB will show its high voltage motors
Come early to avoid the queues!
for the cement and heavy minerals
industries.

Ace Conveyor Equipment

Outdoor, E19
Tel: 01302 718800
Fax: 01302 711998
rob@ace247.com
www.ace247.com
Conveyor belt cleaners, conveyor
drives, conveyors & components,
elevators, maintenance products,
repair & maintenance services, roll-
ers, screening surfaces, spillage con-
trol, training.
Advanced Crusher Spares
Outdoor, G6
Tel: 0121 351 6969
Fax: 0121 351 6966
peter@crusherspares.com
www.crusherspares.com
Advanced Crusher Spares provides
an alternative supply of spare parts
for demolition, quarrying and recy-
cling equipment, examples of which
will be on display.
Alstom Power Conversion
Main Pavilion, P12
Tel: 01782 781000
Fax: 01782 781001
christine.davidson@powerconv.alsto
m.com
www.alstom.com
Alstom provides a full range of control
and automation equipment for the
cement, mining and quarrying indus-
tries, as well as the water, waste-
treatment and power-generation sec-
tors. Specialising in the specification,
design and installation of total drive
systems and power electronics.
A.T. Sack Fillers Ltd
Main Pavilion, P22
Tel: 01487 711114
Fax: 01487 814002
bruce@simplafillsystems.co.uk
www.simplafillsystems.co.uk
Bagging & packaging, weighbridg-
es.
Avery Weigh-Tronix
Outdoor, G9
Tel: 0121 568 1663
Fax: 0121 568 1122
tjeffries@awtxglobal.com
Automation & control systems, bag-
ging & packaging, bulk-handling sys-
tems, repair & maintenance services,
weighbridges, weighing systems,
wheel washers.
BJD Crushers Ltd
Main Pavilion, P6
Tel: 01226 249590
Fax: 01226 296713
sales@bjdcrushers.co.uk
www.bjdcrushers.co.uk
BJD Crushers will be promoting its
full range of products, including pri-
For readers unable to visit this time,
but wishing to contact the companies
detailed below, please prefix +44 to the
tel/fax numbers quoted where no country
code is shown, and delete the first ‘0’.

May 2005 23 GCL: GLOBAL Cement TECHNOLOGY

GLOBAL CEMENT AND LIME MAGAZINE
mary impactors, secondary hammer
mills and double-roll crushers. The
stand will focus on the Flexmill and
Mud Hog crushers that can be used
in a variety of applications.
Bradley Pulverizer Co.
Main Pavilion, P124
Tel: 01322 559106
Fax: 01322 528690
bradley.pulverizer@btinternet.com
www.bradleypulv.com
Bradley Pulverizer will feature a
BM30 Hercules roller mill, one of
which has recently been commis-
sioned in Egypt and a BM20 mill
that is being built for a project in
Indonesia to grind limestone sorbent
for a fluid-bed coal combustor on a
power plant.
Brelko Engineering
Main Pavilion, P16
Tel: 0027 11 838 2991
Fax: 0027 11 836 7124
sharon@brelko.com
www.brelko.com
Brelko designs and manufactures
conveyor belt cleaning equipment
for the trouble-free flow of materials
at transfer and load points. It offers
proactive and ongoing maintenance
for preventive spillage control and
optimum belt cleaning. Its product
range includes: primary, secondary,
v-plough and angle-plough belt scrap-
ers featuring the v-base blade and
torsion holder mounting. The scraper
system is designed to make mainte-
nance and blade changing as simple
from the conveyor structure.
Brigade Electronics plc
Indoor, P58 Outdoor, S13
Tel: 01322 420315
Fax: 0870 774 1502
Web: www.brigade-electronics.co.uk
Reversing safety equipment.
Brimonn Manufacturing Ltd
Outdoor, C33
Tel: 01902 632505
Fax: 01902 631730
brianbrimonn@aol.com
www.brimonn.co.uk
Conveyors & components, Filtration,
grizzly screens/feeders, screening
surfaces, screens, shredders and
trommels, spare parts.
May 2005
HILLHEAD 2005 PREVIEW
sors, computer systems, computer
software, cranes & lifting equip-
ment, dust control/suppression,
filtration, hydraulic breakers,
maintenance products, motors &
gears, pumps, ready-mixed con-
crete plants, spare parts, springs,
tanks/silos/hoppers.
Continental Conveyor Ltd
Outdoor, H9
Tel: 0191 487 8888
Fax: 0191 482 1903
Brindley Chains Ltd p.bancroft@continental-
Outdoor, N12 conveyor.co.uk
Tel: 01925 825555 www.continental-conveyor.co.uk
Fax: 01925 825338 Conveyor drives, conveyors & com-
chris@brindley-chains.co.uk ponents.
www.brindley-chains.co.uk
Conveyors & Components, elevators, Controls Testing Equipment
tyre chains. Main Pavilion, P38
Tel: 01442 828311
David Brown Radicon Fax: 01442 828466
Service p.flynn@controlstesting.co.uk
Main Pavilion, P117 www.controlstesting.co.uk
Tel: 01484 465500 Compaction equipment, computer
Fax: 01484 465587 software, quality control/testing,
sales@davidbrown.textron.com sampling equipment, surface dress-
www.textronpt.com ing.
Gearboxes, hydraulic breakers, repair
& maintenance, transmissions. Corus Process Engineering
Main Pavilion, P35
C.C. Jensen Ltd Tel: 01900 842662
Main Pavilion, P48 Fax: 01900 601111
Tel: 01388 420721 cpe@corusgroup.com
Fax: 01388 420718 www.corusprocessengineering.com
joe.downes@cjcuk.co.uk Historically, Corus Process
www.ccjensen.co.uk Engineering has maintained and
This company will be displaying refurbished large industrial plant and
CJC filters designed to remove both machinery in the steel and nuclear
particulate and water contamina- industries, and now offers these ser-
tion from oil systems within crush- vices to the cement and quarrying
ers, gearboxes, oil-storage facilities, industries. With technical expertise
hydraulic systems etc. On display and vast manufacturing facilities it
will be a selection of off-line fine fil- can offer customers a range of ser-
ters and water-separator equipment vices including repair, refurbishment,
for gear oil, lube oil and hydraulic oil enhancement and manufacture of
systems. new plant items. Examples of projects
completed include: kiln fan assem-
Conspare Ltd blies; classifier shafts, impactor shaft
Outdoor, F6 assemblies; clinker breaker rotors
Tel: 01773 860796 and bucket-wheel shaft assemblies;
Fax: 01773 860055 and gyratory crusher shafts, cores
david@conspare.com and crusher shells.
www.conspare.com
Abrasion-resistant materials, admix- Davis Derby Ltd
tures, automation & control systems, Main Pavilion, P61
bulk-handling systems, castings, www.davisderby.co.uk
compaction equipment, compres- Conveyors & components.
24 GCL: GLOBAL Cement TECHNOLOGY
GLOBAL CEMENT AND LIME MAGAZINE
Dustech Engineering Ltd
Main Pavilion, P75
www.dustech.co.uk
Dustech Engineering will be showing
the latest developments in its range
of custom-designed, heavy-industrial,
air-pollution-control equipment. A
photographic display will show recent
installations together with a back
catalogue of filtration, cyclonic and
scrubber plants.
DustScan Ltd
Main Pavilion, P75
www.dustscan.co.uk
Consultancy services
DustScan operate consultancy and
monitoring services across a growing
spectrum of industry. The directional
dust-monitoring system launched
at Hillhead 2003 is now used by a
number of quarrying companies and
operators of landfill sites and recy-
cling centres.
Endress + Hauser Ltd
Main Pavilion, P93
Tel: 0161 998 0321
Fax: 0161 998 1841
chris.nolan@uk.endress.com
Endress + Hauser’s latest innovations
will be on display including its new
Cerabar S and Deltabar S ‘Evolution’
pressure range that features an inte-
grated HistoROM memory chip to
allow simple acquisition, back-up and
display of data with simulation and
analysis for improved process con-
trol. New is the Micropilot M FMR250
radar device for solids level measure-
ment up to 70m.
Eriez Magnetics Europe Ltd
Main Pavilion, P123
Tel: 029 208 68501
Fax: 029 208 51341
info@eriezeurope.co.uk
www.eriez.com
Feeders, magnetic and non-fer-
rous separation, metal detection/
separation, quality control/testing,
recycling equipment & plant, sam-
pling equipment.
Eutectic Co. Ltd
Main Pavilion, P9
Tel: 01527 582200
Fax: 01527 582201
jburke@eutectic.co.uk
May 2005
HILLHEAD 2005 PREVIEW
www.eutectic.co.uk of operations incorporating quarry
Abrasion-resistant materials, mainte- after-use, and geotechnical assess-
nance products. ment and quarry design required
by the Quarries Regulations 1999.
Fairport Engineering Ltd Ground and surface water expertise
Outdoor, F1 is applied in relation to both opera-
Tel: 01257 484000 tional design and the environmental
Fax: 01257 483312 impact of workings. GWP also offers
lwhite@fairport.co.uk comprehensive land survey services
www.fairport.co.uk and specialises in quarry surveys.
Bulk-handling systems, design &
installation services. GFG Gurtec UK Ltd
Outdoor, H24
Fenner-Dunlop Ltd Tel: 01782 594294
Outdoor, E19 Fax: 01782 593935
Tel: 01772 331300 frank.morris@gurtec.co.uk
Fax: 01772 621486 www.gurtec.co.uk
jsimm@fennerdunlop.com Abrasion-resistant materials, con-
veyor belt cleaners, conveyors & com-
Flender Power ponents, dust control/suppression,
Outdoor, G7 wearparts.
Tel: 01274 657700
Fax: 01274 669863 Goodyear Dunlop Ltd
ngarthwaite@flender-power.co.uk Outdoor, X4
www.flender-power.co.uk Tel: 0121 306 6329
Conveyor drives, gearboxes, motors Fax: 0121 306 6320
& gears, power transmission equip- andy.morris@goodyear.com
ment. Over the last 18 months Goodyear
has introduced a number of new
Flexible Steel Lacing Co. products on to the earthmover tyre
Main Pavilion, P97 market. On display at Hillhead 2005
Tel: 01457 891000 will be its 65-series tyres, which offer
Fax: 01457 854847 traction, comfort, durability and
rbarton@flexco.co.uk increased machine stability especially
www.flexco.com on wheel loaders operating in high-
Conveyor belt cleaners, elevators, volume applications. Also on show
maintenance products, repair & will be the RT-4A, Goodyear’s newest
maintenance services, spillage con- radial haulage tyre, the TL-3A, which
trol. is proving popular in the earthmover
market, and the RT-5C, the latest in
Fuchs Lubricants (UK) plc the company’s expanding earthmover
Outdoor, X3 range.
Tel: 01782 203706
Fax: 01782 203775 Graepel Perforators Ltd
rosemary.mellor@fuchs-oil.com Main Pavilion, P110
www.fuchslubricants.com Tel: 01925 229809
Fax: 01925 228069
Geoffrey Walton Practice alistair@graepeluk.com
Main Pavilion, P139 Jones & Thomas (Wireworkers) have
Tel: 01608 810374 recently been awarded preferred-
Fax: 01608 810093 supplier status by the Cemex Group
gwp@gwalton.co.uk and, in association with Graepel
www.gwalton.co.uk Perforators Ltd, will be showing its
GWP is an independent partnership range of metal screens in woven, self-
offering a range of consultancy ser- cleaning and perforated metals.
vices to the quarrying and mining
industries. Geological and geotechni- Guttridge Services Ltd
cal services include mineral deposit Main Pavilion, P127
evaluation, design and scheduling Tel: 01775 765300
25 GCL: GLOBAL Cement TECHNOLOGY
GLOBAL CEMENT AND LIME MAGAZINE
Fax: 01775 765301
pdg@guttridge.co.uk
www.guttridge.co.uk
Bulk-handling systems, conveyors &
components, elevators, feeders
H & H Services Ltd
Main Pavilion, P36
Tel: 01623 759836
Fax: 01623 755103
mike@handh-services.co.uk
www.handh-services.co.uk
H & H Services will be exhibiting the
full range of single- and multi-idler
belt weighers, together with a range
of volumetric feeders and gravimetric
weigh feeders. Also on the stand will
be a full range of silent turbine vibra-
tors from VIBCO that, say H & H, can
reduce air consumption by up to 50%
and noise in the workplace by 40%.
From H&H Services...
They are said to be the only units on
the market that offer high force with
silent operation by using a patented
principle. In addition, there will be a
comprehensive range of air cannons
and fluidising aids and level probes,
including rotary, capacitance and
ultrasonics.
Hardtop
Main Pavilion P130
Tel+49 391 532 969-0
Fax+49 391 532 969-21
Email: info@hardtop-gmbh.de
www.hardtop-gmbh.de
Hardtop presents composite-cast
wear-parts for heaviest-duty applica-
tions made from material combina-
tions appropriate to the application
in question. These bi-metallic cast
parts have already proven them-
selves worldwide in the most varied of
industrial sectors. For example, the
good impact-resistant characteristics
of steels are combined with the high
wear-resistance of chrome cast-iron
in a single construction. The advan-
May 2005
Clinker hammer
from Hardtop
tage is to be found in a high level of
structural quality, prolonged lifespan
and resultant reduced downtime of
plants, which would otherwise need
its wear-parts changing.
Haver & Boecker
Outdoor, S11
Web: www.haverboecker.co.uk
Hazemag UK Ltd
Outdoor, S11
Tel: 01924 280014
Fax: 01924 831181
g.mansfield@hazemaguk.com
www.hazemaguk.com
Crushers, dryers, feeders, griz-
zly screens/feeders, recycling
equipment & plant, screens,
shredders and trommels.
Horizon Conveyor
Outdoor, C16
Tel: 01384 566204
Fax: 01384 566179
alan@horizon-conveyors.co.uk
www.horizon-conveyors.co.uk
Horizon will be showing many new
products at Hillhead including: steel
rollers with turnback steel bearing
housings and pressed tubes, which
eliminate welding distortion and
excess run-out problems; trough and
return tracking systems fitted with an
independent braking system; and its
range of light-, medium- and heavy-
duty plastic rollers that are now
available in a fire-retardant material.
The company’s range of belt clean-
ers, electrically powered rotary brush
cleaners, impact bars and beds, skirt-
ing systems and clamps will also be
on show.
Hosch (GB) Ltd
Outdoor, E7
26
HILLHEAD 2005 PREVIEW
Tel: 01642 751100
Fax: 01642 751448
marketing@hosch.co.uk
www.hosch.co.uk
Conveyor belt cleaning company
Hosch will be exhibiting its new Type
HD 2/3 pre-scraper together with
the established generation of Hosch
sprung-blade scrapers, tracker roll-
ers for belt alignment, lift-off devices
for reversing conveyors, encapsula-
tion units, top-belt tracking sets and
wear-resistant troughing and return
rollers.
Ibis Intergrid Ltd
Main Pavilion, P5
Tel: 01706 220123
Fax: 01706 231850
a.ford@ibis-int.co.uk
www.ibis-int.co.uk
Ibis, a company with more than 20
years’ experience in materials han-
dling, will be exhibiting its Moduflex
loading bellows. These are designed
for loading various products, ranging
from dust up to 70mm, into tankers,
rail wagons, tipper trucks and stock-
piles. Working units will be on the
stand to show the different combina-
tions available, including units with
integral filter systems. The company’s
range of rotary valves and slide
valves will also be on show, together
with a range of items from its stan-
dard dust-control range of products
including: Ibismix ash/dust condi-
tioners, Ibisvent pulse-jet silo filters,
diaphragm valves/kits, PCB timers,
and filter bags and cages.
Instant Crusher Spares Ltd
Outdoor, Q3
Tel: 01352 711988
Fax: 01352 712016
brian@instcrush.com
www.ics-instantcrusherspares.co.uk
GCL: GLOBAL Cement TECHNOLOGY
When the going gets tough, the tough get going
. . . HARDTOP ®- Wear Parts HARDTOP
Giessereitechnologie
GmbH

Your contact partner:

Armin Issleib
Agnetenstrasse 14
D-39106 Magdeburg

Phone: 0049 391 532 969 - 0

Intelligent wear part solutions Fax: 0049 391 532 969 - 21
for the aggregate and cement industry, info@hardtop-gmbh.de
especially bi-metallic wear castings. www.hardtop-gmbh.de

We are exhibiting at Hillhead Quarrying & Recycling Show, Buxton/UK, 21-23 June.
Please visit us in the Main Pavilion, Stand P130 - we look forward to meeting you.
GLOBAL CEMENT AND LIME MAGAZINE
Invicta Vibrators
Outdoor, B26
Tel: 01476 566301
Fax: 01476 590145
mike.caldwell@invictavibrators.co.uk
www.invictavibrators.co.uk
The Invicta stand will feature the
latest range of base-mounted, rotary
electric vibrators - the BLz series
- which has been certified as comply-
ing with ATEX Directive 94/9/EC for
An Invicta industrial vibrator.
use in Zones 21 and 22 areas. Also
on display will be examples from the
company’s air-operated piston vibra-
tor range, which has been approved
for use in Zone 1, Zone 2, Zone 21
and Zone 22 areas, and hydraulic
vibrators from the HV and HVL rang-
es. Information on all Invicta products
will be available on the stand.
JMJ Bulk Packaging Ltd
Outdoor, U7
Tel: 01642 782784
Fax: 01536 261180
info@packaging.uk.com
www.packaging.uk.com
JMJ is a supplier of single- and
multi-trip bulk bags to the minerals
and aggregates markets. It will be
showing a range of products includ-
ing: Crohmiq static-protective fabric
for type-D FIBC, designed and engi-
neered to operate safely in flammable
or explosive atmospheres without
the need for ground connection
and complying with the forthcom-
ing IEC61340-4-4 standard; Mortar
bags, designed to replace convention-
al mortar tubs, that can be collapsed
for storage and have replaceable
liners and four strong lifting loops;
Squareform bags, designed for better
utilization of container space with a
non-woven geotextile top to maximize
the filling capacity within the FIBC;
and Easylift bulk bags with additional
May 2005
sleeves, allowing lifting with one fork-
lift operator.
Kingfisher Industrial
Outdoor, C15
Tel: 01299 251121
Fax: 01299 251021
pconnolly@kingfisher-
industrial.co.uk
www.kingfisher-industrial.co.uk
Abrasion-resistant materials, bulk-
handling systems, castings, design
& installation services, maintenance
products, pipe systems, repair &
maintenance services, restoration
materials, steel, tanks/silos/hoppers
etc, trailers, wearparts.
John King (Chains) Ltd
Main Pavilion, P55
Tel: 01977 681910
Fax: 01977 681899
admin@johnking-chain.com
www.gefa-chain.com
Land Instruments
Main Pavilion, P39
Tel: 01246 417691
Fax: 01246 410585
infrared.sales@landinst.com
www.landinst.com
Land Instruments will be exhibiting
a comprehensive range of new non-
contact temperature measurement,
infrared line-scanning and thermal-
imaging systems that are suitable
for a range of applications. Products
on show will include: a range of new
stand-alone infrared thermometers
and an extensive range of System 4
high-precision thermometer systems
used for process monitoring and con-
trol; Land Cyclops and PockeTherm
hand-held thermometers for rou-
tine spot measurement; the latest
Landscan LSP infrared line-scanning
systems for rotating kiln shell and
conveyor protection; and the Cyclops
TI 814 portable thermal imager for
preventive maintenance applications.
LVS IMAS Ltd
Main Pavilion, P88
Tel: 01257 263666
Fax: 01257 241821
angela@rubberbelts.co.uk
www.rubberbelts.co.uk
LVS IMAS, UK stockists and distribu-
tors of IMAS conveyor belting, will
28
HILLHEAD 2005 PREVIEW
be displaying its specialist range of
conveyor belting suitable for min-
ing and quarrying applications. The
range includes: chevron belting up
to 1500mm wide, steelcord belting up
to 2600mm wide, and textile belting
up to 2800mm wide. In addition to
standard wear-resistant rubber cov-
ers its range includes specifications
to protect against damage from heat,
fire or oil.
Magotteaux SAS
Main Pavilion, P62
Tel: +33 3 24413680
Fax: +33 3 24413696
Crushers, wearparts.
Martin Engineering Ltd
Outdoor, B23
Tel: 0115 9464746
Fax: 0115 9464746
dave.harasym@martin-eng.co.uk
Conveyor belt cleaners, convey-
ors & components, dust control/
suppression, rollers, spillage control,
vibrators.
Master Magnets Ltd
Outdoor, C7
Tel: 01527 65858
Fax: 01527 65868
joe.cetti@mastermagnets.co.uk
www.mastermagnets.co.uk
This company manufactures and
supplies a wide range of magnetic
and non-ferrous separation equip-
ment for use in quarrying and recy-
cling applications. Overband separa-
tors can be used to lift ferrous metal
from a material stream on a moving
conveyor and discharge it continu-
ously; permanent or electromagnets
can be used. Magnetic drums and
pulleys will automatically separate
and discharge ferrous metals in pro-
cessing plants and very heavy-duty
versions are used in fragmentiser
plants to separate the constituents of
shredded vehicles.
Materials Handling Products
Main Pavilion, P87
Tel: 01283 226624
Fax: 01283 226623
brian@m-h-p.co.uk
www.m-h-p.co.uk
Abrasion-resistant materials, con-
veyor belt cleaners, dust control/
GCL: GLOBAL Cement TECHNOLOGY
HFB. Technology – in motion

Whether it is an individual single-unit production or a traditional standard

product our philosophy is determined by quality. Uncompromising
product quality and innovative problem solutions are the cornerstones
of our success. This is why the development and production of Plummer Block Housings and S-type
housings, bearings and accessories is based on state-of-the-art Bearing Housing for large volume
conveying systems, and small volume
computer-supported production plant. Our services for customers conveying systems

and sales partners are reliable and of the highest quality.

Wälzlager-Gehäusetechnik GmbH
Siemensstr. 33
74722 Buchen Oil- and grease lubricated housings
for air-, fan- and air conditioning
Germany industries

Tel. 0049 6281 5266-0

Fax 0049 6281 5266-33
E-Mail: info@hfb-waelzlager.de
Internet: www.hfb-waelzlager.de

Grease lubricated Plummer Block

Housings for assembly of self-aligning
ball bearings and spherical roller
bearings

ASHGUARD, INC. is a protective coatings firm,

specializing in corrosion control in the cement
industry with an emphasis on the flue gas
equipment. We apply heat and corrosion resistant
coatings to internal kiln shells, flare stacks, bag
houses and many other related equipment and
structure. Our application approaches are among
the most innovative techniques available. Our
articles related to this work have been published in
World Cement and Concrete Society.

We use only the finest, most dependable materials

to support our customers project’s needs, and
provide a “hands-on” management approach to
achieve the excellence in quality that our
customers have come to expect. We are pleased to
introduce our Ashguard, Inc. line of kiln and vessel
coatings this year.

For more information, please contact our website

at www.ashguard.com or phone us at (830)935-
3400. Our address is P.O. Box 1847, Canyon Lake,
Texas 78133. Ashguard, Inc. “Small enough to care”..
..Large enough to carry through!”

Talweg 15-17 . 74921 Helmstadt/Germany

Tel. +49-7263-91290 . Fax:912912 . E-mail: info@mrs-greifer.de
GLOBAL CEMENT AND LIME MAGAZINE HILLHEAD 2005 PREVIEW

suppression, grizzly screens/feeders, Nilos Hans Ziller PRo Publications

screening surfaces, scrubber barrels,
shredders and trommels, spillage
control.
Mato Industries Ltd
Outdoor, F3
Tel: 01254 387638
Fax: 01254 238023
info@mato.co.uk
www.mato.de
Mato will be exhibiting a wide range
of products including conveyor belt
fasteners, belt cleaners, industrial
rubber products and lubrication
equipment.
Midland Industrial Designers
Registration Pavilion, R2
Tel: 0115 938 2154
Fax: 0115 938 6315
alex.marshall@mid.uk.com
www.mid.uk.com
Abrasion-resistant materials, bulk-
handling systems, conveyors & com-
ponents, pipe systems, rotary valves.
MMD Mineral Sizing
Outdoor, L25
Tel: 01773 835533
Fax: 01773 837818
awithers@mmdsizers.com
www.mmdsizers.com
This year’s display will include MMD’s
new design features developed using
practical experience and the latest
computer-analysis systems for break-
ing hard rock using MMD Sizing
technology. There will be a number of
different Sizers on show to reflect the
diversity of applications that can take
advantage of the compact, high-ton-
nage machines. An MMD plate feeder
will also be available for inspection on
the static display.
Muller Beltex UK Ltd
Main Pavilion, P76
Tel: 01535 630369
Fax: 01535 631137
paul.haywood@mullerbeltex.com
www.mullerbeltex.com
Abrasion-resistant materials, con-
veyor belt cleaners, instrumentation
and level control, wearparts.
Nerak-Wiese Ltd
Outdoor, N19
www.nerak-uk.com
Indoor, Main Pavilion, P69
Tel: +49 2103 951217
Fax: +49 2103 951219
keithsawden@aol.com
www.nilos.com
Nilos manufacture a range of convey-
or belt equipment including: vulcaniz-
ing equipment; mechanical fasteners;
Topgum cold-adhesive materials; rub-
ber lining, lagging and reflex materi-
als; scraper systems; and moulded
rubber and PU products. The compa-
ny also designs and supplies complete
conveyor belt reconditioning plants,
idlers, drive and return pulleys.
PCME Ltd
Main Pavilion, P14
Tel: 01480 468200
Fax: 01480 463400
lindaf@pcme.co.uk
www.pcme.co.uk
PCME, manufacturers of continuous
particulate emission-monitoring solu-
tions for the minerals industry, will
be showing a range of systems used
extensively in quarrying and asphalt
applications. The MCERTS-approved
DT990 system, with multi-calibra-
tion factor capability, offers accurate
monitoring on varying multi-mix com-
positions. In addition, the utilisation
of patented, fully insulated sensors
provides effective monitoring in moist
conditions. Filter failure detection in
single- or multi-compartment bag-
houses is achieved via the BBS220
that provides maintained baghouse
operation at optimum levels. Also on
display will be the new SC602 cross-
stack optical measuring system with
outputs in both dust concentration
(mg/m3) and opacity (%), which is
designed to meet QAL 1 requirements
of EN-14181/13284-2.
Precia-Molen (UK) Ltd
Outdoor, G4
Tel: 01527 590320
Fax: 01527 590301
sales@preciamolen.co.uk
www.preciamolen.com
Bulk-handling, computer systems,
weighbridges, weighing systems.
Main Pavilion P130
Publishers of GCL Magazine, Global
Gypsum Magazine, Global Slag
Magazine. For the slag and fly-ash
sector we recently announced the
publication of ‘Global Slag Magazine’
and our first ‘Global Slag Conference’
will take place in Düsseldorf,
Germany, 14-15th November this
year. Come and meet GCL’s staff!
Quarry Manufacturing
Outdoor, H11
Tel: 01530 811081
Fax: 01530 510960
jonathon@qmsupplies.co.uk
www.qmsupplies.co.uk
Castings, contract crushing etc,
crushers, recycling equipment &
plant, repair & maintenance services,
spare parts, wearparts.
RAP Conveyors
Outdoor, S1
www.rapconveyors.co.uk
Abrasion-resistant materials, con-
veyor belt cleaners, conveyors & com-
ponents, conveyor belting, rollers,
screening surfaces, waste disposal.
Raytek
Main Pavilion P11
Tel: 01908 630800
Fax: 01908 630900
swilliams@raytek.de
www.raytek-europe.com
Automation & control systems,
instrumentation and level control,
maintenance products, quality
control/testing, testing and analysis.
Rema Tip Top UK Ltd
Main Pavilion P13
Tel: 0113 277 0044
Fax: 0113 272 2139
tim.hunt@tip-top.co.uk
www.tip-top.co.uk
Abrasion-resistant materials, con-
veyor belt cleaners, conveyors & com-
ponents, screening surfaces.
Renold Power Transmission
Main Pavilion P106
Tel: 01706 751000
Fax: 01706 751001
tpriestley@gears.renold.com
www.renold.com
Renold will be displaying a number

May 2005 30 GCL: GLOBAL Cement TECHNOLOGY

GLOBAL CEMENT AND LIME MAGAZINE
of products from the group’s power
transmission factories in Europe and
the US. Transmission and conveyor
chains designed for use in the min-
ing industry will be on show with a
number of heavy-duty general chain
products. Gear units of all types will
be shown, including loose gears, wor-
mgear units, bevel/helical and shaft-
mounted helical units.
Rowecon Systems Ltd
Main Pavilion, P113
Tel: 0114 254 0660
Fax: 0114 254 0661
sales@rowecon.co.uk
www.rowecon.co.uk
Automation & control systems,
feeders, instrumentation and level
control, metal detection/separation,
weighing systems.
RSG Inc
Main Pavilion, P41
Tel: +1 256 378 3836
Fax: +1 256 378 3856
sales@airclassify.com
www.airclassifying.com
RSG Inc is a first time exhibitor
to Hillhead, and its products will
be introduced to the UK quarry-
ing Industry at Hillhead 2005, the
company’s first attendance at any
European trade event. The company
manufactures processing equip-
ment for the mineral, chemical and
quarrying industries. The current
product line includes several styles
of air classification equipment suit-
able for a wide range of duties and
capacities in calcium carbonate, clay,
coal and cement. The ufg mill is a
dry, airswept media mill, suitable for
RSG’s M600 air classifier suitable for
feeding 150t/h of cement or limestone
May 2005
HILLHEAD 2005 PREVIEW
producing powders typically less than skako@skako.freeserve.co.uk
45 microns. The ufg mill is currently www.skakocomessa.com
operating on limestone, wollastonite, Feeders, grizzly screens/feeders,
diatomite and gypsum. screens, scrubber barrels, vibrators.
RUD Chains Ltd SKF (UK) Ltd
Outdoor, W4 Outdoor, F2
Tel: 01227 276611 Tel: 01582 490049
Fax: 01227 276586 Fax: 01582 496324
alan@rud.co.uk marketing.uk@skf.com
www.skf.co.uk
Bearings, castings, lubrication sys-
tems, maintenance products, oils
& lubricants, repair & maintenance
services, training, vibration and
noise monitoring.
SSAB Swedish Steel Ltd
Main Pavilion, P51
Tel: 01905 795794
Fax: 01905 794736
The largest tyre-chains in the world, dave.cowling@ssabox.com
recently fitted by RUD to a loader www.hardox.co.uk
for Taiheiyo Cement, Japan.
SSAB Oxelosund will be showing its
new Hardox 550 wear plate that com-
bines extra hardness and wear resis-
Rulmeca UK Ltd tance without compromising crack
Main Pavilion, P80 tolerance or workshop performance.
Tel: 01536 200322 The hardness of 550 Brinell make it
Fax: 01536 748535 a suitable alternative to wear parts
rball@rulmeca.com made from castings, 12% manganese
www.interroll.com steels or standard 500 Brinell steel.
Conveyor drives, conveyors & com-
ponents. Vision Techniques Group
Indoor, P2 Outdoor, A6
Shaw-Almex Industries Ltd Tel: 01254 679717
Main Pavilion, P68 Fax: 01254 690919
Tel: 01453 829900 mhanson@vision-techniques.com
Fax: 01453 829928 www.vision-techniques.com
sales@rako-almex.com All-round vision, CCTV systems,
www.rako-almex.com mobile plant reverse warning sys-
Conveyors & components, repair & tems, reversing safety equipment,
maintenance services. security systems.
Siemens Automation Wyko Industrial Services
Main Pavilion, P99 Main Pavilion, P135
Tel: 0161 446 6400 Tel: 0121 508 6341
Fax: 0161 446 5280 Fax: 0121 508 6464
ian.bowman@siemens.com sarah.evans@wyko.co.uk
www.siemens.co.uk/automation www.wyko.co.uk
Communication systems, com- Abrasives, anti-vibration mounts,
puter systems, computer software, bearings, conveyor belt cleaners,
conveyor drives, instrumentation conveyor drives, conveyors & com-
and level control, motors & gears. ponents, electrical services, filtration,
gearboxes, generators, hydraulic com-
Skako Comessa Ltd ponents, lubrication systems, motors
Outdoor, N24 & gears, oils & lubricants, pumps,
Tel: 01937 838010 repair & maintenance services, vibra-
Fax: 01937 838011 tion and noise monitoring. GCL
32 GCL: GLOBAL Cement TECHNOLOGY
 GCL View from Brussels
G LOBAL C EMENT & L IME M AGAZINE
JEAN-MARIE CHANDELLE’S
JEAN-MARIE CHANDELLE IS THE CHIEF EXECUTIVE OF
T
he results of the Complementary
Business Impact Study on the European
Commission’s new chemical proposal
(REACH) for the ‘inorganics sectors’ have been
made public. The study confirms that there are
no additional health and safety or environmental
benefits to be gained from applying the REACH
registration requirements to raw materials and
fuels used in the cement industry.
The 12 member sectors of the REACH Alliance (cement,
ceramics, glass, gypsum, iron & steel, lime, minerals, non-
ferrous metals, ores, paper, precast concrete and ready-
mixed concrete), support the basic aims of REACH, but
share a number of concerns about the proposal. These 12
sectors represent a total turnover of Euro360bn, manu-
facture 1.5bn tonnes of products per annum and provide
employment to 2 million people in the EU.
These sectors will, of course, be impacted by the pro-
posed Regulation as downstream users and importers of
chemicals. However, we have serious concerns specific for
our industry sectors related to the nature of the raw mate-
rials we use (input streams such as e.g. minerals, ores,
concentrates and other naturally occurring substances
and recycled or recovered wastes) and the products we
manufacture. These impacts were studied for the first
time in the ‘Further REACH Impact Assessment.’
Based on the findings of the impact study, the REACH
Alliance suggests a limited number of key amendments to
improve the workability of REACH. These ideas are also
supported by UNICE (Union of Industrial and Employers’
Confederations of Europe).
1. Our industries manufacture products in quantities
which exceed by far the total worldwide volume (400 mil-
lion tonnes per year) of chemicals referred to in the White
Paper on the Chemicals Policy Review of February 2001.
As high volume manufacturers of mainly low risk prod-
ucts derived from minerals, ores or substances occur-
ring in nature, we question the relevance of prioritisation
(including timing for implementation) by volume and pro-
pose a risk-based prioritisation system instead.
2. The REACH proposal has been developed mainly
with the objective of safe use of man-made products from
the chemical industry. However, as currently presented,
it would also cover other products such
as those that our companies manufac-
ture, as well as our raw materials.
We feel that including our raw
Contents Subscribe
May 2005 33
CEMBUREAU, THE EUROPEAN CEMENT ASSOCIATION
materials and products in REACH under the
same regime as chemicals, clearly cannot be
the intention of the legislator. Safety data
sheets (SDS), produced according to the exist-
ing European legislation, describe very clearly
how to use our products without jeopardising
workers’ health and safety and the quality of
the environment. We therefore welcome their
prominent role in the REACH proposal.
We propose a more focussed scope of REACH to bring
it back to what was originally intended i.e. to protect man
and environment from the negative impacts of the use of
chemicals:
• Exempt wastes and secondary raw materials/
alternative fuels from the scope of REACH. Recovered
waste and recycled materials are used as feedstock for
our industrial processes according to the provisions of
the IPPC Directive (96/61/EC on Integrated Pollution
Prevention and Control) and/or Community waste legisla-
tion.
• Exempt from registration all those minerals, ores,
substances occurring in nature, and materials derived
from them by mineralogical processes or physical trans-
formation processes (the basic raw materials for our sec-
tors), as is the case for natural gas, crude oil and coal
(the basic raw materials for the organic chemicals sec-
tors). Potential risks arising from the use of basic raw
materials in our sectors are already addressed under the
IPPC Directive and/or under workplace legislation; their
inclusion puts our sectors at an unfair and significant
competitive disadvantage.
• Remove the overlaps between REACH and existing
legislation, in so far as the environmental and health
aspects are already adequately covered. Examples include
the Construction Products Directive and Community leg-
islation on waste.
3. The requirements on the unintentional release of
substances are already adequately covered in the regis-
tration and authorisation requirements: protecting final
consumers is more efficiently done via vertical product
legislation.
For CEMBUREAU it is evident that any cost to the cement
industry related to implementing REACH is too high a
price to pay when there are no correlated benefits. The
cement industry is already sufficiently regulated
under Community law. GCL
Ad index
GCL: View from Brussels
 N Contents
E W S Subscribe Ad index

E UROPE HeidelbergCement has announced figures tribution to results made by North America and Africa-
for the first quarter of 2005 which are only slightly Asia-Turkey was counterbalanced by the effects of unfa-
above those for 2004, and has given a guardedly opti- vourable weather conditions in Europe.
mistic appraisal of future prospects. HeidelbergCement The financial results improved by Euro16m to Euro
said in its report, “The international economic growth -54m compared to previous year’s result of Euro-70m,
has weakened slightly in recent months. However, the US primarily due to the fact that unlike in the previous
and China continue to provide the strongest impetus. In year, Indocement incurred no foreign exchange losses.
the EU countries, the considerable slowdown in economic Loss before tax amounts to Euro-99m, compared to the
dynamics was partly caused by the heavy increase in raw previous year’s Euro-83m result. In accordance with the
material prices. The severe winter impaired major parts revised German tax laws, no tax assets resulting from
of Europe in the first quarter. In Germany the growth losses were recognised.
forecast was lowered significantly as a result of the con- HeidelbergCement has announced that the German
tinuously weak domestic economy and the strong Euro. cartel office has approved a takeover of a majority stake
In the first quarter of 2005, cement and clinker sales vol- in Teutonia Zementwerk AG. HeidelbergCement said
umes decreased by 2% to 12.7Mt. HC was able to achieve that it now owns 99.4% of the voting rights and 91.7%
increases in sales volumes in North America, Northern of the equity capital in Teutonia Zementwerk, after a
Europe and Africa-Asia-Turkey. Excluding consolidation voluntary takeover offer of EUR660/share in cash to
effects, the decline amounted to 3.7%. outstanding shareholders was concluded on April 19.
In the first quarter, turnover increased slightly in com- HeidelbergCement had bought 51.7% of the equity capital
parison with the previous year by 0.6% to Euro1355m. in Teutonia Zementwerk on December 10, 2004.
Welcome growth in turnover was achieved in Northern
Europe, Central Europe East and North America. In Holcim up 67% in first quarter of 05
North America, turnover in US dollars increased by
around 17%. Excluding currency and consolidation E UROPE Holcim Ltd., the world’s second-largest cement
maker, has reported a 67% rise in first-quarter net profit,
effects, Group turnover rose by a total of 0.8% in to Euro110m, due to acquisitions and a change in the com-
comparison with the previous year. The positive con- pany’s reporting standards since 2004. Net profit rose despite
being hit by higher energy and transport costs, as well as
Italcementi blames it on the rain the weaker US dollar. First-quarter sales fell 1.1 percent, to

I TALY/WORLD Italian cement producer and dis- Euro1.8bn, because of poorer weather conditions and an early
tributor Italcementi SpA posted an attributable net Easter, which restricted construction activity in Europe and
profit of Euro292m in 2004, up by 5.7% year-on-year. North America. Holcim expects to improve its results for the
The company expects to fulfil its 2005 targets and full year 2005: “Weather-related and seasonal losses sustained
to keep its 2005 operating results in line with 2004, in the first quarter ought thus to be offset over the remainder
the president of Italcementi, Giampiero Pesenti, said of the year,” Holcim said.
after the shareholders’ meeting approved the 2004
results. The revenue of Italcementi rose by 5.7% year Akmenes falls prey to ‘the dirty stuff’
on-year to Euro4.528bn in 2004. Italy’s construction
market is expected to grow between 0.5% and 2.0% in L ITHUANIA Akmenes Cementas, Lithuania’s only cement
manufacturer, saw its sales drop by 6.3% year-on-year
2005, according to the director-general of Italcementi, to Euro3.13m in the first quarter of this year. “It is difficult
Rodolfo Danielli. to compete with Belarusian cement which does not comply
Chairman Giampiero Pesenti confirmed that group with the EU directives but is cheaper. It is being imported into
targets for 2005 gave only a modest outlook for the Lithuania in large amounts,” said Akmenes Cementas CEO
year due to high costs and bad weather. Italcementi Arturas Zaremba. A EU directive, in place since January 17,
said in a results statement that it expected 2005 oper- bans cement manufacturers from using hexavalent chrome,
ating income to be in line with 2004, “given that the which is toxic and is known to be carcinogenic when inhaled,
beginning of the year was affected by disastrous mete- in their products.
orological conditions in many European countries.” “To comply with the EU directives, we have invested almost
The group made a gross operating profit of Euro1.1bn Euro300,000 in equipment that removes this element from
in 2004, up 3.5% on the year but restrained by high cement products. This has made competition with cheap
fuel costs. A weak US dollar hit earnings from abroad. Belarusian cement even more difficult,” Zaremba said. Cemex
Italcementi has been keen to strengthen its presence controls a 33.95% stake in the company through a subsidiary
in emerging markets and recently took a controlling company, while four Lithuanian private individuals hold a
stake in Egypt’s Suez Cement. combined stake of 51%.

May 2005 34 GCL: European CEMENT

 6th
E uropean
CEMENT
Conference and exhibition

‘Global cement trends’

Contacts Environment Markets
Trade Technology Fuels Emissions trading
Including the Global Cement Awards 2006

LONDON
13-14 March 2006
Call for papers, programme details:

www.EuropeanCement.com
Register your interest today!

Organising magazine

GCL
GLOBAL CEMENT AND LIME MAGAZINE
 N E W S
Lafarge’s first quarter up
W ORLD Lafarge has reported that its first quarter sales
were up 2.2% to Euro2945m as at March 31, 2005
compared to first quarter 2004 sales of Euro2881m. “The
underlying favourable trends in many of our markets have
allowed for positive pricing. Volumes were held back this
year compared to the first quarter of 2004 due to harsher
winter weather, but this is quite usual given the seasonal-
ity of our business” said Jean-Jacques Gauthier, Executive
Vice President, Finance. He added “this first quarter vol-
ume trend does not alter our view for the year for which
we expect overall favourable market conditions.”
In Western Europe price increases were realised in
many countries and in particular in Germany and the
UK. However sales were down due to lower volumes sold,
essentially being the result of the winter weather across
the region, which was more harsh than in the first quarter
of 2004 as well as fewer working days.
North American sales continued to strengthen in a
favourable demand environment. Higher volumes and
prices were seen across much of the United States,
where strong demand levels were recorded in markets
not impacted by unfavourable weather. Average prices
increased in both the US and Canada. The full impact of
these price increases will continue throughout the year.
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Holcim goes for 100% of AI
W ORLD Holcim has initiated a compulsory buyout
of the remaining 5% of UK quarrying-to-concrete
group Aggregate Industries” shares after acquiring a
95% stake in the company. Holcim had bid Euro2.7bn
for Leicestershire-based Aggregate in a deal which will
help Holcim diversify from cement, while also giving it a
UK presence and expanding its US business. Holcim said
Aggregate would add Euro2.9bn to its sales, an increase
of just under 30%. Aggregate runs 142 quarries in the
UK and the US, with more than 5bn tonnes of reserves,
164 readymix concrete plants, 90 asphalt plants and 32
pre-cast concrete factories.
Lafarge dump wins plaudits
U K A former landfill site owned by Lafarge Cement
UK which was used for the disposal of inert materials
such as waste cement and rubble up to 2003 has been
found to be in the top 3% most biologically diverse sites
in its region. On the Cauldon site, 73 different plant spe-
cies were identified, and it has now been classified as a
Site of Biological Importance, Grade 1, meaning that it is
one of the best examples of flower rich grasslands in the
county. Lafarge is to enable local people to see this biodi-
versity for themselves with a footpath inside the site.
Clinker storage pan conveyor. Cem
 N E W S
Holcim plans Spanish investment
S PAIN Holcim Espana SA, the Spanish subsidiary of
Swiss cement company Holcim Ltd, plans extraordinary
investments of Euro140m in addition to regular annual
investments until 2008, according to the CEO of the com-
pany, Saverio Banchini. Between 2005 and 2008, Holcim
Espana plans regular investments of Euro50-60m. Half of
the extraordinary investments planned until 2008 will be
allocated for boosting aggregates production. Holcim Espana
is planning production of between 20 and 25Mt a year after
2008, up from the current annual output of 15Mt of aggre-
gates. The company also plans to invest Euro12m in a mix-
ing plant and Euro20m in a milling plant in the Andalusia
region, in southern Spain.
Bulgaria sees Euro15m investments
B ULGARIA Italcementi says that it plans to invest some
Euro15.4m in its two plants in Bulgaria by 2006
to improve quality and reduce environmental impacts.
Italcementi bought via its Ciments Francais unit the Devnya
cement plant near the Black Sea port of Varna in 1998 and
cement maker Vulkan in southern Bulgaria a year later. The
plants produce roughly 2.5Mt a year. The two plants boosted
their combined turnover by 21.9% to Euro83m last year.
Italcementi claims a 40% share on the Bulgarian market.
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Change at the helm for Cimpor?
P ORTUGAL/WORLD Shares in Cimpor have risen in
value after analysts welcomed a decision by share-
holders to abolish a 10% ceiling on voting rights. “This
is very positive for Cimpor; meaning further dynamics
in its strategy, more transparency and possibly an
improvement in the communication with the mar-
ket,” Sonia Baldera of Caixa Banco de Investimento
said in a note. “Besides that, with the end of voting
rights limit it might be possible to see an increase in
speculation about a future change in the control of the
company,” the Caixa BI analyst said.
The decision is “positive for Cimpor, but potentially
negative for leading shareholder Teixeira Duarte,”
according to Banco BPI analysts. ‘While this news may
open doors for a change in the leading shareholder
through a takeover, for Teixeira Duarte it represents
a threat of losing its most valuable asset at prices
that may not be enough to compensate the 10% stake
bought in a pricey privatisation,” they said.
Pedro Maria Teixeira Duarte, Cimpor chairman,
said he does not expect a hostile bid from Lafarge SA
or any other company. Lafarge proposed the abolition
of the ceiling, while Teixeira Duarte did not proceed
with a proposal to raise the ceiling to 33%.
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 N E W S
D I A R Y D A T E S
2005 C EMENT INDUSTRY CALENDAR AND YEAR PLANNER NOW AVAILABLE
FOR FREE DOWNLOAD AT WWW . PROPUBS . COM

IEEE-IAS/PCA 47th Cement Industry Technical confer-
ence, 15-20 May 2005, Kansas City. Contact: Marty Adler Conference, Cancun, Mexico, 8-9 September 2005.
Tel: + 1 816 356 8400 Fax: + 1 816 353 1873 Email:
madler@bha.com www.ieeepca2005.org
The Theory and Practice of Pneumatic Conveying. May
24-26, 2005, York, NE, USA. Tel 1-800-445-0730.
Environmental Technology & Management Services
Exhibition, 24-26 May 2005, NEC Birmingham/UK
www.et-expo.co.uk
4th North and South American CEMENT
www.AmericanCement.com
POWTECH 11-13 October 2005, Nuremberg
www.powtech.de
Global SLAG Conference and Exhibition, (global produc-
tion, handling and storage crushing, analysis, uses,
shipping, trading and markets), 14-15 November 2005,
Düsseldorf, Germany. www.GlobalSlag.com

VDMA Symposium for the Russian cement, lime, gypsum Environment Protection in Cement Industry Conference,
and dry mortar industries, June 1 – 3, 2005, Moscow: ale 21-23 November 2005, Algeria. Contact: Eng. Ahmad Al-
ssandro.colucci@vdma.org, www.vdma.org/construction Rousan Tel: +963-11-6115412 Fax: +963-11-6121731

2nd International Symposium. Non-Traditional Cement
& Concrete. 14-16 June 2005, Brno, Czech Republic.
www.fce.vutbr.cz/stm/fracture/symposium2005
Phillips Rema Kiln Services kiln maintenance seminars:
Southern Ireland – 14-16 June or Prague 20-22 June
www.phillipsrema.co.uk
Hillhead 2005, Buxton, 21-23 June 2005
(penny.lewin@qmj.co.uk)
6th International Congress on Global Construction, 5-7
July 2005, University of Dundee, Scotland Tel: +44 1382
344347 Email: r.k.dhir@dundee.ac.uk
The International Congress on Fly Ash, December 4-7,
2005, New Delhi, India. flyash.conference@gmail.com
6th European CEMENT Conference, 13-14
March 2006, London. ec2006@propubs.com,
www.EuropeanCement.com
IEEE-IAS/PCA 48th Cement Industry Technical confer-
ence, 10-13 April 2006, Phoenix, Arizona
Asian CEMENT Conference, 5-6 June 2006, Vietnam.
Please see www.propubs.com/ac2006 for details.

European News in brief...

an independent benchmark of our performance,” said the firm’s
R ussia In the first three months of 2005, Russian cement
companies produced 7.8Mt of cement, up 3.0% year-on-
year. In 1Q2005, the Eurocement Group produced about 1.9Mt
managing director Jeff Sautin.

of cement, thus matching the 1Q2004 level. Eurocement Group,

Russia’s biggest cement holding company, controls 20% of the
Russian and 60% of the Moscow cement market.
R ussia Eurocement has announced that it will insist on
100% prepayment as a condition of product delivery.
Observers suggest that this action is in response to the compa-
C roatia Mexico’s Cemex has appointed Juan Carlos Ernesto
Rincon Restrepo as the chief executive officer of its Croatian
subsidiary Dalmacijacement. The change comes after Cemex
completed the acquisition of UK-based RMC Group, the Croatian
cement manufacturer’s parent company. Dalmacijacement’s net
profit for 2004 fell 29% to Euro20.4m.

ny’s lack of funds after its acquisition of Inteko.

U K Lafarge Cement in Westbury, Wiltshire, is in the middle
of a 12 week, Euro15m kiln refurbishment programme.

Z imbabwe One of Zimbabwe’s largest cement producing

companies, Circle Cement, has purchased Mbubu limestone
deposits from Anglo-American Corporation for an undisclosed
amount, to boost its limestone reserves. Circle Cement mining
engineer Mr Javali Juma says that the company is now inviting
tenders to carry out a topographical survey of the area, which
lies 190km north-east of Harare.
U K Lafarge Cement UK has been named as the construc-
tion and building materials sector leader in Business in the
Community’s annual Environment Index, for the second year in
a row. “The index is something we value highly as it provides
P oland Sales of cement in Poland dropped by about 25%
year-on-year to 1.1Mt in the first quarter of 2005, mainly
due to the prolonged winter, which caused a halt in construc-
tion works. In the first quarter of 2004, demand for cement grew
significantly due to the expected introduction of a 22% value
added tax (VAT) on building materials. The new tax came into
force in May 2004, leading to relative weakness in cement and
building material markets in 2005.
Nevertheless, Polish cement producers are optimistic about
the future of the sector. They believe it will recover in 2006,
when a boom in the construction market is expected.

May 2005 38 GCL: European CEMENT

 N E W S
Clouds part over Rugby, at last
U K Campaigners fighting plans to incinerate tyres
and other waste at Cemex’s Rugby cement plant have
been dealt a double blow, after the government blocked
an application for a public inquiry into the proposals and
the High Court ruled that no laws were broken when the
permit was granted. It means alternative fuels can be
burned at the plant in Rugby when trials - which were
halted in May 2004 following problems - are resumed at
a later date.
Rugby Borough Council said it would not request
another public inquiry, since this was the fourth time
its application had been blocked. The Department for
Environment, Food and Rural Affairs said the issue was
not of national importance. Local councillor Carolyn
Robbins said: “I do not think there would be any point
trying again. We have tried and failed four times. The time
has come to say “enough is enough”.”
In addition, High Court judge Mr Justice Lindsay ruled
that the permit to burn alternative fuels at the plant was
legal. Paul Quinn, the agency”s environment manager,
said he was pleased the judge upheld the decision to allow
a permit following the agency’s “very detailed and consci-
entious determination of the application.”
Eurocement still out shopping...
R USSIA The Eurocement group is to buy two plants
from the SU 155 group for about Euro80m. The
plants are Ulyanovskcement and Zhiguli Construction
Materials (Zcm). In 2004, Ulyanovskcement produced
1.36Mt of cement and ZCM 700,000 tonnes. As reported
in GCL, early in April, the Eurocement group bought the
Inteko cement business for Euro800m. The deal made
the Eurocement group the largest cement manufacturer
in Russia, bringing it controlling stakes in six Russian
plants and one Ukrainian plant, and minority shares in
Ulyanovskcement and ZCM, whose controlling stakes then
belonged to SU-155.
Demand both up and down...
S PAIN Cement consumption in Spain decreased 0.3%
year-on-year to 11.4Mt in the first quarter of 2005,
according to the Spanish Cement Makers Association,
OFICEMEN. The decrease resulted from the fewer work
days in Spain for the period due to the Easter holidays
in March 2005. Cement production in Spain increased by
2.9% year-on-year to 11.2Mt in the first quarter of 2005.
Spanish cement exports went up by 16.9% year-on-year to
360,558 tonnes in the first three months of 2005. Imports
for the period fell by 11.8% year-on-year to 1.6Mt. Most
imports came from Egypt, Turkey and Portugal. In the
twelve months to March 2005, cement demand in Spain
stood at 47.9Mt, a 2.4% year-on-year rise.
May 2005 40
Lagan starts on MBM quest
I RELAND Lagan Cement, which operates a cement plant
and quarries at Kinnegad, Co Meath, is proposing to
incinerate meat and bone meal to replace up to 45% of the
coal currently burned at the plant. The sale of meat and
bone meal has been banned in the Irish Republic since
2000 amid fears that it is the contaminant which spreads
the animal ‘mad cow’ disease BSE, and its human equiva-
lent CJD.
There is no other licensed incinerator of meat and bone
meal in the Republic. Stocks are stored or sent abroad
for incineration. Previous plans for a meat and bone meal
incinerator in south Tipperary led to a long-running dis-
pute in 2003 between millionaire racing enthusiast John
Magnier of Coolmore Stud and National By-Products. Mr
Magnier threatened to take his business abroad if the
incinerator went ahead. The plans were withdrawn.
Lagan Cement, which holds an Environmental
Management Systems Accreditation ISO 14001, is part of
the Belfast-based Lagan Group of companies which had
combined turnover approaching Euro364m in 2004. The
Kinnegad operation produces 0.6Mt of cement a year.
Jude Lagan, speaking for the company, described the pro-
posals as “research which the company had undertaken
as part of its obligations to reduce fossil fuels under the
Kyoto protocol” Documents originating from the company
state that ‘The MBM (meat and bone meal) that will be pro-
duced at the Killaskillen cement plant will conform to spe-
cific quality standards. Any material that does not conform
to these standards will be refused, and will be returned to
the rendering plant where it originated.’ The meal would
be transported to the plant in leak-proof tankers, and silos
would use an enclosed system.
GCL says, “Public fear of MBM means it will take very
slick PR work on Lagan’s part if the company’s plans are
to come to fruition. Given the potential savings, it is worth
sticking with the fight, however long it turns out to be.”
Profits dip while project builds
S LOVAKIA Slovak building materials producer Holcim
(Slovensko) posted a loss Euro1.8m for 2004, mainly
due to the large investments of Euro63.2m in a two-stage
modernisation project at the company’s plant in Rohoznik,
western Slovakia. Holcim (Slovensko) generated a revenue
of Euro83.4m from the sales of own products and services
for 2004, down by nearly 4.0% year-on-year. The compa-
ny’s grey cement output decreased by 9% year-on-year
to 1.16Mt for the period. Most of the grey cement output
was sold on the domestic market and 25% was exported.
Holcim (Slovensko) white cement sales rose by more than
11% year-on-year to 102,000 tonnes. The company’s white
cement exports accounted for 94% of its white cement
sales. Concrete sales increased by 6.0% year-on-year to
417,000 cu.m.
GCL: European CEMENT
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 N Contents
E W S Subscribe
U S/CANADA St. Lawrence Cement Group Inc. has
scrapped plans to build a new US$353m cement plant
in Greenport, N.Y., after failing to get regulatory approval
from the New York state government. The Montreal com-
pany said that its board had decided not to appeal a rul-
ing by New York State, denying approval for construction
because the proposed plant would have affected New York
state’s coastal areas. The proposed plant - which had been
proposed in 1998 and needed up to 17 federal, state and
local approvals before construction could begin - would
have replaced St. Lawrence’s cement plant operating in
nearby Catskill.
Among the required permits, the New York Department
of State (DOS) certification was key to qualify for other
approvals. On April 19, 2005, St. Lawrence Cement
received a negative determination from the DOS, which
ruled that the proposed plant was inconsistent with the
Fancesa hands out dividends
B OLIVIA Bolivian cement producer Fancesa achieved
a record net profit of US$10m in 2004. The Sucre-
based Fancesa’s board decided to issue dividends to the
company’s three shareholders: the Sucre municipality,
local San Francisco Xavier University, and fellow cement
maker Soboce. Each will receive US$1m with the remain-
ing US$8m going to capital reserve. The company has a
policy commitment to reinvest the greater part of profits
to continue the second stage of an expansion program.
The expansion will allow the company to participate
in the Tarija-Potosí southern highway project - being
carried out by Brazilian construction company Queiroz
Galvao - where Fancesa and Soboce have an agreement
to supply cement. Fancesa made a commitment in 2004
to spend US$60m over three years for this work in Sucre
and Potosí. Reinvested profits are projected to provide
US$15m of the total US$60m.
Stable demand reigns in Peru
P ERU Peru’s cement production remained stable in
March at 344,000t compared to the same month in
2004, according to the producers’ association, Asocem.
The local cement market is dominated by Cementos Lima
with 43.2%, followed by Cementos Andino with 21.9%,
Cementos Pacasmayo (16.5%), Cementos Yura (15.7%),
and Cementos Selva (2.7%). Cementos Lima’s sales
improved 4.9% year-on-year due to increased activity
in the housing sector and a growth in commercial infra-
structure investment. Cementos Andes and Cementos
Pacasmayo both registered depressed sales, with figures
down more than 7% each on sales for the same month in
2004. Fourth place Cementos Yura was the big winner for
the period with a 36.9% increase in sales year-on-year.
May 2005
Ad index
state’s coastal zone policies. The project’s configuration,
size and location, as proposed, would affect the state’s
coastal areas in a manner which is inconsistent with the
state’s coastal policies.
“I wish to sincerely thank our supporters for their
continuous encouragement in this undertaking and our
employees who dedicated their efforts to move this project
forward,” said Philippe Arto, president and chief executive
officer of St. Lawrence Cement.
“In light of this decision and in the context of the cement
shortage experienced in many states, we are taking a num-
ber of steps to reinforce our supply lines. This includes a
new US$10m investment program at our Catskill plant
to improve its reliability and overall performance. We will
also strengthen our network of distribution terminals and
our long-term contracts with Holcim Trading to secure
sufficient imported cement to meet needs in excess of
domestic production in the region. In addition, we will
continue to focus on developing long-term solutions to
maintain our ability to supply the cement needs of our
customers in the northeast United States market on the
most competitive basis,” Mr. Arto added. The company
will write off US$29m of charges on the project.
St. Lawrence Cement Group Inc. has posted a larger
loss in the first quarter, due to poor weather in its markets.
The company notes that it traditionally loses money in the
first quarter, due to low demand for construction products
during the winter. However, it said the poor weather in the
latest period did boost its construction services business,
due to an increased volume of snow-removal work. The
company said it expects demand for cement in Canada
and the US to be slightly above the strong 2004 level, and
price increases have been implemented in all markets.
“Despite cost pressures coming from higher energy and
imported cement prices, the company expects to improve
sales and margins in 2005.”
News in Brief
C HILE Cementos Melon, controlled by Lafarge, plans invest-
ments of US$20m to expand its cement production by
300,000t/year, setting up a plant at Puerto Montt to be com-
pleted by 2007. During 2004 Melon had an output of 1.4Mt (up
5,7% from 2003). Melon leads the Chilean cement market with
a 36,7% share.
B RAZIL The Brazilian Polimix Concretos is investing US$28m
by the end of 2006 in a cement plant with a capacity of
1.2Mt in Rio Branco do Sul (Parana) to supply the domestic
market. The plant is being designed with technology developed
in the country and with modern equipment imported from
China. Investments in the acquisition of equipment demanded
US$8m. Polimix has three industrial cement sites in Brazil and
130 distribution facilities. The Sergipe-based unit, for instance,
has a capacity of 360,000t/year.
42 GCL: N&S American CEMENT
 Re
1 Ju gister be

4 A
ne a
nd $ fore
N&S merican $$AV
E!

CEMENT
TH
Conference & Exhibition
‘PROCUREMENT 2005’
Procurement, production enhancement, refractories,
case studies, alternative fuels, construction and
reconstruction, modernisation, optimisation, blockages and
flow, production efficiency, problems and solutions,
kiln alignment and service, de-bottlenecking...

Register NOW!

...and since the Spouse Tour Programme

is FREE, maybe a little fun too!
5th
a b o r D a y is Monday Organising Not sure?
L r
te m b e r .. .. Now is you Show this
Sep magazine to your
a week in
chance for ing all spouse an
a n c u n w ithout tak d see
C s! what they
o u r v a lu a ble holiday think!
y
Cancun, Mexico,
Thursday 8 - Friday 9 September 2005
Hilton Cancun Beach and Golf Resort

Full details at www.AmericanCement.com

 Got a maintenance period

A
coming up in 2005-06?
N&S Select your suppliers in
CEMENT only two days
- IN CANCUN!
Conference & Exhibition
Fulfil all your procurement needs over two days at the best forum for
buyers and sellers of cement products and equipment in the Americas!

Provisional Programme
Wednesday 7 September 2005
08.00 Golf game at the Hilton’s Championship Course - for the American CEMENT Cup.
16.00 - 19.00 Conference registration. The conference language is English.
19.00 - 21.00 Welcome cocktail reception for all delegates....Let’s get the show started with a bang!

Thursday 8 September 2005

08.00 onwards - Conference registration and coffee.
09.00 Official Welcome. and conference opening ceremony
9.15 Keynote Speech: Internationally-known cement industry speaker - to be confirmed
Session 1: Optimising your shutdown period
10.30-11.30 Coffee in North and South American CEMENT Conference 2005 exhibition area.
12.30-14.00 Lunch
Session 2: Solutions to your plant’s problems....If it doesn’t work, your money back!
15.00 Coffee in North and South American CEMENT Conference 2005 exhibition area.
17.00 Cocktail reception in the North and South American CEMENT Conference 2005 exhibition area.
19.00 onwards Gala Dinner: A fabulous Mayan extravaganza with mesmerising music, sensual
dancing and awesome food and drink....the high-point of the year and
well worth writing home about!

Friday 9 September 2005

08.00 onwards - Conference registration and coffee.
Session 3: Now it works, how can we get it to work better? Optimisation case studies.
10.30-11.30 Coffee in North and South American CEMENT Conference 2005 exhibition area.
12.30-14.00 Lunch
Session 4: Refractories, alternative fuels, conveying, monitoring, kiln problems
15.30-16.00 Coffee in North and South American CEMENT Conference 2005 exhibition area.
17.00-19.00 Mexican Fiesta Farewell Party - NOT TO BE MISSED! It’s
Please Note: The organiser reserves the right to rearrange or reschedule the programme
not all hard work...take
the vacation you’ve been
promising yourself
Hilton Cancun Before it’s too late!
Sumptuous luxury, superlative hospitality, championship golf and much more at Cancun’s world-class,
oceanfront resort. In this storied playground of ancient Mayan royalty, the Hilton Cancun Beach & Golf Resort is
a true tropical paradise, nestled on 150 acres of park-like natural beauty.

World class restaurants, championship-class golf, the amazing main pool, acres of clean sandy beaches,
swimming, snorkeling, scuba diving and jet skiing - the Hilton Cancun is a recreational dream come true!

Spouse Tour Programme

Wednesday 7 September, morning: Jungle tour - by speedboat! Including the
opportunity to snorkle with the colourful tropical fish in the quiet turquoise
waters of a Caribbean lagoon. Evening: Welcome Party.
Thursday 8 September, morning: Cancun city tour (and shopping
opportunites!) Includes a short visit to the fascinating Museum of Mayan
Civilisation. Evening: Mayan Gala Dinner.
Friday 9 September, full-day: Isla Mujeres ‘Island of Women:’ A short cruise
from Cancun, the tour includes a variety of activities - shopping, snorkeling,
glass-bottom boat tour, or just working on your tan! Evening: Farewell Party!

Sometimes, hard work doesn’t have to be so hard!

 Heavywei
ght
days... N&S
A
Industry
Sp e n d 2 merican
m
A V E W EEKS! CEMENT
Sponsorsh
ip
...S to be confi
rmed!
Conference & Exhibition
The following have already expressed their interest in registering for
the 4th North & South American CEMENT Conference, Cancun Mexico:
up to 200 delegates expected to attend!
3L&T Inc. Linas Mazeika ABB Max Berner Advanced Wear Systems Marty DiClemente Aecometric Mike Fenton Albany
International Gustavo Rosales Albany International Javier Martinez Alstom Power Inc. Richard Grzelak AMEC Engineering
Thomas Dodson Aumund USA Thomas Cedorge Bachmann Dampjoint Frank Logeat Beumer Corp. Henning Von Der Wroge
Beumer Corp. Frank Boate Beumer Corp. Elko Hoettges Bulk Materials International Co. CEMAG Anlagenbau Peggy Rennick
Cemento Andino Jaime Viloria Christian Pfieffer Xavier Riera Cimentec Nathan Schachter Claisse Marcel Dessureault Claudius
Peters Luis Chavarro Claudius Peters Mike Barron Control Ambiental Marco Ramirez Control Ambiental Daniela Gonzalez
Dustmaster Scott Adama Ecochem Edul Chikhliwala Energy One P.R. Talluri Engineering Data Greg Galbraith Engineering
Data James Moore Envirocare Magnus Rundquist Environmental Quality Management Ronald Hawkes FCT International Tony
Bubb FCT, Inc. Sanjiv Dhanjal Flowcare Engineering Vern Martin FLS Automation Hassan Yazdi FLSmidth John Salmento
FLSmidth Robert Shenk FLSmidth Christopher Sweeney Fuchs Lubritech Klaus Holz Fuchs Lubritech Renko Balders Fuchs
Lubritech David Brealey G & R Plant Maintenance John Housh G & R Plant Maintenance Bill Sanford GCC Rio Grande Cement
Ltd Francisco Ortega Lopez GCC Rio Grande Cement Ltd Luis Lardizabal GCC Rio Grande Cement Ltd Mike Bohl GCC Rio
Grande Cement Ltd Leroy Cockrell Graycor Harvey Cohen Holcim Miguel Olgiun Holcim Erica Lamar Holcim Eric Drennan
Invensys Fayyaz Hussain IPMA Dan Deaver ITECA Anis Haider J Shah Engineering Jay Shah Kiln Flame Systems Sam Cooper
Larox Flowsys Todd Loudin Lehigh Cement Barry Hilchey Lehigh Cement Justin Bucks Loesche Jose Luis Casero Loesche
America Alex Gorosito Magnesita Manfredo Kayser Megadoor Inc. John Zimmerman Nicklas & Partner Andreas Droege Norcast
Castings Inc. Dave Smith PCME Ltd Steve Werrell Penta Engineering Andrew Hollingshead Pillard Max Vaccaro Pneumat
Systems Inc. Greg Nelson Process Solutions Canada Wayne Bullock RAB Inc. Donnie Vaughn SAR Inc. Ed Labarre Scantech
Silvere Compos SOR Inc. Christophe Sailly Spraying Systems Co. Wes Bartell Sympatec Stefan Steigerwald The KCP Ltd Prasad
Doddapaneni Thorwesten Vent Vincent Grosskopf TXI David Perkins Unifield Engineering Jim Stevenson Welding Alloys Marc
Landragin WTW Americas Jürgen Bäumer

4th North & South American CEMENT Exhibition

N&S American Cement Exhibtion will run concurrently with the cement conference, and will be held directly
adjacent to the conference hall. A number of events will take place in the exhibition area, and all coffee breaks will
take place in the exhibition area. The exhibition area is open during the meeting,
so that the possibility of meeting contacts is maximised.
All confirmed exhibitors will receive 100 complementary invitations, to distribute to favoured cement producer
contacts: using the invitation, the cement producer can register for a substantial discount.
Note: there are a maximum of 31 exhibition stands.

The following 52 companies have already expressed their interest in exhibiting at the
4th North & South American CEMENT Exhibiion, September 2005, Cancun Mexico.
3L&T Inc. ABB Advanced Wear Systems Aecometric Albany International Alstom Power Inc. Aumund USA Bachmann Dampjoint
Beumer Corp. CEMAG Anlagenbau Cemento Andino Christian Pfeiffer Cimentec Claisse Claudius Peters Control Ambiental
Dustmaster Ecochem Engineering Data Envirocare Environmental Quality Management FCT International FCT, Inc. FLS
Automation FLSmidth Fuchs Lubritech G & R Plant Maintenance GCC Rio Grande Cement Ltd Graycor Holcim Invensys IPMA
ITECA J Shah Engineering Kiln Flame Systems Larox Flowsys Lehigh Cement Loesche America Magnesita Megadoor Inc. Nicklas
& Partner Norcast Castings Inc. Penta Engineering Pillard Pneumat Systems Inc. Process Solutions Canada SOR Inc. Spraying
Systems Co. Sympatec The KCP Ltd Thorwesten Vent TXI Unifield Engineering Welding Alloys WTW Americas
For further information about exhibiting, see the conference web site, or contact Paul Brown, at pgbrown@propubs.com

Call for papers

The conference will concentrate on technical developments and case studies in the cement industry in the
Americas. Priority will be given to papers concerned with production problems and their solution.
The conference organisers are interested to hear from companies or individuals who are interested in present-
ing a first class paper at the N&S American Cement Conference 2005.
Conference delegate fees will be reduced to US$500 for one presenter per paper.
All presentations will be 25 minutes in length, with an additional 5 minutes at the end of each presentation for
questions and discussions. All presenters should use PowerPoint software. All presenters must provide a
written version of their presentation and their powerpoint file for the conference proceedings by 1 August.
In the first instance, all prospective presenters should contact the conference convenor, Dr Robert McCaffrey,
with a presentation title and author name, as soon as possible.
Fax (+44) 1372 743838, email ns2005@propubs.com
See us at th e Thank you for your efforts....
The event you’ve
IEEE-IAS/PCA See you in Cancun! been waiting for...
in Kansas City, You won’t regret it!
booth #15!
 4th North & South American CEMENT Conference
Registration form: Part 1 GCL May 05
Fill in your details, and fax to (+44) 1372 743838
or mail to ‘PRo Publications International Ltd’, to Elise House, 6b East Street, Epsom, Surrey, KT17 1HH, UK.
Delegates must book their own accommodation (See Part 2).
__________________________________________________________________________________________________________________________________________________

Given name ___________________________________________ Family name ___________________________________________

Position ____________________________________ Company___________________________________________________________
Address__________________________________________________________________________________________________________
________________________________________________ Zip/post code __________________ Country_______________________
Phone ____________________________________________________ Fax _________________________________________________
Email (required for acknowledgment and eGCL)____________________________________________________________________
__________________________________________________________________________________________________________________________________________________

Conference registration fees:

The conference fee includes attendance at the North and South American CEMENT conference and exhibition,
conference proceedings on CD, conference and exhibition handbook, conference briefcase, lunches, cocktail
receptions and gala dinner.
Cement/lime/gypsum producers: US$425 for payment before 1 June 2005, US$500 after 1 June 2005
Non-cement/lime/gypsum producers: US$750 for payment before 1 June 2005, US$850 after 1 June 2005
Conference registration fee discounts:
10% discount for 3rd and subsequent delegates from the same company.
10% discount if you have been an attendee at any previous North and South American CEMENT Conference
(2000 Puerto Rico, 2002 Miami, 2004 Miami)
10% discount for delegates younger than 35 years or older than 65 years.
10% discount for delegates affiliated to universities.
I am a participant in the global cement and lime industry and I would like to receive
free electronic copies of eGCL Magazine every month (email address required - see above).
Confirmed speaker: US$500 (no-further discounts) (fee waived for cement producer presenters).
Participation in Golf game, including golf cart hire, green fees, drinks, tax, valet and lunch: US$165.
Full spouse programme (including tours on Wednesday, Thursday and Friday, and the Gala Dinner) FREE!
(Name of accompanying person: Mr/Mrs Given name _________________Family name __________________________)
__________________________________________________________________________________________________________________________________________________

Total due US$__________ (Please show calculations here:)

__________________________________________________________________________________________________________________________________________________

Conference Payment
A cheque is enclosed (made payable to PRo Publications International Ltd)
Payment has been made to PRo Publications International Ltd, NatWest Bank, High Street, Dorking, Surrey, UK,
Sort code 60-07-02, Account No. 31604412 (Swift Code NWBKGB2L). If you are paying by bank transfer, please
attach a copy of the transfer document. Please note that you must pay all bank charges.
Credit card number _________ _________ _________ _________ Expiry date (mm/yy): _________
Security code (last three numbers on signature strip) _________ Card type (Visa/Amex etc) __________________
__________________________________________________________________________________________________________________________________________________

Part 2: Accommodation
Full details of the Hilton Cancun Beach and Golf Resort are available on the conference web site.
Hilton Cancun Beach and Golf Resort: Boulevard Kukulcan, Km.17, Cancun, Quintana Roo, Mexico 77500,
Tel +52-998-881-8000. Standard room in this five-star hotel is just US$123/night single, US$137/night double.
You are required to book and pay for your own accommodation direct with the hotel.
PLEASE USE THE CONFERENCE WEB SITE (WWW.AMERICANCEMENT.COM) TO BOOK YOUR HOTEL ACCOMMODATION - IT’S SO EASY!
 N E W S
Florida Rock sees booming East Coast markets
U S Florida Rock Industries, Inc. has announced record
net income of US$35.14m for the second quarter of
fiscal year 2005 versus $24.5m for the same quarter of fis-
cal year 2004. This year’s second quarter included $2.6m
of after tax gain from the sale of the largest portion of an
abandoned quarry property near Baltimore, Maryland.
The proceeds from the sale of the closed Greenspring
quarry were reinvested in additional land with potential
aggregate reserves near Naples, Florida, using an interme-
diary to effect a tax-deferred exchange.
Consolidated total sales for the quarter increased 14%
to $260m from $228m in the same quarter in 2004, driven
principally by improved pricing. While product volumes
were decreased in aggregates (5.2%) and ready-mix con-
crete (1.4%), they increased in cement (1.8%) and concrete
block (12.8%). Selling, general and administrative expens-
es for the second quarter of fiscal year 2005 of $25.9m
Votorantim invests in distribution
B RAZIL Brazil’s industrial group Votorantim’s cement
production arm, Votorantim Cimentos, has invested
US$1.8m in a distribution centre in Salvador, in the
northeastern state of Bahia. The centre, which will dis-
tribute Votorantim’s production to 700 points-of-sale in
the state of Bahia, is expected to lead to an improvement
of the company’s results by between 20% and 25%.
Votorantim Cimentos registered sales of US$1.882bn
in 2004. According to the company’s commercial direc-
tor, Marcelo Chama, Bahia is Votorantim Cementos’
fifth largest market in the country. The state’s cement
consumption is estimated at 150,000 tonnes per month
and Votorantim holds a 60% market share. Votorantim
Cimentos, founded in 1936, is based in the southeastern
state of Sao Paulo. In Brazil the company is leader in the
production of cement, hydrated lime and concrete. The
company operates 25 plants in Brazil and in other Latin
American countries.
Visit us at the IEEE Conference Kansas City - Booth 107
ACRO Products is a line of industrial coating materials manufactured
by Vickers Industrial Coatings, Inc., and distributed by
Vickers-ACRO Distributing, Inc.
ACRO Products has grown from a specialty manufacturer of water/
wastewater and Army corps of Engineers spec materials to providing
a full line of dependable industrial coatings for a wide variety
of markets and uses.
These services and high-performance coating formulations are
available from
Vickers-ACRO Distributing, Inc.
16531 Shady Lane, Channelview, Texas 77530
Phone: 281-452-5040 / 800-392-5459 - FAX: 281-452-9010
e-mail: sales@vickers-acro.com Web: WWW.VICKERS-ACRO.COM
Vickers is a family-owned business,
incorporated in the state of Texas in 1974.
FAMILY PRIDE SINCE 1974
May 2005
were 10.0% of sales, up from 2004’s $21.9m, principally
due to increases in incentive compensation and profit
sharing which are tied to earnings growth exclusive of
real estate gains.
Commenting on the results, President and CEO John
Baker stated that: “Our second quarter results ben-
efited from continuing strong demand in our Florida and
Washington, D.C. area markets. Despite some unsched-
uled maintenance challenges at our Newberry facility,
our cement team still managed to increase shipments
slightly through adept coordination of shipments through
our import facilities in Tampa and Port Manatee. With
substantial operating profit improvement in all three seg-
ments, our employees deserve real credit for their demon-
strated commitment to continuous improvement.”
“The strong product demand levels experienced in most
of our markets during our first two quarters appears likely
to stay strong through the third quarter. Mid-summer
pricing improvements appear feasible at levels that should
overcome, if not exceed, the higher operating costs attrib-
utable to rising energy and commodity prices.”
600 workers to join TXI’s project
U S Texas Industries, Inc. plans to add at least 600
temporary workers as part of a $350-million expan-
sion and modernization of its Oro Grande cement plant
in California. The additional workforce will remain during
the two or three-year construction project, said Frank
Sheets, communications and government affairs manager
for TXI in California. But once the modernisation and
expansion are completed, Sheets added, there will be an
expected reduction in the approximately 300 employees
who work at the Oro Grande facility today. Mel Brekhus,
the company’s chief executive officer, said the changes to
the plant will allow it to increase its capacity dramatically
and make the company more competitive in California
- the US’s largest cement market. Currently, the plant
manufactures 1.2Mt each year, Sheets said, and will
expand to 2.3Mt a year after construction.
New boss at Venezuela’s ‘local’ plant
V ENEZUELA Venezuelan cement maker Cementos
Catatumbo has a new chairman and board for
the period 2005-2008 after shareholders approved the
appointments. New chairman Esteban Pineda Hernández
(42), an economist and graduate of Duquesne University,
Pennsylvania, has been working in the construction
and the cement industry since 1985. Zulia state-based
Catatumbo produces 750,000t/y for local consump-
tion and export from its plant in Villa del Rosario. It is
Venezuela’s only locally owned cement maker.
48 GCL: N&S American CEMENT
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 N E W S
Lehigh hits sludge slick
U S Lehigh Cement Co. in Union Bridge, Pennsylvania,
has sought permission from local Carroll County offi-
cials to build a 130-foot silo to store dried sewage sludge,
called biosolids, that the company plans to use as an alter-
native fuel source to fire its kiln. Union Bridge wants to
be the first company in the United States to burn human
sewage sludge as fuel. However, the Carroll County zon-
ing administrator has said that the county code prohibits
the storage of sewage sludge in all zoning districts except
public wastewater treatment plants. Zoning Administrator
Neil Ridgely said the plant could build the silo but that
Lehigh could not fill it with pelletized sludge.
Commissioners Gouge and Minnich both withheld their
support for Lehigh’s desire to store and burn biosolids for
fuel in their cement kiln. Their reticence was less about
matters of law than it was about concern for the public’s
health. Commissioner Minnich said: “I am not ready to
open the doors to this kind of fuel until I know it is safe.“
Lehigh Cement may now submit an appeal to the Board
of Zoning Appeals or petition the county to amend the zon-
ing ordinance to allow Lehigh to store biosolids in its silo
to burn in its cement kiln.
Loma Negra goes to Camargo Corrêa
B RAZIL/ARGENTINA Brazilian holding company Camargo
Corrêa’s, a construction company which is Brazil’s
fifth-biggest cement maker, has signed an agreement with
Grupo Fortabat, which controls Argentina’s Loma Negra.
Camargo will purchase Holdtotal, the holding company
that controls Loma Negra, for US$1.03bn. The deal could
be closed by the end of May, following approval from
Argentina’s antitrust commission. Loma Negra has nine
plants and employs almost 1900 people, and produces
more than 3Mt/year of cement. Included in the deal are
Loma Negra, other cement related business including
Cementos del Plata and the cargo railway Ferrosur Roca.
These assets are estimated at US$825m, plus US$200m
in net debts, thus the deal is worth around US$1025mil,
lower than the initial price asked by Fortabat.
Loma Negra is the main asset involved in the deal, with
sales of US$252m in 2004 and a 48% share and the major
player in Argentinean the cement market. Since the 2002
Argentine crisis, the cement industry has been running
at 40% of the 16Mt installed capacity, but prospects for a
recovery are good. The deal is the biggest foreign invest-
ment in Argentina since the economic crisis. The other
major player in the market is Juan Minetti, controlled
by Holcim, with a 34% share; Cementos Avellaneda from
Lafarge with 14%; and Petroquimica Rivadavia with 4%.
Amalia Lacroze de Fortabat, head of Fortabat group and
the widow of the company’s founder, Alfredo Fortabat, is
to keep 13 farms totalling 150,000 hectares.
May 2005 50
Holcim grilled over slag
U S A Montana state agency has announced a new
delay in responding to a cement company’s plan
to burn old tyres as kiln fuel. Release of a draft envi-
ronmental impact statement on the proposal by Holcim
Inc., which makes cement near Three Forks, Montana,
has been postponed, the Montana Department of
Environmental Quality (DEQ) said. The agency previ-
ously anticipated releasing the document this spring,
but had not given a specific date.
The duration of the delay depends on findings in
an analysis of substances Holcim already burns in
the manufacture of cement, including slag from the
defunct Asarco Inc. lead smelter in East Helena, DEQ
said. The slag is the residue from smelting. It would be
irresponsible to release the draft environmental impact
statement before “we have a good feeling about what is
presently going into the plant and what is coming out,”
said Richard Opper, DEQ’s director. “At this time, I’m
not comfortable that we have that information.”
Holcim has proposed using tyres as fuel for up to 15%
of the heat its kiln requires. The tyre fuel would supple-
ment use of coal, petroleum coke and natural gas. It
has been just over two years since Holcim applied for
a permit to burn tyres, something the company said
would cut costs and get rid of tyres that otherwise pres-
ent disposal problems. Holcim says cement plants the
world over burn tyres without harming the environment,
but Montana critics fear burning them would threaten
the environment and human health in the Three Forks
area, plus make Montana a regional dump for tyres from
other states.
In response to Holcim’s application, DEQ issued a
draft permit and a draft environmental assessment. The
agency then stepped up its analysis by preparing a final
assessment and starting work on the environmental
impact statement.
Early this month, some local legislators and two envi-
ronmental groups asked Montana’s state administra-
tion to order that Holcim stop burning the Asarco slag.
Holcim lacked the necessary air-quality permit, said the
legislators and two groups, Montanans Against Toxic
Burning and the Montana Environmental Information
Center. They said the slag is laced with toxic metals and
the burning could pose a health risk.
At the time, DEQ said its chief attorney was likely to
release within a week an opinion on whether the burn-
ing makes the Holcim plant an incinerator in need of a
permit. Federal law does not classify the slag as hazard-
ous waste. However, the DEQ has now said that release
of the legal opinion is unlikely before late May, because
the slag must first be analysed and DEQ must study the
results.
GCL: N&S American CEMENT
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 Contents Subscribe Ad index
N &S American
CEMENT
CASE STUDY - SUGAR CREEK

SUGAR CREEK: DOWN BY THE BIG MUDDY

A TOUR OF LAFARGE’S NEW SUGAR CREEK CEMENT PLANT

BY ROBERT MCCAFFREY

Lafarge’s Sugar Creek cement plant is unusual in a number of respects. For

example, it has one of the few underground limestone mines in the US, even
though this is no historical relict: the mine is brand new. The plant is on
the outskirts of Kansas City, and will be visited by this year’s IEEE-IAS/PCA
cement conference field trip.

Main Picture: The entrance to the plant offers

a dramatic view of silos and preheater tower.
Below: The winding gear over the main prod-
uct shaft, where skips disgorge limestone for
conveying to the limestone storage A-frame.
Opposite: The plant’s well-proportioned cen-
tral control room.
Opposite above: Badge-bedecked miner in
Sugar Creek’s limestone mine.

May 2005 52 GCL: N&S AMERICAN CEMENT

GLOBAL CEMENT AND LIME MAGAZINE SUGAR CREEK: DOWN BY BIG MUDDY

May 2005 53 GCL: N&S AMERICAN CEMENT

GLOBAL CEMENT AND LIME MAGAZINE SUGAR CREEK: DOWN BY BIG MUDDY

G
CL recently took the oppor-
tunity to tour Lafarge’s new
cement plant at Sugar Creek,
Missouri, which is one of the three
plants which will be visited by the
IEEE-IAS/PCA cement plant confer-
ence in May 2005. The plant property
is situated on a bluff overlooking a
bend of the wide Missouri river- Big
Muddy - which some locals say is
‘just too thick to drink and just too
thin to plough.’ Sugar Creek is locat-
ed within the greater Kansas City,
Missouri metropolitan area.
GCL was hosted by Bill Mason,
Plant Manager, Rick Toedtman,
New Works Manager, Terry Dengler,
Human Resources Manager, and
Mike Marksberry, Mine Manager.
completely rebuilt, with two new kiln ect. The new plant is located in the
lines, new raw and finish mills and former surface quarry. The location
additional cement storage. In the takes advantage of its close proxim-
1960s, the underground mining of ity to Missouri Highway 291.
the Bethany Falls limestone ceased, In 2001 the kilns at the River facil-
and surface quarrying of limestone ity were shut down, although three
began again. finish mills, cement storage, truck,
In 1991, Lafarge acquired the and barge loadout facilities at the old
Sugar Creek plant from Missouri site are still in use today.
Portland Cement Company, and
quickly saw the potential for a new New Sugar Creek project
facility on the site. In 1998, Lafarge The plant consists of an under-
broke ground for the new plant proj- ground limestone mine, limestone
Below: Nordberg winding gear for the underground limestone mine at
Lafarge’s Sugar Creek cement plant.

History
The original ‘River’ plant was built
in 1907 by the Kansas City Portland
Cement Company between the bluff
and the river, using the Iola lime-
stone from the crest of the bluff as
the original raw material. In 1938,
the ‘Old Silos’ at the old plant were
built, and underground mining of the
Bethany Falls limestone commenced.
In the 1950s, the River facility was

Below: Mike Marksberry, mine manager,

with the limestone storage A-frame and
cement plant in the background.

May 2005 54 GCL: N&S AMERICAN CEMENT

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storage, raw material and fuel receiv-
ing and storage, raw mill, preheater/
precalciner pyroprocess, finish mill,
cement storage and bulk shipping.
Terry Dengler started off by giving
some background to the start of the
construction of the new plant, and
of the huge amount of work that is
needed in advance of such an impor-
tant construction project. “Before we
stuck a single spade in the ground,”
started Terry Dengler, “Lafarge had
to acquire appropriate environmental
Below: Conveyors and gate apparatus for feeding of tyres at Sugar Creek.
May 2005
and local permits. This was followed
by the successful negotiation of a new
contract with our union workforce.
Once the new contract was in place,
we began to plan and implement
training. During plant construction
we had a phased start-up, which
began with the opening of our under-
ground mine.”
Workforce issues
Rick Toedtman went on to explain
about the plant’s staffing policy: “One
56
SUGAR CREEK: DOWN BY BIG MUDDY
of the unusual things we do here is
the extent to which we use salaried
employees in the plant. In most
plants, the hourly-paid workforce
operates the control room, hourly
workforce operates the laboratory,
and hourly workforce handles sys-
tems and instrumentation. At this
plant those are all staff jobs. The con-
trol room is run by a process control
supervisor: we have two per shift, one
in the plant running the control room
and one out in the field and they are
both trained to be in either place.
Our laboratory is operated with sala-
ried staff, all of whom have either
technology or engineering degrees.
On the systems side, our instrumen-
tation systems people have degrees,
either in electrical engineering or in
electronics technology. Jobs that at
other plants are traditionally hourly-
paid are all staff jobs here.”
Unique mine facility
The former surface quarry had limited
remaining limestone reserves. Lafarge
decided to develop a new source of
limestone, which was identified 700
feet below the former quarry. This is
the St. Louis limestone formation.
The mine was developed by sinking
Below: Terry Dengler beside the
Polysius two-pier rotary kiln.
GCL: N&S AMERICAN CEMENT
GLOBAL CEMENT AND LIME MAGAZINE
two vertical shafts; one for produc-
tion and one for men and material.
Limestone is mined using common
drilling and blasting techniques. The
formation is thick enough in part of
the mine to take up to 55 feet in two
benches. The miners leave behind
50 x 50 foot pillars to support the
ceilings, and a comprehensive roof
bolting program is in place to further
support the mine roof.
The mine was fully operational in
the Autumn of 2000; the initial rock
was used in the River plant before
the old kilns were shut down.
Phase two
Systems were put in place in the fall
of 2001 to control the remaining fin-
ish mills at the River facility at the
new central control room at the new
plant. The River facility kilns were
shut down in November 2001. At the
same time, the new plant finish mill
was commissioned.
The new finish ball mill is driven
by a 4000hp motor, and has a capac-
ity of 73t/hour. This mill can grind
approximately 60% of the clinker
produced at the new pyro-line. The
remainder is trucked to the River
facility to be ground there. A ball
mill was chosen due to the relatively
inexpensive electrical power available
to the plant.
After starting up the new finish
mill, the rest of the new plant was
commissioned including a Gamma
Metrics on-line analyser, the raw
material handling facility, the raw
meal vertical roller mill, and finally
the kiln system. The fast response
of the Gamma Metrics analyser, in
particular, has been a great success
at the plant, allowing plant personnel
to see the forecast chemistry coming
through in the produced clinker.
Rick Toedtman described the
startup further: “There was a three
month gap when we did not have
kilns running in either the old or
the new plants, but we had enough
clinker either from the old plant or
purchased so that we could go ahead
and produce cement all through
that period. The first clinker was
produced by the new pyro-line on
March 21, 2002 and the quality was
excellent from the very beginning. We
May 2005
put the first-produced clinker in little
acrylic blocks - which we give away to
visitors to this day - and even on that
first day the clinker looked beauti-
ful.” GCL notes that it perhaps it is
only cement industry professionals
who can describe clinker as ‘beauti-
ful (although the clinker in question
was indeed small, sweet and perfectly
formed).
Rick Toedtman added further,
“Within the first couple of weeks of
operating we had hit our production
reliability targets. We had said that
it would be six months before we
were able to produce a certain level
of product, but we hit that level by
the end of the first month. The plant
came on line very well.”
“We did a lot of preparation, and
a lot of training. Plant management
compiled notebooks which were 5-
6 inches thick for each shop which
included checkout requirements,
training, safety protocols, fire protec-
tion, environmental requirements,
everything. Those notebooks were
the ‘Bibles’ for each shop. There was
a team of people to work for each
department leader to prepare the
shop for startup and it really worked
well. We had champions for each
department as it started up.”
Terry Dengler interjected, “I think
- more than anything - this probably
attributed to a great start up. I think
also too we had our people trained
Below: One of Martin Engineering’s Big
Blaster air cannons in use on the
preheater tower at Sugar Creek.
58
SUGAR CREEK: DOWN BY BIG MUDDY
and out in the field doing inspections
and observations as the plant was
still being finished, and that helped
no end.”
Problems and solutions
As Rick Toedtman says, “In a project
of this size, there will always be a few
‘loose ends.’ We still have a small
problem with cracking around the X
blocks: Under the ring that supports
the kiln shell, there are X blocks
which have a tendency to crack, but
the supplier has been working with
us on the problem during our down-
times. Apart from that, the kiln has
run very well and we have had good
brick performance.”
“The 2000hp vertical roller mill
has displayed some wear on its
tables and rollers, but that is some-
thing that I think everybody finds is
difficult to keep up with. We take the
mill down periodically to do inspec-
tions, and every three months or so
we do a significant build up on the
table. Otherwise the roller mill is run-
ning well.” In 2005, the plant started
to use a ceramic-impregnated roller
table to counter the wear issue.
Terry Dengler reiterated though
that “this plant as a whole is oper-
ating above 98% reliability, and has
since start up, and it is hard to be
critical.”
GCL: N&S AMERICAN CEMENT
 Improved material transport
optimises mill operation

With the 4th generation of mill dia- Advantages:

phragms, Christian Pfeiffer has • enlargement of effective grind-
once again considerably improved ing length by full utilisation of
the material transport between the ball charge close to the dia-
grinding compartments. phragm
• reduced wear of grinding
Constructive details of the balls and at the diaphragm
diaphragm centre assure that plates
material flow during trans- • higher efficiency and high-
port into the next compart- est availability of ball mill
ment is strictly separated
from the air flow. With the 4th generation
diaphragms from Christian
Hence, material discharge Pfeiffer another decisive step
is only effected at the lateral has been made to further opti-
openings of the diaphragm – mise your ball mill – so you
at 9 and 3 o’clock position. should also profit from our latest
innovation results.

HEADQUARTERS GERMANY AUSTRIA ITALY USA SOUTH AMERICA

Christian Pfeiffer
Maschinenfabrik GmbH
Sudhoferweg 110-112
59269 Beckum
Tel. +49 (0) 25 21/8 49-00
Fax +49 (0) 25 21/8 49-123
office@christianpfeiffer.de
www.christianpfeiffer.de
Christian Pfeiffer Christian Pfeiffer American Pfeiffer Corporation Christian Pfeiffer
Maschinenfabrik GmbH Mezzomerico SpA 3407 West Chester Pike Latinoamericana S.A.
Werkstraße 5 Via Marano Ticino 7 Newtown Square, Parque Industrial Liviano
8940 Liezen 28040 Mezzomerico (NO) PA 19073-4227 Av. Brasil Calle # 1
Tel. +43 (0) 3612/270-0 Tel. +39 (03 21) 92 3010 Tel. +1 (610) 35 66 995 Santa Cruz, Bolivia
Fax +43 (0) 3612/270-5 89 Fax +39 (03 21) 92 3141 Fax +1 (610) 35 68 987 Tel. +591 (3) 34 81768
office@cpb.at info@christianpfeiffer.it cpb@americanpfeiffer.com Fax +591 (3) 34 92 597
www.christianpfeiffer.de www.christianpfeiffer.it www.americanpfeiffer.com christianpfeiffer@unete.com
GLOBAL CEMENT AND LIME MAGAZINE
Future projects
Even though the Kansas City site
has just come through a major con-
struction project, the staff at Lafarge
Sugar Creek are focusing on the
future, with a number of significant
projects in the pipeline.
Chlorine bypass
Rick Toedtman continued, “We found
that the chlorine level in the rock
was higher than we anticipated, and
although we did not include a chlo-
rine bypass when we built the plant,
we had made some design provisions
for a chlorine bypass should we need
it. We functioned well without a
bypass for some time, but then even-
tually it caught up with us and we
started to see a lot of chokes in the
tower - particularly at stage 5, wher-
ever the chlorine was precipitating
out. We also wanted to use petcoke
as a fuel, and the higher sulphur in
the petcoke combined with the extra
chlorine would have been unwork-
able.”
“In consequence, we started to
use a combination of the St Louis
limestone and the Bethany Falls
limestone. A couple of our Lafarge
construction materials plants have
operations in the area and they pro-
duce Bethany Falls limestone: we run
at about a 50/50 or 60/40 blend of
St Louis and Bethany Falls limestone
in order to suppress the chlorine
Above: An IST Pyrometer kiln camera
May 2005
levels and continue to run without
choking. Our chlorine bypass should
be operational by the end of the sum-
mer 2005. IEEE-IAS/PCA delegates
will see the project under construc-
tion when they come to visit.”
“Around 10% of the gases are
extracted out of the feed end of the
kiln, and go up into a quenching
chamber where the gases are cooled
quickly so that the chlorine can pre-
cipitate out on to the dust particles.
The gas is then drawn into a bag
house where the dust is collected and
the clean gases from the process are
once again conveyed back over to the
roller mill.” The current design calls
for reintroducing the bypass dust into
the clinker cooler.
Alternative fuels
“We are also doing some testing
with whole scrap tyres as a partial
fuel substitute,” says Rick
Toedtman. “Right now with the
new burner, we are running a
mix of around 60% coal and
40% coke. We are new to this
because of the changes to the
burner and we are doing some
testing with tyres. We don’t
know if that is going to be suc-
cessful, since it’s really very
early in the testing stage. At
the moment the tyres are going
in to the riser duct right above
the fuel feed inlet in the sus-
in place at Sugar Creek.
60
SUGAR CREEK: DOWN BY BIG MUDDY
pension burner. The tyres are pushed
in on grizzlies: we close the door and
they sit there and burn on the griz-
zly. Then, when they are consumed,
we push another one in and so on. It
will probably morph into a full-blown
system if we are successful.”
“What he has done so far,” adds
Terry Dengler, “is to install a piece of
what would be a capital project. We
have already put in the feed system,
but if the experiment is successful,
there would be the matter of getting
the tyres to the feeder and that’s
where the biggest part of the expense
would come in.”
Terry Dengler continued, “At the
Whitehall plant, we just put in a dou-
ble gate arrangement and our tyres
were rolled in with the feed. We took
the tyres up manually and we put
them on the gate and let them fall in:
we spent a relatively small amount of
Sugar Creek’s main kiln burner.
money, but once we saw that it was
successful, then we put the entire
system in to get the tyres up there
and stage them and automatically
feed them into the system. So that’s
what will come next if the tyre feed-
ing experiment is successful and
if it is economically feasible to go
ahead. We already have permission
from a regulatory standpoint. If we
go ahead, the tyres will come in on
trucks.”
Slag cement project
Rick Toedtman mentioned another
project for the future of the plant:
“In the future we will be adding sil-
ica fume and slag into some of our
cement products. We are consider-
GCL: N&S AMERICAN CEMENT
GLOBAL CEMENT AND LIME MAGAZINE
Flender gearbox in use on
the Vertical Roller Mill for
raw meal.
ing both interground and blended
products. Slag would come from our
East Chicago grinding facility: the
funds for the project have already
been appropriated and the engineer-
ing is underway. Slag will be barged
down from Chicago, off-loaded at our
Kansas City terminal facility and
then trucked over here. It will then
be blown up into a 200t bin to be
blended with the type I/II product
using state-of-the-art feeders and
blenders, before being loaded back
onto the truck and being shipped off
to the market. It is a market driven
development.”
Safety
Safety is of the greatest importance
at the plant. The plant recently cel-
ebrated four years without a lost time
accident in July 2004, and is close to
a million man-hours without a lost
time accident. The plant’s goal in
2004 was to have a normalised medi-
cal incident rate of less than 10, and
the plant achieved 5.7. Tick!
Markets
Bill Mason outlined the plant’s
markets for its Type I/II and Type
III cements: “Around 60% of our
production, 550-600,000t, is used
locally, with the rest being shipped
longer distances. We ship to termi-
nals in Omaha, Nebraska, West Des
Moines, Iowa, Springfield, Missouri,
and Minneapolis, Minnesota. We can
ship to Minneapolis either by barge
May 2005
SUGAR CREEK: DOWN BY BIG MUDDY
or rail; it depends on whether the
Missouri river shipping season is
open or not. Our main competitors
in the Kansas City market would
be the cement plants in southeast
Kansas and south of Omaha.”
Terry Dengler detailed the plant’s
shipping operations: “The plant is
designed to dispatch everything by
bulk truck, since we do not produce
bagged cement here at all. In 2004
we shipped about 140,000 tons by
barge, but in 2005 that volume will
probably be shipped out by rail.”
“Our increased production capac-
ity has been absorbed pretty well
in our primary market of Kansas
City, with perhaps the exception
of the 100,000t that is going up to
Des Moines. The intent was to grow
the market as we were building
the plant, and to grow the market
by virtue of having other plants in
the network feed the Kansas City
area. Once this plant came on line,
then we would begin to be able to
satisfy those needs using local pro-
duction.”
Rick Toedtman concluded:
“Marketing and Distribution did a
really good job in terms of building
the market to a point where we were
ready to satisfy demand if it was
there. They prepared the customers
for our product, and it is a product
which they like very much.” GCL
Automated Ingredient Systems has
supplied automation for coal dosing. GCL thanks Lafarge for co-operation
during the creation of this article.
The Hazemag primary crusher at the bottom of
the limestone mine kicks up a lot of dust!
Here a conveyor leads away from the crusher,
up to the skips which are hoisted to the surface
by the Nordberg winding gears.
61 GCL: N&S AMERICAN CEMENT
 Lafarge’s new Sugar Creek cement plant: Key Suppliers
Krupp Polysius (raw mill to Kiln
Process design
cement mill)
Length: 50m
Impact hammer mill
Diameter: 4.2m
Single-impact crusher with
Type: Power: 450hp VFD drive
blowbars
Speed: < 4 RPM
Supplier: Hazemag
Clinker cooler
Design capacity: 480t/hour
Supplier: Krupp Polysius
Power: 700 hp
Model: RS-2423-2F
Online analyser
Undergrate air: 2m3/kg clinker
Supplier: Gamma Metrics
Clinker temperature
Raw mill
- Inlet: 1400°C
Type: Vertical roller mill
- Outlet: < 60°C above ambient
Supplier: Krupp Polysius
Grate sections
Model: RM41/20/315
- Inlet: Static
Power: 2000hp
- No. upstream roll crusher: 4
Table diameter: 4.1m
- No. downstream 2
Roll diameter: 2.15m
Roll Crusher: 4 rolls, hydraulically driven
Separator: Caged rotor
Clinker cooler vent dedust
Design capacity: 175t/hour
Baghouse: Mikropul
Product: 85% <75mm
- Type: Polyester bags, HP air cleaned
Kiln/raw mill baghouse
Air-to-air heat exchanger: Amerex
Type: Low-pressure pulse baghouse
- Outlet temperature: < 135°C (all cases)
Supplier: Solios
Refractory
Bag length: 7m
Manufacturer: National Refractory
Air-to-cloth ratio: <1m/min
Installer: Reintjes
Process fans
Solid-fuel grinding mill
Supplier: ABB
Supplier: Williams
Blending silo
Model: DF 69 Pendulum Roller Mill
Supplier: Krupp Polysius
Power: 450hp VFD Drive
Tangential Blending silo with
Type: inverted cone and mixing Fuel: Coal, coke or combined
chamber
Product:
Capacity: 2640t
Coal: 88% <75mm
Blending efficiency: 10 to 1
Coke: 91% <75mm
Diameter/height: 2m/21.3 m
Solid fuel weighing and
Blowers make: Aerzen feeding equipment
Kiln feed/airlift Supplier: Pfister
Supplier: Krupp Polysius Cement mill circuit
Model: Poldos SR Airlift Ball mill:
Design capacity: 210t/hour Type: 2 compartment ball mill
Blowers make: Aerzen Supplier: Krupp Polysius
Pyroprocess Motor capacity: 4000hp
Design capacity: 2574t/day clinker Diameter: 4.2m
Spec. fuel design cons.: 719kCal/kg-clinker Length: 12.75m
Preheater/precalciner Separator:
Low NOX, Multistage com- Caged rotor high-efficiency
Type:
Type: bustion with combustion separator
chamber and preheater
Supplier: Krupp Polysius
Supplier: Krupp Polysius
Model: SEPOL NSV 215 / 0
Dopol 1536/1717161517/
Model: Power: 150hp VFD drive
MSC-CC
Electrical and controls
Preheater: 5 stage, single string
Switchgear, MCCs: Square D
Tertiary air duct: 1770/1940mm dia.
Motors: Toshiba
PLCs: Modicon
 Contents Subscribe
IEEE-IAS/PCA EXHIBITION 2005
Not only does the IEEE-IAS/PCA stage the world’s largest cement conference, but it also
stages the world’s largest cement equipment and services exhibition. Here we detail the
offerings of selected companies which will be present in Kansas City, 15-20 May 2005.
1 - Sabia, Inc.
Founded in May of 2000, SABIA, Inc.
has quickly established itself as a
leader in easy-to-install, high-perfor-
mance nuclear elemental analyzers
for cement, coal and minerals. SABIA
also provides nuclear analyzer ser-
vices such as source replenishment,
leak tests, maintenance contracts,
and nuclear gauge services. Visit us
at www.sabiainc.com.
2 - C-Tec
C-Tec specializes in repairing con-
crete storage silos and other confined
space concrete reinforced steel liners,
hoppers, explosion, fall-outs, apply-
ing roof coatings, and positive drain-
age concrete for roof decals. C-Tec
is MSHA trained, fully insured, and
travels nationwide.
3 - Metco Environmental
Metco Environmental is the largest
company in the U.S. specializing in
Source Emissions Testing. With over
a quarter of a century in the busi-
ness, METCO has provided industry
with Quality Data to demonstrate
compliance with Federal and State
air emission regulations as well
as source testing for engineering
requirements. METCO has extensive
experience with the cement industry
regulations and regulatory require-
ments. METCO specializes in Trial
Burns/Risk Burns and other source
sampling projects for cement kilns,
hazardous waste incinerators and
BIF units, municipal waste and
medical waste incinerators. METCO
provides expertise in Trial Burn Plan
and QAPP preparation and assis-
tance in project development.
4 - Petron Corporation
Petron Corporation supplies high
performance lubricants to the cement
May 2005
Ad index
N &S American
CEMENT
IEEE-IAS/PCA EXHIBITION
and mining industries. Petron Gear through continuous improvement in
Shield lubricates the open gearing manufacturing processes, raw mate-
of mills and kilns in 50 plus cement rial acquisition, and technically com-
plants throughout North America. petent field services.
Our lubricants are also used in over
40 countries throughout the world. 11 - KEITH Mfg. Co.
Petron Gear Shield is widely accepted Keith Walking Floor metering sys-
as the most cost effective open gear tems conveniently store and meter
lubricant available. It has earned tyres to the kiln. The speed can be
extensive OEM endorsement and regulated making Walking Floor
enjoys the best FZG wear test results metering systems ideal for automat-
of all participating products. ing the fuel feed process. Systems
also conveniently store shredded,
6 - Fox Valve chipped or whole tyres until they are
Fox offers highly-reliable pneumatic needed.
conveying of CKD, cement, kiln
The V-Floor unloading system from Keith.
spill at 1500°F and alternative
fuels using venturi eductors.
With no moving parts, educ-
tors have provided the cement
industry with a low-mainte-
nance alternative to airlocks
and screw pumps since 1980.
Fox blower + eductor systems
are widely used to convey waste
to kilns, such as tyre chips,
shredded carpets, rice husks,
oily rags, paper waste. Max
rate about 20,000 lbs/hr. Max
distance - about 400 ft.
Durable Walking Floor conveyors
8-9 - Midwesco Filter have low power requirements and no
Midwesco Filter Resources, Inc. is additional energy is needed for start-
a world leader in dry filtration and up. The foundation of all Walking
dust collection filters since 1968. Floor systems is a series of hydrauli-
Midwesco Filter has developed and cally powered floor slats, which run
maintains one the largest inventories the length of the bin. As each slat
of dust collector and baghouse filter moves under the load, the material is
bags, cages, accessories, parts, and indexed forward.
cartridge elements in the industry.
Midwesco Filter, along with its 13 - Motofrenos S. A.
subsidiaries; TDC Filter and Nordic Motofrenos S.A., a 25-year old manu-
Air, are committed to provide their facturing and metal-mechanic com-
clients with the most cost effective, pany, produces plates for furnace
highest value products and services seal in the charge as well as in the
available that will enhance their discharge stage. We produce these
baghouse and cartridge systems. plates in Colombia of steels 100%
We bring our clients the best value from Germany, which makes our
64 GCL: N&S AMERICAN CEMENT
GLOBAL CEMENT AND LIME MAGAZINE IEEE-IAS/PCA EXHIBITION 2005

Abresist 60 Larox Flowsys, Inc. 90 prices highly competitive.

A-C Equipment Services 45 Lechler 55 The latest developments of
kiln manufacturing companies in
Aerzen USA Corp 44 Lord Corp 51
Denmark and US offer the customer
Air Control Techniques 18 Megadoor 89 composite plates that are made with
Albany International 61 Metco Environmental 3 3 elements: stainless steel, ceramic
paper and a high carbon steel-like
Alstom Power Inc 82 Midwesco 8/9
plate offering higher durability. These
Ashguard, Inc. 107 Motofrenos 13 plates are used to avoid the infiltra-
Barrier Corp 54 Oldenburg Group, Inc. 42 tion of air which increases the fuel
consumption.
C & C Oil Co. 43 P.J. Wiese & Assoc 81
Cadence Environmental 41 Pavilion Technologies 52 15 - GCL Magazine
Caltex BMH Systems 19 Pennsylvania Crusher 85 Global Cement and Lime Magazine
includes global cement and lime
Canadian Overhead 84 Penta 7
news, technical articles, country
Cement International 81 Petron Corp 4 and plant reports and conference
CMD Gears 20 Pillard 70 previews and reviews. It is the only
Columbia Steel 62 Plattco 38/39
cement magazine available for free
download each month, after regis-
Conservatek Industries 77/78 Pneumatic Conveying 28 tration at www.propubs.com. GCL
Consultants
C-Tec, Inc 2 is the organizing magazine for the
Process Solutions 101 American Cement Conference, to be
Custom Instrumentation 30
Process Solutions Canada 40 held in Cancun in September 2005.
DCL 58
Promecon 49
Digital Control Lab 63 16 - TLT Co-Vent Fans Inc.
RAB, Inc. 36 TLT Co-Vent Fans Inc. (member of the
Durag, Inc. 94/95
Rockwell Automation 56/57 New York Blower Company) designs
DustMaster 29
and fabricates custom engineered fans
Sabia, Inc. 1
Endress & Hauser 64 near Montreal, Quebec, Canada. TLT
Sick 24 Co-Vent provides fans to the complete
Envirocare 100
Siemens Energy & 5 cement plant from the under-grate
F.L. Smidth, Inc. 104/106
Automation cooler ventilation to the preheater
FCT Inc 67 kiln and raw mill fans. Innovations
Solios 83
Fox Valve 6 such as our “Dust Deflectors” provide
SOR 73
extended wear life in highly abrasive
Fru-Con 66
Spraying Systems 76 applications.
GE Automation Systems 22 The quality program is registered
Standard Filter 71
Global Cement and Lime 15 in accordance with ISO 9001-2000
Stedman Machine Company 97
and welding is performed by weld-
Golden Energy Services 23
Sympatec Inc 72 ers in accordance with Canadian
Hagglunds Drives 88 Welding Standards (equivalent to
T.E. Ibberson 46
Hazemag 96 AWS D1.1). TLT CO-VENT also pro-
Temcor 103
vides Finite Element Stress Analysis
Herzog 79
Thermoteknix 74 and shop mechanical run and perfor-
IBAU Hamburg 26/27 mance tests.
TLT Co-Vent 16
IPM Project Management 25
Tramco, Inc 68/69
Inspec 65
17 - Unicast, Inc.
TurboSonic 86 Unicast product lines include divert-
Intersystems 47 er and shut-off valves for pneumatic
Unicast Inc 17
Iris Power Engineering 87 conveying, crusher and clinker ham-
UniField Engineering 91
Iteca 75
mers, drag conveyor chains, kiln
Vezer’s PIC 59 nose ring segments, mill liners and
Keith Manufacturing 11 custom castings. Unicast special-
W. L. Gore 92/93
Kirk & Blum / CECO 48
Wear-Concepts 98/99
izes in the manufacture and supply
Koppern Equipment 80 of replacement parts for the Cement
Welding Alloys 14 Industry and provides an on-site
Laffey 50
Younglove Construction 102 casting design service. They carry

May 2005 65 GCL: N&S AMERICAN CEMENT

GLOBAL CEMENT AND LIME MAGAZINE
a large inventory of diverter
valves and hammers and can
usually deliver custom castings
in less than 10 weeks.
20 - CMD Gears, LLC
CMD Gears LLC is the newly
formed North American
corporation of Compagnie
Engrenages et Reducteurs
Messian-Durand, France, com-
monly known as CMD, a world-
leading manufacturing compa-
ny of ‘Low Speed - High Torque’
power transmission products.
From open gearing to enclosed
drives and coupling, CMD designs,
builds and installs high-performance
drives for the most demanding
cement applications, including mill
drives (central, vertical, integrated,
single and dual side drives) and kiln
drives. Today, more than 100 years of
CMD’s knowledge and experience are
here to help you replace your exist-
ing drives with upgraded output and
under minimum downtime.
22 - GE/TM GE Automation
Systems
TM GE Automation Systems is a joint
venture between General Electric,
Toshiba, and Mitsubishi Electric in
the industrial system drives busi-
ness. The companies came together
starting in 2000, to create an orga-
nization of 2200 people with annual
sales of $2.1B.
TM GE is built upon the combined
and proud heritage of these great
companies. TM GE focuses on the
customer, working to provide supe-
rior products and excellent service,
delivering customer success every
project, every time.
This joint venture has achieved
the economies of scale required in
this market and responded with:
• A new family of low voltage AC sys-
tem drives, the TMdrive-10
• A new family of DC system drives,
the TMdrive-DC
• A new family of Medium Voltage
drives, the Dura-Bilt5i.
23 - Golden Energy Services
Golden Energy Services, Inc. is an
energy management company spe-
cialized in the development and on-
May 2005
C-Tec (Booth 2) specialises in
repairing concrete storage silos
going management of natural gas and
electricity supplies for large energy
users. Golden’s customers include
large multinational companies
throughout the US and Canada.
Golden provides the following ser-
vices:
• Natural gas and electricity supply
development
• Risk management strategy develop-
ment;
• Real-time metering and market pric-
ing monitoring, analysis and opera-
tions management;
• Natural gas pipeline construction
and operation;
• Power generation project develop-
ment.
26 - 27 - IBAU Hamburg
Founded in 1975, the Hamburg-
based engineering company Ibau
Hamburg has been among the top
players and general contractors in the
field of turnkey projects of silo tech-
nology for the cement, lime and gyp-
sum industries as well as for power
plants throughout the world.
The product portfolio ranges from
central cone-, storage-, blending- and
multi-compartment silos, including
those with integrated mixing plants,
to loading systems for tank trucks,
railway wagons and ships, dosing
stations for all types of dust goods,
pneumatic conveying systems with
screw pumps, blow tank conveyors,
dosing feeders and blending systems
for special cements, shore-based
terminals to self-unloading cement
ships and barges, ship unloaders and
floating terminals. The Ibau Hamburg
Product lines are available in the USA
66
IEEE-IAS/PCA EXHIBITION 2005
and Canada through
Haver Filling Systems,
Inc.
28 - Pneumatic
Conveying
Consultants
Pneumatic Conveying
Consultants is a team of
professionals with over
75 years of experience,
offering expert solutions
with proven results.
Our experience is
based on a total under-
standing of all facets of
pneumatic conveying systems from
the theoretical science to the practi-
cal reality of what actually works.
29 - Dustmaster Enviro
Systems
The Dustmaster system conditions
CKD with water for landfill disposal
or blending CKD with other ingredi-
ents for after market use. The unit
can handle high temperatures of
350°F to 500°F plus the exothermic
reaction. The mixer is a batch type
mixer mounted on load cells that
allow for exact mixture repeatability
for each batch. The control system
has a PLC and has 100% manual
override to operate the Dustmaster
system. CKD and water are added
concurrently with the amounts of
each material metered at specific
ratios of each other to control the
reaction and steam generation within
the mixer.
30 - CiSCO
CiSCO custom-builds CEMS in
racks, cabinets or rugged, climate-
controlled, all-weather steel shel-
ters. Environmental and Software
Departments assure meeting permit
requirements and other DAHS needs.
In addition, we offer start-up, certifi-
cation assistance, training and field
services.
CiSCO’s only business is manufac-
turing CEMS/DAHS solutions. Over
20 years, we have built 700+ CEMS
solutions and have a Certification
Success Rate of 99+%, on the first
attempt.
GCL: N&S AMERICAN CEMENT
 Example:
Vertical roller mill systems,
used to grind the raw material
in cement plants, work with a
lower energy consumption than
ball mill systems. Continually
improved wear resistance
means that this mill system can
be used to grind raw materials
which are very abrasive. All
auxiliary equipment, therefore,
also has to be adapted to the
arduous working conditions.

Venti Oelde Result:

Constructional wear protection

Process technology –
measures on volute casing and
inlet box using wear plates re-
present an economical method
of increasing wear resistance
and service life. Impeller back

new solutions for plate and blades are totally or

partially hard-faced with wear-
resistant armouring plates.

the cement, lime Take advantage of our know-

how and request information
about our new systems and
technology in the field of wear-

and gypsum industry protection.

Just fax or e-mail us!

Process gas fans

Process gas
dust collection

Ventilatorenfabrik Oelde GmbH

Process gas
P.O. Box 37 09 cleaning plants
D-59286 Oelde
Phone: + 49 25 22 75 - 0
Fax: + 49 25 22 75 - 2 50 Secondary fuel
info@venti-oelde.de technology
www.venti-oelde.de
Ventilating and
air-conditioning
plants

Optimization
of air-handling
systems
GLOBAL CEMENT AND LIME MAGAZINE
36 - RAB, Inc.
RAB, Inc. was established in
1993 and specializes in refrac-
tory and corrosion-resistant
masonry. The managers of
RAB, Inc. have approximately
140 years of hands-on indus-
trial masonry experience. Our
customer base includes the
cement, lime, paper, chemical,
incinerator, utility and molten
metals industries.
38-39 - Plattco
Corporation
Plattco Corporation invented
the Double Flap Airlock Valve
over 40 years ago to provide the criti-
cal performance that no other valve
could accomplish. We manufacture
high performance flap gate Airlock
and slide gates for use in material
handling systems. Our foundry, pat-
tern shop, machine shop, and expe-
rienced design team give us complete
flexibility when delivering solutions
for custom applications. We stand
behind our product and offer full
after-market field service & genuine
spare parts.
40 - Process Solutions
Canada - Cement
Distribution Solutions
A leading supplier of innovative
software-based solutions to the
cement industry for 20, years,
Process Solutions integrates proven
technologies with its software to
provide systems for distribution of
finished product and bulk load-
ing automation. With more than
200 installations across the United
States, Canada and Mexico, Process
Solutions is a leader in providing
both attended and unattended bulk
loading and logistics solutions to the
cement industry.
42 - Oldenburg Group
Oldenburg Group Incorporated is
a diversified supplier of engineered
solutions, serving the industrial min-
erals, mining, defense and architec-
tural lighting industries. Our product
line for the cement and aggregate
industries include Stamler feeder-
breakers, feeders and sizers; Cannon
rock drills, jumbos and bolters; and
May 2005
IEEE-IAS/PCA EXHIBITION 2005
Environmental provides
unmatched solutions to
cement ventilation proj-
ects.
49 - Promecon
Promecon provides process
instrumentation for mea-
suring coal, air, and high
temperature gas streams
as well as unburned car-
bon-in-ash. On-line air
A two kiosk installation of Process Solutions flow measurement in hot
Canada Limited’s Self-Service Loading system. dusty applications where
it was not possible before.
In cement plants, appli-
Oldenburg scalers, anfo trucks and cations are the raw mill
utility vehicles. These products are discharge to control the ID fan, ter-
designed to optimize production at tiary air flow up to 2000°F, air flow
the lowest cost per ton over the life of through the finish mill to control the
the machines. consistency of the grind, primary air
to control flame shape, and several
43 - C & C Oil Co. others. Rugged sensors for high tem-
For more than 25 years, the innova- perature and abrasion with no pres-
tive team at C&C Oil Company has sure drop, no drift, no calibration,
been developing superior lubrication and no scheduled maintenance.
technology to help our customers
reduce operating costs and energy 51 - Lord Corporation
expense, while protecting their equip- For 80 years, Lord Corporation has
ment investments. Our cornerstone provided innovative products for
product providing the most signifi- the Aerospace, Transportation and
cant impact is our patented Easy Bar Process Industries. These include
rotary kiln lubricant. high performance-formulated prod-
The Easy Bar rotary kiln lubricant ucts for coating, bonding, product
is a proven, cost effective lubricant assembly, performance-designed
designed to increase the life of the components and systems for con-
kiln’s filler bars, stop blocks and rid- trolling vibration, shock, motion and
ing ring. C&C has a full line of high noise.
performance lubricants for the girth Lord Balancing Systems provide a
gear, thrust roller, trunnion bearings unique alternative to the traditional
and drives for rotary kilns and dry- on-site field balancing methods. The
ers. Lord balancing system is able to
detect the unbalance, identify the cor-
48 - CECO Environmental rection capacity required to offset the
Kirk & Blum and CECOaire, both unbalance and automatically make a
units of CECO Environmental, form balance correction while the piece of
a partnership unmatched in provid- rotating equipment is running. Once
ing emission solutions to the cement installed, you do not have to stop the
industry, especially those involving piece of rotating equipment to per-
MACT compliance. Kirk & Blum, one form a balance correction.
of the nation’s largest industrial sheet
metal contractors, fabricates duct- 59 - Vezer’s PIC
work systems and provides turnkey Vezer’s PIC is one of the most expe-
dust collection systems. CECOaire, rienced specialty industrial service
managed by cement veteran Dale providers in North America. Our
Arvin, designs and manufactures primary activities are: new construc-
custom dust collectors. With Kirk tion, shutdown repairs and planning
& Blum’s 8 fabrication facilities and programs, emergency repairs, engi-
70 years of project experience, CECO neering, large gear, pinion, mill head
68 GCL: N&S AMERICAN CEMENT
Manage your process with
real information.
Kiln Reliability (%) 325M, Type I Portland

Blaine, Type III Portland Production – Clinker (*1000 tons)

✔ Automated production and reliability data

✔ Performance, budget & forecast analysis
✔ Quality control and document generation
✔ Online personnel and expense tracking
✔ Seamless integration with external systems
CMS: A web-based portal for
process data management.
Engineering Data Corp. www.ed2c.com
105 Daventry Lane Suite 100 info@ed2c.com
Louisville KY 40223-2879 502-412-4000
USA 888-335-8600
GLOBAL CEMENT AND LIME MAGAZINE
supplier to OEM specifications, turn-
key project capabilities, and ASME
certified.
We operate nationwide. A key goal
in our mission statement is that ‘we’ll
take care of it.’ Our experienced staff
is available 24-hours a day and 7-
days a week.
62 - Columbia Steel
Columbia Steel is a manufacturer of
quality replacement wear parts to the
cement industry worldwide. Its prod-
uct line includes parts for equipment
such as crushers, impactors, ham-
mer mills, roller mills, pulverizers,
preheaters, kilns, clinker coolers,
clinker breakers, grinding mills, min-
ing shovels, drag chain conveyors,
apron feeders, bucket elevators, and
more.
Above: Columbia Steel’s casting of a roller mill tyre for Loesche.
Columbia Steel offers a full range
of alloys. Engineering, patternmak-
ing, casting, machining, heat treating
and inspecting all take place in one
vertically integrated manufacturing
facility in Portland, Oregon U.S.A.
63 - Digital Control Lab
Digital Control Lab is at the forefront
of technology, offering its customers
the revolutionary MillScan DSP2000
for measuring fill-levels in mills.
Unlike present analog technology,
MillScan uses vibration sensors that
sit directly on the mill shell and elim-
inates all traces of crosstalk interfer-
ence. With MillScan, customers are
able to get real-time results and triple
the accuracy of their readings when
compared to traditional instruments.
In turn, they can increase mill effi-
ciency by eliminating mill output
May 2005
spills and lowering production costs
with little maintenance costs.
64 - Endress + Hauser
Endress+Hauser is a global supplier
of process automation solutions. Its
products are excellent in both per-
formance and price; the services are
ground-breaking. Both aid custom-
ers’ competitiveness with a maxi-
mum of quality, safety and efficiency.
Endress+Hauser stands for continu-
ity, industry know-how and long-term
customer relationships.
65 - Inspec Fibres
Inspec Fibres GmbH is a Degussa AG
company located in Austria, providing
the best possible fibres and technical
services to the industry with regards
to high temperature filtration.
Inspec Fibres’ major product, P84
Polyimide, with its unique multilobal
shaped cross section is providing the
best filtration efficiency of all fibres.
In cement and lime kiln applications,
P84 shows outstanding performance
even under the given severe condi-
tions of high dust loads and mechani-
cal stresses due to the process which
originally has been designed to fit
other dedusting equipment.
Besides the polyimide fibre P84
which is manufactured in Austria,
Inspec Fibres also markets Procon
PPS made by Toyobo in Japan and
has taken over the sales and market-
ing activities for the high performance
acrylic fibres Dolanit.
66 - Fru-Con Construction
A premier general contractor, Fru-Con
Construction Corp. provides compre-
70
IEEE-IAS/PCA EXHIBITION 2005
hensive construction, engineering
and maintenance services to five pri-
mary markets - industrial process,
environmental, power, transportation
and government facilities. Ranked in
2004 by Engineering News Record as
the 68th largest United States con-
tractor, Fru-Con is a wholly owned
subsidiary of Bilfinger + Berger AG.
Fru-Con performs virtually every
major discipline: civil, structural,
mechanical, electrical, instrumenta-
tion, process piping and equipment
installation. Services offered range
from pre-project planning, design,
procurement, construction, con-
struction management, start up and
commissioning, to long-term mainte-
nance.
67 - FCT, Inc.
FCT offers the first true on-line min-
eral analyser, COSMA, which gives
a continuous mineral analysis of a
stream of cement or clinker using
XRD and Rietveld analysis. These
mineralogical trends allow for the
prediction and control of cement
strength and setting times, and
allow for control of limestone addi-
tion, gypsum addition and gypsum
dehydration.
Using proprietary modeling
techniques, FCT also supplies kiln
and calciner burners that produce
remarkable benefits, such as reduced
fuel consumption, reduced build up
and better quality.
68 - 69 - Tramco, Inc.
Tramco provides bulk conveying
equipment for the cement manufac-
turing industry with a complete line
of enclosed drag chain conveyors,
bucket elevators, and apron convey-
ors.
Tramco also is the manufacturer
of the Jetbelt, a totally enclosed air
supported belt conveyor, which is
both environmentally friendly and
reduces a substantial amount of the
maintenance involved with a belt
conveyor by eliminating the trough-
ing idlers. Tramco can also offer an
integral horizontal dust collector with
our Jetbelt that drops the dust back
onto the conveyor belt during pulse
cleaning of the pleated cartridge ele-
ments.
GCL: N&S AMERICAN CEMENT
GLOBAL CEMENT AND LIME MAGAZINE
70 - Pillard
The Pillard Group, with Head Office
and Research Centre in France, and
subsidiary companies in Germany,
Spain, Italy and China, employs 280
persons, of which 150 are qualified
engineers and 50 commissioning
engineers.
Based on decades of experience,
innovation, competence and creativ-
ity, the Pillard Group constantly sets
new records in supplying the most
advanced firing systems worldwide.
As a result of a dedicated commit-
ment and cooperation with its cus-
tomers, the Pillard name represents
the most reliable and technologically
advanced solution when a need for
supply or optimization of combustion
equipment arises.
73 - SOR, Inc.
Since 1946, SOR, Inc. has offered a
comprehensive line of level, pressure,
temperature and flow instrumenta-
tion for a wide variety of industries
and applications. SOR, Inc. has the
one and only echOsonix non-contact
ultrasonic transmitter. This sophis-
ticated measuring device provides
accurate and reliable level measure-
ment in difficult situations. A few of
these applications include powdered
cement, pre-mix silos and limestone.
The echOsonix will revolutionize the
non-contact level sensing market
Below: The Conservatek Alumadome at Midlothian, Texas.
May 2005
because it is more powerful, capable
and reliable than any other ultrasonic
transmitter on the market.
74 - Thermoteknix
Thermoteknix is the leader in infrared
temperature measurement technology
for the global cement industry. The
award winning WinCEM 3D Graphic
Kiln Shell Scanning System provides
real time 3D kiln data visualization
and has had many significant new
features added in the last year. The
company is also launching a new
Kiln, Cooler & Furnace Camera.
ThermaScope HTV provides low cost,
high performance real time imaging
for improved efficiency, increased
combustion control and lower pol-
lution with direct output to CCTV
display. Also being demonstrated on
Stand 74 are Thermoteknix’ WinBrix
Refractory Expert Software and
VisIR handheld infrared camera for
Predictive Maintenance applications
from pre-heater refractory check to
motors, drives and wiring.
77-78 - Conservatek
Environmentally compatible, techni-
cally sound and reliably constructed,
Conservatek Alumadome roof sys-
tems offer the perfect solution to
challenging bulk storage enclosure
requirements.
Conservatek’s aluminum roof sys-
71
IEEE-IAS/PCA EXHIBITION 2005
tems are custom-designed to accom-
modate clearance requirements,
basin configuration, and bulk han-
dling equipment. The structurally
efficient weight-to-strength ratios of
our geodesic domes provide depend-
able protection from the elements
and reduced foundation costs. Our
goal is to maximum your storage
capacity as efficiently and economi-
cally as possible.
Utilizing the highest qual-
ity aluminum alloys throughout, a
Conservatek Alumadome roof offers
unmatched durability and low main-
tenance costs and a single-source
responsibility for the complete
design, fabrication and installation
process.
79 - Herzog Automation
Herzog Automation is a leading
manufacturer of laboratory sample
preparation machines and systems.
Herzog manufactures automatic and
manual versions of all machines
such as crushers, mills, presses
and fusion machines. Herzog manu-
factures samplers for hot meal and
clinkers, plus screw, piston and air
slide samplers. For automated solu-
tions, the samplers are delivered to
your lab via Herzog’s plant stations
and pneumatic tube systems.
Herzog’s range of fusion machines
include manual, semi-automatic and
fully automated versions of both gas
and the new electric, high frequency
(HF) type machines.
80 - Koppern Equipment
Since 1898, Köppern has been
manufacturing roller presses and
plants for briquetting, compaction,
and comminution. More than 800
Köppern roller presses are in opera-
tion today for cold briquetting/com-
pacting; hot briquetting; high pres-
sure grinding. We are represented
in the USA, Venezuela, Australia,
India, China, and other countries
with the group’s Head Offices locat-
ed in Hattingen, Germany.
Köppern’s Corporate Technical
Centre & Laboratory for mate-
rial testing is located in Freiberg,
Germany in affiliation with the
Technical University of Freiberg.
Laboratories for material testing are
GCL: N&S AMERICAN CEMENT
GLOBAL CEMENT AND LIME MAGAZINE
also located in Perth, Australia and
Charlotte, NC, USA.
82 - Alstom Power, Inc
Alstom Power, Inc., Air Preheater
Company, Raymond Operations is a
leading supplier of engineered prod-
ucts and services that address size
reduction, classification, and drying
applications. Raymond equipment
is known for its quality and perfor-
mance, and is supported by our tech-
nical staff, pilot plant testing facility,
and aftermarket products/services.
Raymond supplies size reduction
and classification systems incorpo-
rating pendulum mills, vertical table
mills, impact mills, flash drying aux-
iliaries and the new, ‘hybrid’ turbine
dynamic classifier.
83 - Solios Environment
Solios is a world-wide turnkey sup-
plier of emission control systems for
cement processes. Supply includes
baghouses and gas-to-air heat
exchangers for kiln and raw mill,
finish mill high efficiency separator,
coal mill, alkali by-pass and clinker
cooler applications. The Solios TGT
Filter low-pressure pulse-jet bag-
house features a number of innova-
tions that lower emissions, increase
bag life and result in the lowest total
cost of ownership. The TGT Filter is
widely employed for new projects and
for replacement of older baghouses
and electrostatic precipitators.
85 - Pennsylvania Crusher
Pennsylvania Crusher will display
the Posimetric Feeder, known for its
proven high accuracy and extremely
low maintenance even when feeding
sticky and/or abrasive materials.
This revolutionary feeder - with only
one moving part - operates on the
principle that, when confined, solid
materials will form a self-support-
ing bridge. The Posimetric has been
installed to replace both coal feeders
and triple gates. If you have problems
feeding difficult materials or want to
reduce your feeder maintenance
costs, stop at our booth for a dem-
onstration.
Pennsylvania Crusher also manu-
factures crushers of many types,
including impactors, hammer-
May 2005
mills, granulators, and cage mills.
Information on these products will be
available.
86 - TurboSonic
TurboSonic is a leading supplier of
equipment for air pollution control
and industrial process
improvement. SoniCool
Evaporative Gas Cooling
and Conditioning (seen at
right) provides accurate
temperature and humid-
ity control to condition
flue gases and particulate.
The TurboSorb Semi-Dry
Scrubber removes SO2
and HCl from process
gas streams. SonicBURN waste fuel
burner nozzles and lances provide
high efficiency combustion in kilns.
Dry Fog Dust Suppression systems
control virtually all types of airborne
dust and mists and are widely used
in the cement/limestone/aggregate
industries. TurboSonic has signifi-
cant industry experience and appli-
cation knowledge in hundreds of
installations.
87 - Iris Power
Iris Power Engineering is a world
leader in the use of partial discharges
to detect problems with the stator
The CSMeter, seen below, is the world’s
first hand-held broken rotor bar detec-
tor and can be applied to squirrel cage
induction motors rated 50hp or more,
both low voltage and high voltage. The
CSMeter was developed by combining
advanced current signature analysis
(CSA) algorithms with modern digital
electronics. The CSMeter needs only
one input from a current probe that is
clamped directly to one of the phase
leads to a motor right at the MCC.
72
IEEE-IAS/PCA EXHIBITION 2005
insulation of generators and large
motors. Studies indicate 40% of
motor failures result from the aging of
stator winding insulation. Iris offers
sensors, instrumentation and soft-
ware for online partial discharge test-
ing. With products such as PDTrac,
which collects data continuously
and archives the results impor-
tant for trending and comparison
of similar machines, and CSMeter
which detects broken rotor bars
in induction motors and prob-
lems in driven components, Iris
provides several systems for
implementing a predictive main-
tenance program.
88 - Hagglunds Drives
Hägglunds has a leading interna-
tional position in hydraulic motors
and drive systems, primarily for
heavy duty industrial and marine
applications. We have developed
from being a manufacturer of motors
to a supplier of complete direct drive
solutions. Our customized systems
are often developed in co-operation
with our customers and we build our
business on long-term relationships
and reliability. Our deep system
knowledge and thorough under-
standing of the applications are two
of our greatest strengths. We not
only provide hydraulic motors and
drive systems; we provide service
and parts throughout the respective
international community.
98 - 99 - Wear-Concepts
Wear-Concepts, is a specialty sup-
plier, designer, and installer of wear
and abrasion resistant products.
With nearly 75 years combined ser-
vice in the steel fabrication industry,
Wear-Con offers solutions to some
of the toughest wear problems in
conveying systems, clinker handling
systems, crushing operations, and
pipelines in sand and gravel plants.
Wear-Con even offers turn-key
installations with MSHA Part 46 cer-
tified field crews.
100 - EnviroCare
For the past 24 years, EnviroCare has
supplied over 175 evaporative gas
conditioning systems to the cement
industry. We are able to apply our
GCL: N&S AMERICAN CEMENT
Nuremberg, Germany
11 – 13.10.2005
POWTECH 2005
The fascination of innovation
International Trade Fair for Mechanical Processing
Technologies and Instrumentation

POWTECH presents the

European technology forum for
powder, granules and bulk solids
Organizer
with all the innovations of mechanical processes NürnbergMesse GmbH
as key technology in many industries Tel +49 (0) 9 11. 86 06 - 49 44
with the use of the promising nanotechnology visitorinformation@nuernbergmesse.de
for mechanical processes – can be experienced
Sponsor
live in the „Nano goes POWTECH“ theme pavilion
VDI-Gesellschaft Verfahrenstechnik
with explosion protection and industrial safety und Chemieingenieurwesen
segments for powder and dust processing

More information on the exhibition available at

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Order reduced entrance tickets the easy way online:

www.powtech.de/ticketshop
GLOBAL CEMENT AND LIME MAGAZINE
experience into solving the most dif-
ficult of gas cooling requirements.
Applications include; preheater
GCT, alkali bypass, downcomers,
clinker coolers, preheater cyclones
and raw mills. We have patented
our ‘ML’ SO2 and detached plume
abatement system and continue to
use our patented spray technology
and cement process knowledge to
improve plant operation and com-
pliance.
101 - Process Solutions
Process Solutions is a Canadian soft-
ware developer, with more than 90%
of its business derived from products
and services for the cement industry.
With over 200 installations, Process
Solutions is a principal supplier
of quality management, advanced
control and environmental manage-
ment to the cement industry across
North America and Australasia.
Leading products include Laboratory
LIMS, Raw Mix Control and Process
Data Historians. For over 20 years,
Process Solutions has been success-
ful in partnering with major cement
corporations for the supply of mul-
tiple vertically integrated software
and hardware solutions.
103 - Temcor
Temcor Aluminum Domes are in
service worldwide, storing everything
from cement to coal to gold and sil-
ver. A Temcor Aluminum Dome has
the inherent advantages of increased
storage capacity, reduced construc-
tion and maintenance costs, envi-
ronmental protection and design
flexibility.
The domes protect materials from
contamination or losses from wind
and rain, but also protect the envi-
ronment from potential air pollution
problems. Temcor has been building
May 2005
IEEE-IAS/PCA EXHIBITION 2005
has recently been launched within
the FLSmidth organization as a
self-contained group that will be
dedicated to sales and order execu-
tion for modernization and upgrade
projects. The overall objectives of
the group are to take a more proac-
tive approach and to serve custom-
ers’ requests with greater focus,
higher efficiency, and quicker
response time.
FLSmidth Airtech is a complete
supplier of air pollution control sys-
tems to the cement industry. From
state of the art technology for partic-
ulate and gaseous removal, through
the Ful-Serve Group which offers
comprehensive aftermarket support
including inspections, spare parts,
retrofits, installation and mainte-
nance services. Advanced Filtration
aluminum domes and other struc- Technologies offers expert applica-
tures for nearly 40 years and has tions support and the highest quality
more than 6,000 installations world- filter bags available made of polyester
wide. Temcor is ISO: 9001 Certified. through membrane using state of the
art filter media.
104 - 106 - FLSmidth, Inc.
FLSmidth is the lead-
ing supplier of equip-
ment, systems and
services for the cement
industry. FLSmidth Inc.
(USA) maintains a full
complement of engineers
and project managers
capable of carrying out
an array of projects
from complete greenfield
plants to minor process
upgrades. FLSmidth is
organized into divisions
which are capable of
addressing special cli- FLSmidth’s newly formed Customer Services Projects
ent needs. The following department was responsible for the recent upgrading of the
D.G.Khan cement plant in Pakistan, pictured above.
divisions will participate
in FLSmidth’s technical exhibit. 107 - Ashguard, Inc.
FLSmidth Cement Services Division Ashguard, Inc. is a specialty coatings
is capable of supplying our custom- firm specialising in temperature and
ers with assistance from mechanical corrosion control in cement industry
and electrical inspections, process flu gas systems. We apply specialty
inspections and optimization, emis- coatings to structural steel, heat and
sions investigations, and thorough corrosion-resistant linings to the
training of your plant personnel. Our interiors of bag houses and other
highly experienced engineers can high heat vessels. One of our popu-
analyze your problems, provide cost lar applications is our internal kiln
effective recommendations and prop- lining coating system which extends
erly train personnel to increase plant the service life of the kiln shell and
productivity and availability. saves expensive replacement costs
Customer Services Projects (CSP) and down time. GCL
74 GCL: N&S AMERICAN CEMENT
 N Contents
E W S Subscribe
I NDIA Holcim Ltd has been unsuccessful in acquiring
a controlling stake in Associated Cement Companies
(ACC). Holcim acquired only an additional 20.8% stake
in ACC through the open offer price of R370/share made
through its Indian holding company, Ambuja Cement
India Ltd. With the acquisition, Holcim has been able to
increase its stake in ACC to 34.6% as against the targeted
50.01%. Analysts suggest that the offer price was not sig-
nificantly higher than the market price and hence did not
attract investors to offer shares.
Foreigners shut out of Uzi deal
U ZBEKISTAN Uzbekistan will not allow foreign investors
to participate in the privatisation of cement producer
Kyzylkumtsement, the country’s biggest cement plant,
according to the State Property Committee. Instead the
30% share package that had been reserved for sale to
foreign investors will remain in state ownership, enabling
the state to retain control. Kyzylkumtsement was opened
in 1977 and can produce 3.08Mt of cement a year.
Kyzylkumtsement will be the only remaining company
in the cement industry controlled by the state. In the past
18 months the government has sold controlling shares in
three of the four largest cement plants to foreign investors.
The privatisation of the country’s second largest cement
plant, Akhangarantsement, will conclude in 2005,
‘Cibinong’ loss up to US$14m
I NDONESIA Cement firm PT Semen Cibinong - now bland-
ly renamed Holcim Indonesia - said its first quarter to
March net loss widened to Rupiah138.94bn (US$14m), up
31% from its net loss of Rupiah105.67bn (US$11m) a year
earlier because of higher operating expenses. The com-
pany said its first quarter sales rose by 24%. Cement pro-
ducers faced higher operating costs after the government
raised fuel prices by an average of 29% on March 1.
Cibinong aims to produce 7.25Mt of cement this year,
up from 6.22Mt in 2004, according to its president,
Timothy Mackay. The company has set aside US$30m to
expand its production capacity, Mackay said. He said the
company has reduced its export target to 1.5Mt this year
from 2Mt last year, since the price of cement has declined
in international markets.
He said to make up for an increase in production cost
as a result of the rise in the price of coal fuel, the com-
pany will raise its cement price by 5% from an average
of 420,000 rupiah ($43.41) a tonne in 2004. He said the
company also plans to restructure a debt of US$500m to
reduce its repayment burden. “Our forex debt is $500m.
This year we plan to restructure $300m of it. It can be
a buyback or a bond issue,” said Mackay. Cibinong is
77.3% owned by Holcim.
May 2005 75
Ad index
Holcim now plans to increase its controlling 35% stake
at Associated Cement Companies Ltd. to around 50% over
time, according to CEO Markus Akermann. According to
Indian law, Holcim could raise the stake by 5% annually,
Akermann said. The Reserve Bank of India has said that
foreign funds can now buy shares in Associated Cement
Companies Ltd. since its holdings in the companies have
fallen below the permissible limit. The central bank moni-
tors foreign shareholdings in Indian companies and issues
an alert once the level reaches its ceiling. The Indian
government sets various limits on the foreign portfolio
shareholdings in different sectors. However, the boards of
companies can choose to impose lower limits.
Holcim is also exploring the option of amalgamating
ACC with Ambuja Cement Eastern Ltd (ACEL). The idea
is to augment its shareholding in ACC to over 50%, which
would make ACC a subsidiary of Holcim in India.
All change at Siam Cement
T HAILAND Chumpol NaLamlieng, president of Siam
Cement Group, has stepped down from the helm
of the country’s largest industrial conglomerate. Kan
Trakoonhul, the group’s executive vice president, is
expected to take over as head of the group. SCC directors
approved the early retirement of Mr. Chumpol, effective
next January 1. The board also assigned its corporate
governance and nomination committee to start a search
process for a new president.
Mr. Chumpol, 58, has held the top spot at Siam
Cement since 1993, and is widely considered to be one of
the country’s most influential business executives. “I am
no longer young, I want to have leisure time for playing
golf and something else,” said NaLamlieng.
Mr. Kan, 50 and currently No 2 at SCC, is widely tipped
to be Mr. Chumpol’s successor. An electrical engineer by
training, he is a 30-year veteran of SCC, and has built
up strong support among colleagues for both his ability
and easy-going nature. For the first quarter performance
of Siam Cement, Mr. Chumpol said operations were bet-
ter than expected, despite a number of uncertainties.
Even cement, the product hardest hit by diesel prices,
performed well. Sales grew by 16% in the first quarter of
2005, higher than the industry average of 10%.
Subscribe and get more news...!
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tant extra Asian cement news by email, including
details of corruption allegations in Azerbaijan, Malaysia’s
cement price war, full details of Indonesia’s impending
cement plant building bonanza and lots more besides. If
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 N E W S
Two new plants for Baku?
A ZERBAIJAN Preparations for the modernisation of
Garadagh Cement in Baku are nearly finalised,
with the construction of a new Kiln 5, and the disman-
tling of the four current kilns by 2007. Specific energy
consumption is expected to drop by at least 40%.
The chairman of the board of Garadagh Cement, Uwe
Koehler, has said that the executive board of Holcim was
ready to sanction investments in Zurich in June in the
refurbishment of the Garadagh Cement plant in Baku.
‘The tender for the main project contract is in process at
present. It involves companies from Denmark, Germany
and China,” Herr Koehler mentioned. The refurbishment
cost is estimated at up to $75m, and work will last for at
least two years. Consequently, production of cement will
rise to 4000t/day. It is expected that imports of clinker
into Azerbaijan will be discontinued altogether.
However, the Ministry of Economic Development
has raised the possibility of backing a competing new
cement plant in Azerbaijan, to provide competition.
News in Brief
S audi Arabia Siemens Power Generation Group has
announced that Yamama Saudi Cement had ordered four
25MW gas turbines. The turbines will be used in a new power
facility, which will supply electricity to the company’s cement
factory in Riyadh. The power plant is due to come on stream
later in 2005.
I ndia All cement companies have increased cement prices
in Mumbai by Rs2 to Rs5 per bag effective from 25 April
2005. Similar price hikes are also expected in other parts of
Maharashtra in the near future. Cement prices could see further
upward hikes in the period prior to the monsoon.
I ndonesia Cemex Asia Holdings Ltd says that it wants to
invest in new cement project in Indonesia to meet the possible
scarcity of cement in Indonesian in 2007-2008. The arbitration
process at the International Centre for Settlement of Investment
Disputes between the Indonesian government and Cemex will be
continued on July 18th to July 30th in Washington DC.
A sia Holcim has decided to consolidate its data centre
operations for the entire Asia-Pacific region with NIIT
Technologies, in Bangkok. Until recently, NIIT Technologies
was operating a dedicated data centre for Holcim’s business-
critical IT applications in Thailand. As part of a new contract,
NIIT Technologies would use its data centre and disaster recov-
ery centre in Bangkok to help Holcim Group companies in the
Asia-Pacific region access SAP applications and services round-
the-clock. NIIT Technologies was selected by Holcim in the year
2000 to design and set up a data centre for SAP services for the
group’s Thailand subsidiary, Siam City Cement.
“Holcim chose to expand its existing relationship with NIIT
Technologies because of its excellent performance record and
flexibility. As Holcim grows further, it has an excellent platform
in NIIT Technologies, to move fast, very fast,” Holcim Services
(Asia) Limited CEO Felix Hochner said.
May 2005
New cement plant for Jordan?
J ORDAN The Jordanian-Kuwaiti Holding Company
(JKHC) plans to set up a US$200m cement factory in
Jordan. The project is the first for JKHC in Jordan and,
according to CEO Reem Badran, will be followed by other
schemes in industrial, tourism, electricity, gas, water and
infrastructure spheres. The decision to build the factory
was based on a feasibility study that showed a fast grow-
ing demand for cement. She pointed out that there is great
potential for exporting the cement to neighbouring coun-
tries especially Iraq, Saudi Arabia, Palestine and Syria.
Established in 2004 with a $119.2m capital JKHC is 85%
owned by Kuwaiti investors and the rest by Jordanians.
Badran indicated that at least 500 Jordanians will be
employed by the new factory which is expected to start
production in 2008. At present, Jordan produces cement
at two locations, one in Fuheis near Amman and the other
in Shidiyeh in southern Jordan. The concession granted
in 1950 to the Jordan Cement Factories Company (JCFC),
which operates the two plants, expired in 2001.
Y emen Tender documents are due to be released by the end
of May for the turnkey contract to build a greenfield cement
plant for the privately-owned Arab Yemen Cement Company
(AYCC). India’s Holtec has been selected as the consultant.
The project, a local/Saudi joint venture including Saudi Arabia’
Eastern Province Cement Company, calls for the construction of
a 4000t/day facility and a captive power plant with capacity of
30MW. Total project costs are estimated at $250m-300m. The
plant will be located at Mukalla in Hadramout governorate.
O man Tender documents are due to be released imminently
for the contract to expand the existing plant of Oman
Cement Company (OCC) and to build a greenfield grinding facil-
ity at Sohar. The 27-month contract calls for the addition of a
5000t/day clinker line and a 3000t/day grinding unit at OCC’s
plant near Muscat, and the construction of a 3000t/day grind-
ing plant at Sohar. India’s Holtec is the consultant. See also GCL
December 2004 - January 2005.
A sia Italcementi SpA chairman Giampiero Pesenti said the
group plans to expand in emerging markets, especially India
and other Asian markets, through acquisitions and the moderni-
sation of existing plants.
I ndonesia Indonesia’s largest cement maker PT Semen Gresik
said its auditor PricewaterhouseCoopers has given a disclaim-
er on the company’s 2004 financial report due to disagreement
over some accounts presented by its unit PT Semen Padang. It
said the auditor found that there were no supporting documents
for several accounts.
P hilippines Holcim Philippines, Inc. has swung to profits last
year with net income after tax of P1.2 billion from a net loss
of P318.7m in 2003. In a statement, the company attributed
the turnaround to a recovery in cement prices, increased export
volume and low level of cement import.
76 GCL: Asian CEMENT
 N E W S
Is this the end for China’s cement industry boom?
C HINA Following on from a series of worrying signs
from China’s general economy and from the cement
industry in particular, GCL asks ‘Could we have an Asian
Crisis melt-down in China?’ The straight answer is cer-
tainly ‘Yes.’ Senior economists have warned about the
existence of a dual economy in China for some time - a
stable hinterland and a bubble coast - and the Chinese
government has become worried enough about the situ-
ation to take what for it is dramatic action to curb the
worst excesses of the market. These actions are now hav-
ing their desired effects, but not without bringing some
pain to China’s cement producers.
China’s cement industry suffered a loss of RMB350m
(US$42.3m) in the first quarter of 2005, as compared with
a profit of RMB3.1bn (US$400m) in the same period of
2004. Cao Yushu, spokesman of the State Development
and Reform Commission, pointed out that the turnabout
from profit to loss implied adverse consequences of blind
construction and low-level expansion in some industries
in previous years. He added that the appearance of the
new circumstances marked the correctness of the state’s
macro control policies implemented since the second
half of 2003. Cao also said that that enterprises taking
measures as early as possible in positive response to the
state’s macro control policies have successfully prevented
possible losses.
However, the message is apparently not getting
through. China’s 25 key state-owned enterprises in the
building materials industry showed a profit of US$22.97m
in the first quarter of 2005, a turnaround from a loss of
US$2.3m in the first two months, according to the State
Assets Supervision and Administration Commission. But
the first quarter figure still represented a sharp fall of
84.3% from the same period of last year, due mainly to
the government’s macro control measures.
Although China’s largest cement producer Anhui
Conch Cement produced 31.8Mt of clinker in 2004, up
52% year-on-year, due to higher raw material prices, the
company’s gross profit rate fell in 2004 to 33.4%, from
41.97% in 2003. The gross profit rate in clinker produc-
tion was 31.56% in 2004, down from 45.2% in 2003.
Spending on energy materials accounted for 61% of pro-
duction costs in 2004, up from 54% in 2003. Government
macro-control measures taken to cool the economy have
led to weakened demand for cement, the company said.
It expects a more than 50% year-on-year decrease in net
profit for the first half also due to government efforts to
slow new construction.
Hong Kong’s Macquarie Securities said it is maintain-
ing its ‘underperform’ rating on Anhui Conch Cement Co
Ltd to reflect a continued decline in cement prices. Anhui
Conch’s average selling price was RMB186/t (US$22.4/t)
May 2005 77
in the first quarter, down 27% from the same period last
year while sales volume was also weak at 10.2Mt, against
13Mt in the fourth quarter 2004. Macquarie said it had
lowered its 2005 earnings forecast for the company by
22% to US$61m and by 23% to US$71.9m in 2006 to
reflect lower selling prices. Anhui Conch Cement Co spent
US$347m in capital investments and stake purchases in
2004, and plans to invest US$314m in 2005.
Despite the current weakness in prices, Anhui Conch
is still optimistic about the medium to long term pros-
pects for the Chinese cement industry. The group plans
to invest US$362m in building three production lines,
each with a daily capacity of 10,000t of cement clinker, in
Chizhou. The project, to be undertaken in three phases,
will raise the total production capacity of Chizhou Conch
to 15Mt per year. The factory, which currently has two
production lines, each with a daily capacity of 5000 tons,
and one production line with a daily capacity of 8000
tons at present, will become the world’s largest single
cement producer and will become the clinker-supply base
of the Group. The project also includes a 45MW pure low
temperature, residue heat power generator and an 11Mt
special purpose wharf.
It is not just private companies that are still gung-ho
about the healthy prospects of cement markets in China
- despite signs to the contrary. The annual cement pro-
duction capacity of Guangdong province, southern China,
will increase by 85Mt between 2005 and 2010, according
to Guangdong’s recently published development strategy
for the construction materials industry. Guangdong cur-
rently ranks second in terms of cement production capac-
ity in China, although vertical shaft kilns still account for
80% of Guangdong’s cement production capacity, with dry
kiln production accounting for only 7.6% of Guangdong’s
production. About 30Mt of the planned new capacity
will be built in western Guangdong, 30Mt in northern
Guangdong and 25Mt in eastern Guangdong. The bases
with the biggest new capacity will be Yunfu, western
Guangdong, with 20Mt; Yingde, northern Guangdong,
with 20Mt; and Longmen, eastern Guangdong, with 10Mt.
The development strategy has been published despite the
aim of central government to hit the brake pedal on over-
development in the cement industry.
As they say, you can’t make an omelette without break-
ing eggs, and in many areas of China, you can’t make
cement without coal. But here lies a major problem:
China will experience a worsening coal shortage as a
result of increasing demand and falling supply, according
to the National Development and Reform Commission,
due to a series of recent coal mine accidents...
This article is continued in this month’s Subs+ email news
- for subscribers only.
GCL: Asian CEMENT
 N E W S
Westport’s cement crisis: the bar’s nearly dry
N EW ZELAND Holcim Cement’s Westport plant - its only
New Zealand works - is facing its worst transport
crisis in years because of problems at the Westport port.
The company’s two cement carriers have been unable to
use the port for almost a week because of poor harbour
bar depths. Holcim New Zealand general cement manager,
Jeremy Smith said the bar depth problems were the worst
for 20 years.
The company ships cement from Westport to silos at
ports around the country, then distributes it by road. But
a recent dry spell has limited the flow of the Buller River,
which helps flush out the bar, and southwesterly winds
have pushed sand towards the bar, making it too shallow
for the ships to cross safely. The company had dispatched
bulk cement carriers, Milburn Carrier II and Westport
elsewhere in the meantime. They can each carry more
than 3500 tonnes.
Holcim was relying more on imported cement, road and
rail transport, to supply its customers, Mr Smith said. It
trucked Westport cement in 25 tonne loads to Nelson, at a
Pakistan’s cement boom
P AKISTAN The MD of Dadabhoy Cement Industry Ltd,
Senator Muhammad Amin Dadabhoy, has said that
Pakistan will soon start exporting cement to Iraq, Iran,
and Dubai. Pakistan will also supply cement to tsunami-
hit countries, including Indonesia and Sri Lanka, to accel-
erate rehabilitation work there. Pakistan produces around
10.8Mt of cement per year. “The cement manufacturers
are expanding their production capacity as well as estab-
lishing new units,” he said, adding that by the year 2006
Pakistan’s cement production capacity will exceed 20.4Mt
per year.
Consumption up in Indonesia
I NDONESIA Indonesia’s cement consumption rose 16.5%
by volume in March from a year earlier, amid an
improved economy. Semen Gresik said Southeast Asia’s
largest economy used 2.65Mt of cement in March, up from
2.27Mt a year before. Domestic sales of Semen Gresik
alone grew 8.7% to 1.13Mt. Including exports, Gresik
sales rose 5.5% to 1.25Mt. In 2004, Indonesia consumed
30.04Mt of cement, up from 27.54Mt in 2003. Analysts
had expected strong demand for cement from massive
infrastructure projects expected to start this year.
The government plans to offer billions of dollars worth
of projects to revive the country’s ailing public facilities
in a bid to boost investment and economic growth, as
well as rebuild areas of Sumatra island hit by a massive
December 26 tsunami. The state budget has forecast the
economy will grow 5.4% this year against 5.1% last year,
partly due to an expected pick up in investment.
May 2005 78
substantially higher cost than shipping, and railed cement
to Christchurch. It had also started shifting more cement
stored at other ports around the country, particularly
Dunedin, to keep up with customer demand.
Holcim provides about half the country’s cement from
its Westport cement works. The works had not reduced
production, Mr Smith said. “Our main concern is to
ensure continuity of supply for our customers. Presently
we are maintaining that through contingency measures.”
The temporary measures however, would come under
increased pressure the longer the bar remained shut, Mr
Smith said. “We have a clear path through for another
week and we have another import shipment coming in
so we will just find ourselves relying more heavily on
imports.” Holcim was not losing money, but its contin-
gency measures were costly. Dredging will resume as soon
as conditions allow.
Indonesia: shortages imminent
I NDONESIA PT Semen Gresik’s president, Satriyo, has
predicted that Indonesia’s cement market will continue
to expand despite a 5%-6% hike in price. Satriyo said the
price hike is inevitable with the increases in the prices
of coal fuel and transport cost, adding that distribution
accounts for 20-30% of cement production cost. He said
that Gresik has carried out surveys for a place to build
a new factory with an annual capacity of 3Mt needed to
meet growing demand. He estimated that the country
will need up to 33Mt of cement in 2005, compared to the
country’s production capacity of 45Mt. Semen Gresik has
a 44% share of cement market in the country.
Semen Gresik has projected a shortfall in cement sup-
ply in 2007 due to the high demand from government-
driven infrastructure projects. The state-owned company’s
forecast of a cement shortage in 2007 is earlier than it’s
previous prediction of 2010.
Indocement reports profits
I NDONESIA PT Indocement Tunggal Prakarsa reported a
net profit of Rupiah149.39bn (US$15.6m) for the first
quarter to March, against a net loss of Rupiah2.99bn
(US$0.3m) a year earlier, on the back of improved mar-
gins and lower foreign exchange losses. The company said
sales increased 26%, while, operating profit surged 63%.
Both gross and operating margins improved to 36.52%
and 22.62% respectively from 31.97% 17.59% a year
ago thanks to cost efficiencies. The company says that it
expects the impact of Forex rate movements on its earn-
ings to diminish after it switched US$150m or around
a third of its US$475m outstanding debt into Rupiah.
Indocement, Indonesia’s second largest cement maker, is
a unit of Germany’s HeidelbergCement AG.
GCL: Asian CEMENT
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GLOBAL CEMENT AND LIME MAGAZINE
A VISIT TO OMAN CEMENT COMPANY
O M A N C E M E N T

EXPANSION PLANS AT OMAN CEMENT

A VISIT TO OMAN CEMENT COMPANY,

BY ROBERT MCCAFFREY

Paid GCL
BLOCK
KID ON THE
THE ‘NEW’

2007. AND LIME

MAGAZINE
GLOBAL CEMENT cement. When
an n manager for

Europe
Now you can decide
the productio Simon Buxton
of the bag’ around the world.” of Simon became plant project was started,
CEMENT to

subscription
cement plant cement and was promoted
l’ouverture est prévue pour the brand-new UK’s the new project manager
2007, au sein de son usine CL recently visited Buxton in the

G
the deputy plant opened
when the new
de Muscat. Start at the start... Industries, near man- was
BUXT ON LIME INDUS
TRIES
Buxton Lime with the plant the plant manager
“Let me tell you a little bit and spoke is a become
about why we are here,” Peak District, Buxton. Simon earlier in 2004. 42, who generally
Fabrik nahe Muscat in Betrieb
zu nehmen.
continued Mr Al-Habsy.
“The Oman Cement sly-named Simon his career king (for now) has not
ager, the eponymou by training, who started Simon is a young-loo day: the plant project
K
Company decided back
ON THE BLOC
in 1981 that it engineer divested to 12 or 13 hour
mechanical site was then

THE ‘NEW’ KID

n works a

(This form)
would construct a cement
plant with a in 1992 with ICI: the whereupo
capacity of 600,000t of clinker at the site of Anglo-American)
fábrica ubicada cerca de
Muscat, que se inaugurará per financial arm
en 2007. year. The contract was award- CEMENT PLANT Minorco (the
’ NEW TUNSTEAD
Bed LIME INDUSTRIES
to Polysius, MCCAFFREY
UXTON and the D BY ROBERT
original S IMON B
plant UXTON INTERVIEWE
PLANT MANAGER started
in 1983. However it

AUCBM CEMENT CONFERENC

Middle Eastern
AUCBM
CEMENT
C O N F E R E N C E
GLOBAL CEMENT AND LIME MAGAZINE

Conference conduct
The conference took place cement-related companies.
AUCBM OMAN REVIEWED
how to subscribe! Your own print
copy - every
The
E REVIEWED days, and by unanimous
over four contacts that
consent, tion alone
I made at the exhibi-
this was too long. The made the trip to Oman
THE 13TH ARAB UNION

FOR
The Arab Union for Cement
Cement Conference and
Paid eGCL
CEMENT number of worthwhile.
AND BUILDING MATERIALS INTERNATIONAL papers submitted to the It was notable that the
CEMENT CONFERENCE oranisers
AND EXHIBITION, OMAN filled four days, but unfortunately busiest exhibition stand was that
REVIEWED BY the audience voted with of Sinoma, the largest
ROBERT MCCAFFREY their feet, cement equipment Chinese
and attendance for the manufacturer.
later pre- Another
and Building Materials sentations was sparse. feature of the exhibi-
(AUCBM) held its 13th International As an invet- tion was

month
Exhibition in Oman. Around erate attendee of these the ‘Business Oasis’
of

subscription
440 delegates from around kind of con- FLSmidth,
world attended the meeting, ferences, many of the imaginatively modelled
while 70 companies took the papers were on a Bedu
La «13th International Cement part in the successful exhibition. familiar to me, and only
a handful distinctive
tent, decked out in a
Conference and Exhibition» Arabian woven pattern
l’Union arabe du ciment et des (13ème conférence-exposition internationale had much new to say,
venus du monde entier
matériaux de construction,
s’est tenue cette année sur le ciment) de l’AUCBM, but this is and complete
ont pris part au congrès dans le sultanat d’Oman. a common complaint with water pipes.
et 70 entreprises ont participé Environ 440 délégués nowadays.
à la prestigieuse exposition. Many of the papers could
just have
Mit rund 440 Besuchern been included in the

(This form)
aus der ganzen Welt und conference
für Zement und Baustoffe 70 sich präsentierenden
AUCBM Unternehmen war die von proceedings, which were,
Zementkonferenz und Ausstellung) im Oman durchgeführte 13. International Cement der arabischen Vereinigung however,
auch in diesem Jahr ein Conference and Exhibition impressively ready at
großer Erfolg. (Internationale the start of
the conference.

gates who would happily

acudieron al encuentro have vis- TURKMENBASHI’S TEMPLE
y 70 empresas participaron
it was difficult for full ited both events if that
en la exhibición, que tuvo
un gran éxito. a respectable proportion dialogue to physically had been
of cement take place possible. However, from GLOBAL CEMENT

Asian
producers, compared to between
largest limestone
presenters and all accounts,
equipment - Europe’sof
quarrymembers on. those who decided to
vendors. Equallyof impressive
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n of constructi However,
there were plenty of opportunities attendCEMENT
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e is the self-styled father

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bottom the completio
was the AUCBM event made
December 2004 - January the roster of quarry - shortly after
exhibiting right choice.
the
for
2005
58 which topped 70, all
companies, for discussions
to continue in the TURKMENISTAN Turkmen people – president
arrayed in a coffee breaks, For me, the combination His
life, ruler of all he surveys.

Or take
CEMENT
huge air-conditioned which were hosted in of the
Decemberthe
tent pitched 2004 - Januaryarea. AUCBM conference, a hair and strong
in the grounds of the
hotel. The
exhibition 2005
interior59of Oman, the
trip into the youthful portrait - dark
I greatly enjoyed visiting hospitality 65 years - beams
tent did get rather hot jaw-line belying his

TURKMENBASHI’S TEMPLE
at times, so exhibition the and friendliness CEMENT
area, since it was a very of the Omanis and every street and
down on virtually

advanta
that it was best visited the fabulous conference
in the early good opportunity location, in Ashgabat, the
morning or late afternoon. to meet repre- joined
together to make one from every office wall
sentatives from a large His Excellency

Extra news by Extra news by

of the
, number of high-points capital of Turkmenistan.
BY GCL’S SPECIAL CORRESPONDENT of the year. GCL Niyazov – or
President Saparmurad

ge of
father of the

the gre
ROBIN ACKROYD
simply Turkmenbashi,
benevolently
people - smiles broadly,
has just opened even, on his subjects.

at offer
A new cement plant capital Here in this former
Soviet republic,
in the desert near Ashgabat, with vast petroleum
and natural gas
Gap Insaat of desert sands, the
city of Turkmenistan.

email email
reserves under its

o
plant to take an extraordinary

n
Turkey has built the president is building
gold leaf, and, of

this
demand for new city in marble,
advantage of the booming

month’s
and concrete.
of the lowest course, of cement
cement, and for some It is Valentine’s Day
and I wake
20costs in
energy the world. furniture and
surrounded by walnut
stands out my opulent room
While the cement plant gilt-edged mirrors in

tear-ou
- January 2005
December 2004 This is the City
as an example of world-class at The President Hotel.
the next few
es of Love and I am spending
engineering, the circumstanc and

t
of Turkmenistan’s
hours at the opening

subscrip
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surrounding its construction new cement factory,
less than an hour’s
authoritarian
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the plant all the a night at a state-
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copyright Robin Ackroyd, 57
Words and pictures
March 2005
GCL: Asian CEMENT
56
March 2005

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Robert McCaffrey has
G LOBAL C EMENT & L IME M AGAZINE
the last word
ROBERT MCCAFFREY REVEALS HIS BRUSH WITH THE LAW....
I
t is interesting the way something innocuous
from your past can come back and bite you
when you least expect it. This month, I want
to tell you a story, which will explain my absence
from this year’s IEEE-IAS/PCA conference.
Picture the scene, 18 years ago, when I was a
student, with hair. My friends and I were in my
room on the fourth floor of the student halls of
residence in Dundee, Scotland, taking a break
from revision. I looked out of my window, which was oppo-
site a bank, and saw a queue of people at the cashpoint.
Next to them was a dog which was defecating on the pave-
ment. Having trodden in enough of the stuff during my
time in Dundee, I shouted down to them that they ought
to do something about this dog. However, there was no
response from any of them.
As students we used to have frequent water fights, and
among the instruments we had in our possession was a
water pistol in the shape of a rifle. In those more inno-
cent days, I stuck it out the window and gave the trigger
a squeeze, to give the mutt a soaking and to encourage
it to move along. It ignored me, finished its business and
moved on.
Five minutes later, we heard a call from along the cor-
ridor, that the police were coming. Bless them all, my
friends all ran away, locking themselves in their rooms.
A large policeman entered my room and asked where was
the gun. I answered that I had no gun, only a water pis-
tol. He radioed through to his colleagues to stand down
- it seemed as if the centre of Dundee had been closed on
account of what the police believed to be an attempted
bank robbery from the fourth floor of the student resi-
dence opposite the bank.
I was arrested and marched out of the halls of residence
by two large policemen, who then put me into the back of
a police car. One of them stepped into the pile of excre-
ment left by the dog, and he used the water pistol to wash
off the bottom of his shoe.
I was taken to a police station, and had my belt and
shoe laces taken away, and was put into a cell, where I
stayed overnight. I was not allowed a telephone call, to
see my friends or to see a lawyer until the next morn-
ing. The duty lawyer advised me to plead guilty to a
Contents Subscribe
May 2005
charge of breach of the peace, but I disagreed,
and pled not guilty, and a trial was arranged.
On the day of the trial in May 1987, I recall
coming down to breakfast in the student halls of
residence, to see a large banner created by my
so-called friends, saying in red yard-high letters,
‘Hang the b*stard.’ How I laughed.
At the trial, the police were commended
by the Sheriff (as the magistrate is called in
Scotland) for their bravery in attending to a scene where
they believed there may have been a gunman. The police
did not produce any member of the public who had been
alarmed that day (as technically they ought to have done).
They were also censured by the Sheriff for keeping me
overnight in the cells without contact. I was given an
absolute discharge (no penalty, and no criminal record),
which implies that the process of prosecution and finding
of guilt is punishment enough. As the Sheriff said, ‘I don’t
want to ruin this promising young man’s future career.’
Despite my brush with the law, I look back on my days
in Dundee with great fondness. Since then, I have finished
my degree, been awarded a PhD, started a business, got
married and had children. In the intervening time, I have
visited the US well over 50 times, for business and plea-
sure. I like America. However, the new US Department of
Homeland Security has tightened their rules. On a trip to
Kansas City in February, the immigration officer asked me
‘Have you ever been arrested or convicted for any offense
or crime...have you ever unlawfully distributed or sold a
controlled substance (drug), or been a prostitute or pro-
curer for prostitutes?’ to which I had to truthfully answer
‘Yes,’ on account of a misunderstanding on the part of
the Dundee Constabulary in 1987. The immigration offi-
cer revoked my visa, and now I have to jump through the
hoops to get another one - and it won’t be ready until after
the IEEE-IAS/PCA event in Kansas City. Oh brother.
However, whenever I think that the US is being a bit silly
with its new rules, I just replay the mental images that I
have in my head of the events of Monday 11 September
2001. Sometimes, it is better to be safe than sorry.
rob@propubs.com GCL
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