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Hoffmeier Industrieanlagen GmbH + Co. KG:
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Dear Readers, ISSN: 1473-7940

Welcome to the September 2013 issue of Global Cement Magazine, which will be Published by:
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Looking through the global cement news in this issue, we see, once again, that Europe peter.edwards@propubs.com
continues to hold back multinational cement producers’ bottom lines. Results for the
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The Editor welcomes editorial contributions (letters,
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• Your own copy, on time, every issue!
production and sales respectively so far in 2013.
We hope that you enjoy this issue of Global Cement Magazine! Dr Peter Edwards
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is printed on Forest Stewardship Council (FSC®) certified
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globalcementMAGAZINE September 2013 3

CONTENTS
REFRACTORIES
Dirk Basten & Klaus Kassau, Refratechnik Cement GmbH
KRONEX® 20 / REFRACLAY 25 - An extension
of the alkali-resistant lining concept
Above - Figure 1:
Typical appearance of
KRONEX® 20 (left) and
REFRACLAY 25 (right).
Below - Figure 2:
Bulging of refractory lining
at cyclone sidewall.1
13
54 globalcementMAGAZINE September 2013
ALTERNATIVE FUELS
Boris Sassenrath, Vecoplan FuelTrack GmbH
DG Khan: Prepared for
the future
DG Khan`s cement plant at Chakwal, Pakistan,
is one of the largest cement plants in Asia.
With the support of Vecoplan FuelTrack it is
successfully using alternative fuels.
Above: The VecoBelt
VFR 800 fits neatly into
existing infrastructure
at DG Khan Cement’s
Chakwal cement plant.
Below - Figure1: A
Vecoplan VAZ 2000 MF
T crusher fed by a belt
conveyor form part of
the DG Khan alternative
fuel system at Chakwal.
Material fed by
belt conveyor
20
20 globalcementMAGAZINE September 2013
TESTING AND ANALYSIS
Compiled by Global Cement staff
Right: Bruker S8 TIGER
Eco ‘Cement’ caters to the
specific elemental analysis
needs of cement plants.
Below: Berthold
Technologies’ SmartSeries
LB 414 Densitometer for
liquids and slurries.
24
24 globalcementMAGAZINE September 2013
FUTURE INDUSTRY
Fives Group
Plants of
the future
Above: Cement plant
designed and supplied by
Fives in Qatar. Photo: ©
FD Fives.
Below: Looking to the future
at a sugar plant designed and
supplied by Fives in Turkey. What
lies ahead for heavy industry in
the coming decades?
Photo: © FD Fives.
54
54 globalcementMAGAZINE September 2013
Peter Edwards, Global Cement Magazine
South American
cement focus
Argentina
F ollowing Spanish colonial occupation and a series10000
of dictatorships, the Argentine Republic’s civilian
governments have presided over gradual economic 8000
advances in the past 30 years (See Figure 1). However, 60006000
the country experienced a severe economic crisis from
1999 to 2002. This saw it default on its foreign debt 4000
with a lost decade of growth, the collapse of the gov- 20002000
ernment and widespread riots.
Cement industry
After a number of false starts Argentina’s 15 plant
strong cement industry has now become the second-
largest in South America after Brazil. It is dominated
by Loma Negra, which is 100% owned by Brazil’s
Camargo Corrêa. It has seven integrated plants and a
capacity of 7.7Mt/yr. It is investing US$400m in new
capacity in the period 2012 - 2014.
Three local producers, Cementos Avellaneda, PCR
and Cementos Artigas have a combined capacity
of 7.0Mt/yr. The only multinational in Argentina is
Holcim, with four plants and a capacity of 3.1Mt/yr.
Although the Argentine cement industry has a ca-
pacity of 16.8Mt/yr, the country produced 10.7Mt of
cement in 2012. This is lower than in 2011, when it
made 11.6Mt and indicates a capacity utilisation rate
of 60%. Despite this, production is now higher than
before Argentina’s crash (See Figure 1).
There have been a number of changes in the Ar-
gentinian cement industry in 2012 and so far in 2013.
Cementos Avellaneda commissioned its 2.5Mt/yr
Olavarria plant in February 2012 and in January 2013,
Spain’s Cementos Molins sold a 16.1% stake in Cemen-
tos Avellaneda to Votorantim Europe.
So far in 2013 the industry is on an upward trend
with regards to output, with substantial increases in
monthly production relative to 2012. In May 2013, the
country produced over 1Mt of cement in a month for
the first time since November 2011.
Looking ahead, Argentina is forecast to see eco-
69
nomic growth of 4.6% in 2013.1 If the past relationship 2500 2500
between cement production and GDP continues, this
should see a substantial increase in cement production
for the rest of 2013. This should bolster the balance 1500
sheets of major producers like Loma Negra, which saw
its profit halve year-on-year to US$43.9m in 2012.
Despite the implied likelihood of growth for the ce-
ment industry, there is plenty of headroom for higher 500
consumption within the country’s existing cement ca-
pacity. This trend has been seen for the past 20 years,
with capacity utilisation as low as 52% in the early
4 globalcementMAGAZINE September 2013
The refractory products
KRONEX® 20 and
REFRACLAY 25 are a
technically worthwhile
addition to the high-
grade alkali resistant (AR)
lining concept that was
introduced a few years
ago (See Figure 1). These
products permit a cost-
optimised expansion
of Refratechnik Cement
GmbH’s standard
refractory solutions as well
as its premium solutions.
W ith this new development, Refratechnik
Cement GmbH has reacted to the contin-
uously-increasing use of alternative fuels and the
associated problems of these, especially in preheaters.
Refratechnik Cement GmbH’s extended AR lining
concept merges together the established combina-
tion of professional refractory consultation, material
selection, detailed refractory engineering and expert
installation, including its supervision, into a modern,
customised refractory package. KRONEX® 20 and
REFRACLAY 25 impressively demonstrate that fur-
ther technical developments do not always mean ‘even
better, more complex and more expensive.’
More than any other refractory producer,
Refratechnik Cement GmbH has documented,
evaluated and applied its experience in the design and
installation of complete new plants for the purpose
C ement demand in Pakistan is strongly correlated
with gross domestic product (GDP). For a few
years, however, the growth rate of the GDP has stag-
nated in the south Asian republic. The rising cost of
fuels such as oil, diesel and coal on the international
markets (now and in the future) represents a seri-
ous threat to the economy. It is therefore logical for
Pakistani cement manufacturers to substitute their
primary fuels with alternative fuels to a very high pro-
portion in the medium term. DG Khan is a pioneer in
this field in the Pakistani cement market.
Founded in 1978, DG Khan has belonged to the
Nishat Group, which is active on diversified markets
since 1992. Since September of that year the company
has also been listed on the stock market. It is currently
Pakistan’s largest cement manufacturer with a capacity
Vecoplan shredder
VAZ 2000 MF T.
Laboratory and testing round-up
cost-efficient and can be used for many years without the need for
maintenance or re-calibration.
wick Roell, a leading manufacturer of materials test-
ing equipment, has created a new technical centre for its
customers from the UK and Ireland. Located in an company
manufacturing facility in Brierley Hill, West Midlands,
England, the centre is specifically designed to help custom-
ers to evaluate technical solutions that fully satisfy their
specific testing requirements.
Simply smart - The new radiometric
densitometer SmartSeries LB 414 ability to offer more effective explanations of Zwick
B erthold Technologies has introduced a new den- Roell’s technological offerings and extensive range of
sitometer, the SmartSeries LB 414, which is based testing products and will also offer high-quality semi-
on non-contact gamma transmission technology. The nars and training sessions for customers.
detector can measure the density, concentration and
solid-content of all kinds of slurries and liquids. It The Bruker S8 TIGER Eco ‘Cement’
combines both detection and evalua-
tion in one single unit.
Besides its high level of accuracy
and repeatability, the detector’s ease of
use and handling is a major advantage.
Parameters can be set directly on the
detector or via a HART communicator,
PC or infrared remote control. The local
user display interface and the software,
which focuses on the main functions,
makes calibration and operation of a
HART device straight-forward.
The SmartSeries LB 414 has been
designed for the harshest of process
conditions and
is best suited
for stand-
ard density
measurements in non- elemental analysis in a cement plant and is fully com-
hazardous, non-explosive pliant to ASTM C 114, EN 196-2 and ISO 29581. With
environments but where con- its dedicated configuration the close monitoring of raw
ditions can be tough, for example in mix, clinker and cement is done on just one unit . The
the cement industry. SmartSeries detectors process is under control, covering all relevant elements
are characterised by their high mechanical robust- from sodium to strontium at more than 15 samples
ness, verified by the Fraunhofer Institute. They are per hour.
To mark its bicentenary in 2012, Fives asked the people of France about their feelings on
the subject of industry and industrial plants. A clear grasp of industrial realities, a desire
for more information and confidence in the future: this survey revealed just how much
affection French people have for their industrial base and how convinced they are of its
ability to reinvent itself. This initiative has since progressed, with the same survey being
conducted in two other leading industrial nations where Fives also has a strong presence:
the USA and China. Conducted at a time of globalisation in world trade, this survey
Fives Observatory for the Plants of the Future
As part of its Observatory for the Plants of the Future
launched in 2012, Fives brought the public face-to-face
with industry experts to initiate a debate about tomor-
row’s industry as the basis for defining the industrial
plants of the future. This was
achieved by organising a year-
long cycle of events including the
intial survey of French attitudes
to industrial plants and French
industry in general, 15 inter-
views with specialists expert in
the issues facing industry and a
citizens’ conference that sparked
public debate and led to a charter
of recommendations regarding
the conditions under which peo-
ple would be prepared to accept
an industrial site close to their
own home .
The conclusions derived from
all these initiatives have been
compiled and interpreted in the
first edition of the Report of Fives
Observatory for the Plants of the
Future, which Fives has made
available online.1 In 2013, this
initiative is being extended inter-
nationally by bringing together
leaders in innovation to share
12000
12,000
10,000
8000
GDP/capita (US$)
4000
00
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
1 3 5 7 9 11 13 15 17 19 21
Year
1990s. Global Cement is not aware of further planned
or ongoing expansion projects in Argentina at present
other than Loma Negra’s investment plans to 2014.
Bolivia
B
olivia fully broke away from Spanish colonial rule
in 1825 but then endured ~200 coups and counter-
coups until 1982. These prevented significant political,
economic or social progress during this period. Bo-
livia is the least socially- and economically-developed
country in mainland South America.
Despite these issues, Bolivia’s economy has devel-
oped over the past 20 years (See Figure 2), with GDP/
capita rising by a factor of over 2.5 in the 20 years
between 1991 and 2011. Oil discoveries in the 2000s
have the potential to transform the country’s prospects
but political disputes surrounding the best course of
action regarding the oil have hampered development.
Many are concerned that policies will widen the gap
between rich and poor despite Bolivia already having
one of the largest income disparity gaps in the world.
Cement industry
Bolivia has one of the smallest cement industries in
South America, with a total capacity of 2.8Mt/yr over
Bolivia
six integrated cement plants.
20002000
GDP/capita (US$)
1500
10001000
500
00
1 3 5 7 9 11
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
of technical optimisation. Also from this experience
come the latest developments: the highly acid and
alkali-resistant alumina product KRONEX® 20 as
a brick, and REFRACLAY 25 / MCG / JC, which is
intended as a castable, dry gunning concrete and as
JETCAST® concrete.
As a result, Refratechnik Cement GmbH now
provides a full range of modern refractory linings in
the field of highly-acidic fireclay materials. Together
with the proven, alkali-resistant fireclay materials,
KRONEX® 30, REFRACLAY 40 LCC, and high-quality
AR products containing SiC and zirconium oxide,
every refractory requirement in the entire cement pre-
heater can now be satisfied in the optimum manner.
Particular features of KRONEX® 20 and REFRA-
CLAY 25 / MCG / JC are their lower density, their
alkali resistance and their resistance to unwanted min-
eral after expansion.
Regarding the preheater, unwanted
mineral after-expansion of the refractory
material in the two lowest cyclone stages,
and also in the entire calciner, can often be
observed after just a few years. The standard
alumina materials with an Al2O3 content
of at least 35%, which are typically used in
these areas, are always affected. Bricks, as
well as refractory concretes, show the typi-
cal protrusion and bulging of the bricked or
casted/gunned wall areas.
of 14,000t/day (4.2Mt/yr). The company operates three
plants, two in Dera Ghazi Khan and another one in
Khairpur District in Chakwal.
In November 2009 DG Khan Cement and the parent
company of Vecoplan FuelTrack, Vecoplan AG, signed
a contract for an extensive system for the handling of
alternative fuels at the Chakwal plant.
With the experience gained by the German com-
pany from its decades in the field of alternative fuel
preparation, storage and promotion, Vecoplan AG is
atechnology leader in this area today. With this knowl-
edge it was possible to realise a future-oriented project
for Pakistan.
As early as 2008, immediately after commissioning
of the new kiln line, DG Khan began to plan the targeted
use of alternative fuels, the first cement plant to do so in
the country. The company had earlier developed its own
experiences with the use of rice straw before it turned to
an experienced supplier.
Stage 1 of the plant at DG Khan went to operation
in August 2010. Since then 20t/hr of alternative fuels
have been used. The concept of a future-oriented system
was designed so that it is possible for the operator to use
all available (solid) fuels on the market. In the present
operation, biomass consisting of agricultural waste and
a pre-treated light fraction from a municipal waste pro-
cessor are used. The system was designed in a modular
fashion so that it can be expanded without interrupting
the flow of material at any time.
The core element of the system is the Vecoplan stor-
age system, which is fed through a common line in the
first stage. Before the material gets stored by one of
Laboratories, on-the-job testing and analysis
equipment all play a vital role in the manufacturing
and use of cement because ‘what gets monitored
gets managed’ and good process control can lead to
higher margins. Here Global Cement rounds up new
products and supplier news.
New Zwick Roell technical centre
Z
The new facility will help improve the company’s
T
he brand new S8
TIGER ECO Bruker
offers wavelength disper-
sive X-ray fluorescence
(WDXRF) performance
at a unique low cost of
ownership. Based on
Bruker’s established ‘Plug
‘n Analyze’ technology
the S8 TIGER ECO op-
erates with little power
and without any need for
cooling water or com-
pressed air.
The S8 TIGER ECO
‘Cement’ provides op-
timal performance for
shows that, just as in France, the values
conveyed by industry are positive, although
expectations and levels of optimism vary
between the three countries.
their vision of an ‘industrial plant for the world’ via a
series of events. The survey has been expanded to take
in the views of residents in China and the United States.
China and USA enthusiastic about
European industry
China and the USA are united in their perceived image
of European industry, which is very positive overall.
They believe it to be innovative (92% and 80% respec-
tively) and competitive (92% and 76%) and that as a
result, it plays an important role in global industry (91%
and 78%) and will continue to do so in the future (81%
in both countries).
This means that the Chinese and Americans are a
great deal more enthusiastic than the French themselves,
54% of whom believe that it is no longer possible to
reindustrialise France due to competition from emerg-
ing countries. French perceptions of the overall image
of industry are also much more pessimistic than those
of people in China and America: only 36% see it as an
appealing sector of the economy, especially for young
people, compared with 82% in China and 67% in the
USA. Far from adopting the traditionally downbeat
attitude to industry, people in France, China and the
USA share the same optimistic vision of industry and
the potential for economic growth it represents: re-
spondents in all three countries agree that industry is an
economic sector of the future, as long as its focus is on
cutting-edge industries (France 82%, China 83% and the
USA 87%).
SOUTH AMERICA
The countries of South America are at different stages
of economic development, with cement industries of
varying size and ages. Nine countries, namely Argentina,
Bolivia, Chile, Colombia, Ecuador, Paraguay, Peru, Uruguay
and Venezuela, have integrated cement facilities. These
have a combined cement industry that is the same size as
that Argentina
of Brazil, which is not covered in this review.
1212
1010
Cement production (Mt)
88
66
44
22
00
GDP/capita (red) in 2011
US$ and cement production
in million tonnes (blue) for
Argentina, 1991 - 2011.
GDP US$755bn
GDP/capita US$18,400
Population 42.6m
Area 2,780,400km2
Above: Summary economic
and geographical statistics
for Argentina.
Below: Summary economic
and geographical statistics
for Bolivia.
GDP US$56.1bn
GDP/capita US$5,200
Population 10.5m
Area 1,098,581km2
Below - Figure 2:
GDP/capita (red) in 2011
US$ and cement production
in million tonnes (blue) for
Bolivia, 1991 - 2011.
3.03
2.52.5
2.02
Cement production (Mt)
1.51.5
1.01
0.50.5
0.00
13 15 17 19 21
Year
globalcementMAGAZINE September 2013
REFRACTORIES
Above - Figure 3: Torn steel As expansion con-
construction parts. tinues on the hot side,
the expansion joints
close, anchors are
torn out completely
and even the com-
Right- Figure 4: Formation
of feldspathoids in products pensator movement is
that contain >35% Al2O3. reduced to zero. Even
particularly
areas lined with
tongue and groove
bricks, as shown in
Figure 2, will finally
be destroyed. The re-
sult is loss of the wear
lining, so that entire
segments can drop down and block the cyclone tip.
After that, failure of the existing insulating layer,
which is mostly made of relatively weak calcium
silicate, is only a question of time. Only if suitable in-
sulating gunning concretes such as REFRALITE® 40 G
with emergency running properties are used, can op-
erations temporarily continue.
The crystallisation forces due to the mineral con-
version are strong enough to bend anchors and
supporting brackets and even burst the steel
shell. The most impressive consequence of
this phenomenon is probably the entire
calciner housing being lifted by several
Right - Figure 5:
Friction compensator.
56 globalcementMAGAZINE September 2013
Drag-chain system
for material distribution
and discharging.
1 or 2 string material discharge
(currently) three loading and unloading conveyors, a
shredder downsizes it to the desired particle size (See
Figure 1). A modern Vecoplan shredder type VAZ 2000
MF T, is used for this application. The rotor is driven by
a patented, energy-efficient 203kW high-torque motor.
This shredder also has a built-in protection mecha-
nism that reduces the susceptibility of the cutters to
undesired interaction with hard parts of the fuel and
impurities that could not be removed (despite pre-treat-
ment of the material). This is a ‘must-have’ in view of the
quality of the RDF that is currently-available.
The pre-selected fraction of the household waste is
fed either separately or in combinationy with the waste
from agricultural biomass and shredded to <70mm in
the Vecoplan shredder.
The high level of sophistication of the materials to
be delivered (in terms of their density, moisture and the
caloric value) require an intelligent and flexible form
of storage. The loading and unloading conveyor of the
Space for expansion
The Tecnotest automatic tester
T ecnotest has been manufacturing equipment for
testing various building materials since 1968. One
such piece of testing equipment is its automatic tester
which, used with compression and flexural jigs, tests
cement samples to EN and ASTM standards.
The automatic tester can be used for tests on cellular
concrete, rock cores, soil-cement samples and similar
materials and has a single testing bay with two, coaxial
load cells having, respectively,
capacities of 20kN and 300kN.
The lower capacity load cell
is safeguarded from over-
loading by means of an
automatic deformation
arrest - the choice of dynamometer
is made simply at the touch of a button. The frame’s
columns are assembled on the crossbeams by pre-
tensioned joints. The ball seating in the oil bath has
the capacity to settle effortlessly and lock when load
increases. A guard is supplied with safety switches for
user comfort and security.
The console houses a motor pump, electric devices
and Tecnotest’s own, patented SC ‘Silent & Cold Power’
technology for extremely low heat and noise genera-
tion, even during continuous usage. The interface, also
available in a touch-screen version, is connectable to
any PC by means of Tecnotest’s TCM software, which
also enables piloting from the PC, generation of graphs
and test data processing in real time.
VICAMATIC-2: New automatic setting
time tester for cement and mortar
C ONTROLS has long tradition in designing and
manufacturing automatic setting-time test-
ers and a new generation is now available. The new
machine has been completely re-designed following
the innovative ‘CVi-TECH’ philosophy built on four
key principles: efficient technology, intuitive and
smart software, functional and industrial design and
modular expandability.
The new VICAMATIC-2 features superior func-
tionality thanks to the easy-to-use interface and
software, the large accessibility to the test space, the
The industrial plant of tomorrow
Respondents in China, France and the US share the
same vision of the industrial plant of tomorrow. Most
importantly, it will be innovative (88%, 93% and 84%
respectively), international in outlook (85%, 87% and
81%) and more environmentally friendly as a result of
reducing its consumption of energy and raw materials
(81%, 86% and 83%). The most optimistic views come
from China, where there is clear confidence about what
the industrial plant of tomorrow will be, and very high
expectations about its more effective integration into the
urban environment (63%, compared with 15% in France
and 23% in the USA). When asked about the possibility
of building clean industrial plants, the Chinese feel that
this would not be possible at the moment, but could be
envisaged in the future (56%, compared with only 23%
in France and 19% in the USA).
The current state of the Chinese industry crystallises
high expectations amongst the population in respect of
environmental protection: 63% of Chinese respondents
cite this value as the most important to be respected by
any industrial plant, compared with only 46% of French
respondents and 40% of Americans. Frédéric Sanchez,
Fives Group Executive Board Chairman, commented on
the outcomes, saying, “Despite being at different stages
in their industrial history, the expectations of our stake-
holders are the same in all three countries. It is therefore
up to us in industry to work towards delivering the in-
novative solutions that respond to those expectations.
That is the ambition of Fives, which supplies equipment
and industrial plants that impose less impact on the en-
vironment and are more eco-friendly.”
It began with the establishment of the SOBOCE
(Sociedad Boliviana de Cemento) Viacha plant in
1928. Initially with a capacity of 65t/day, the plant has
since expanded to 0.5Mt/yr. Today SOBOCE has an
integrated capacity of 0.7Mt/yr over two plants. The
remainder of the industry is split between four cement
players, which share 2.0Mt/yr of capacity between
them. The USGS reports that Bolivia produced 2.8Mt
of cement in 2011 (See Figure 1).
In the coming years FANCESA will set up a plant at
Maragua and a new state-owned company Ecebol will
set up a 0.7Mt/yr plant in 2014.
Chile
Chile declared independence from colonial Spain
in 1810 but was only decisively victorious in 1818.
Gradually developing, its 20th Century history saw
a mixture of progressive, conservative and socialist
Above - Figure 1:
governments. Between 1973 and 1990 Chile was ruled
by military strongman Augusto Pinochet, who rose to
power in a coup-d’etat. He was replaced by a demo-
cratically-elected President. This has led to increased
stability and economic progress, allowing Chile to take
Chile
a leading political position in South America.
20000
20,000
15000
5,000
GDP/capita (US$)1
10000
10,000
5000
5000
00
1 3 5 7 9 11 13 15 17 19 21
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
Cement industry
Chile has seven integrated cement
plants with a combined capacity GDP/capita US$18,700
of 5.5Mt/yr. The plants are mainly Population 17.2m
located in the centre of the coun- Area 756,102km2
try close to the capital Santiago,
with one plant in the north. Chile’s
largest producer is Cementos Bío Bío (CBB), which
has 2.4Mt/yr (44% of Chilean capacity) across four
sites. CBB was formed in 1957 with a capacity of just
0.12Mt/yr at Talcahuano. CBB expanded in 1978 with
the acquisition of the INACESA (National Cement)
plant at Antofagasta.
In 1995, CBB constructed a new line at Curico.
Also in 1995 the Talcahuano plant reached 0.75Mt/
yr. In mid-1998 it launched a 0.5Mt/yr expansion at
Antofagasta. The 1Mt/yr Curico plant was completed
by the end of the same year.
Elsewhere, Cemento Mélon has been part of
Lafarge since 2000. Mélon has a single cement plant at
La Calera, with a total capacity of 0.85Mt/yr. Cemen-
tos Polpaico, which is a Holcim subsidiary, operates
the largest cement plant in the country, the 1.6Mt/yr
facility at Cerro Blanco.
69
Global technology, trends & AFR
6 Diary dates
centimetres. Unfortunately, this
damage is usually discovered only
when it is too late for preventive
measures (See Figure 3).
Taking downtime, repair costs
and the considerable safety risk
during inspection and repair into
account, one has enough convincing
8 Refractories round-up - Part 1
arguments for providing a suit-
able technical solution right from
the start.
In the temperature range of 700-
800°C, refractory concretes and
bricks with medium to high alumina
content (35-75%) are converted into
Without addition of SiC
13 KRONEX® 20 / REFRACLAY 25 - An extension of the
strong
alkali-resistant lining concept
crystalline alkali-alumino silicates of the feldspar and
feldspathoids group (See Figure 4). The fine-grained
matrix as well as the coarser grains of the alumina car-
rier are affected by this. A prerequisite for this is the
presence of gaseous alkali oxides. So, the more intense
the progress of mineral conversion up to a concen-
tration of about 75% Al2O3, the higher the alumina
18 Refractries round-up - Part 2
component in the refractory material. Typical mineral
phases are therefore leucite, kalsilite, carnegieite
and nepheline (among others). The associated ir-
reversible increase in volume of up to 20% due
to recrystallisation into feldspathoids leads to
surface cracks and spalling (alkali bursting) as
also seen in kiln operation.2
20 DG Khan: Prepared for the future
24 Laboratory and testing round-up
ALTERNATIVE FUELS
30 Silos in the cement industry
34 Grinding contracts and news
1 or 2 string material inlet
Left - Figure 2:
Section view of a filled
loading and unloading
conveyor system.
Stored material 36 Valves in the cement industry
company Vecoplan AG, which has demonstrated suc-
cess worldwide, exactly matches these requirements.
The storage system has already proven itself hundreds
of times in the past and has been successfully used for
many years for alternative fuels in cement plants. The
loading and unloading conveyor, like the storage sys-
tems, is also suitable for ATEX protection areas.
In this storage system, the material is spread by
a huge drag chain conveyor that hangs via steel wires
from the ceiling (See Figure 2). In this way the mate-
rial is spread and delivered from above. This results in a
European cement
layer-wise storage of the fuel. Due to self-compression of
the RDF, a high storage volume can be obtained.
During discharge of the material with the scraper,
the upper layers of material can be easily removed, as
the material is released in the above-supported lay-
ers. The fuel slips over the angle of repose that was
produced during the entry in separate intermediate
bins. From there, the material gets dosed with type
37 The View from Brussels
RDF
Rice husks Left- Figure 3:
Loading and unloading
Tyre chips conveyor storage boxes
38 European cement news
globalcementMAGAZINE September 2013 21
TESTING AND ANALYSIS
48 International VDZ Congress - Programme
50 VDMA: Industrial plant manufacturing in 2012
practical in-water testing accessory and the
capability to be expanded over the time to
create a network with up to 32 independ-
ent units all controlled by a single PC
through LAN hubs.
The unit is suitable both for standard
tests and for research purposes, allowing
easy setting and storage of user-defined
test profiles including: test start delay, pen-
etration points position, manual or automatic
54 Plants of the future - Fives Group
penetration rate, free or driven falling
mode, automatic end-test detec-
tion, automatic determination of
initial and final setting time at
customisable depth thresholds.
Thermo Fisher
Scientific expands XRF
range for cement applications Above: The CONTROLS
I
VICAMATIC-2.
n less than two minutes the new 200W version
of the Thermo Scientific ARL OPTIM’X Cement
56 RWM 2013 - Preview
Analyzer delivers reliable analysis of major and minor
oxides in the raw materials and products of the ce-
ment industry. Thanks to the superior performance
Left: The Tenotest
automatic tester.
of wavelength dispersive X-ray fluorescence (XRF)
light elements like fluorine and sodium can also be
reliably determined. The compact instrument does
not require water cooling or compressed air. Tempera-
ture regulation of spectrometer and
crystals ensures excellent stability and
repeatability to comply with ASTM and
ISO regulations.
The Thermo Scientific ARL 9900
Total Cement Analyzer is a unique
XRF instrument that features an inte-
grated X-ray diffraction (XRD) system.
This permits analysis of typical phases
in raw meal, clinker and cement in ad-
dition to the major and minor oxides
usually determined for process control.
Gains of productivity can be impres-
Cement in the Americas
sive when excess quartz in raw meal
is controlled or through monitoring of
the free lime level in clinker. Thanks to
the integrated phase analysis, including
alite and belite, the instrument enables Above: 200W version of
tighter control of the kiln, lower fuel consump- Thermo Fisher Scientific
ARL OPTIM’X.
tion and better prediction of the three day
compressive strength.
Sites equipped with Thermo Scientific Below: Thermo Fisher
Cross-belt analysers can further ben- Scientific ARL 9900 Total
Cement Analyzer.
efit from the high accuracy of the lab
instrument. The recently introduced
Acculink software effectively connects
62 American cement news
any Thermo Scientific XRF analyser
with the Cross-belt analyser and synchro-
nises results between the two equipments,
thereby improving the calibration and ac-
curacy of the on-line analyser.
globalcementMAGAZINE September 2013 25
68 Retrofit and capacity increase for South America’s
A very strong attachment to industry
FUTURE INDUSTRY largest bridge scraper-reclaimer
France, China and the USA share the same positive vi-
69 Latin American cement review
sion of the values described by the terms ‘innovation’,
‘engineer’, ‘work’ and ‘enterprise’, all of which attract the
agreement of almost all those individuals interviewed.
Differences emerge over the term ‘industrial plant,’
which has positive connotations for only 55% of French
respondents, compared with 79% of Chinese respond-
ents and 69% of Americans. It is notably the case that
social perceptions of industrial plants and the working
conditions experienced by those who work in them are
where the greatest differences can be seen between the
USA and China on the one hand, and France on the
other. In the USA and China, more respondents believe
that industrial plants create jobs (90% and 86% respec-
tively, compared with 69% in France), that they create a
social link (77% and 82%, compared with 68%) and that
those who work in them are given responsibility (92%
and 65%, compared with 55%).
Interestingly, these wide discrepancies have a direct
parallel in people feeling that they are ill-informed
about industrial plants and what they do: 86% of French
respondents feel that the general public knows too lit-
tle about industrial plants, compared with only 39%
in China and 65% in the USA. Frédéric Sanchez said,
Asian cement
“Chinese and American people have a clear under-
standing of these issues: since their industrial plants are
often central to a particular region, they have a better
understanding of industry as a source of innovation and
social links. It is by throwing the doors of our industrial
plantswide open that we will sweep away the essentially
negative view held in France.”
Below: Cement plant
designed and supplied
76 Asian cement news
by Fives in Mexico.
Photo: © FD Fives.
Middle East and African cement
globalcementMAGAZINE September 2013 55
Figure 4 shows that Chilean cement production
SOUTH AMERICA
82 Middle East and African cement news
declined after peaking in 2008 at 4.6Mt. It has since
recovered to 4.4Mt in 2011 and 4.7Mt in 2012. In the
first six months of 2013, Chile produced 2.36Mt of
cement. Averaging cement production of 393,000t/
month, Chile is on course to produce 4.72Mt in 2013,
a similar amount to 2012. The country’s economy is
expected to grow by 4.6% in 2013.2 This should enable
continued growth in cement demand in the short to
Regulars and comment
medium term.
Colombia
Like Ecuador and Venezuela, the Republic of Colom-
bia emerged from the break-up of Gran Colombia in
1830. The country endured a hard 20th Century, with
periods of war, political conflict and intense battles be-
tween the government and anti-government guerilla
forces, notably the Revolutionary Armed Forces of
Colombia (FARC), which has fought to overthrow the
government for almost 50 years.
87 Global cement prices
Cement industry Below- Figure 5: GDP/capita
(red) in 2011 US$ and cement
Colombia’s 16 cement plants are mainly located in the
Colomiba
north and west of the country. As well as being large,
production in million tonnes
for Colombia, 1991 - 2011.
5.05 8000
8000 12
12.0
7000
7000
4.04 10
10.0
Cement production (Mt)
6000
Cement production (Mt)
6000
8
GDP/capita (US$)
5000 8.0
3.03 5000
4000
4000 6
6.0
2.02
3000
3000
4
4.0
2000
2000
1.01
2
2.0
88 Subscription form for Global Cement Magazine
1000
1000
0.00 00 0
0.0
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
1 3 5 7 9 11 13 15 17 19 21
Year Year
GDP US$326bn
(~13.4Mt/yr) the industry is fairly well de- Above left - Figure 4:
veloped, with Mexican multinational Cemex GDP/capita (red) in 2011 US$
and cement production in
(4.1Mt/yr) and domestic/regional player million tonnes (blue) for Chile,
Cementos Argos (6.2Mt/yr) the two main 1991 - 2011.
players up the market. Holcim is also present
Left: Summary economic
through the 2.1Mt/yr Holcim (Colombia)
89 The Last Word
and geographical statistics
Nobsa plant. Three other local players share the re- for Chile.
maining 0.75Mt/yr of capacity. Cementera San Marcos
started operations in Yumbo in the Valle del Cauca
GDP US$511bn
region of Colombia in June 2012.
Outsiders Holcim and Cemex entered the Colom- GDP/capita US$11,000
bian market in 1969 and 1996 respectively, However, Population 45.7m
Cementos Argos, which operates a number of subsidi- Area 1,138,910km2
aries, is a native Colombian group. It began operations
out of Medellín in 1934 and is the leader in cement,
Above: Summary economic
ready mix, and aggregates in the country. Since 1998, and geographical statistics
the group has been international, with units in the for Colombia.
90 Advertiser Index & Forthcoming issue features
Dominican Republic, Venezuela, Haiti and Panama.
In 2012 it acquired three cement plants in the United
States from Lafarge. These foreign plants make it the
only non-Brazilian South American cement producer
to operate cement plant assets outside its own borders.
globalcementMAGAZINE September 2013 71
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 Contents Subscribe Ad Index
DIARY DATES
XXX Congreso Técnico FICEM 9th Global Slag Conference & Exhibition
2-4 September 2013, Lima, Peru 10-11 December 2013, Dubai, UAE
www.ficem.org www.GlobalSlag.com

UNITECR 2013 1st Global Well Cem Conference & Exhibition

10-13 September 2013, Victoria, British Columbia, Canada 13-14 January 2014, Dubai, UAE - See Below
www.unitecr2013.org www.Well-Cem.com

8th Global Insulation Conference & Exhibition 1st Global Boards Conference & Exhibition
23-24 September 2013, Aachen, Germany 30-31 January 2014, London, UK
www.GlobalInsulation.com www.GlobalBoards.com

7th International VDZ Congress 2013 8th Global CemFuels Conference & Exhibition
25-27 September 2013, Düsseldorf, Germany 24-25 February 2014, Vienna, Austria
www.vdz-online.de www.CemFuels.com

12th TÇMB International Technical Seminar & Exhibition

8-10 October 2013, Antalya, Turkey
www.tcma.org.tr

13th Global Gypsum Conference & Exhibition Links to all events: www.Cement-Events.com
21-22 October 2013, Toronto, Canada
www.GlobalGypsum.com

13th NCB International Seminar & Exhibition Full 2013 Media Book: www.propubs.com/advertise
19-22 November 2013, New Delhi, India
www.ncbindia.com

13-14 JANUARY 2014 DUBAI, UAE

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1st Call for papers,

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exhibition information
and further details at

www.Well-Cem.com
CONFERENCE & EXHIBITION 2014
Sponsored by
Global Cement is pleased Arab Union for
to present the first-ever Cement and Building
conference dedicated to the Materials:
production and optimisation
of well cements. Bringing
together producers and
users in one centrally-
located venue, the Global
Well Cem conference
and exhibition will focus
on making contacts, on Founding sponsors:
networking, on technical
information exchange and
on business. If well cement is
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 Contents Subscribe Ad Index
REFRACTORIES
Compiled by Global Cement staff
BEROA Group 18

Refractory round-up - Part 1

Brokk 12
Calderys Refractory Solutions 8
Höganäs Bjuf 19
Magnesita SA 18
Essential in the high-temperature environments necessary in Magnezit Group 8
contemporary cement and lime plants, refractory bricks and monolithic Malco 19
pre-cast products are crucial for production success. Here Global Cement Möller Feuerfesttechnik 19
looks at a variety of suppliers of refractory products. The refractory focus P-D Refractories 19
continues on page 13 with a detailed look at Refratechnik’s KRONEX® 20 Prime Monolithics Pvt. Ltd 18
and REFRACLAY 25 alkali-resistant lining concept and again on page 18 REFKO Feuerfest GmbH 8
with a continuation of this supplier feature. Refract 12
Refratechnik 13-16
RHI AG 12
Vesuvius 19
vhi Group 12
Magnezit Group Wahl Refractory Solutions 12
Magnezit is a Russian refractory manufacturer with over 100 years of
production at its site in Satka, Chelyabinsk Region. It also produces
refractories at Slovmag in Lubenik (Slovakia) as well as in Ukraine
and China. It predominantly supplies the metallurgy sectors but REFKO Feuer-
also has an important interest in the cement industry, for which it fest GmbH
makes refractory bricks for rotary kilns. The company also makes
refractories for other zones in the cement plant where there are high- REFKO Feuerfest
temperature processes. is a market leader in
For the kiln Magnezit supplies a range of products for the: 1. monolithic refractory
Cooling zone; 2. Lower transitional zone; 3. Sintering zone; 4. Upper products for the cement in-
transitional zone and; 5. Preparation zone of the kiln. dustry, manufacturing products
for the whole process: from
the ceramic shock blower to
entire kiln hood and bull nose
systems. REFKO’s ZSI material
concept offers very high chemical
5
resistance, high abrasion resistance
and extreme thermal shock stability.
REFKO was one of the first global sup-
pliers to establish this material concept,
1 2 3 4 which is based on a combination of SiC
and ZrO2.
Calderys Refractory Solutions
Calderys has been working for over 100 years with successful
activity in the global cement and lime industries and is a major its high mechanical strength and abrasion resistance. To withstand
reference supplier. Its pioneering implementation of innovative corrosion, specific materials (such as Silicon Carbide or Zircon)
monolithic products and design solutions safeguard profitability can be added to increase the alkali resistance of the castable. For
thanks to regular operating conditions, reduced downtime and example, the CALDE™ CAST NA 48 SA QD, a Quick Dry product
longer repair cycles. developed specifically for the cement plant, demonstrates high re-
Calderys’ worldwide presence and local experience allows it sistance to alkali. In addition, a family of low cement castables with
to offer the most suitable and cost-effective technical solutions an alkali resistant matrix has recently been developed and installed
and contribute to its customers’ productivity and efficiency. For with excellent results. It does not contain any additives, which are
the cement industry, Calderys is chiefly concerned with supply- often known to decompose in high temperatures and environ-
ing products that ensure the safety, reliability and productivity ments containing alternative fuels like sludge (among others).
of equipment, prevent build-up (even when burning alternative The cement industry also demands short stoppages and fast
fuels), feature abrasion resistant lining and are alkali resistant. installations. Calderys was the first to bring to the market two
All units suffer from severe abrasion and strong corrosion by dedicated product ranges adapted to the new gunning technolo-
alkali, sulphur and chloride, coming from the raw meal, the fuels gies—CALDE™ SPRAYCAST for shotcreting and CALDE™ GUN
and alternative fuels. Calderys has developed a dedicated product L for low porosity dense gunning. Both ranges are low cement
range that meets the requirements of the specific cement plant wear products with high abrasion and alkali resistance. Calderys has
conditions for abrasion and corrosion. Against abrasion, Calderys also developed a specific range of Quick Dry monolithic refractory
offers the CALDE™ CAST GIBRAM, which is used worldwide for products, which can reduce the dry-out time by 50%.

8 globalcementMAGAZINE September 2013

 Refractories AND MORE
First in Quality!

Unshaped
monolithic materials Fast heat up Ceramic shock blower

Bull nose preshaped block Anchor concepts:

system Seal anchor Preshaped block systems

REFKO Deutschland

Concordiastraße
D-56235 Ransbach-Baumbach

Tel : + 49 (0) 26 23 - 2075

www.refko.de
Fax: + 49 (0) 26 23 - 1738

email: info@refko.de
REFRACTORIES

RHI AG
RHI AG is a world-leader in refractory products for the cement industry, pro-
ducing magnesite bricks, alumina bricks, alumina monolithics and castables,
insulation material and mortars. It can provide refractory materials for the ro-
tary kilns, preheater cyclones, calciners, riser ducts, inlet chambers, kiln hood
and grate coolers and planetary coolers. Its global brands include ANKRAL,
REXAL, RESISTAL, MAXIAL, COMPRIT and DIDURIT.
The image shows Miguel Cano, head of operations at RHI, firing a new kiln
at RHI’s Dalian refractory plant in China in 2010 for the first time.

Wahl Refractory Solutions

Wahl Refractory Solutions produces hybrid precast thimbles, nose blocks,
dampers and lifter and tumbler refractory products for the mineral
processing sector.
For environments requiring extreme abrasion resistance and strength,
like those found in the cement industry, Wahl’s SIFCA® or WIREMAX pre-
cast shapes can be used. These are a modular block design that install in less
than 30 minutes per block. They have a long lasting design custom tailored
to the sector’s demanding needs. Wahl has installed nose blocks (shown) in
more than 100 locations worldwide.
Brokk
Brokk is a leading supplier of
remote-controlled cleaning,
demolition and refractory
installation equipment. In the
cement industry, its expertise
often means that its equip-
ment is applied to cleaning
and re-bricking applications in
hard-to-reach and potentially
dangerous spaces like the in-
side of rotary kilns. The Brokk
90, Brokk 300 and Brokk 50
are routinely used for these
purposes.
The image
shows a Brokk
330 stripping
the refractory
lining inside a
rotary kiln.
vhi Group
vhi manufactures round bar anchors for refractory
installations with diameters of 4-12mm. Various ver-
sions of anchors satisfy the requirements of different
applications and types of mounting.
While the connector of the anchoring to the steel
casing of the component part is able to absorb con-
siderable force, special attention must be paid to the
transmission of retention forces into the refractory
concrete. The corrugation of the anchor is decisive in
this respect, by which one means the depth of cor-
rugation in relation to the diameter of the anchor.
The corrugation of anchoring manufactured by vhi is
usually 1.0 d. Where special demands are placed on
the mounting, we recommend corrugation of 1.5 d or
the use of anchors with double corrugation.
The angle of spread is generally 80°. This can be
changed for longer installation lengths in order to
maintain a small distance between anchor ends. This
takes place either using a smaller angle of spread
along the entire installation length or using a smaller
angle in the lower part with a wider angle at the
upper end of the anchor.

Refract
Refract is a refractory installation contractor that leads and manages installa-
tion teams during refractory installations. It ensures effective communication
between suppliers, the installation team and customer so that projects proceed
according to plan and any issues can be resolved quickly and effectively. It has
over 70 references for major international, regional and local cement producers
in countries all over the world. Photo taken by Silvio Dreysse of Refract.

12 globalcementMAGAZINE September 2013

 Contents Subscribe Ad Index
REFRACTORIES
Dirk Basten & Klaus Kassau, Refratechnik Cement GmbH

KRONEX® 20 / REFRACLAY 25 - An extension

of the alkali-resistant lining concept

The refractory products

KRONEX® 20 and
REFRACLAY 25 are a
technically worthwhile
addition to the high-
grade alkali resistant (AR)
lining concept that was
introduced a few years
ago (See Figure 1). These
products permit a cost-
optimised expansion
of Refratechnik Cement
GmbH’s standard
refractory solutions as well
as its premium solutions.

W KRONEX® 30, REFRACLAY 40 LCC, and high-quality Above - Figure 1:

ith this new development, Refratechnik
Typical appearance of
Cement GmbH has reacted to the contin- AR products containing SiC and zirconium oxide, KRONEX® 20 (left) and
uously-increasing use of alternative fuels and the every refractory requirement in the entire cement pre- REFRACLAY 25 (right).
associated problems of these, especially in preheaters. heater can now be satisfied in the optimum manner.
Refratechnik Cement GmbH’s extended AR lining Particular features of KRONEX® 20 and REFRA-
concept merges together the established combina- CLAY 25 / MCG / JC are their lower density, their
tion of professional refractory consultation, material alkali resistance and their resistance to unwanted min-
selection, detailed refractory engineering and expert eral after-expansion.
installation, including its supervision, into a modern, Regarding the preheater, unwanted mineral after-
customised refractory package. KRONEX® 20 and expansion of the refractory material in the two lowest
REFRACLAY 25 impressively demonstrate that fur- cyclone stages, and also in the entire calciner, can
ther technical developments do not always mean ‘even often be observed after just a few years. The standard
better, more complex and more expensive.’ alumina materials with an Al2O3 content of at least
More than any other refractory producer, 35%, which are typically used in these areas, are always
Below - Figure 2:
Refratechnik Cement GmbH has documented, affected. Bricks, as well as refractory concretes, show Bulging of refractory lining
evaluated and applied its experience in the design and the typical protrusion and bulging of the bricked or at cyclone sidewall.1
installation of complete new plants for the purpose casted/gunned wall areas.
of technical optimisation. Also from this
experience come the latest developments:
the highly acid and alkali-resistant alumina
product KRONEX® 20 as a brick, and RE-
FRACLAY 25 / MCG / JC, which is intended
as a castable, dry gunning concrete and as
JETCAST® concrete.
As a result, Refratechnik Cement GmbH
now provides a full range of modern
refractory linings in the field of highly-
acidic fireclay materials. Together with the
proven, alkali-resistant fireclay materials,

globalcementMAGAZINE September 2013 13

REFRACTORIES
Above - Figure 3: Torn steel
construction parts.
Right- Figure 4: Formation
of feldspathoids in products
that contain >35% Al2O3,
without addition of SiC.
Right - Figure 5:
Friction compensator.
14 globalcementMAGAZINE September 2013
centimetres. Unfortunately, this
damage is usually discovered only
when it is too late for preventive
measures (See Figure 3).
Taking downtime, repair costs
and the considerable safety risk
during inspection and repair into
account, one has enough convincing
arguments for providing a suit-
able technical solution right from
the start.
In the temperature range of 700-
800°C, refractory concretes and
bricks with medium to high alumina
content (35-75%) are converted into
As expansion con-
tinues on the hot side,
the expansion joints
close, anchors are
torn out completely
and even the com-
pensator movement is
reduced to zero. Even
particularly strong
areas lined with
tongue and groove
bricks, as shown in
Figure 2, will finally
be destroyed. The re-
sult is loss of the wear
lining, so that entire
segments can drop down and block the cyclone tip. crystalline alkali-alumino silicates of the feldspar and
After that, failure of the existing insulating layer, feldspathoids group (See Figure 4). The fine-grained
which is mostly made of relatively weak calcium matrix as well as the coarser grains of the alumina car-
silicate, is only a question of time. Only if suitable in- rier are affected by this. A prerequisite for this is the
sulating gunning concretes such as REFRALITE® 40 G presence of gaseous alkali oxides. So, the more intense
with emergency running properties are used, can op- the progress of mineral conversion up to a concen-
erations temporarily continue. tration of about 75% Al2O3, the higher the alumina
The crystallisation forces due to the mineral con- component in the refractory material. Typical mineral
version are strong enough to bend anchors and phases are therefore leucite, kalsilite, carnegieite
supporting brackets and even burst the steel and nepheline (among others). The associated ir-
shell. The most impressive consequence of reversible increase in volume of up to 20% due
this phenomenon is probably the entire to recrystallisation into feldspathoids leads to
calciner housing being lifted by several surface cracks and spalling (alkali bursting) as
also seen in kiln operation.2

Alkali cup tests at 1100°C / 5hr
KRONEX® 20
If the mineral phase conversion penetrates deeper
into the refractory lining, this is known as after-ex-
pansion. At the start of this relatively slow process, the
volume increase is partially absorbed by the existing
expansion joints. However, as soon as the expansion
joints remain closed when cold, stress build-up in the
brickwork is inevitable, with destructive
results. Therefore, regular inspection of
the expansion joints during downtime
periods provides important indications
regarding the progress of after-expan-
sion. Consequently, routine expansion
joint inspections are recommended.
The critical wall areas in the calciner
and the lower cyclone stages should
be checked regularly and be re-
worked if necessary by cutting
free the expansion joints and
refilling with insulating material.
An alternative technical de-
sign option to absorb
Calciner
the growing pressure (falling part)
in the medium term,
is the friction compensator
(See Figure 5). In combination
with an optimised refractory
design, this instrument, which
was developed by Refratechnik
Cement GmbH, is particularly
suited for use in the cylindrical sections
of the calciner. The friction compensa-
tor can be installed together with the
initial lining, but it can also be retrofit-
ted with ease.
Another option for preventing after-
expansion is a change to higher-grade SiC
and zirconium oxide containing AR products. Due to
oxidation of the SiC in the matrix, the proportion of
alkali resistant acid components is increased, while the
alumina component is simultaneously reduced by the
zirconium oxide. At corresponding temperatures, a
dense glassy protective layer is formed on the material
surface, which helps to inhibit after-expansion.3
A genuine refractory solution is provided by the
new products KRONEX® 20 and REFRACLAY 25.
REFRACTORIES
REFRACLAY 25
Here, the proportion of acid components has been Above - Figure 6: Cup
corrosion tests, proving high
increased so far that only real feldspars with reduced
resistance to alkali attack.
volume increase (of about 1%) are formed due to the
very low Al2O3/SiO2 ratio. As can be seen in the cup
tests, after-expansion occurs far less (or even not at
all) at temperatures up to 1100°C (See Figure 6). This
advantage of the acidic fireclay material can be used
to provide reliable protection against after-expansion
in all areas of the preheater as far as permitted by
the temperatures.
The fields of application of the new,
highly-acidic fireclay materials
Cyclone KRONEX® 20 and REFRACLAY 25
include all cyclone stages, as well as
the falling part of the calciner (Figure 7).
All cylindrically shaped areas and, if possible,
roofs, can be lined using Refratechnik Cement
GmbH’s innovative tongue and groove brick
concept. Depending on specifications and the on-
site possibilities, castables, dry gunning concretes Left - Figure 7: Fields of
application of KRONEX® 20
or JC concretes are used for all other wall areas.
and REFRACLAY 25.
The refractory concept is rounded off by the use
of application-specific insulating gunning con-
cretes with emergency running properties, such as
Cooler
(cold part)
REFRALITE® 20 G, 30 G, and 40 G.
Refratechnik Cement GmbH designs the
preheater in all new plants with the new refractory
materials as a standard procedure. The use of bricks
in the cooler and in the calcining zone of the kiln is
already being discussed.
Apart from the above benefits, the application of
products with considerably lower Al2O3 contents, such
as KRONEX® 20 and the refractory concretes of the
REFRACLAY 25 group, offers several other interesting
advantages (See Figure 8).
The bulk density is considerably lower, by 5-7%.
Compared with a standard fireclay or a high-grade,
globalcementMAGAZINE September 2013 15
REFRACTORIES
Conventional bricks
containing 35% SiC-containing bricks
alumina
Bulk density (g/cm3) 2.20 2.30-2.45
Apparent porosity (%) 14-16
Cold crushing 65
strength (N/mm2)
Right - Figure 8:
Refractoriness under 1350
Alkali-resistance of
alumina products. load (ta) (°C)
Thermal conductivity at 1.1
700°C (W/°C)
Alkali-resistance Poor Very good
SiC-containing alumina material, this leads to an at-
tractive weight-saving and cost-reducing potential of
15-50%. Particularly in the preheater, which accounts
for more than 50% of the total refractory tonnage,
simply this reduction in weight is a decisive advantage
over standard or high-grade materials. Together with
the attractive price per tonne and the technically-
innovative solution to counteract after-expansion, the
result is a significant technical and commercial advan-
tage when compared with standard linings.
The thermal conductivity of KRONEX® 20 is nearly
40% lower than that of SiC-containing products and
even 10% lower than that of conventional fireclay
materials (see Figure 8). Taking the typically very long
lifetime in the preheater into account, this leads to an
additional significant energy saving potential.
Thanks to the considerably lower alumina content
and the very favourable alumina/SiO2 ratio, the mate-
rials offer very good alkali resistance and protection
against possible after-expansion, which could lead to
high repair and downtime costs.
Refractoriness is 1200°C (ta). During normal
operation, this value lies far above the temperature
ranges specified by the plant manufacturers. Even
short-term maximum values above 1200°C are
no problem, as the application-limiting tempera-
ture of more than 1350°C for KRONEX® 20 offers
adequate reserves.
Within the intended operating range, the slightly
lower cold crushing strength compared to that of
standard fireclay is completely adequate. Normally,
the raw material exists in the form of extremely fine
meal, so that, for temperature-related reasons, abrasive
clinker minerals will not appear.
Summary
With the introduction of its high-grade AR prod-
ucts (KRONAL® series, SiC-containing and Z AR
castables), Refratechnik Cement GmbH has made
pioneering developments, particularly in the highly
16 globalcementMAGAZINE September 2013
KRONEX® 20 REFRACLAY 25
2.00-2.15 2.00
13-15 17-19 21
70 40 45
1450 1200 1200
1.6 1.0 1.1
Very good Very good
thermochemically stressed areas of preheater, kiln
hood and cooler.
After the installation of several thousand tonnes of
the new products REFRACLAY 25 and KRONEX® 20
in more than 30 modern plant types and plant units,
the new products have become firmly established and
have been fully accepted by cement producers and
plant manufacturers. In combination with the new
easy-to-install REFRALITE® insulating concretes, a
technically high-grade, but extremely economic sys-
tem solution is available. This has already convinced
many customers to use some of the named products
in their new project. The application in other areas
(rising section of calciner and cold section of cooler,
as well as the inlet zone of the kiln) is presently the
subject of intensive discussions.
All known conventional refractory installation
systems can be used. The castables, gunning and
JETCAST® concretes of the REFRACLAY 25 range
are available, just as KRONEX® 20 bricks for lin-
ing cylindrical and roof sections using Refratechnik
Cement GmbH’s standard tongue and groove shapes.
With its highly acidic (low alumina content), alkali-
resistant products KRONEX® 20 and REFRACLAY 25
/ JC / MCG, Refratechnik Cement GmbH has created
another important product range that supplements the
existing and successful alkali-resistant systems in an
optimum manner.
References
1. Södje, J. ‘Refratechnik investigative report no. 90/08,’ Göttingen,
Germany, 2008.
2. Freund, H. ‘Handbuch der Mikroskopie in der Technik,’ Vol. IV, part
5, Umschau publisher, Frankfurt am Main, 1974.
3. Basten, D. ‘High alumina bricks with improved resistance to volatile
alkali compounds,’ Intercem Cement Technology Workshop China,
Shanghai, China, 7-9 September 2004.
 We are setting the
standards for refractory
solutions and services
Development, engineering and
installation of refractory systems
for new and existing plants

REFRATECHNIK
Refratechnik Cement GmbH
Rudolf-Winkel-Strasse 1
37079 Göttingen
Germany
Phone +49 551 69410
Fax +49 551 6941104
refra@refra.com
www.refra.com

Anz.Setting the.indd 1 05.08.13 14:34

 Contents Subscribe Ad Index
REFRACTORIES
Compiled by Global Cement staff

Refractory round-up - Part 2

A continuation of Global Cement’s look at suppliers of refractory

products and solutions. Part 1 can be seen from page 8.

Magnesita SA
Magnesita SA was created in 1939, after the discovery of
magnesite deposits in Brumado in the state of Bahia, Brazil.
Its industrial activities started in 1944 in Contagem, State
of Minas Gerais, with the production of alumina and silica-
alumina refractory products. Since 1948 it has also produced
magnesia and magnesia-chrome products.
Starting from 1960, Magnesita acquired and founded
companies for production of inputs for ingot teeming,
refractory concrete production and electro-cast grain
production among other items. These companies use raw
material obtained in Brumado for production of basic In the 1990s, a terminal port was inaugurated in Aratu, Bahia,
refractory products. The 1960s also marked the opening of the from which Magnesita now exports sintered magnesia. In the same
company capital, with the trading of its shares in the São Paulo period, the marketing department was restructured with the inten-
Stock Exchange. tion of opening up the cement sector.

Prime Monolithics Pvt. Ltd BEROA Group

Prime Monolithics Pvt. Ltd. is a manufacturer of a com- BEROA is a diversified refractory and chimney
plete range of refractory monolithics, which includes manufacturing group. It offers refractory solutions
wide variety of castables, ramming masses, refractory for rotary kilns and heat exchangers in the global
cements, insulating materials and precast refractory cement industry and various shaft kiln designs, ro-
shapes of various sizes and shapes. It caters to the needs tary and push-slab kilns in the global lime industry.
of cement producers as well as the metal industry, ther- In the cement industry it has references from Arabian Cement, Buzzi
mal power plants, foundries and the glass industry Unicem, Cemex, Holcim, Italcementi and Lafarge, among others.
among others.
Its low cement castable (LCC) product can be used
in the kiln hood, inlet zone, pre-heater tower, kiln risers,
hot-air ducting and grate cooler areas. Its medium cement
castable (MCC), which offers enhanced resistance, can also
be used in these same plant areas.
Its PCC range of gel-bonded refractory offers three-
times the abrasion resistance of its LCC product due to
the absence of CaO, FeO and MgO. In the cement industry
it can be used for the burner pipe, outlet tip casting, sus-
pension pre-heaters, ducts, cyclones, complicated-shaped
elements, exhaust gas ducts and cooler. It has the best ther-
mal shock performance in Prime Monolithic’s range.

18 globalcementMAGAZINE September 2013

 Silo systems Conveying Dosing Alternative Fuels Processing

Efficient and economic handling

of your alternative fuels
With over 40 years of experience, DI MATTEO has • ODM-DiscSCREEN SSM is used to separate oversized
set many standards in the business of handling from pourable transported material of different
alternative fuels. fractions

An excerpt of our products & services:
• The MultiFUEL system, an original DI MATTEO
concept, unites all required procedural steps on
smallest places (including unloading, storage,
dosage and feeding)
• Injector rotary valve IZS® for stable pneumatic
feeding. With a capacity of up to 30 t/h and den-
sities between app. 0,05 t/m3 and 1,3 t/m3.
• Screw conveyors: e.g. ODM-ScrewFEED and
ScrewDOS® serve as means of transportation for
horizontal to vertical handling of bulk materials

DI MATTEO Group
Römerstr. 6 - 16
D-59269 Beckum
Tel: +49 (0) 25 21. 93 44 - 0
Fax: +49 (0) 25 21. 93 44 - 32
www.dimatteo.de
info@dimatteo.de

DiMatteo Anzeige Alternative Fuels Anzeige 1-1 01-2013 2.indd 1 28.08.13 09:25
 THORWESTEN VENT

Explosion protection
for industries typically using coal, lignite, pet coke and secondary fuels

Thorwesten Vent are your experts in explosion
venting and pressure shock resistant design and
construction. Thorwesten Vent offers explosion
protection-related consultancy for the planning of
new as well as the correction of existing grinding
facilities for solid fuels. We provide for your safety!
Highly efficient self-reclosing explosion vents
Customized safety solutions comprising
engineering and hardware supply
Professional consulting and assistance

We provide for your safety

THORWESTEN VENT GmbH

Daimlerring 39 59269 Beckum / Germany . Phone. +49(0)2521/9391-0
.
thorwesten.vent@thorwesten.com . www.thorwesten.com

TW V NEU 1-1 Seite A4 04-13-02.indd 1 17.04.13 15:18

 REFRACTORIES

Möller Feuerfesttechnik Malco

Möller has specialised in the field
of refractory linings for differ-
ent industry sectors since 1966.
In the cement industry, Möller
has supplied and installed refrac-
tory linings for a large number of
plants in the cement industry both
in its home country of Germany
and abroad. It is familiar with ro-
tary kilns, grate-fired and cyclone
pre-heaters, and coolers for the pro-
duction of cement by both the dry
and wet method, whether as part of
a new line, a retrofit to an existing
line or as an ongoing maintenance
contract.
Möller has cement refractory
references in 25 countries world-
wide, including Germany, Russia,
Greece, the USA, Iran, Nigeria, In-
donesia, Vietnam and Saudi Arabia.
Vesuvius
Vesuvius has a range of refrac-
tory solutions for cement plants.
For rotary kilns it recommends a
total of nine different products,
(CRITERION® low cement castables, CERCAST™ conventional
castables, SURSHOT® shotcrete refractories, CERGUN™ conven-
tional gunmixes, ALRO® chemically-bonded bricks, NETTLE®
Founded in 1982 in Ponca City, Okla-
homa, USA, Malco is a producer of
refractory anchors for the cement
industry and other industries.
Höganäs Bjuf
Höganäs Bjuf is a diversified refractory
manufacturer that makes refractory prod-
ucts for the pre-heater, kiln, kiln hood and
cooler in the cement industry. The com-
pany has cement references in more than
60 countries on six continents.
Höganäs offers both refractory bricks
and castable materials. For the cement
industry it produces Bjuf SX, Victor 80
RK, Viking 330, Alsic 500 and Alsic 4000
bricks and Victor Korund ES QF, Dens-
cast Sicto and Denscast AXL QF castables.
It offers a wide range of suggested solutions for different areas.
The company has extensive experience of dealing with refractory linings for cement plants
that use alternative fuels. The conditions in plants that use these are often more chemically
aggressive than in plants where conventional fuels are used.
The image shows installation of Bjuf SX bricks in a tertiary air duct.
fired bricks, STEIN® fired chemically-bonded bricks, ALUMAG®
magnesia-alumina spinel bricks and CONTEX® magnesia-chrome
bricks) spread over the 1. Inlet, 2. Chain-zone, 3. Caclining zone,
4. Security zone, 5. Transition zone, 6. Burning zone and 7. Outlet.

P-D Refractories GmbH

P-D Refractories makes a very wide range of refractory products for a variety of industries,
including cement. For rotary cement kilns, it recommends a seven-zone approach,
with different regimes for the: 1. Kiln outlet,
2. Lower transition zone, 3. Burning
zone, 4. Upper-transition zone, 5.
Safety zone, 6. Calcining zone and
7. Inlet cone.

globalcementMAGAZINE September 2013 19

 Contents Subscribe Ad Index
ALTERNATIVE FUELS
Christian Pickhan & Wolfram Zschiesche, Vecoplan FuelTrack GmbH

DG Khan: Prepared for the future

Wolfram Zschiesche

Christian Pickhan

DG Khan’s cement plant at Chakwal, Pakistan, is one of the largest cement plants in
Asia. With the support of Vecoplan FuelTrack it is successfully using alternative fuels.

Above: The DG Khan

cement plant at
Chakwal, Pakistan.
C ement demand in Pakistan is strongly correlated
with gross domestic product (GDP). For a few
years, however, the growth rate of the GDP has stag-
nated in the south Asian republic. The rising cost of
fuels such as oil, diesel and coal on the international
markets (now and in the future) represents a seri-
ous threat to the economy. It is therefore logical for
Pakistani cement manufacturers to substitute their
primary fuels with alternative fuels to a very high pro-
portion in the medium term. DG Khan is a pioneer in
this field in the Pakistani cement market.
Below - Figure 1: A Founded in 1978, DG Khan has belonged to the
Vecoplan VAZ 2000 MF Nishat Group, which has been active in diversified
T crusher fed by a belt
markets since 1992. Since September of that year the
conveyor form part of
the DG Khan alternative company has also been listed on the stock market. It is
fuel system at Chakwal. currently Pakistan’s largest cement manufacturer with a
Vecoplan shredder
Material fed by VAZ 2000 MF T.
belt conveyor
capacity of 14,000t/day (4.2Mt/yr). The company oper-
ates three plants, two in Dera Ghazi Khan and another
one in Khairpur District in Chakwal.
In November 2009 DG Khan Cement and the parent
company of Vecoplan FuelTrack, Vecoplan AG, signed
a contract for an extensive system for the handling of
alternative fuels at the Chakwal plant.
With the experience gained by the German com-
pany from its decades in the field of alternative fuel
preparation, storage and promotion, Vecoplan AG is a
technology leader in this area today. With this knowl-
edge it was possible to realise a future-oriented project
for Pakistan.
As early as 2008, immediately after commissioning
of the new kiln line, DG Khan began to plan the targeted
use of alternative fuels, the first cement plant to do so in
the country. The company had earlier developed its own
experiences with the use of rice straw before it turned to
an experienced supplier.
Stage 1 of the plant at DG Khan was commissioned
in August 2010. Since then 20t/hr of alternative fuels
have been employed. The concept of a future-oriented
system was designed so that it is possible for the opera-
tor to use all available (solid) fuels on the market. In the
present operation, biomass consisting of agricultural
waste and a pre-treated light fraction from a municipal
waste processor are used. The system was designed in
a modular fashion so that it can be expanded without
interrupting the flow of material at any time.
The core element of the system is the Vecoplan stor-
age system, which is fed through a common line in
the first stage. Before the material is received by one of

20 globalcementMAGAZINE September 2013


Drag-chain system
for material distribution
and discharging.
1 or 2 string material discharge
(currently) three loading and unloading conveyors, a
shredder downsizes it to the desired particle size (See
Figure 1). A modern Vecoplan shredder type VAZ 2000
MF T is used for this application. The rotor is driven by
a patented, energy-efficient 203kW high-torque motor.
This shredder also has a built-in protection mecha-
nism that reduces the susceptibility of the cutters to
undesired interaction with hard parts of the fuel and
impurities that could not be removed (despite pre-treat-
ment of the material). This is a ‘must-have’ in view of the
quality of the RDF that is currently available.
The pre-selected fraction of the household waste is
fed either separately or in combination with the waste
from agricultural biomass and shredded to <70mm in
the Vecoplan shredder.
The high level of sophistication of the materials to
be delivered (in terms of their density, moisture and the
calorific value) require an intelligent and flexible form
of storage. The loading and unloading conveyor from
Space for expansion
RDF
Rice husks
Tyre chips
ALTERNATIVE FUELS
1 or 2 string material inlet
Left - Figure 2:
Section view of a filled
loading and unloading
conveyor system.
Stored material
the company Vecoplan AG, which has demonstrated
success worldwide, exactly matches these requirements.
The storage system has already proven itself hundreds
of times in the past and has been successfully used for
many years for alternative fuels in cement plants. The
loading and unloading conveyor, like the storage sys-
tems, is also suitable for ATEX protection areas.
In this storage system, the material is spread by
a huge drag chain conveyor that hangs via steel wires
from the ceiling (See Figure 2). In this way the mate-
rial is spread and delivered from above. This results in a
layer-wise storage of the fuel. Due to self-compression of
the RDF, a high storage volume can be obtained.
During discharge of the material with the scraper,
the upper layers of material can be easily removed, as
the material is released in the above-supported lay-
ers. The fuel slips over the angle of repose that was
produced during the entry in separate intermedi-
ate bins. From there, the material is dosed with type
Left- Figure 3:
Loading and unloading
conveyor storage boxes
globalcementMAGAZINE September 2013 21
ALTERNATIVE FUELS
Below - Figure 4:
Schematic diagram
of the VecoBelt
VFR 800.
Blower
DFS 400 frequency-controlled double screws in a
collecting conveyor.
The whole process is fully automatic and can be al-
tered at any time from the central console. The different
material streams are mixed together from all boxes ac-
cording to the calorific properties of the flow-streams.
DG Khan`s plant was planned in a modular fash-
ion to keep the investment costs low at the beginning
of stage 1. In the first stage three storage boxes are in-
stalled, (See Figure 3), to store various types of fuels.
Due to the modular design it is possible, at a later
date, to expand the storage capacity without disruption
of the current material flow. The number of storage
boxes can theoretically be as high as desired.
As a further conveying enhancement, an inexpensive
and low-maintenance closed conveying system was re-
quired to feed the calciner. For this purpose, the efficient
Vecoplan transport system VecoBelt type VFR 800 was
used. This is, as illustrated in Figure 4, a completely
closed tube in which the conveyor belt slides on an air
cushion. Fans, which are mounted at regular intervals
Left- Figure 5:
A Vecoplan VAZ 2000
MF T crusher.
22 globalcementMAGAZINE September 2013
along the conveyor path,
Air stream entry
feed a constant air flow
under the belt so that this
Belt slides, almost without
friction. Due to the low
friction, large flows can
be transported over long distances.
Thanks to the lack of casters, which are needed in
conventional conveyor belts, there are, in theory, no
maintenance catwalks required. In addition to financial
savings the visually sleek compact conveyor system
makes a positive visual
Air channels impact at the plant. The
alternative fuel is taken
to the preheater, weighed
Rollers and fed to the calciner.
DG Khan now has the
latest technology for the
use of alternative fuels in the cement manufacturing
process.
Looking ahead
Even during the early stages, DG Khan planned, with
the help of Vecoplan engineers, to not only expand the
alternative fuels facility, but also to establish a separate
alternative fuel processing line. This would give the com-
pany the possibility to have an influence on the quality
of the waste fuel from the available waste streams.
Meanwhile, Vecoplan FuelTrack, the joint venture of
ThyssenKrupp and Vecoplpan AG, dedicated to serve
the cement industry with engineering and equipment
for refuse-derived fuels, took over the further project
development for DG Kahn and is realising the alterna-
tive fuel processing line.
The structure of the processing line started in the
second quarter of 2011. The second and third stages
were mounted on this ground and have been in full op-
eration since January 2012.
Further updates from this ongoing project will be
presented in future issues of Global Cement Magazine.
REGULATES
CONTROLS
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REGULATES

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ADMINISTERS

inert
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UARANTEE OF
inert atmospheres
robecco secure center®
robecco secure center® Fully Automatic
Control Of
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Flaps Automatic
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Control Of
Temperature Sensors
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Inerting Systems
Flaps and Valves
Visually Operation dienungFunk
Temperature Sensors
and Control
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Functionally Supervising
Of SingleOperation
Visually Plant
Components dienungFunk
and Control

Functionally Supervising
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Components

Oxygen
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Fuel
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robecco GmbH
Industriepark 17 • 56593 Horhausen • Germany
Phone.: +49-2687-92626-0 • Fax: +49-2687-92626-20 • email: info@robecco.de • www.robecco.de

TESTING AND ANALYSIS
Compiled by Global Cement staff
Right: Bruker S8 TIGER
Eco ‘Cement’ caters to the
specific elemental analysis
needs of cement plants.
Below: Berthold
Technologies’ SmartSeries
LB 414 Densitometer for
liquids and slurries.
24 globalcementMAGAZINE September 2013
Contents Subscribe Ad Index
Laboratory and testing round-up
Laboratories, on-the-job testing and analysis
equipment all play a vital role in the manufacturing
and use of cement because ‘what gets monitored
gets managed’ and good process control can lead to
higher margins. Here Global Cement rounds up new
products and supplier news.
cost-efficient and can be used for many years without the need for
maintenance or re-calibration.
New Zwick Roell technical centre
Z wick Roell, a leading manufacturer of materials test-
ing equipment, has created a new technical centre for its
customers from the UK and Ireland. Located in a company
manufacturing facility in Brierley Hill, West Midlands,
England, the centre is specifically designed to help customers
evaluate technical solutions that fully satisfy their specific
testing requirements.
Simply smart - The new radiometric The new facility will help improve the company’s
densitometer SmartSeries LB 414 ability to offer more effective explanations of Zwick
B erthold Technologies has introduced a new den- Roell’s technological offerings and extensive range of
sitometer, the SmartSeries LB 414, which is based testing products and will also offer high-quality semi-
on non-contact gamma transmission technology. The nars and training sessions for customers.
detector can measure the density, concentration and
solid-content of all kinds of slurries and liquids. It The Bruker S8 TIGER Eco ‘Cement’
combines both detection and evalua-
tion in one single unit.
Besides its high level of accuracy
and repeatability, the detector’s ease of
T he brand new S8
TIGER ECO from
Bruker offers wave-
use and handling is a major advantage. length dispersive X-ray
Parameters can be set directly on the fluorescence (WDXRF)
detector or via a HART communicator, performance at a unique
PC or infrared remote control. The local low cost of ownership.
user display interface and the software, Based on Bruker’s estab-
which focuses on the main functions, lished ‘Plug ‘n Analyze’
makes calibration and operation of a technology the S8 TIGER
HART device straightforward. ECO operates with little
The SmartSeries LB 414 has been power and without any
designed for the harshest of process need for cooling water or
conditions and compressed air.
is best suited The S8 TIGER ECO
for stand- ‘Cement’ provides op-
ard density timal performance for
measurements in non- elemental analysis in a cement plant and is fully compli-
hazardous, non-explosive ant with ASTM C 114, EN 196-2 and ISO 29581. With
environments but where con- its dedicated configuration, the close monitoring of raw
ditions can be tough, for example in mix, clinker and cement is done on just one unit. The
the cement industry. SmartSeries detectors process is under control, covering all relevant elements
are characterised by their high mechanical robust- from sodium to strontium at more than 15 samples
ness, verified by the Fraunhofer Institute. They are per hour.

The Tecnotest automatic tester
T ecnotest has been manufacturing equipment for
testing various building materials since 1968. One
such piece of testing equipment is its automatic tester
which, used with compression and flexural jigs, tests
cement samples to EN and ASTM standards.
The automatic tester can be used for tests on cellular
concrete, rock cores, soil-cement samples and similar
materials and has a single testing bay with two, coaxial
load cells having, respectively,
capacities of 20kN and 300kN.
The lower capacity load cell
is safeguarded from over-
loading by means of an
automatic deformation
arrest - the choice of dynamometer
is made simply at the touch of a button. The frame’s
columns are assembled on the crossbeams by pre-
tensioned joints. The ball seating in the oil bath has
the capacity to settle effortlessly and lock when load
increases. A guard is supplied with safety switches for
user comfort and security.
The console houses a motor pump, electric devices
and Tecnotest’s own, patented SC ‘Silent & Cold Power’
technology for extremely low heat and noise genera-
tion, even during continuous usage. The interface, also
available in a touch-screen version, is connectable to
any PC by means of Tecnotest’s TCM software, which
also enables piloting from the PC, generation of graphs
and test data processing in real time.
VICAMATIC-2: New automatic setting
time tester for cement and mortar
C ONTROLS has long tradition in designing and
manufacturing automatic setting-time test-
ers and a new generation is now available. The new
machine has been completely redesigned following
the innovative ‘CVi-TECH’ philosophy built on four
key principles: efficient technology, intuitive and
smart software, functional and industrial design and
modular expandability.
The new VICAMATIC-2 features superior func-
tionality thanks to the easy-to-use interface and
software, the large accessibility to the test space, the
TESTING AND ANALYSIS
practical in-water testing accessory and
the capability to be expanded over time to
create a network with up to 32 independ-
ent units all controlled by a single PC
through LAN hubs.
The unit is suitable both for standard
tests and for research purposes, allowing
easy setting and storage of user-defined
test profiles including: test start delay, pen-
etration points position, manual or automatic
penetration rate, free or driven falling
mode, automatic end-test detec-
tion, automatic determination of
initial and final setting time at
customisable depth thresholds.
Thermo Fisher
Scientific expands XRF
range for cement applications Above: The CONTROLS
VICAMATIC-2.
I n less than two minutes the new 200W version
of the Thermo Scientific ARL OPTIM’X Cement
Analyzer delivers reliable analysis of major and minor
Left: The Tecnotest
oxides in raw materials and products of the cement automatic tester.
industry. Thanks to the superior performance of
wavelength dispersive X-ray fluorescence (XRF) light
elements like fluorine and sodium can also be reli-
ably determined. The compact instrument does not
require water cooling or compressed air. Tempera-
ture regulation of spectrometer and
crystals ensures excellent stability and
repeatability to comply with ASTM and
ISO regulations.
The Thermo Scientific ARL 9900
Total Cement Analyzer is a unique
XRF instrument that features an inte-
grated X-ray diffraction (XRD) system.
This permits analysis of typical phases
in raw meal, clinker and cement in ad-
dition to the major and minor oxides
usually determined for process control.
Gains in productivity can be impres-
sive when excess quartz in raw meal
is controlled or through monitoring of
the free lime level in clinker. Thanks to
the integrated phase analysis, including
alite and belite, the instrument enables Above: 200W version of
tighter control of the kiln, lower fuel consump- Thermo Fisher Scientific
tion and better prediction of the three day ARL OPTIM’X.
compressive strength.
Sites equipped with Thermo Scientific
Cross-belt analysers can further ben-
efit from the high accuracy of the lab
Below: Thermo Fisher
Scientific ARL 9900 Total
Cement Analyzer.
instrument. The recently introduced
Acculink software effectively connects
any Thermo Scientific XRF analyser
with the Cross-belt analyser and syn-
chronises results between the two units,
thereby improving the calibration and ac-
curacy of the on-line analyser.
globalcementMAGAZINE September 2013 25
TESTING AND ANALYSIS
Sulphur and carbon testing with the
632 Series from LECO

T he 632 Series from LECO uses high-temperature

combustion followed by infrared detection to
quickly and accurately determine the sulphur and
carbon content in raw cement ingredients, including
limestone, cement products and solid kiln fuels such
as coal, coke and alternative fuels.
Its state-of-the-art design uses
an ASTM-approved technique to
determine sulphur and carbon
simultaneously or individually.
Features include a six-element
heating furnace that is capable of a
Right: LECO’s 632 Series maximum temperature of 1450°C
accurately determines
and a combustion tube with an
sulphur and carbon content
of cement raw ingredients oxygen lance that decreases
and fuels. analysis time and ensures
full recovery of sulphur
from refractory materials.
An optional 50-sample
autoloader increases pro-
ductivity dramatically.

TESTING Bluhm & Feuerherdt Cemtec integrates Insitec sensors

T ESTING Bluhm & Feuerherdt GmbH has been
producing testing equipment for building ma-
terials for more than 30 years and operates very
successfully in Germany and in the international
markets. ‘Made in Germany’ labelling symbolises the
outstanding quality of its products. It has been DIN
EN ISO 9001-certified since 1996.
TESTING Bluhm & Feuerherdt produces testing
equipment for cement, mortar, concrete and other
building materials; Plans and installs complete cement
and concrete laboratories; Provides laboratory equip-
Below: TESTING laboratory ment for schools and universities and; makes stainless
equipment. steel laboratory furniture.
from Malvern Instruments
C emtec, a specialist provider of grinding tech-
nologies for the mining, mineral and cement
industries, is using Insitec real-time particle sizing
technology from Malvern Instruments to provide
fully-integrated, automated milling solutions that
deliver high efficiency at competitive cost. The in-
stallation of an Insitec system for the control of dry
milling at Cemtec’s extensive pilot plant facility now
enables customers of both companies to see how real-
time particle sizing can help process performance.
“Increasingly customers are looking for us to
provide turnkey, often automated, milling circuits,
rather than a stand alone mill,” said Mr Plochberger,
head of research and development and process
technology at Cemtec. “Timely particle size meas-
urement is vital for efficient mill control, which
is why we wanted to be able to integrate a trusted
sensor within our processing solutions. Insitec is
extremely reliable and enables us to provide mill-
ing plant for both wet and dry processing that
efficiently meets customer goals for premium
product quality and low energy consumption.”
Insitec particle size analysers enable the real-
time measurement of both wet and dry process
streams with particles or droplets in the size
range 0.1-2500µm. Built specifically for the plant
environment, they are robust and reliable, de-
manding minimal maintenance but delivering
consistent measurement, 24 hours a day, seven
days a week. The resulting data provides a secure
basis for automated mill control, which typically
reduces waste and energy consumption while
at the same time enhancing product quality and
increasing throughput.

26 globalcementMAGAZINE September 2013

 Industry-leading productivity?
Absolutely.

To power your operation while lowering consumption we provide you with stable and
highly efficient electrical energy supply, distribution and conditioning. ABB’s process
optimization and control systems help you increase productivity and engineering
efficiency, ensure environmental compliance and maintain product quality. High-tech
drive systems improve dynamic performance and reduce power losses. ABB’s
solutions and products help you maximize your return on project investment and
achieve industry-leading productivity. www.abb.com/cement

© 2012 ABB. All rights reserved.

 Automatic Concrete and Cement
Testing Technology
Introducing the innovative EN and ASTM compliant technologies
for the modern Cement and Concrete Laboratories

PC-controlled
Compression machine
for 2“ cubes acc. ASTM C109

Vibration table
Moist Cabinet for 2“ cube and acc. ASTM C109 / EN 196-1
three gang moulds storage
acc. ASTM C109 and EN 196-1

Automatic Blaine
Method Dyckerhoff Manual & Automatic Mortar Mixer
acc. ASTM C204 acc. ASTM C109 and EN 196-1
Air entrainment meter, 1L / 8L
ASTM C185 / C231 / DIN EN 12350-7
and DIN EN 1015-7

High Pressure Automatic Vicat

Autoclave acc. ASTM C191,
acc. ASTM C151 ASTM C472-99
and EN 196-3

Water Bath, temperature controlled

for 2“cube samples, ASTM C109 and
prisms 40,1 x x40 x 160mm, EN 196-1

TESTING Bluhm & Feuerherdt GmbH / Motzener Strasse 26 b / 12277 Berlin / Germany
Phone: +49 30 7109645-0 / Fax: +49 30 7109645-98 / www.testing.de / info@testing.de

Qualified representatives sought worldwide

 Jolting table with counter, EN 196-1

Combined compression-flexure
testing machine, 250 / 15 kN, class 1, Bond strength tester,
digital display and servo-control, servo-control,
EN 196-1 5-10-15-20 kN
EN 1542, 1348,
1015-12
Three-gang mould
40.1 x 40 x 160 mm
EN 196-1

J-Ring, EN 12350-12

Cube mould, cast iron

Vibrating table with 150 x 150 x 150 mm
magnetic clamping EN 12390-1
Cube mould, all black plastic
device for cube moulds
Combi mould 150 x 150 x 150 mm
EN 12390-2
150 x 150 x 150 mm EN 12390-1
EN 12390-1

Water
Curing tank, EN 12390-2 Vibrating table with pedal switch impermeability
EN 12390-2 tester, EN 12390-8

Combined compression-flexure
testing machine

Flexure-testing
machine, 150 kN

Compression testing machine,

2000 / 3000 / 4000 kN

TESTING Bluhm & Feuerherdt GmbH / Motzener Strasse 26 b / 12277 Berlin / Germany
Phone: +49 30 7109645-0 / Fax: +49 30 7109645-98 / www.testing.de / info@testing.de
 Contents Subscribe Ad Index
SILOS
Global Cement staff

Silos in the cement industry

Recent installations and product news from those suppliers
that design, build, construct, maintain, clean and optimise
silos in the global cement industry...

A ‘sound’ solution for cement

movement in silos
Primasonics® Acoustic Cleaners can be used wherever
cement is stored or transported. In cement silos, they
have overcome rat-holing (where material builds up on
the sidewalls) and bridging over the outlet area.
Where the problem is rat-holing with the material
building up on the sidewalls, a low frequency, larger
Primasonics® Acoustic Cleaner is mounted on top of
each silo to dislodge and, thereafter, eliminate the build
up. These units can be located at any position on top
of the silo, as sound waves travel at over 344m/s and
in a 360° radius. They are generally mounted onto an
existing inspection hatch, allowing for simple and in-
expensive installation.
The image shows a recent installation of a PAS 75
model acoustic cleaner on a 5000t cement silo in India.

Martin® Hurricane Air Cannon

Martin® Hurricane Air Cannons improve the
flow of bulk materials and prevent outages due to
discharge blockages, buildups and rat-holes. The
Hurricane features a unique valve concept that
provides more force, uses less air and simplifies
installation and maintenance.
The Hurricane allows cement plant operators
to maximise the discharge strength from high ve-
locity output with half the air volume, reducing
operating costs. Additionally, the complete valve
assembly can be removed in one easy step, work-
ing from one side of the tank. It can be replaced
within minutes to keep processes running. There
is no need to ever remove the tank from the ves-
sel for service.

30 globalcementMAGAZINE September 2013

 SILOS

New Morino vacuum truck for silo cleaning

The photo shows a brand new Morino vacuum truck, a unique and customised installation. It
is a modern semi-trailer with an 18m3 tank that is powered by a Caterpillar C9 engine, capa-
ble of sucking up to 8000m3/hr and blowing thanks to two SiloKing 700 screw compressors.
This machine is used by Morino to clean the bottoms of the silos, particularly cement,
raw concrete, clinker and raw material silos that present the classic problem of dead stock.
Thereafter, the material is removed and crushed and can be discharged into elevators or into
other silos, thus avoiding dust and noise inconvenience.

UWT Level Control: Rapid, accurate and precise silo

measurement in Malaysia
UWT GmbH – Level Control is a producer of level measurement systems for bulk sol-
ids, including clinker, limestone and cement in silos. Recently, a Malaysian customer
was looking for a reliable and accurate measuring technology for its cement storage
silos, which presented a challenging, dusty environment that was complicated by the
humid climate.
After a visit by UWT’s local sales partner, the customer chose to go for a trial instal-
lation of UWT’s NIVOBOB® NB4000 electromechanical solution. Following a number of
weeks of reliable measurement, the customer decided to equip more silos and other applica-
tions with this measuring device due to its easy installation and high precision and accuracy.

A Gironet reaching down into a

storage silo.

The Gironet®: A unique silo

cleaning system
With strong experience in declogging devices,
Standard Industrie International has devel-
oped a unique process to clean storage units in
total safety: the Gironet®. Indeed, a large num-
ber of fine powder producers and users are
sooner or later faced with a clogging problem.
By sticking to the walls of silos and hoppers,
products such as cement, lime or gypsum will
hinder their own evacuation. This causes a
chronic slowdown in production and a reduc-
tion of storage capacity.
The Gironet®, made with a motorised
cleaning tool and an articulated arm, has been
designed to cope with this problem. With 360°
rotation, it provides effective cleaning of all
types of silos, regardless of the diameter. Fully
mechanised and remotely controlled, the
Gironet® process ensures safe intervention,
without a human present inside the silo and
Background: American Cement Company LLC in Florida, USA. An Aumund clinker elevator (left) feeds thus without the risk of injury.
clinker to a silo (centre), which is then processed in a mill house (right) and taken to cement silos (far right).

globalcementMAGAZINE September 2013 31

SILOS

Bolted cement silo from Assentoft Silo in Norway

In the summer of 2012 Assentoft Silo A/S designed, manufactured and erected a 3150m3 cement silo
for Dyrøy Betong in Ålesund, Norway. The 12.36m diameter silo is made from hot-dip galvanised steel
sheets, which are bolted together on site. The silo is equipped with a 45° steel cone and erected upon a
concrete bottom section, prepared by the customer. The complete installation, including erection of the
silo, fitting of filling pipes, filters, augers and other equipment was performed in 10 weeks.
The bottom section has a free throughfare for direct weighing and unloading into trucks.The silo
includes aeration cloth in the steel cone for fluidising the material when unloading. Loading into the
silo is performed via pipes from the quay to silo top.

IBAU HAMBURG: Success

The world’s largest multi-
compartment silo, built by IBAU
HAMBURG in 2010 for Cementa
AB / Heidelberg-Cement in
Malmö, Sweden.
Endress+Hauser: Safe, precise
and efficient silo measurement
Free-space radar metrology has recently posi-
tioned itself beside tried-and-tested ultrasonics
as a state-of-the-art technology for silo level measurement. The
advantage of free-space level measurement is in the non-
contact sensing of the bulk solids.
For cement plant process engineers, a robust
radar design and reliable measurement are the basis
of their automation technology selection. The Micropi-
lot FMR56/57 free-space radar family with ‘multi-echo
tracking’ from Endress+Hauser has new innovative evalu-
ation algorithms that continuously regulate each level echo
signal and monitor the signal curve to remove and com-
pensate for all ambiguous signals.
All echo signals are initially marked, taking into account
the short and long-term history. These include, for instance,
the level and false echoes that are caused by components or
dual echoes. Afterwards, these echoes are monitored and
undergo a plausibility check. Thanks to the new analysis and
the auto-adaptive algorithms, the level signal is recorded
even if it is below the fixed target suppression line. This
ensures that reliable and precise measurement results are
always returned even in the event of strong reflections in
the silo.
The multi-echo tracking of the new free-space radar
can clearly distinguish between multiple reflections and
the current level in the chamber. This technology supplies
the operator of the plant with reliable measuring values,
even under harsh operating conditions in silos with awk-
ward geometries.
The image is of the Micropilot FMR57.
with the inverted silo cone
IBAU HAMBURG started in 1975 as
a solution provider with the patented
IBAU inverted cone silo. IBAU soon
became a major player in high-capacity
silos for pulverised materials. The
IBAU Central cone silo is the most ef-
ficient silo for the storage and dispatch
of pulverised materials such as cement,
raw meal, pulverised limestone, fly ash and other materials.
The concentration of storage, blending and dispatch for a greatly increased num-
ber of bulk materials, interground additives and mixed products calls for an efficient
and economic design, the IBAU Multicompartment silo. In almost 40 years IBAU
HAMBURG has delivered more than 8500 single cell silos and more than 650 multi-
compartment silos worldwide.
Geometrica: Metal storage domes
Geometrica has been providing metal domes to cover
the largest stockpiles of bulk materials used in the ce-
ment industry since 1992. It is well known that domes
are the most efficient solution for long span covers.
Geometrica’s domes are column-free and may span
over 300m.
Geometrica’s galvanised steel or aluminium struc-
tures make domes even more attractive because they
are maintenance-free and can be assembled by local
crews without any specialist equipment. Where un-
covered piles are already in service, these domes may
be installed over the operating piles with little or no
downtime. They are designed with conveyor, vehicle
and access openings tailored to each project. They
may be installed on uneven terrain and can be rectan-
gular, circular or even irregular in shape.
The image shows a 104m-diameter limestone storage
dome at Star Cement in Ras Al Khaimah, UAE.

32 globalcementMAGAZINE September 2013

 A Legacy of
Safety and Commitment
Mole•Master’s silo cleaning expertise can safely and efficiently
solve your two biggest problems – lost storage capacity and
downtime.

When a cement storage silo gets clogged, one of the biggest

problems is the risk of losing usable material in the cleaning
process. We understand that risk. That is why we use special
equipment so your raw meal, finished cement, or clinker will not be
damaged. Additionally, the material we clean from the silo walls can
often be reused as well, saving you material and money.

Mole•Master has completed:

• Over 500 projects in the cement industry alone

Mole•Master has worked in:

• 33 countries around the world

To download a FREE white paper on silo cleaning safety regulations,

or to request a quote, visit www.molemaster.com/cement

Phone: +01.740.374.6726 • Fax: +01.740.374.5908 • Email: info@molemaster.com

gl bal
9th

slag
10-11 DECEMBER 2013 Dubai, UAE

CONFERENCE, EXHIBITION, NETWORKING, BUSINESS AND AWARDS

Global slag markets and trading
globalslag.com
Improving slag performance
New applications for slag

Including Who should attend?

Global Slag Awards • slag producers
Gala Dinner at the • slag users
Burj Khalifa!
• cement producers
• cement users
Organised by: • equipment vendors
gl bal • traders and shippers
cement MAGAZINE
• academics & researchers

GRINDING
Global Cement staff
Grinding contracts
and news
Multiple Dangote contracts for Loesche
Africa: China’s Sinoma International Engineering Co. Ltd.
(Sinoma), which is building a cement grinding plant at Douala,
Cameroon for Nigeria’s Dangote Cement,
selected Loesche GmbH as the sole sup-
plier of vertical roller mills for the project in
March 2013.
One Loesche LM 53.3+3C mill will grind
clinker together with additives such as gyp-
sum, limestone and pozzolana. The product
rate of clinker type CEM I A-L 42.5 will be 155-
168t/hr, while the product rate of clinker type
CEM II 32.5 will be 230t/hr. To cope with the
extremely high feed moisture, the mill feed is
separated into a dry string (clinker and reject)
and a wet string (pozzolana and gypsum).
Additionally to the mill Loesche will de-
liver metal detectors and mill rotary feeders.
The supply is a split between Loesche key Loesche LM 53.3+3 mill, Ait Baha, Morocco
parts and a Chinese manufactured portion
arranged by Sinoma International under su-
pervision of Loesche. Delivery is scheduled
for the beginning of 2014.
Elsewhere in Africa, Sinoma, again on behalf of Dangote,
has also ordered mills for plants that are under construction in
Nigeria, Zambia and Ethiopia.
Loesche provides largest VRM in Bangladesh
Bangladesh: The largest ever vertical roller mill in Bangladesh’s
cement industry, owned by Bashundhara Group (BG), was in-
augurated on 12 November 2012 at a ceremony that attracted
national-level political guests in Khulna.
Mayor of Khulna, Talukdar Abdul Khaleque, along with
Managing Director of Bashundhara Group, Sayem Sobhan, and
other guests inaugurated the factory, the vertical roller mill of
which is supplied by German cement mill expert Loesche GmbH.
While addressing the BG launch ceremony mayor Khalique said
that BG had opened a door of huge employment opportunities for
the people of the region, especially in the Mongla Seaport area of
Khulna Division.
“I express my heartfelt thanks and gratitude to BG Chairman
Akbar Sobhan as he has opened the door of great opportunity
for the people of Mongla by establishing the huge industrial
complex,” said mayor Talukder Abdul Khaleque.
34 globalcementMAGAZINE September 2013
Contents Subscribe Ad Index
While many of the established mill manufacturers are
based in markets that are currently experiencing a
downturn in cement demand, they have been busy
around other parts of the globe in the past 12 months.
Medcem plant to get six Loesche mills
Turkey: The management of Medcem Madencilik ve Yapi
Malzemeleri Sanayi ve Ticaret AS, which is building the
~3.2Mt/yr cement plant in Turkey at
Silifke, ordered six vertical roller mills
for the plant from Germany’s Loe-
sche GmbH in May 2013. Delivery
to Silifke will start at the beginning
of 2014.
The order consisted of two vertical
roller mills type LM 56.6 for the grind-
ing of raw material with a product rate
of 420t/hr each at a product fineness
of 12% R DIN 0.09mm. The mill drives
of both LM 56.6 mills will each have a
capacity of 4600kW. Coal will be ground
on a Loesche mill type LM 41.4 D, which
will operate at 75 t/hr.
For clinker grinding Medcem will
rely on three Loesche vertical roller
mills, each a LM 56.3+3-type mill. Each
mill will produce 210t/hr of OPC at 3200
Blaine and 250t/hr PPC at 5500 Blaine. All mill motors for the
LM 56.3+3 C are planned to have a capacity of 5300kW.
Five Loesche mills for Chinese firm
China: In April 2013 Loesche GmbH signed a contract to
provide five mills to Shanxi Biological Cement Co. in China.
The Shanghai division of Loesche took the order for two raw
material mills and three clinker mills with complete mill key
parts, housings and frames. Shanxi Biological Cement is build-
ing two 4500t/day clinker production lines in Fu Ping and a
1.8Mt/yr ground granulated blast furnace slag (GGBFS) pro-
duction line in Gaoling.
Yura orders Loesche plant
Peru: Yura, a Gloria Group company, ordered a vertical roller
mill from Loesche America for installation at a cement plant in
Arequipa in April 2013. Yura has chosen a Loesche Mill Type LM
56.2+2 C/S to be part of a clinker and pozzolana dry-grinding
plant. The product rates will exceed 170t/hr of cement with
a fineness of 5000cm²/g Blaine. The gearbox has an installed
capacity of 4000kW.
 GRINDING

Gebr. Pfeiffer supply 100th vertical roller mill to India

India: In 1995 Kolkata-based Shree Cement was the first Indian customer to buy an MPS vertical roller mill from
Germany’s Gebr. Pfeiffer. On 6 November, 2012, Shree Cement Ltd and Gebr. Pfeiffer signed a contract for the
100th Pfeiffer vertical roller mill in India. It will be set up at the Bihar Grinding Unit.
The 100th Pfeiffer mill for India will be an MVR 6000 C-6, which incorporates the latest technological
developments of Pfeiffer vertical roller mills. A major feature of the MVR mill is the innovative ‘active re-
dundancy’ concept. The mill, which will come equipped with a variable number of grinding rollers, in this
case six rollers, can be operated even when one or two rollers must be removed from the grinding process
because of maintenance. A schematic of such a mill is shown (right).
The MVR 6000 C-6 grinding plant is designed to produce alternately 270t/hr of OPC at a product
fineness of 3500cm²/g (Blaine) or 180t/hr of ground granulated blast-furnace slag at a product fine-
ness of 4500cm²/g (Blaine). The mill has an installed drive power of 6300kW.

Gebr. Pfeiffer to strengthen its references in India

India: Gebr. Pfeiffer SE has secured an order from India’s Shree Cement in November 2012. The
deal will see the German mill maker supply an MPS 5000 B vertical roller mill with a 3400kW
drive that is designed to grind raw material at 420t/hr. The product will be classified in an inte-
grated high-efficiency classifier of the type SLS-B, Pfeiffer’s latest-generation design.
Petcoke, which is used as fuel at the works, will be ground to a fineness of 1-2%
R 90µm in an MPS 2800 BK coal mill which will come equipped
with a 720kW drive and an integrated high-efficiency classifier of
Colombian coal mill for Gebr. Pfeiffer
the type SLS-BK.
Colombia: Gebr. Pfeiffer Inc., a subsidiary of Gebr.
Pfeiffer SE, has been awarded a contract to supply
Slag mill contract for Gebr. Pfeiffer in Poland an MPS 140 BK Coal Mill at Cementos Tequendama
Poland: In October 2012 Gebr. Pfeiffer announced a new order for a verti- in Suesca, Colombia.
cal roller mill in Poland and will supply an MPS 3070 BC VRM for grinding The contract follows other recent Pfeiffer projects
46t/hr of blast-furnace slag for the Odra works in Opole. It is intended that in Colombia, including installations at Cementos
slag ground to 3800cm²/g (Blaine) will be used as an additive in the Opole Tequendama, Cementos San Marcos and others. The
plant’s cement. 0.3Mt/yr Tequendama Cement plant became opera-
The VRM will feature a main drive with an output of 1350kW for a pro- tional in 2008 after an investment of US$150m.
duction rate of 46t/hr. Exhaust gases produced by the clinker cooler will
allow the slag to be dried from a 9% feed moisture level down to below a
1% residual moisture level, while being ground in the mill. The design of
Gebr. Pfeiffer mill Uzbekistan
the mill will also make it possible to grind as much as 45t/hr of ordinary
Portland cement to a fineness of 3500cm²/g (Blaine). Uzbekistan: The Turkish turnkey cement plant so-
lutions provider DAL Teknik Makina has placed an
order with Germany’s Gebr. Pfeiffer SE for a Pfeiffer
Cemtec integrates Insitec sensors from Malvern MPS 3350 B vertical roller mill for raw meal. It will
Instruments for efficient mill monitoring and control be used for the manufacture of grey and white ce-
ment in Uzbekistan.
Austria/UK: Cemtec, based in Enns, Austria, a specialist provider of grind-
ing technologies for the mining, mineral and cement industries, is using
Insitec real-time particle sizing technology from Malvern Instruments to
New grinding plant for Chimborazo
provide fully integrated, automated milling solutions that deliver high ef-
ficiency at competitive costs. An exchange of equipment between the two Ecuador: Chimborazo Cement Company has
companies has led to the installation of an Insitec system for the control of recently completed the construction and com-
dry milling at Cemtec’s extensive pilot plant facility and now customers of missioning of a new cement grinding and packing
both companies can see for themselves how real-time particle sizing can line with an investment of US$36.5m. The project
transform processing performance. includes a 110t/day ball mill.
Insitec particle size analysers enable the real-time measurement of both
wet and dry process streams with particles or droplets in the size range
0.1-2500µm. Built specifically for the plant environment, they are robust Shoe-mounted Fives mill for Brazil
and reliable, demanding minimal maintenance but delivering consistent
measurement performance. The resulting data provides a secure basis Brazil: In 2012 Fives FCB received an order for
for automated mill control, which typically reduces waste and energy a shoe-mounted slag cement grinding mill for
consumption while at the same time enhancing product quality and in- Cimar’s São Luís plant. The 4.2m diameter, 12.5m-
creasing throughput. long mill has a total installed power of 3400kW.

globalcementMAGAZINE September 2013 35

 Contents Subscribe Ad Index
VALVES
Compiled by Global Cement staff

Valves in the cement industry News and case-studies from the

industry’s valve suppliers...

Flowrox valves solve leakage problems in

pneumatic conveying system
Flowrox offers reliable solutions for abrasive, corrosive and other
demanding shut-off, control, pumping and dosing applications
serving a wide range of process industries worldwide. Its main
focus is on the mining, mineral processing, metallurgy, energy,
construction and environmental industries.
A cement plant in Spain had isolation and leakage problems
with metallic diverter valves in a pneumatic conveying process for
moving cement into storage silos. The diverter valves needed con-
tinuous maintenance and their leaking had been causing quality
problems with respect to the cement product.
These problems were solved by installing two Flowrox open
body pinch valves, which have been in operation for over four
years with no leakage problems. The customer has been satisfied
with this improvement and continues to change its existing old The image shows a Flowrox open body pinch valve installed at
metallic diverter valves into Flowrox pinch valves. the Spanish cement plant.

Aerodyne announces High

Temperature Vacu-Valve®
Aerodyne Environmental® has announced the High Temperature Vacu-
Valve®. This trickle valve system is the lowest-cost, lowest-maintenance dust
collector valve available. The High Temperature Vacu-Valve is equipped with
a replaceable silicone duck bill sleeve that can operate in temperatures of up
to 260°C. The Vacu-Valve is available in two designs, the open construction
of the Platypus and the closed construction of the Armadillo. The replace-
able sleeves are chemical and caustic resistant as well as resistant to abrasion.
It is available in both carbon steel and stainless steel. They are an efficient
and economical solution for emptying particulate from dust collectors and
bag houses.
Both the Vacu-Valve Platypus and Armadillo are cost-effective solutions to
rotary valves for particular applications. These trickle valve systems operate
as constant discharge valves for dust collectors, hoppers, cyclones and other
equipment operating under negative pressure.

IBAU HAMBURG control gates for pulverised goods

The features of the IBAU Flow-control gate make it a success for handling pulverised
goods such as cement, raw meal, lime, fly ash and others. The Flow-control gate offers
extremely high accuracy with reproducible results, requires no maintenance and is
wear-resistant. IBAU also states that the unit is reasonably priced and available at
short notice due to its state-of-the-art storage facility.
Pneumatic conveying systems for pulverised goods often have to feed
several silos sequentially. A perfect solution in this case is the IBAU
Two-way valve. It is either manually or pneumatically operated, highly
wear resistant and well-priced, states the manufacturer.
Over nearly 40 years IBAU HAMBURG has delivered more than 46,000 IBAU
Flow-control gates and 11,500 Two-way valves to customers in over 150 countries.

36 globalcementMAGAZINE September 2013

 Contents Subscribe Ad Index
Koen Coppenholle Chief Executive of Cembureau, the European Cement Association
The View from Brussels
I n its recently published Activity Report for 2012,
Cembureau highlights that global cement production
in 2012 was estimated at 3.6Bnt, 3% increase compared to
2011. China experienced a year-on-year increase of 3.6%
and now represents 59.3% of global cement production.
Without taking into account China, global cement pro-
duction increased by 1.8%, which represented a further
slowdown compared to the 2.8% growth rate registered
in 2011.
While the recovery in cement production gained mo-
mentum in the US and Japan and production continued
to increase in South America, Africa and Asia, a 20%
year-on-year drop in cement production was recorded in
Europe in 2012. Cement production in Europe has now
dropped by 40% compared to pre-crisis levels and some
countries are down by 80% to levels not seen since the
1950s. This drop in production compares to the EU27
industrial output decrease of 10% and shows how hard
the cement industry in Europe has been hit. Cembureau’s
World Statistical Report provides more information on
trends in production, exports, imports and consumption
over the 2011-2012 period.
The evolution of cement production in Europe com-
pared to other parts of the world again emphasises the
need for an international regulatory level playing field.
The cement industry is capital and energy intensive and
its survival in Europe is at stake due to the combined ef-
fect of reduced volumes, low capacity utilisation and a lack
of reasonable returns. Burdensome EU legislation that is
often subject to sudden changes and rising energy prices
leads to high capital expenditure and high operational
costs for the industry. A competitive level playing field
with adequate protection against the risk of carbon leak-
age and access to affordable energy and raw materials are
preconditions for the cement industry to play its unique
role in responding to the challenges society faces today.
Indeed, it’s high time to get positive about what our
VIEWPOINT
industry can do in order to respond to the needs of a
growing population that will need infrastructure and
energy-efficient housing, schools, hospitals and other
constructions. The cement industry can play a pioneer-
ing role in developing cost-effective environment friendly
construction solutions for the sustainable urban environ-
ments of tomorrow.
Given that around 90% of total building life cycle emis-
sions are linked to the in-use phase, the savings potential
provided by concrete buildings during their lifetime off-
sets the initial emissions resulting from the production
of concrete. Buildings account for 35-40% of energy
usage in Europe with traditional buildings consuming
200kWh/m2/yr. Due to the high thermal mass of concrete,
the technology exists today for concrete buildings to con-
sume only 50kWh/m2/yr. In addition, concrete plays an
indispensable role in climate change as it is the material
of choice for comprehensive fire and flood protection as
well as for resilient buildings, ensuring the protection of
people, property and the environment. In transport infra-
structure, the stiffness and rigidity of concrete pavements
can reduce fuel consumption of heavy trucks by 6% as
compared to flexible pavements.
It is these benefits of cement and concrete that need to
be brought to the attention of Europe’s policymakers. This
is in addition to our innovative thinking in promoting the
efficiency of cement manufacturing through, for instance,
the use of alternative fuels and alternative raw materials
whereby waste from other industries is used in a symbiotic
relationship with the cement industry.
Within the right regulatory framework that fosters
competitiveness, the cement and concrete industry
can play a unique role in responding to today’s societal
challenges. Its full supply chain, from quarry to the end
product in structures, promotes a strong local industrial
base that allows innovation both in processes and prod-
ucts to take place in Europe.
globalcementMAGAZINE September 2013 37

NEWSEUROPE
Lafarge profit hit in second quarter
France: The French multinational cement producer Lafarge has
reported that its earnings before interest, tax, depreciation and
amortisation (EBITDA) fell year-on-year in the second quarter
of 2013. Despite this Lafarge said that its EBITDA was ‘steady’
considering the adverse weather conditions, absence of carbon
dioxide sales and the negative impacts of foreign exchange vari-
ations seen during the quarter.
EBITDA for the second quarter of 2013 was recorded as
Euro922m, 8% down on the second quarter of 2012 when it was
Euro1002m. Operating income was also down from Euro750m
in the second quarter of 2012 to Euro667m in the second quar-
ter of 2013. However, Lafarge’s net income for the quarter was
Euro201m, significantly up on the same period of 2012 due to
exceptional items during the year-ago quarter relating to Greek
assets. It reported that it generated a total of Euro260m in the
first half of 2013, which Lafarge described as ‘on track’ with
its plan.
The group sold a total of 36.5Mt of cement in the second
quarter compared to 38.4Mt in the second quarter of 2012. It
sold 65.2Mt/yr of cement in the first half of 2013 against 69.7Mt
sold in the first half of 2012.
Lafarge’s net debt at the end of June 2013 was down by
Euro0.7bn compared to at the end of June 2012, reflecting the
strict control of investments and working capital optimisation.
With the recently announced divestment of its US gypsum op-
erations, the group has secured Euro1.5bn since the beginning
of 2012. Euro0.9bn more will come in the second half of 2013.
Bruno Lafont, Chairman and Chief Executive of Lafarge, said,
“Our results in the second quarter resisted in an environment
that was marked by a conjunction of unfavourable circum-
stances. We increased prices and performance and innovation
results are in line with our 2013 Euro650m additional EBITDA tar-
get. Taking into account first-half volumes, we foresee a cement
demand growth in our markets of 0-3% in 2013, which implies
more positive trends in the second half.”
Lafarge’s sales volumes across all business lines were down
in the second quarter of 2013. It suggested that this was in part
due to a better-than-expected 2012 performance and poorer
weather in 2013, especially in North America. A temporary fuel
shortage in Egypt also put some pressure on cement volumes in
that country.
Across all business units Lafarge’s EBITDA in North America
was Euro141m in the second quarter of 2013, down by 17% (8%
on a like-for-like basis) compared to Euro170m in the same pe-
riod of 2013. EBITDA for this region was flat year-on-year despite
the loss of assets in the US cement industry. This represents a
like-for-like improvement of 17%.
In Western Europe, Lafarge’s EBITDA was Euro145m, down
by 16% (14% like-for-like) compared to Euro173m in the second
quarter of 2012. In the first half overall its EBITDA plummeted
by 45% (38% like-for-like) from Euro255m in 2012 to Euro150m
in 2013.
In Central and Eastern Europe, EBITDA was also down in the
second quarter, from Euro101m in 2012 to Euro80m in 2013. This
was a 21% fall in both absolute and like-for-like terms. In the first
half of 2013 its performance was similarly poor, with a 48% drop
in EBITDA from Euro87m in the first half of 2012 to Euro45m in
the first half of 2013.
38 globalcementMAGAZINE September 2013
Contents Subscribe Ad Index
The Middle East and Africa saw an 8% decline in EBITDA in
absolute terms (1% like-for-like) from Euro329m in the second
quarter of 2012 to Euro304m in the second quarter of 2013.
Over the first half of 2013 its EBITDA for this region fell by 15%
in absolute terms (10% like-for-like) from Euro646m in 2012 to
Euro550m in 2013.
Latin America, however, saw a 1% improvement (7% like-for-
like) in EBITDA year-on-year from Euro70m in the second half of
2012 to Euro71m in the second quarter of 2013. In the first half
its EBITDA for this region fell by 5% year-on-year (up 1% like-for-
like) from Euro129m in 2012 to Euro122m in 2013.
Finally, Lafarge’s best performing region was Asia, where it
recorded EBITDA improvement of 14% year-on-year (16% like-
for-like) in the second quarter to Euro181m from Euro159m. In
the first half, absolute improvement in EBITDA was also 14%
higher (17% like-for-like) at Euro306m compared to Euro268m
in 2012.
Looking towards the future, Lafarge expects cement growth
in its markets of 0-3% in 2013 compared to 2012, factoring in
low volumes in the first-half. Emerging markets continue to be
the main driver of demand and Lafarge says that it will benefit
from its ‘well-balanced geographic spread of high-quality assets.’
The group also expects higher pricing in 2013 and that cost
inflation will continue, although at a lower rate than in 2012.
This, it says, will benefit from positive trends in fuel prices. The
group targets to deliver additional EBITDA of Euro650m in 2013
through its performance and innovation measures.
Holcim saves on outgoings but India weighs
first half down
Switzerland: Swiss multinational cement producer Holcim
has seen a rise in its net income and cash flow in the first half
of 2013 with increased operating earnings before interest, tax,
depreciation and amortisation (EBITDA) in Latin America and Eu-
rope. However, the group said that it saw lower sales volumes in
India, which affected its results badly. Despite this, it said that its
EBITDA growth and operating profit were in line with its outlook
for 2013.
Holcim’s consolidated net sales decreased by 5.1% to
Euro7.75bn. A 3.4% decline in operating EBITDA to Euro1.45bn
was largely attributable to its two Indian group companies as
well as Holcim Canada, Holcim Mexico, Holcim Morocco and
Holcim France. Consolidated operating profit fell by 3.3% to
Euro810m, but on a like-for-like basis moderate growth of 0.1%
was recorded. Group net income increased by 23.8% to Eu-
ro613m. The group’s net financial debt was down by Euro970m
compared to the same period of the previous year at Euro8.87bn.
Europe and Latin America reported year-on-year increases in
operating results. On account of Canada, North America was not
able to match the figures of the previous year and Asia Pacific
and Africa Middle East fell considerably short of the previous
year’s levels owing to India and Morocco, respectively. Holcim
Philippines, Aggregate Industries UK, Holcim Ecuador and
Holcim US achieved substantially improved operating results.
Overall, like-for-like operating EBITDA at group level fell by 0.6%
in the first half. At 0.1%, like-for-like operating profit developed
moderately positively. The corresponding figures for the second
quarter were positive at 2.8% and 5.4% respectively.

Holcim achieved its financial results based on marginally
lower cement sales compared to the first half of 2012. Con-
solidated cement sales were down by 3.7% to 68.6Mt. Price
development in all regions continued to be positive with the
exception of Europe.
Holcim said that it anticipates an increase in sales of cement
in 2013. While Holcim’s group regions Asia Pacific and Latin
America are expected to witness higher cement sales volumes,
Holcim is somewhat less optimistic with regard to Europe and
Africa Middle East. In North America, cement sales are expected
to reach similar levels to 2012.
Turning to operating EBITDA and operating profit, the
board of directors and executive committee expect a further
improvement in margins. Holcim says that its development and
efficiency programme, the Holcim Leadership Journey, is gain-
ing further momentum and will continue to contribute to this
development. Under similar market conditions, organic growth
in operating EBITDA and operating profit should be achieved
in 2013.
HeidelbergCement: Revenue flat but profit up
Germany: HeidelbergCement has announced improved operat-
ing results in the second quarter of 2013 despite claims that poor
weather conditions in Europe and North America had hampered
its performance. The group’s revenue was stable at Euro3.8bn for
the three months to 30 June 2013 and at Euro6.56bn for the first
six months of 2013.
HeidelbergCement’s net profit for the second quarter of 2013
was Euro469m, a 92% increase year-on-year from Euro245m in
the second quarter of 2012. Over the first half of 2013, its profit
rose by Euro285m from just Euro86m in the first half of 2012.
“HeidelbergCement has successfully continued the posi-
tive earnings development in the second quarter despite
challenging conditions,” said Dr Bernd Scheifele, chairman of the
managing board. “The measures that we introduced to improve
margins are showing results. We were able to implement price
increases in our principal markets and our efficiency improve-
ment programmes are progressing according to plan.”
The group saw regional variation in its cement sales during
the period under review. While construction activity in Europe
and parts of North America was hindered due to heavy rain and
flooding in some areas, HeidelbergCement’s cement deliveries
benefitted from the sustained increase in demand in its Asian
and African markets as well as from the continued economic
recovery in other parts of North America, especially in the south-
ern United States.
During the second quarter, the group’s cement and clinker
sales volumes dropped slightly by 0.8% to 24.3Mt from 24.5Mt
in 2012. The Asia-Pacific group area experienced the strongest
growth in sales volumes, followed by North America and Africa-
Mediterranean Basin. Cement sales volumes in the Western and
Northern Europe group area remained broadly stable. Deliveries
in the UK were more than 10% above the values of 2012 due to
the emerging recovery in private residential construction. Sales
volumes in Germany and in the bordering countries of eastern
Europe were adversely affected by heavy rainfall and flooding.
The Eastern Europe-Central Asia group area recorded a de-
cline in sales volumes of more than 10%. Poland, Romania and
NEWSEUROPE
the Czech Republic were the most severely affected. In addition,
the harsh austerity policies of these countries had a negative ef-
fect on public infrastructure construction. In the first half of 2013
cement and clinker sales volumes decreased slightly by 0.8% to
42.4Mt from 42.7Mt in 2012.
Looking ahead, in North America, HeidelbergCement still
expects ongoing economic recovery and consequently a
further increase in demand for building materials, especially
from residential construction and the raw materials industry. A
three-layered economic development is anticipated in Europe
and central Asia. It says that the markets in Germany, northern
Europe and the UK should continue to develop positively and
expects those in central Asia to remain stable. In Benelux and
eastern Europe a continuing weak development of the economy
and demand for building materials is anticipated. In Asia and
Africa, the group still expects sustained positive demand.
Italcementi revenue drops so far in 2013
Italy: Italcementi has reported that its revenue fell by 6.2% to
Euro2.16bn for the first half of 2013 from Euro2.30bn in the same
period in 2012. The Italian-based cement producer commented
that, despite the decrease in sales volumes, its revenue reduc-
tion was smaller (3.6%) in the second quarter of 2013.
“Our programme to contain fixed costs together with close
control of variable costs enabled us to lower our break even
point, slightly ahead of our targets, despite continuing difficul-
ties in market conditions, especially in Italy,” said Italcementi
group chief operating officer Giovanni Ferrario.
Earnings before interest, taxes, depreciation and amortisa-
tion (EBITDA) fell by 10.6% to Euro299m from Euro334m. The
group posted a loss for the period of Euro43.3m compared
with a profit of Euro1.3m in the first half of 2012, when gains of
Euro8.6m were reported on the sale of its subsidiaries Afyon and
Fuping. Net debt for the period was broadly unchanged for the
period at Euro2bn.
Overall cement sales fell by 7.1% to 21.8Mt. By region, ce-
ment sales fell by 12.4% to 7.2Mt in Central Western Europe and
by 11.7% to 6.9Mt in Emerging Europe, North Africa and Middle
East. Cement sales rose by 1% to 2Mt in North America and by
5.3% in Asia. In the cement business, for the second quarter the
group reported a significant reduction in the decline in Europe
and Morocco, positive performance in North America
and stability in sales in Asia. Sales volumes in
Egypt were affected by difficulties in fuel
procurement. A particular poor perfor-
mance in Italy was singled out.
In its outlook, Italcementi
speculated that its results in the
second half of 2013 should be
in line with the second half of
2012 due to market improve-
ments in selected countries
and the impact of cost cutting
exercises, particularly in Italy
and Spain. However, it warned
that full-year profitability would
be hit by the poor first quarter
of 2013.
globalcementMAGAZINE September 2013 39
NEWSEUROPE
Earnings down a quarter at Buzzi
Italy: Buzzi Unicem made a net loss of Euro26.6m in the first half
of 2013, 44% higher than the Euro18.5m loss seen in the first half
of 2012. It recorded a 25% fall in first-half core earnings for 2013,
which it said were hit by lower sales volumes.
Earnings before interest, tax, depreciation and amortisation
(EBITDA) for the six months fell to Euro150.7m from a restated
Euro200.5m in the first half of 2012. Buzzi’s net sales fell by 5.7%
to Euro1.27bn. Buzzi’s cement sales for the first half of 2013 were
12.3Mt, representing a 5.8% decrease compared to the first half
of 2012 when it sold 13.1Mt.
The company said that the results for the first half of 2013
were below its own expectations and were caused by the
extremely difficult economic situation in Italy, flat activity in
Central Europe, the lack of clear signs of recovery in Eastern Eu-
rope and an unforeseen slowdown in Mexico.
Buzzi also said that it believed that there were grounds for
a sizeable improvement of results in the second half of 2013,
thanks especially to a volume recovery in Central Europe, ac-
celeration of sales and prices in the United States and the
attainment of an operating profitability closer to that of the
previous year in Eastern Europe.
Based on the above considerations, for the full financial year
2013, Buzzi expects to report a recurring EBITDA that is 5 - 10%
lower than that of 2012.
Ciments Français profitability stabilises
France: Ciments Français’ earnings before
interest, taxes, depreciation and am-
ortisation (EBITDA) have slowed
their reduction year-on-year
to 5.2% in the first half of
2013. The Italcementi
subsidiary reported that
sales recovered in the
second quarter of 2013.
In the first half of
2012 EBITDA fell by
17.1% year-on-year.
In the first half of 2013
EBITDA fell year-on-year
by 5.2% to Euro305.4m from
Euro323.6m from the same pe-
riod of 2012. Revenue for the half
year decreased by 4.2% to Euro1.83bn
from Euro1.91bn. By quarter, revenue fell by
7.3% in the first quarter of 2013 but only fell by 1.6% in the sec-
ond quarter of 2013.
Cement sales for the first half of 2013 fell by 4.8% to 19.2Mt.
By region, cement sales fell by 5.8% to 4.5Mt in Western Europe
and by 11.7% in Emerging Europe, North Arica and Middle East.
Sales rose by 1% in North America and by 5.3% in Asia. By coun-
try, cement sales were particularly down in Egypt, due to fuel
supply issues, and in Morocco.
In its outlook Ciments Français expected that its full year re-
sults would be comparable to those in 2012. However, market
trends in territories such as Egypt present significant variables
in making forecasts.
40 globalcementMAGAZINE September 2013
Titan increases sales in second quarter
Greece: Titan Cement has increased its sales year-on-year in the
second quarter of 2013 by 2% to Euro329m from Euro323m. The
Greek-based multinational cement producer said that recovery
in the US and ‘resilient’ demand in Egypt had compensated for
continued decline in the Greek market.
Despite the increase in sales, net profit fell by 81% to
Euro5.3m from Euro27.8m. Earnings before interest, tax, depreci-
ation and amortisation (EBITDA) fell by 12.6% to Euro67.9m from
Euro77.7m. Overall for the half-year to 30 June 2013, sales rose
by 4.4% to Euro572m and EBITDA fell by 17.8% to Euro92.2m.
In Greece, demand for cement continued to decline with
domestic cement sales at around just a sixth of Titan’s cement
production capacity. In the US, the rebound of the housing
market, particularly in Florida, has had a positive effect on de-
mand for building materials. In south-eastern Europe demand
for building materials remained low and profit margins ‘shrank’
due to competition. In Egypt, despite political instability and
problems with production, demand remained stable and Titan
was able to increase sales by importing clinker. In Turkey, con-
struction activity grew, both in the private and public sectors,
as did exports.
In its outlook Titan reflected upon the mixed fortunes of its
major production territories, with continued growth expected
for the US, instability in Egypt and continued gloom in Europe.
Vicat holds sales steady in first half of 2013
France: The Vicat Group has reported that its sales rose by
1.7% year-on-year to Euro1.15bn in the first half of 2013 from
Euro1.13bn in the same period of 2012. The group’s earnings
before interest, taxes, depreciation and amortisation (EBITDA)
remained static year-on-year at Euro201m.
“Performance in Turkey, Kazakhstan and the United States
improved substantially, making up for the tough competitive
environment in India and the uncertainty that continues to pre-
vail in Egypt. Operating performance in France also improved
despite the persistently unfavourable market climate,” said Vicat
chief executive officer Guy Sidos.
Vicat’s cement sector saw its volumes increase by 3.8% year-
on-year to 9.21Mt from 8.87Mt. Operational sales increased
slightly by 1.2% to Euro693m from Euro685m. EBITDA for the
cement sector fell by 5.2% to Euro147m from Euro155m.
By region for its cement business, sales in France fell by 10.5%
in the first half of 2013, mostly caused by a poor first quarter and
a decline in export markets. Vicat declined to present specific
figures for certain territories. In Switzerland its cement business
saw its EBITDA fall by 6.2% and in Italy sales fell by 16%. In the US
sales rose by 4.1% with strong growth from new infrastructure
projects.
In Turkey sales rose by 18.9% due to volume and price rises.
In India overall sales rose by 18.4% to Euro87.3m as Vicat built
up its cement businesses. However competition, increased pro-
duction costs and start-up costs for Vicat Sagar caused EBITDA
to fall by 77.7%. In Kazakhstan overall sales rose by 42.8% to
Euro38.9m. In Egypt sales fell by 11.8% to Euro47.2m despite a
sharp increase in prices. In West Africa sales fell by 4.1% due to
a fall in prices.
 NEWSEUROPE
Cementos Molins first half profit down
Spain: Cementos Molins has reported a drop of 58% in its
profit for the first half of 2013 to Euro8.3m. The Spanish
cement producer announced a loss of Euro22.4m which
was offset by a Euro30.7m net profit registered abroad. It

OUR
reported sales of Euro416m. The company’s net debt was
reduced year-on-year by Euro7m to Euro309m.

Eurocement production up 5% in first half CUSTOMERS

PLAY FIRST
Russia: The Eurocement Group has reported that it has pro-
duced more than 11.5Mt of cement in the first six months
of 2013, a year-on-year rise of 5%, in its 16 cement plants
in Russia, Ukraine and Uzbekistan. Cement shipments have
increased by 7% in the period.
FIDDLE
The Russian-based cement producer announced plans
to upgrade all of its production facilities to make cement
using a dry-process by 2018. Currently only 25% of its plants
use the dry process. Eurocement also plans to increase its
annual cement production capacity by 4Mt/yr.
According to the Russian newspaper Kommersant, half of
Russia’s regions are not meeting housing construction tar-
gets due to a lack of building materials. The country needs
more than 20 new cement factories, according the govern-
ment, but companies are refusing to build new plants due
to a lack of potential returns on investment. Eurocement
responded to the claims by saying that it is cheaper to mod-
ernise existing plants.

CSI: Embodied CO2 per tonne of cement

down 17% since 1990
Switzerland/World: Global cement producers have reduced
CO2 emissions by 17% per tonne of cementitious product
since 1990. Participating cement producers reduced their
specific net CO2 emissions per tonne of cementitious prod-
uct to 629kg/t in 2011 from 756kg/t in 1990. The World
Business Council for Sustainable Development (WBCSD)’s
Cement Sustainability Initiative (CSI) has published the data
in its ‘Getting the Numbers Right’ (GNR) database update HARDTOP® Bimetal Castings provide
for 2011.
“GNR has become established as a valuable source of
high wear resistance
independently-verified emissions data, which is now used increased durability
globally by the cement industry to improve energy effi- reduced overall costs
ciency and further reduce emissions,” said Philippe Fonta,
WBCSD managing director. The WBCSD added that the
high efficiency
GNR figures provide evidence of the gradual decoupling reduced expense for maintenance
of emissions and cement output, which demonstrates the minimised downtime
significant progress made by the cement industry.
According to the data, the four main drivers for the
raised production
reduction in emissions have been investment in more ef- added profit
ficient kiln technology, increasing use of alternative fuels
such as biomass, reduction in clinker content and an 8%
decrease in electricity use per tonne of cement since 1990.
The 2011 GNR data comprised 55% of cement pro- Agnetenstrasse 14
duction outside of China, with 96% coverage in Europe D-39106 Magdeburg
spanning 967 individual facilities. The 2011 report included Germany
data from Thailand, Morocco, Philippines and Egypt for the
first time.
phone: +49 (0) 391 532969-0
fax: +49 (0) 391 532969-21
e-mail: sales@hardtop-gmbh.com
globalcementMAGAZINE September 2013 41 web: www.hardtop-gmbh.com
NEWSEUROPE
UK cement market accused of anti-competitive practices by Irish cement importer
UK/Ireland: Irish cement importer Eircem has told the UK’s Com-
petition Commission that ‘there is no free competition’ in the
cement market in Europe. Managing director Peter Goode sub-
mitted the comments as part of the evidence being gathered by
the UK Competition Commission in its ongoing investigation on
the UK cement industry, as reported by the Irish Independent.
“The most recent act of such practices and anti competitive
activity by [European Cement Producer 1] and [European Ce-
ment Producer 2] against me, my business and my family
is so blatant that it defies reality and logic,” said
Goode in his submission to the Competition
Commission.
Goode alleges that his previous company
suffered anti-competitive measures from a
European cement producer in 2009 when it
attempted to import cement from Turkey. Further claims include
an incident on a visit to a UK cement plant in 2012 when an em-
ployee of a cement producer refused to supply him with cement
because it had a pre-existing agreement with another company
not to supply cement to Ireland.
Goode previously owned Goode Concrete, which collapsed
in early 2011. The company is currently attempting to sue Irish
building materials manufacturer CRH for damages also related
to alleged anti-competitive behaviour.
The Competition Commission’s investigation on the UK
aggregates, cement and ready-mix concrete market is due
to be completed in late 2013 with a publication date set
for December 2013. Evidence from the investigation has
been published on the Competition Commission website.

MPA survey suggests UK improvement

Irish Cement visited by
Taoiseach UK: The results of a survey conducted by the Mineral
Products Association (MPA) has shown a significant
Ireland: The Irish Taoiseach (Prime improvement in sales of ready mixed concrete,
Minister) Enda Kenny, has taken aggregates and asphalt in the second quar-
an extensive tour of Irish Ce- ter. Following a poor first quarter, second
ment’s Platin plant in Platin, quarter sales volumes increased by 14% for
County Meath, as part of the crushed rock aggregates, 9% for sand and
firm’s celebration of 75 years of gravel aggregates, 18% for ready-mixed
continuous cement production close to concrete and 9% for asphalt, all compared
the town of Drogheda and another plant in with the same period of 2012. However, the
Limerick, Munster. MPA did not release data for cement sales, which it
Kenny was shown the plant’s alternative fuels said was not yet available. Despite this, a strong up-tick in
depot, its 123m-tall pre-heater tower and control room, among ready mixed concrete sales means that at least this sector
other highlights, which included the plant’s third kiln line, com- used more cement year-on-year during the second quarter
pleted in 2008 at a cost of Euro200m. of 2013.
The original Drogheda plant, along with Irish Cement’s Limer- Even in the absence of cement statistics these figures
ick cement plant, came into operation in 1938. Cement deliveries represent welcome improvements but also reflect some
commenced from Limerick on 11 April 1938 and from Drogheda carry over of work from the first quarter due to bad weather
on 9 May 1938. In the 1970s the plant at Drogheda was moved to and comparisons with a very poor second quarter of 2012.
the greenfield site at Platin. It now has a capacity of 3Mt/yr, a large For the underlying market change, the moving annual
increase from Drogheda’s original 0.15Mt/yr cement capacity. trend figures (i.e. the year to June 2013 compared with the
year to June 2012) provide a better guide. These figures
have been improving in recent months but not at the
New sales manager for Fairport pace apparently seen in the second-quarter figures.
UK: Fairport Engineering has ap- There is evidence that private housebuilding has
pointed Jeff Buxton as the Sales picked up significantly from the extremely low levels
Manager for Heavy Industries. of activity in 2012, but depressed areas of construction
Buxton holds over 35 years of expe- remain.
rience working in the bulk materials Jerry McLaughlin, Chief Economist MPA, commented,
processing and handling industries “Private housebuilding has improved, but this sector rep-
and is a fully-qualified mechanical resents only 14% of construction and it is sobering to see
and electrical engineer. the latest GDP figures showing that construction output
Buxton’s industry knowledge in the first half year was 4% lower than the same period
includes the technologies and sys- of 2012. However, the better MPA figures suggest that
tems used in the cement, gypsum, more construction work is underway and that this market
aggregates and alternative fuels should flatten out during 2013. For a sustained recovery,
sectors, among others. Previously however, we need the government to deliver fully on the
Buxton has worked for a number of infrastructure commitments made in the 2012 Autumn
the leading suppliers of proprietary Statement and for the increased confidence in the hous-
Jeff Buxton
equipment to the same markets. ing market to spread to other construction sectors.”

42 globalcementMAGAZINE September 2013

 NEWSEUROPE
Lafarge Tarmac celebrates 50 years of Dunbar
UK: Lafarge Tarmac has celebrated a milestone anniversary at its landmark Dunbar Plant, Scotland’s only cement manufacturing
facility. Based in East Lothian, the Dunbar Plant marked its 50th birthday with a party for over 200 people, including past and current
employees, plant managers and members of the community councils. Many of its employees have been at the plant for a large part
of its life, with three 35-year long service awards also being awarded to current employees at the event.
In a speech recognising the achievements of the plant, managing director of Lafarge Tarmac’s cement and lime business in the
UK, Charles Law, said, “The Dunbar site remains a key part of our business as the only cement plant in the whole of Scotland. All
those who have worked at the plant over the years are part of its considerable success story.”
The Former Dunbar Plant manager Nigel Blair led the commemorative speeches and highlighted the investment that the plant
has attracted over the years, first in efficiency and production potential, then for revolutionising health and safety and in reduc-
ing the plant’s environmental impact. With reference to
improved environmental performance, Lafarge Tarmac
has recently entered into an agreement with the Royal So-
ciety for the Protection of Birds Scotland (RSPB Scotland)
regarding the development of a former quarry as a nature
and leisure facility. Referencing the deal, Blair said, “We are
delighted that one of the jewels in our crown in the future
will be the legacy of the former north-west quarry. The
management agreement we have recently entered into
with RSPB Scotland will be critical in delivering a facility we
can all be proud of, of pivotal importance to wildlife and
the community,”
The image shows (from left to right): Charles Law
(Managing Director for Cement and Lime), Peter Lennon
(recipient of long service award) and Nigel Blair (former
Plant Manager).

Manifold to succeed Lee as CRH chief exec...
Ireland: Irish cement conglomerate Cement Roadstone Holdings
(CRH) has announced that Albert Manifold will become group
chief executive on 1 January 2014 following the retirement of
current chief executive Myles Lee after 32 years with the group.
Manifold, a board member and CRH’s CEO since January
2009, has held a variety of senior positions within the company,
including managing director of the Europe Materials Division
and group development director. Prior to joining CRH in 1998,
he was CEO with a private equity group.
Commenting on the appointment,
CRH’s chairman, Nicky Hartery, said, “I am
delighted to announce Albert’s appoint-
ment as the next chief executive of CRH
plc. This follows a comprehensive selec-
tion process led by the Board’s Succession
Committee.”
“Albert will succeed Myles in the New
Year, facilitating an orderly transition at
chief executive level,” continued Hartery.
“Albert brings to his new role a deep
knowledge of the industry and proven
international executive experience.”
... as CRH board gets new member
Ireland: Donald A McGovern, Jr has joined the board of CRH as a
non-executive director, effective from 1 July 2013. McGovern, a
US national aged 62 years, is currently Vice Chairman for Global
Assurance at PricewaterhouseCoopers (PwC), a position he has
held since July 2008. McGovern retired from PwC on 30 June
2013, following a 39 year career with the firm, during which time
he directed the US firm’s services for a number of large public
company clients. He is a member of the American Institute of
Certified Public Accountants and holds a Master’s Degree in
Business.
CRH releases 2012 sustainability report
Ireland: Irish building materials supplier
CRH has shown continued improvements
in most of its cement sustainability initia-
tive key performance indicators in its 2012
sustainability report.
Of note, CRH improved its net CO­2 emis-
sions per tonne of cementitious product
by 5% to 637kg/t. Fuel substitution rose to
20.8% from 17.3%. The Lost Time Incident
(LTI) rate per million man-hours for direct
employees fell from 2.54 to 1.49. Particu-
lates per specific g/t of clinker fell to 108
from 328.
However, CRH’s emission for SOx per
specific g/t of clinker rose to 304 from 204.
CRH blamed this rise on an increased use of alternative fuels in
some plants.
In his forward to the report, chief executive office Myles Lee
commented that CRH’s Materials Division had substantially in-
creased alternative fuel usage in its European cement operations
in 2012 that softened cost inflation in energy related inputs.

globalcementMAGAZINE September 2013 43

 7th International VDZ Congress 2013
Process Technology of Cement Manufacturing

25 - 27 September 2013, Duesseldorf, Germany

The 7th International VDZ Congress on Process Technology of Cement Manufacturing will take place in
Duesseldorf from 25 to 27 September 2013. The congress will start on Wednesday at 12:00 and end on
Friday at 14:00.

Location:
Maritim Hotel
Maritim Platz 1
40474 Duesseldorf, Germany

The programme covers the following themes: Further information and registration:
www.vdz-congress.org
 Future Challenges and Visions
of Cement Process Technology
 Cement and Concrete
 Burning Technology
 Sustainability, Use of Energy and Resources
 Grinding Technology
 Environmental Technology

Verein Deutscher Zementwerke e.V.

P.O. Box 30 10 63 Phone: +49 (0) 211 45 78 - 342
40410 Duesseldorf, Germany Fax: +49 (0) 211 45 78 - 296
Tannenstrasse 2 www.vdz-congress.org
40476 Duesseldorf, Germany info@vdz-congress.org

4_5229_Anz_VDZ_Congress_2013_A4.indd 1 21.05.13 17:40


Hope joins World Economic Forum’s Global Growth Companies community
UK: Hope Construction Materials, the UK’s newest cement
producer, has become the UK’s first construction firm to
join the World Economic Forum’s Global Growth Companies
(GGC) community.
The company has been recognised by the
Forum after demonstrating strong growth
potential during its first six months of trading.
Hope Construction Materials was one of just
two European construction firms to show that
they meet membership criteria.
Formed in 2007, the GGC has accepted
more than 370 companies worldwide, seek-
ing out businesses it believes have the
potential to not only become leaders in their
field, but also to drive greater economic and
social change.
Criteria for inclusion include a double-digit
annual growth rate, a turnover of US$0.1-5bn,
executive industry leadership and the ability
to demonstrate significant growth potential.
It is believed that Hope Construction
Materials’unique contribution to what has historically been a con-
servative UK construction industry is one of the key drivers behind
its inclusion.
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a dynamic group with clear potential to shape
the future across the many markets in which
it operates and so is a perfect fit for our GGC
community.’
Hope’s chairman, Amit Bhatia, said that
he was delighted that the company’s fresh
approach and aspirational goals had been
recognised by a global organization like the
World Economic Forum. Bhatia said, “It’s still
early days for the business but we have am-
bitious and innovative growth plans and are
pleased they have been acknowledged by
such a highly regarded body.”
“This industry is typically seen as traditional
and staid, so we aim to buck the trend in the
way we work and the products and services
we offer,” continued Bhatia. “By being accepted into the GGC
community we stand alongside some of the world’s most dy-
namic firms, which is exactly where we feel Hope Construction
Materials should be.”
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Positive future for TCK in face of continued headwinds Heracles fined Euro7500
Bosnia-Herzegovina: The Bosnian-Herzegovinian cement producer Tvornica Cementa for breaking lay-off law
Kakanj (TCK) has announced that it expects its net profit to increase by 20 - 25% to Euro5.6 Greece: The Labour Inspectors’
- 6.1m in 2013, while it expects cement sales to be broadly flat at around 425,000t. The ef- Corps has fined AGET Heracles
fects from ongoing investment and process-optimisation measures are expected to kick in cement industry, a subsidiary
in 2013, generating savings that should lead to the projected rise in net profit, according of Lafarge Group, Euro7500 for
to company director Branimir Muidza. Speaking to the regional See News local press, he violating mass lay-offs legislation
described the targets as ambitious and optimistic but not unrealistic. after ruling in favour of former
TCK is making its claims in the midst of a Bosnian market that is estimated to require only employees recently laid off from
1.05Mt of cement in 2013, a decrease from the 1.10Mt/yr consumed in 2012. In 2008 - 2009 its cement plant in Halkida
cement consumption was as high as 1.85Mt. Muidza expects that the lack of new invest- and essentially shutting down
ments in the industrial sector and new infrastructure, rising unemployment, illiquidity in the the plant.
construction sector and a crisis in the real estate market would lead to a continued slump. By closing the unit and laying-
Muidza said that the expected impact on TCK’s business from the recent EU accession of off 236 employees, Heracles was
Croatia, which is the company’s largest export market, would not cause problems for TCK, as found in violation of article 4 of
its cement is already made to EU standards. He added that if Croatia benefits from EU acces- Presidential Decree 240/2006
sion further down the road, so will TCK. according to which, employees
Going forward, TCK’s investment pipeline for the 2013 - 2014 period features a pro- have to be notified and consulted
ject for the automation of cement milling and packing operations, modernisation of its in advance. The producer said that
sampling laboratory, upgrade of its weighing system, construction of an administrative it had proceeded with the shut-
building and procurement of new IT equipment. No production capacity upgrades have down of its unit in Halkida due to
been planned over the medium term as the existing capacity is sufficient to meet the current financial reasons and as a result of
market demand. the plunge in domestic construc-
When it comes to long-term investments, which covers the period until 2018, the com- tion activity and after failing to
pany plans the construction of a cement silo which should further expand the range of its distribute its surplus production
products and therefore put it in a better competitive position. The cost of the investment is to international markets.
currently thought to be US$10.3m.

Changes to Lafarge’s executive committee

France: Lafarge has announced changes to its Executive Com-
mittee due to start from 1 September 2013. Sonia Artinian and
Peter Hoddinott will join existing committee members Eric
Olsen, Guillaume Roux and Alexandra Rocca.
Sonia Artinian, currently Country CEO for Romania, is ap-
pointed as Executive Vice-President of Organization and Human
Resources, taking over from Eric Olsen.
Artinian, a French national, joined Lafarge in 2008 as Senior
Vice-President Organization, Learning and Development. She
started her career as a strategy consultant, notably working for
Cap Gemini Consulting. She is a graduate of École nationale de
génie rural des eaux et forêts and of Ecole Normale Supérieure
de Lyon (section biology).
Peter Hoddinott, currently Head of Energy and Strategic
Sourcing at the Performance department, is appointed as Execu-
tive Vice-President of Performance, taking over from Guillaume
Roux.
Hoddinott, a British national, joined Lafarge in 2001 with the
acquisition of Blue Circle by Lafarge. He worked for the mining
industry before joining Blue Circle in 1995, where he held several
operational positions in the UK, before being appointed General
Director for the Philippines in 1999. He is a graduate of Impe-
rial College and holds a Master of Business Administration from
London University.
Eric Olsen, currently Executive Vice-President Organization
and Human Resources, is appointed Executive Vice-President
of Operations, taking over from Jean-Carlos Angulo, who has
decided to retire. Olsen, a US national, joined Lafarge in 1999
after starting his career at Deloitte &
Touche. He became Chief Financial
Officer of Lafarge North America in 2004. Olsen holds a Bachelor
of Science degree in finance and accounting from the University
of Colorado, and an MBA from the HEC international business
school in Paris.
Alexandra Rocca, currently Senior Vice-President Group
Communications, is appointed as Executive Vice-President Com-
munications, Public Affairs and Sustainable Development. Rocca,
a French national, joined Lafarge in 2010 as Senior Vice-President
Group of Communications and has been a member of the group
Executive Committee since January 2012. She began her career
at Printemps Group in 1986 with subsequent roles at Air Liquide
Group, Galeries Lafayette and Crédit Agricole S.A. group. She is a
graduate from the HEC international business school in Paris, the
Institut d’Etudes Politiques in Paris and holds a BA in
French literature.
Guillaume Roux, currently Executive Vice-President Perfor-
mance, is appointed Executive Vice-President of Operations.
Roux, a US-French dual national, has spent his entire career with
Lafarge which he joined in 1980 as an internal auditor. Subse-
quent roles since have included Chief Executive for Turkey in
1999, taking responsibility for Lafarge’s cement operations in
South-East Asia in 2002 and becoming Executive Vice President
and Co-President of the Cement Division with the responsibility
for the Cement business in Eastern Europe, the Middle East and
Africa in 2006. In 2008 he supervised the integration of Oras-
com’s operations with Lafarge. He is a graduate of the Institut
d’Etudes Politiques in Paris.

46 globalcementMAGAZINE September 2013

 NEWSEUROPE
Heidelberg interested in Nasicecement
Croatia: HeidelbergCement is interested in bidding for
the Croatian cement plant Nasicecement, according to
HeidelbergCement’s regional director Branimir Muidza.
“We are still very interested in the acquisition and we
are carefully monitoring the situation of Nasicecement’s
pre-bankruptcy settlement. If an opportunity arises we are
ready to invest,” said Muidza to SeeNews. HeidelbergCe-
ment has previously held a 8% stake in Nasicecement.
In February 2013 Nexe Grupa, Nasicecement’s owner,
revealed that it had submitted a motion for the opening
of a pre-bankruptcy settlement procedure. Its subsidiaries
did likewise. Acquiring Nasicecement could complement
HeidelbergCement’s strategy in the Balkans as it holds ce-
ment plants in Hungary and Bosnia & Herzegovina.

Vecoplan founder gets medal for

outstanding commitment to economy
Germany: Minister Eveline Lemke has presented a medal
for outstanding commitment to the economy in Rhine-
land-Palatinate to Irene Scheidweiler, one of the joint
founders of Vecoplan. Lemke described Scheidweiler as a
model for younger generations.
Scheidweiler founded the recycling technology firm
based in Bad Marienberg in 1969, when she was aged 22.
In 1995 Vecoplan AG became a subsidiary of MAX Auto-
mation AG of Düsseldorf. Today the company employs
more than 400 staff at locations in Germany, the US, the
UK, Austria and Spain.

Irene Scheidweiler Eveline Lemke

New appointment at Aumund

Germany: Dr Michael Mutz
has been appointed the head
of cement sales at Aumund
Fördertechnik. In his new role
Mutz will oversee sales of both
new equipment and retrofits. The
new position will be in addition
to Mutz’s exisiting job as head of
the Mineral Processing division
(previously Mining & Minerals), Intercem Engineering GmbH
which he assumed in April 2012. Oelde | Germany
Michael Mutz info@intercem.de
Phone+49 2522 92058-0
|trainat.ch

globalcementMAGAZINE September 2013 47

 Contents Subscribe Ad Index
VDZ CONGRESS
Global cement staff

7th International VDZ Congress - Programme

One of the most prestigious cement conferences in the world, the 7th International VDZ Congress
2013 will be held in Düsseldorf, Germany on 25-27 September 2013. Held in 2009, the previous
edition of the Congress attracted over 500 delegates from 40 countries, with around half cement
producers and half suppliers, academics and other interested parties. In 2013 the will again be held
in English with 38 high-quality presentations on three days. A full event programme is below.

Wednesday 25 September
Afternoon session : 13:30 - 18:00
HALL ‘MARITIM’
OPENING OF THE CONGRESS
Gerhard Hirth, President of VDZ
Philippe Fonta, Cement Sustainability
Initiative - ‘Sustainability developments in the
cement industry’
Cecilia Tam, International Energy Agency -
‘Current developments in energy markets’
Joachim Harder, Onestone Consulting
- ‘Developments in the global cement market’
Andreas Schaab, Hochtief Construction
- ‘Modern cements: Requirements as seen
from the construction industry’
Martin Schneider, VDZ - ‘Technology devel-
opment in the cement industry’
Thursday 26 September
Morning sessions : 09:00 - 12:15
HALL ‘MARITIM’ - Future Challenges and
Visions of Cement Process Technology
Afternoon sessions : 13:45 - 17:00
Per Mejnert Kristensen, FLSmidth - ‘How
will the industry move ahead in cooperation
with equipment suppliers?’
Jouni Salo, Co-author Heiko Schürmann,
KHD Humboldt Wedag -‘Customer-focused
clean technology’
Wang Wei, Sinoma International Engineer-
ing - ‘A new solution to maximising the ROE
management of clients’
Frank Ruoss, ThyssenKrupp Resource
Technologies - ‘ThyssenKrupp Resource Tech-
nologies: A new company rich in tradition’
HALL ‘DUESSELDORF’ - “Sustainabil-
ity, use of Energy and Resources”
Michael Rademacher, Heidelberg
-Cement - ‘Protection of biodiversity in
quarries: A contribution to the long-term
sustainability of natural resources’
Fabio Wider, Holcim - ‘Experiences with
ORC at plant Untervaz, Holcim (Schweiz)’
Andreas Werner, TU Vienna, Co-author
Helmut Leibinger, Rohrdorfer Gruppe -
‘Waste heat recovery and power generation
in cement clinker production: An energetic
comparison’
Gernot Kirchner, Lafarge Zement, Co-
author Volker Hoenig, VDZ - ‘Energy
efficiency of cement production: Levers,
potentials and limitations’
Stefan Schäfer, VDZ - ‘Motivating, effi-
cient and flexible: VDZ’s enhanced cement
training’
Philipp Fleiger, VDZ - ‘Mill audits: Tools
to increase grinding efficiency’
LUNCH 12:15 - 13:45
HALL ‘MARITIM’ - Environmental
Technology
Rüdiger Matheis, Co-author Bernward
Goedecke, Dyckerhoff - ‘High-efficiency
SNCR for non-calciner kilns: Potentials
and limits’
Detlef Edelkott, SCHWENK Zement -
‘High-dust SCR technology: Operational
experience with catalytic NOx abatement’
Bernhard Köck, Lafarge CTEC Vienna -
‘Semi dust SCR: Cement plant
Mannersdorf ’
Helmut Leibinger, Rohrdorfer Gruppe -
‘Tail-end SCR technology for mitigation of
NOx and NH3: Operational experience at
Rohrdorfer Zement’
Gerhard Philipp, Wopfinger Baustoffin-
dustrie - ‘The new regenerative thermal
oxidation (RTO) with integrated NOx re-
duction at the Wopfing cement plant’
Daniel Crowley, TITAN America - ‘Mer-
cury emissions and abatement measures’
HALL ‘DUESSELDORF’ - Grinding
Technology
Jesper Havn Eriksen, FLSmidth - ‘OK mill
- The optimised and versatile grinder’
Robert Schnatz, Gebr. Pfeiffer, Co-authors
Dr Caroline Woywadt, Gebr. Pfeiffer &
V. K. Jain, Jaiprakash Associates - ‘Op-
erational experience from India’s first MVR
vertical roller mill’
Daniel Strohmeyer, Loesche -‘VRM grind-
ing technology: A comprehensive approach’
Thomas Schmitz, ThyssenKrupp Resource
Technologies - ‘Quadropol QMC-RD:
World’s first vertical roller mill with driven
rollers’
Anton Kollmann, HeidelbergCement -
‘Production of slag-containing cements
by separate grinding of the components
Portland cement and GGBF slag and sub-
sequent mixing’
Bao Wei, Hefei Cement Research Institute
- ‘HFCG Roller Press and its application in
cement grinding’
19:00 DINNER - HALL ‘MARITIM’
Includes Award Ceremonies for the
VDZ Safety at Work Award 2012 and
the Klaus-Dyckerhoff-Prize

48 globalcementMAGAZINE September 2013

 VDZ CONGRESS
Friday 27 September
Morning sessions : 09:00 - 12:15
HALL ‘MARITIM’ - Burning Technology

Sandro Buzzi, Buzzi Unicem - ‘From municipal solid waste

to energy’

Jaroslaw Sawecki, CEMEX Poland - ‘Improved RDF quality

and combustion due to the drum drier at Chelm’

Giovanni Cinti, Italcementi Group - ‘New 3000t/day line in

Rezzato, Italy: Innovation for sustainable production’ ConsTruCTion
ExPErTs for ThE
Marcel Bieri, Jura-Cement-Fabriken - ‘How to protect the kiln
shell against corrosion’

Christian Suchak, VDZ, Co-author Volker Hoenig, VDZ -

CEmEnT indusTry
‘Low-temperature corrosion in cement plants’

HALL ‘DUESSELDORF’ - Cement and Concrete

Michel Delort, ATILH - ‘Low-clinker ternary cements: Preheater Tower | Phoenix Cement Beckum
Performance and standardisation’

Karen Scrivener, Ecole Polytechnique Fédérale de

Lausanne - ‘10 Years of Nanocem: Research highlights’

Wolfgang Dienemann, HeidelbergCement - ‘Belite calcium-

sulfoaluminate rernesite (BCT): A new low-carbon clinker
technology’

Sui Tongbo, Sinoma International Engineering - ‘Belite-rich

Portland cement and concrete’

Hendrik Möller, SCHWENK Zement - ‘Celitement: Where are

we standing?’

Christoph Müller, VDZ - ‘Durability requirements for concrete

today and in the future’

Global Cement will once again attend the

International VDZ Congress - See you there!

Below: Delegates at the 6th International VDZ Congress in Düsseldorf in 2009.

We at KRANZ engineering are a team of specialists!

We will plan, design, and renovate for you the
essential structures required for cement production:
silos, storage facilities for alternative fuels, laboratories,
and support bridging to carry ducts and conveyor belts.

For more information, visit www.kranz-engineering.de

globalcementMAGAZINE September 2013 49
Oelde-Stromberg | Germany | phone +49 (0) 2529 9314-0
 Contents Subscribe Ad Index
PLANT MANUFACTURING
Klaus Gottwald, Large Industrial Plant Manufacturers’ Group, VDMA & Global Cement staff

The Large Industrial Plant Manufacturers’ Group, known

VDMA: Industrial plant by its German acronym AGAB, is part of the Verband
Deutscher Maschinen- und Anlagenbau (VDMA). AGAB
looks after the interests of German companies involved in
manufacturing in 2012 the production of large-scale industrial plants, including
cement plants. Excerpts from and analysis of its latest
Status Report are presented below.

Above: Humboldt
Wedag GmbH cement
pyro-processing lines at
T he large industrial plant manufacturing industry is
a major sector of the German economy with an av-
erage new order volume of nearly Euro25bn/yr between
In recent years
Germany’s large plant engineering sector was booming
until the second half of 2008, when the global economic
Shree Cement’s RAS plant in
Rajasthan. German cement 2008 and 2012. Germany has a 17% share of the sector crisis set in. The number of accessible projects on the
plant manufacturers have worldwide. market collapsed due to a combination of weak demand,
won numerous contracts in The large-scale plant engineering contractors in the funding shortfalls and general pessimism, with a cor-
India in recent years as that
country expands its cement VDMA maintain business ties with customers in nearly responding decline in incoming orders. Figure 1 shows
manufacturing base. all parts of the world and in recent years they have de- recent trends in AGAB’s order book.
livered around 80% of products abroad. South Asia, East The situation did begin to stabilise from the mid-
Asia and the United States are key customer countries at dle of 2010 onwards, but the situation has remained
present. By opening up new markets, the large industrial volatile, with variations between regions and the project
plant engineering industry provides a significant contri- structures. The number of projects is still well below
bution to Germany’s international economic relations. the level before the economic crisis. There has been a
The sector frequently acts as a pioneer for Germany in substantial reduction in the number of medium-sized
emerging markets, leading to exports in other areas of projects in particular, while megaprojects are becoming
the economy. more common.
“The trend towards size and the award of
32 complete packages in plant manufacturing
30 continues unabated,” said Helmut Knauthe,
28 member of the Executive Board at Thyssen-
Right - Figure 1: Total
annual new orders taken by
26 Krupp Uhde GmbH. “Customers prefer to
AGAB members from 2003 24 negotiate and deal with only one contractor.
New order volume (Billions of Euro)

to 2012. 22 On the other hand, however, the markets

20 have shifted and there are plenty of smaller
Total incoming orders
18
Three-year average projects for special products. Those plant
Foreign orders 16
manufacturers with a flexible set up and far-
Domestic orders 14
reaching international scope are at a clear
12
advantage here.”
10
Growing supply is thus accompanied by
8
a level of demand that tends to be consist-
6
4 ent in terms of volume but different in terms
2 of structure. Customers’ expectations have
0 changed: for large-scale projects, a growing
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 number ask for a main contractor.

50 globalcementMAGAZINE September 2013

 PLANT MANUFACTURING
Project breakdown industries created significant challenges for large indus-
The services provided in today’s typical EPC projects trial plant manufacturers.
are roughly divided up as follows: 10-15% of the order In this economic climate, German industrial plant
value is made up of engineering, 45-60% is made up of manufacturers were unable to maintain the momen-
procurement and 30-40% is from construction. tum built up in 2010 and 2011. Order intake reported
In the Middle East in particular, German plant man- by AGAB by fell 18% to Euro20.5bn, compared to
ufacturers have been unable to build on the successes Euro24.9bn in 2011.
of the boom years. Competition from Korean and also In Germany the large industrial plant market de-
Chinese plant manufacturers is intense. Many of the clined by 41%. According to AGAB’s Status Report,
plant construction projects in the Middle East are cur- “This leaves no doubt that the industry should not be
rently managed by Asian companies. The only role left relying on static or possibly even increasing demand
for established, technology-driven plant manufacturers inside of Germany’s borders. The companies have no
tends to be that of a technology provider, licensor and a choice but to fight for their export markets.”
partner in basic planning.
Cement manufacturers
AGAB contains the following companies
China 11% South Korea 9%
that are involved in the cement sector:
ABB Automation AG, Claudius Peters Pro- Left - Figure 2: Total
India 6% jects GmbH, FLSmidth Hamburg GmbH, annual new orders taken by
Humboldt Wedag GmbH, Thyssen AGAB members in 2012 by
nation (excluding
Krupp Resource Technologies and parts of
Russia 5% domestic orders).
Siemens AG.
USA 5% When one looks at the figures for 2012,
one finds large variations in the different
Others Poland 5% sectors of the industrial plant manufactur-
44% ing industry. While many other sectors saw
Turkey 4% Below - Figure 3: Total
a drop in incoming orders, German cement value of new cement plant
Brazil 4% plant manufacturers saw a 4.2% year-on- orders taken by AGAB
UAE 3% members between
year increase in order volumes in financial
2003 and 2012.
Vietnam 3%
1400
1400
Order intake volume for AGAB member cement plants

1200
1200
Given that new Asian competitors are making
massive efforts to achieve technological advances, it 1000
1000
is not enough for German suppliers simply to opti-
mise their capacity for innovation. The sector must 800
800
(Millions of Euro)

rather improve in all relevant areas of competition.

This specifically includes measures targeted at the 600
600
classic project parameters of price, quality and time.
Also of great relevance are procurement and con- 400
400

struction, which account for by far the biggest part

of a given project cost at ~85%. 200
200

On top of all these measures to secure their

00
competitiveness, globalisation is a crucial issue
1
2003 3
2004 2005 2006 5
2007 2008 7
2009 9
2010 2011 2012
for the large plant manufacturing industry. There
is no uniform approach to organisational design
to manage globalisation. The greatest challenge in
this process of change is incorporating expertise from terms, with orders increasing from Euro384m in 2011
foreign subsidiaries. The companies must enhance their to Euro401m in 2012. While this represents an increase,
inter-cultural skills in support of the internationalisa- (the cement plant manufacturing sector has increased
tion process. To make globalisation a success, these skills orders every year since 2009), the order volume for 2012
are just as important as the standardisation of processes was still well down on 2007 and 2008’s peak order vol-
and tools. umes of over Euro1bn.
The rise and fall of cement plant order volumes taken
Latest figures: 2012 by AGAB members in the past decade can be seen in
2012 was a year of economic and political uncertainty. Figure 3. There were no domestic cement plant orders in
Slower global economic growth, uncertainty in finan- 2012. This has frequently been the case in recent years.
cial markets in the wake of the Euro crisis, political Figure 4 shows the contribution from German ce-
instability in parts of the Arab world, unsettled global ment plant orders to total foreign industrial plant order
energy markets and massive overcapacity in core values in percentage terms. This shows that between

globalcementMAGAZINE September 2013 51

PLANT MANUFACTURING
AGAB member companies also take an
77
optimistic view of the medium-term pros-
pects for their Eastern European business,

Contribution of cement plant manufacturers to

66
particularly in the Russian market. Asia,

German large plant order intake (%)

55 including the two core markets of China
and India along with South Korea, Indo-
Right - Figure 4: 44
Percentage contributed by nesia, Vietnam and Thailand, remains a
cement plants to overall 33 key sales region. Turkey is also expected
foreign industrial plant to provide a continuous stream of orders.
orders of AGAB members 22 In contrast, the outlook for the
between 2003 and 2012.
western European market is less en-
11
couraging. The downturn in southern
00 Europe is likely to continue in 2013.
1
2003 3
2004 2005 5
2006 2007 7
2008 2009 9
2010 2011 2012 Furthermore, there are currently few
encouraging signs from South America,
North Africa and the Middle East.
2004 and 2008 cement plant orders contributed 4.5-6.5% Intense competition from Asian engineering compa-
of the total. In 2009 the percentage was sharply down to nies is making it more difficult for German industrial
just 1.9%. The contribution by AGAB members’ cement plant manufacturers to acquire orders in the Middle
plant orders has since gradually increased up to around East, particularly megaprojects, which are currently
3%, the same as in 2003 prior to the cement plant build- very popular.
ing boom of the mid-2000s. Beyond that, the plant engineering industry is notic-
ing the effects of a general uncertainty on the part of
The future - Across all industries Middle Eastern investors and hence a declining number
Following the marked decline in new order intake in of project starts as the focus of investment shifts back
2012, no major upturn in demand is expected for the to the US.
German large industrial plant manufacturing industry
Below: Russia is a promis- in 2013. The International Monetary Fund expects the The future - Hiring outside Germany
ing market for large plant world economy to expand by 3.3 % in 2013, so a moder- Highly skilled employees are a crucial success factor
manufacturing companies,
ate increase in order intake by AGAB members is the for AGAB member companies. In the period between
including cement plant
manufacturers. The plant most likely scenario. 2005 and 2010, the industry increased its domestic
shown is a KHD-designed “The large industrial plant manufacturing sector headcount to 60,000 and the proportion of engineers
clinker production plant expects the increase in order intake during the current in the workforce also rose. Since then, the number of
in Russia produced for
year to be in the single digit percentage range,” said employees in Germany has remained essentially un-
Mordowcement.
AGAB Spokesman Helmut Knauthe. changed and is unlikely to increase in 2013.
There is momentum in the However, AGAB member companies are hiring
United States and eastern Eu- at their international sites. More than 120,000 pro-
rope, while demand is expected fessionals already work for German industrial plant
to remain stable in Asia. The manufacturers worldwide. This strong international
US is currently seen as the ‘El presence is imperative because it places the industry in
Dorado’ of the plant industrial a position where it can exploit sales opportunities in the
manufacturing industry. Gas growth markets of Asia, South America and eastern Eu-
prices are now at an historic rope. Besides price aspects, proximity to the customer
low and this has triggered an and local requirements are also crucial considerations.
investment boom in the US
chemical industry with no end Conclusion
in sight. The project pipeline Despite a moderate improvement in orders in 2013,
is filled for years to come in long-term growth factors remain intact for large plant
the steel industry and en- manufacturers. Long-term growth trends include rising
ergy sector as well. Based on world-wide demand for energy as well as the increas-
their strong positions in the ing importance of energy-efficiency and resource
US market, German large conservation. The long-term outlook for the large
industrial plant manufactur- industrial plant manufacturing industry beyond 2013
ers believe that chances are is encouraging.
good that they will acquire
orders for many projects.

Note
This summary has been compiled by Global Cement staff using portions of AGAB’s ‘2012/2013 Status
Report’ sub-titled: ‘Globalisation and flexibility keeps companies competitive,’ July 2013. Figures 3 and 4
have been generated from the data contained therein.

52 globalcementMAGAZINE September 2013

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 Contents Subscribe Ad Index
FUTURE INDUSTRY
Fives Group
To mark its bicentenary in 2012, Fives asked the people of France about their feelings on

Plants of the subject of industry and industrial plants. A clear grasp of industrial realities, a desire
for more information and confidence in the future: this survey revealed just how much
affection French people have for their industrial base and how convinced they are of its
the future ability to reinvent itself. This initiative has since progressed, with the same survey being
conducted in two other leading industrial nations where Fives also has a strong presence:
the USA and China. Conducted at a time of globalisation in world trade, this survey
shows that, just as in France, the values
conveyed by industry are positive, although
expectations and levels of optimism vary
between the three countries.

Above: Cement plant

designed and supplied by
Fives in Qatar. Photo: ©
FD Fives.

Below: Looking to the future
at a sugar plant designed and
supplied by Fives in Turkey. What
lies ahead for heavy industry in
the coming decades?
Photo: © FD Fives.
Fives Observatory for the Plants of the Future
As part of its Observatory for the Plants of the Future
launched in 2012, Fives brought the public face-to-face
with industry experts to initiate a debate about tomor-
row’s industry as the basis for defining the industrial
plants of the future. This was
achieved by organising a year-
long cycle of events including the
intial survey of French attitudes
to industrial plants and French
industry in general, 15 inter-
views with specialists expert in
the issues facing industry and a
citizens’ conference that sparked
public debate and led to a charter
of recommendations regarding
the conditions under which peo-
ple would be prepared to accept
an industrial site close to their
own home .
The conclusions derived from
all these initiatives have been
compiled and interpreted in the
first edition of the Report of Fives
Observatory for the Plants of the
Future, which Fives has made
available online. In 2013, this
initiative is being extended inter-
nationally by bringing together
leaders in innovation to share
their vision of an ‘industrial plant for the world’ via a
series of events. The survey has been expanded to take
in the views of residents in China and the United States.
China and USA enthusiastic about
European industry
China and the USA are united in their perceived image
of European industry, which is very positive overall.
They believe it to be innovative (92% and 80% respec-
tively) and competitive (92% and 76%) and that as a
result, it plays an important role in global industry (91%
and 78%) and will continue to do so in the future (81%
in both countries).
This means that the Chinese and Americans are a
great deal more enthusiastic than the French themselves,
54% of whom believe that it is no longer possible to
reindustrialise France due to competition from emerg-
ing countries. French perceptions of the overall image
of industry are also much more pessimistic than those
of people in China and America: only 36% see it as an
appealing sector of the economy, especially for young
people, compared with 82% in China and 67% in the
USA. Far from adopting the traditionally downbeat
attitude to industry, people in France, China and the
USA share the same optimistic vision of industry and
the potential for economic growth it represents: re-
spondents in all three countries agree that industry is an
economic sector of the future, as long as its focus is on
cutting-edge industries (France 82%, China 83% and the
USA 87%).

54 globalcementMAGAZINE September 2013


The industrial plant of tomorrow
Respondents in China, France and the US share the
same vision of the industrial plant of tomorrow. Most
importantly, it will be innovative (88%, 93% and 84%
respectively), international in outlook (85%, 87% and
81%) and more environmentally friendly as a result of
reducing its consumption of energy and raw materials
(81%, 86% and 83%). The most optimistic views come
from China, where there is clear confidence about what
the industrial plant of tomorrow will be, and very high
expectations about its more effective integration into the
urban environment (63%, compared with 15% in France
and 23% in the USA). When asked about the possibility
of building clean industrial plants, the Chinese feel that
this would not be possible at the moment, but could be
envisaged in the future (56%, compared with only 23%
in France and 19% in the USA).
The current state of the Chinese industry crystallises
high expectations amongst the population in respect of
environmental protection: 63% of Chinese respondents
cite this value as the most important to be respected by
any industrial plant, compared with only 46% of French
respondents and 40% of Americans. Frédéric Sanchez,
Fives Group Executive Board Chairman, commented on
the outcomes, saying, “Despite being at different stages
in their industrial history, the expectations of our stake-
holders are the same in all three countries. It is therefore
up to us in industry to work towards delivering the in-
novative solutions that respond to those expectations.
That is the ambition of Fives, which supplies equipment
and industrial plants that impose less impact on the en-
vironment and are more eco-friendly.”
FUTURE INDUSTRY
A very strong attachment to industry
France, China and the USA share the same positive vi-
sion of the values described by the terms ‘innovation’,
‘engineer’, ‘work’ and ‘enterprise’, all of which attract the
agreement of almost all those individuals interviewed.
Differences emerge over the term ‘industrial plant,’
which has positive connotations for only 55% of French
respondents, compared with 79% of Chinese respond-
ents and 69% of Americans. It is notably the case that
social perceptions of industrial plants and the working
conditions experienced by those who work in them are
where the greatest differences can be seen between the
USA and China on the one hand, and France on the
other. In the USA and China, more respondents believe
that industrial plants create jobs (90% and 86% respec-
tively, compared with 69% in France), that they create a
social link (77% and 82%, compared with 68%) and that
those who work in them are given responsibility (92%
and 65%, compared with 55%).
Interestingly, these wide discrepancies have a direct
parallel in people feeling that they are ill-informed
about industrial plants and what they do: 86% of French
respondents feel that the general public knows too lit-
tle about industrial plants, compared with only 39%
in China and 65% in the USA. Frédéric Sanchez said,
“Chinese and American people have a clear understand-
ing of these issues: since their industrial plants are often
central to a particular region, they have a better under-
standing of industry as a source of innovation and social
links. It is by throwing the doors of our industrial plants
wide open that we will sweep away the essentially nega-
tive view held in France.”
Below: Cement plant
designed and supplied
by Fives in Mexico.
Photo: © FD Fives.
globalcementMAGAZINE September 2013 55

RWM
Daniel Bator-Brown, Global Cement Magazine
1: The German-based BRT
Recycling Technologie
GmbH, a well known sup-
plier of specialised recycling
equipment in Great Britain,
presented its new machine
solutions at RWM in 2012.
Andre Berlage manned
the stand.
2: The Blue Group stand
formed part of the extensive
outdoor exhibition area at
RWM 2012.
56 globalcementMAGAZINE September 2013
Company name Hall/Stand
A
4B Braime Elevator Components 19/W44
a1-cbiss 20/F70
AAF Ltd 19/W51
AB Systems 19/P51
Abraservice UK 19/R51
Accent Wire UK Ltd
Advanced Cyclone Systems 20/J08
Advanced Plasma Power
Advantage Austria 18/L08
Aerzen Machines Ltd 20/K48
Al-jon Inc 19/P48
Allcode (UK) Ltd 20/L03
Allcontrols Ltd
2
Contents Subscribe Ad Index
RWM 2013 - Preview
The Resource & Waste Management
(RWM) Exhibition will take place
on 10-12 September 2013 at the
NEC in Birmingham, UK. The event
will be held by RWM in partnership
with CIWM, and is dedicated to
the resource efficiency and waste
management sector; with last
year’s attendee count at 13,500;
and the exhibitors representing 72
countries. This year, 569 suppliers
of equipment, services and vehicles
will be exhibiting. A shortlist of
216 exhibitors relevant to the use
of alternative fuels in the cement
industry can be found below.
19/W11-V10
20/F59-E58
1
Allgaier Process Technology GmbH 19/S18
19/S21-R20 Amandus Kahl GmbH & Co KG 19/T45
AMB Project GmbH 17/G58
AMCS Group 18/M45-L44
Associated British Ports 19/X09
Astute Technical Recruitment Ltd 20/L59
ATEX Explosion Hazards Ltd 19/W69
Atlas Copco Construction Technique 17/A58
ATM / Esel Recycling 17/D11
Atritor Ltd 19/S20
Avery Weigh-Tronix 20/C75
AXO Shredders Ltd (UK) DA7
 RWM

B
Babcock & Wilcox Volund A/S
Bakker Magnetics BV 20/D08
Bano International S.R.L.
Baughans Barrel Screens O/A101
Bell Equipment O/A196
Bergmann Direct Ltd O/A23
Bezner Anlagen- und Maschinenbau 18/N31-M30
Blue Machinery Spares Ltd O/A194
Brelko Conveyor Products 20/A40
Brigade Electronics plc
BRT Recycling Technologie GmbH 19/S44
BS&B Safety Systems (UK) Ltd
Bulk Handling Systems
Bunting Magnetics Europe
20/J21-H20 3: Blue Group staff also
presented Doppstadt’s
static recycling technol-
19/Q61-P60 ogy equipment in 2012.
17/C23-B22 3
17/C59-B58
18/L19-K18
20/B09-A08
E
E H Hassell & Sons Ltd
(Sennebogen / Ing. Bonfiglioli) O/A111
Eggersmann Anlagenbau 19/T41-S40
Ebbsfleet Engineering Services Ltd 19/S68
EMS Shredders 17/E11
Entsorga Italia S.p.A 19/R40 4: The Chain+Conveyor
stand was busy at RWM
nvironmental Integrated Solutions Ltd 19/R44 2012. Here Helen Stott
Environmental Recycling Technologies plc 19/V48 (left), Partner, Samantha
Erg air Pollution Control 19/V28 Wheeler (right), sales,
Eriez Magnetics Europe Ltd 19/P19-N18 take a moment out on
the stand.
ESG 20/K29

4 F
Fairport Containers Ltd 17/A09
Fichtner Consulting Engineers Ltd 20/G19-F18

C
C F Nielsen
c-trace Ltd 17/E31
Cargotec UK Ltd O/A27
CBI Europe B.V 19/Q58
Centurion Industrial Packaging Ltd 17/F59
Chain and Conveyor
Challenger Handling Ltd &
SSI Shredding Systems 17/G48
CHO-Power 20/G71
CK International Ltd 17/F68
Clifton Rubber Co. Ltd 17/E07
Clugston Construction 06/N30
Cobb Lloyd Refractories 20/K28
CPM Europe BV 20/A48
Crow Environmental Ltd
Currenta GmbH & Co OHG
Cyclelink UK 17/D39
19/W19-V18
Fike UK 19/W49
First Grade Recycling Systems O/A204
Fisia Babcock Environment GmbH 20/L31-K30
FleetRoute 19/W08
FPE LTD 20/H39-G38
Freshfilter B.V. 17/B60
Frutiger 19/R59
17/E41-D40
G
Geminor A/S 19/Y11
GIG Karasek GmbH 20/J08
Glen Creston 20/A59
Goudsmit Magnetics Systems Bv 19/S21-R20
Gradeall Ltd 19/T69
Grecon Ltd 19/Q09
17/C11-B10 Grindermax GmbH 17/F09
19/W31-V30 Günther Environtech GmbH 20/L18

D
Derek Parnaby Cyclones International Ltd 17/F48
5: Grindermax staff pos-
ing on the company stand
Derwentside Environmental Testing Services 19/X54 at RWM 2012. Michael
Disab Vacuum Technology Ab O/A122 Grein (left) and André
Dulevo International SPA 20/E69-D68 Weikinger (right).
Dust Control Systems Ltd 17/F51
Dustcheck 19/V68
Dynamic Handling Systems Ltd O/A151
5

globalcementMAGAZINE September 2013 57

RWM
6 7
6: The busy stand of Lindner
Recyclingtech and Mach-
Tech Services, Lindner’s
UK and Ireland supplier of
industrial shredding ma-
chinery.
7: Jonathan King (right) and
William Wadsworth (left) of
John King Chains.
8: Liebherr’s outdoor stand
at RWM 2012.
9: Karsten Mennerich,
Business Development
Manager (left), and Piet
Gilbos, Regional Sales
Manager (right) from MeWa
Recycling Anlagen at RWM
2012. MeWa manufactures
three core machines, pri-
mary shredders, secondary
granulators and its patented
QZ machine.
58 globalcementMAGAZINE September 2013
8
H
Haas Recycling Systems 17/G58
M
Machtech Services Ltd 18/M29-L28
Haith Industrial Ltd 17/C51-B50 Magnapower Equipment Ltd 19/S45
Hako Machines Ltd 20/D59 Masias Recycling SL 19/Q31-P30
Heil Farid European Company O/A105 Master Magnets Ltd 17/F19
Hofmann Group S.r.l. 19/S69 MEGTEC 20/B17
HSM (UK) Ltd 17/E69-D68 Meltog 18/N19-M18
Metso Denmark As 20/G59-F58
I
IFE Aufbereitungstechnik GmbH 19/Q39-P38
MeWa Recycling
MID UK Recycling
18/L49-K48
20/J10
Middleton Engineering Ltd 19/W29
IFM Electronic Limited 19/T51 Mist Air Environmental 19/X45
Impact Air Systems 18/J39-H38 MK Group 8/K19-J18
Industrial Blower Services Ltd 19/V59 MMH Recycling Systems Ltd 18/H60
Indusvent 19/V39-T38 Mogensen 19/R08
Innovative Safety Systems 20/B18 Moovmor Engineering Ltd 18/J35-H34
Interlube Systems Ltd 17/G59
International Tyre & Wheel Solutions Ltd 19/R39-Q38
J
Jackson Engineering UK 19/N29
Jarshire Ltd 17/E68
John Hanlon & Co Ltd O/A201
John King Group 19/V29-T28
John Moore Tractor Parts Ltd O/A266
Johnston Sweepers 20/C38
K
KAMADUR Industrial Knives B.V 19/Q29
9
Keith Walking Floor Europe
Kingfisher Industrial
KMH/ VM Press
20/C79
20/L20
19/P44
O
O.KAY Engineering 18/N41-M40
Odour and Dust Solutions Ltd 19/V09
L
L&K Recycling Ltd 17/B21
One Seven of Germany GmbH 17/E19
Oschatz UK 20/F20
Legras Industries O/A103
Libra Weighing Machines Ltd O/A21
Liebherr-Great Britain Ltd O/A200
P
Parsons Brinckerhoff Ltd 19/S50
Lodge Cottrell 06/Q11 PCME 20/D74
Luhrfilter Ltd 06/P68 Pellenc Selective Technologies 18/M39-L38
Peter Ridley Waste Systems 18/L09
 Recyclingtechnology
StatiC Equipment

Efficiently and effectively set up by specialists

Flexible, unique, economical, environmentally

friendly and fast – using advanced technology
tailored to your requirements - that is what
Doppstadt offers you by way of its attractive
range of machinery.
Just get in touch.

More
Information
at:

www.doppstadt.com
You can find your nearest dealer on our
website:
http://www.doppstadt.com/en/sales-service/
doppstadt-sales-partners/

Doppstadt Systemtechnik GmbH

Steinbrink 4, D-42555 Velbert
T +49 (0) 20 52 / 889 - 0
WE CARE F +49 (0) 20 52 / 889 - 157
systemtechnik@doppstadt.de

AnzCementMagazine303x216_DR.indd 1 27.08.2013 15:35:27

RWM
PILANA Knives s.r.o. 9/P28
Pmi Analytical 19/W72
Presona AB 18/M69-L68
PRM Waste Systems Ltd 18/L49-K48
Q
Quality Recycling Machinery Solutions Ltd 17/A79
R
REMEX 20/K68
Renby Ltd 17/G08
Rentec NV 19/N50
Riverside Machinery 20/B59
Rotajet Systems Ltd 17/C43
Rotex 19/W48
Ruf UK Ltd 19/Q50
Russell Finex Ltd 20/G31-F30
10: Renby, in conjunction
with Hydratech BV, showed
their range of moving floors
and the new Spyro Toploader,
an economical system for
receiving bulk materials such
as alternative fuels and SRF
at RWM 2012.
Hans Smit (right), managing
director of Hydratech in the
Netherlands is pictured with
Ben Travis, managing director
of Renby Ltd.
10
S
S+S Inspection Ltd 18/J69
Saxlund International 20/L29
Scarab Sweepers Ltd
Schuster Engineering 20/M21
Shred Tech Ltd 20/D01
Simon Carves 20/E60
SLR Consulting Ltd 20/B19
Smartlift Bulk Packaging Ltd 19/Q48
Smiley Monroe Ltd 17/A20
Smurfit Kappa Recycling (UK) Ltd 17/G68
SN Engineering 18/W59
SpecDrum Engineering 17/D09
SSI Schaefer Ltd
11: The Vecoplan team were
out in force at the 2012
event. Left to right: Connor
Crane (Sales), Arno Möller
(Sales), Jarry Quickenden
(Managing Director), Frank
Merrbach (Sales), Michael J
Marks (Engineer).
11
60 globalcementMAGAZINE September 2013
Ssi Shredding Systems Inc 17/G48
Stadler UK Ltd 18/K35-J34
Stahlwerk Augustfehn 20/A33
Standprime Ltd 19/R10
Steinert Elektromagnetbau GmbH 19/S19-R18
Stratus Environmental 20/L19
Summit Systems
Sutco UK Ltd
19/P49-N48
18/K29-J28
T
TAIM WESER GmbH 18/N61-M60
Tamar Energy Limited 06/P69
Terberg Matec (UK) 20/C29-B28
The BMI Group 20/G79-E78
The Compressor Specialists O/A151
The Power Industrial Group Ltd 20/E09
Titech UK 17/H19-G18
TrennSo-Technik, Trenn- und Sortiertechnik 7/H41
U
Ulrich Attachments Ltd O/A220
Ulster Shredders Ltd 17/D20
Unger UK Ltd 17/E08
Union Industries 19/V41
Untha Recyclingtechnik Gmbh 17/H31-G30
UNTHA UK 17/H39-G38
V
Valvan Baling Systems NV 19/Q56
Van Schijndel Maasbracht b.v. 20/D09
Vecoplan Ltd 19/X29-W28
Vehicle Weighing Solutions Ltd 17/A18
VeriLocation 19/Q60
Vogelsang Ltd 20/L40
20/C39-B38 Vyncke Energietechniek Nv 20/K18
W
W. L. Gore 20/K19
Warwick Ward Machinery Ltd O/A206
Waste Recycling Technologies Ltd O/A125
Weighsoft Ltd 19/V20
Weightron Bilanciai Ltd 19/R41-Q40
Weltec Biopower (UK) Ltd 06/Q19
17/G19-F18 Wertstoffaufbereitung Gmbh 19/R47
Westcon Equipment (UK) Ltd 17/C69-B68
Westcon Equipment (UK) Ltd D/A8
Wirtschaftskammer Osterreich - Messebereich 18/L08
Worthington Creyssensac O/A151
Wrights Dowson Group 19/V11-T10
Wrights Recycling Machinery Ltd 18/J59-H58
WTI UK Ltd 20/K39
WYG Environmental 17/H09
Z
Zauner Anlagenbau GmbH 20/A09
Zehnder Clean Air Solutions 20/E68
 COMPETENCE IN
AFR CO-PROCESSING
Service, Engineering and Equipment for Alternative Fuels
and Raw materials in Cement and Lime Industry

• Tailor-made Alternative Fuel processing by shredding, sieving/sifting & re-shredding

• RDF Handling & Dosing from receiving to storage loading & unloading system
• RDF Injection and burner for Kiln & Calciner

Vecoplan FuelTrack GmbH

Bad Marienberg | Germany | Telefon +49 (0) 2661.62 67-871
info@vecoplan-fueltrack.com | www.vecoplan-fueltrack.com

FuelTrack_AFR_Anzeige_210x148.indd 1 08.01.13 16:43

State of the LindnerART:

Tina Roßmann
Marketing
Reduce to the max
We reduce everything. Almost everything. But never our know-how.
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NEWS THE AMERICAS
Cemex Q2: Revenue up, debt down but
still in the red
Mexico: Cemex has reported that consolidated net sales reached
US$4.0bn during the second quarter of 2013, an increase of 4%
compared to the comparable period of 2012.
Operating earnings before interest, tax, depreciation and
amortisation (EBITDA) also increased by 4% year-on-year during
the quarter to US$730m. Adjusting for the higher number of
business days in its operations during the quarter, consolidated
net sales improved by 2% and operating EBITDA increased by
2% year-on-year. Operating earnings before other expenses,
net, during the second quarter increased by 24% to US$451m.
Cemex said that an increase in consolidated net sales was mainly
due to higher prices in local currency terms and higher volumes
in most of its regions. However, controlling interest net income
was a loss of US$152m, an improvement over a loss of US$187m
during the same period of 2012.
Fernando A González, executive vice president of finance and
administration, said, “We are pleased to report that this is the
eighth consecutive quarter with year-over-year improvement in
EBITDA. We also saw an increase in our consolidated prices in
local-currency terms for cement, ready mix and aggregates dur-
ing the quarter. On the cost side, our alternative fuel substitution
initiatives remain a very high priority. On a consolidated basis,
our alternative fuel utilisation reached 28% during the quarter.
In addition, we are implementing targeted cost-reduction initia-
tives in Mexico and northern Europe, which we expect will result
in savings of about US$100m during the second half of 2013.”
Net sales in Cemex’s Mexican operations increased by 2%
year-on-year in the second quarter of 2013 to US$847m. Operat-
ing EBITDA decreased by 17% to US$250m. In the United States,
Cemex reported net sales of US$868m for the quarter, up by 9%
year-on-year compared to the 2012 quarter. Operating EBITDA
increased to US$80m in the quarter, compared to US$27m in
the same quarter of 2012. Cemex’s operations in South, Central
America and the Caribbean reported net sales of US$561m dur-
ing the second quarter of 2013, representing an increase of 6%
over the same period of 2012. Operating EBITDA increased by
Cemargos reports fall in profit
Colombia: Cementos Argos (Cemargos) has reported a
year-on-year fall of 79.2% in net profits to US$38.9m for
the first half of 2013. The Colombian cement producer at-
tributed the decline to a sale of assets in the first half 2012
that had artificially inflated net profits.
Revenue for the first half of 2013 was US$1.24bn, a
rise of 9% from US$1.2bn in the first half of 2012. Earn-
ings before interest, taxes, depreciation and amortisation
(EBITDA) increased by 23% to US$261m from US$212m.
In the first half of 2013 Cemargos shipped 5.5Mt of ce-
ment, a 1% year-on-year increase.
“The results reflect the positive trends being seen in
our markets and the strategies of segmentation, price
and penetration being implemented,” said the company
in its financial statement. Cemargos said that volumes
recovered in Colombia in the second quarter of 2013 and
the Caribbean region continued to support growth.
62 globalcementMAGAZINE September 2013
Contents Subscribe Ad Index
12% to US$211m in the second quarter of 2013, from US$189m
in the 2012 quarter.
In Cemex’s Northern Europe region, net sales for the second
quarter of 2013 decreased by 1% to US$1.09bn, compared with
US$1.1bn in the second quarter of 2012. Operating EBITDA was
US$108m, 11% down year-on-year. Second-quarter net sales in
the Mediterranean region were US$400m, 4% higher compared
with the US$384m taken during the second quarter of 2012.
Operating EBITDA in this region decreased by 2% to US$94m.
Operations in Asia reported a 14% increase in net sales for
the second quarter of 2013 at US$162m. Operating EBITDA
for the quarter was US$38m, up by 29% from the same period
in 2012.
Cemex Latam sales leap 8%
Colombia: Cemex Latam has reported that its consolidated net
sales rose year-on-year by 8% to US$431m in the second quar-
ter of 2013. The Cemex subsidiary, based in Colombia, Panama,
Costa Rica, Nicaragua, El Salvador, Guatemala and Brazil, attrib-
uted the rise to higher volumes that were driven by improved
construction activity and higher prices. Cemex Latam’s operating
earnings before interest, taxes, depreciation and amortisation
(EBITDA) increased year-on-year by 16% to US$166m.
“We are very pleased with the favourable results in the
second quarter, as evidenced by the record level of operating
EBITDA margin that reached 38.5%. We are also very encouraged
with the results seen so far in connection with our new strategy
based on commercial solutions that are allowing us to capture
incremental value,” said Carlos Jacks, CEO of Cemex Latam.
By region, Cemex Latam’s operating EBITDA in Colombia in-
creased by 12% to US$103m in the second quarter of 2013 and
net sales increased by 6% to US$238m. In Panama, operating
EBITDA increased by 14% to US$40m and net sales increased
by 8% to US$81m. In Costa Rica, operating EBITDA increased by
37% to US$19m and net sales increased by 28% to US$42m. In
Cemex Latam’s remaining territories operating EBITDA increased
by 7% to US$21m and net sales were US$74m.
Lafarge agrees to pay Ravena fine
US: Lafarge North America has agreed with the US Environmental
Protection Agency (EPA), the US Department of Justice and New York
State to provide US$1.5m towards projects to reduce air pollution in
the community surrounding its Ravena cement plant. The agreement
also grants Lafarge additional time, until 1 July 2016, to reduce air pol-
lution from the plant. “This agreement will reduce the pollution limits
required by the settlement at this facility by providing a significant
amount of funding for projects that will improve local air quality,” said
EPA Regional Administrator Judith A Enck.
A March 2010 settlement between the federal government and
Lafarge North America over violations of the Clean Air Act required
that the cement producer either install controls on two kilns at its
Ravena plant or replace those kilns with a lower emitting kiln by 1
January 2015. In return for the extension, Lafarge has committed to
interim air pollution limits at the existing kilns intended to result in
the same or greater reductions as would have been required by the
original agreement in addition to funding local air pollution measures.

Capitol Aggregates Cement to build
carbon capture plant
US: Texas-based cement producer Capitol Aggregates
Cement is preparing to retrofit a carbon capture plant
to its cement plant. The project, in conjunction with
Skyonic Corporation, is expected to profitably remove
more than 300,000t of CO­2 from the plant’s emissions.
“The Capitol SkyMine plant will mark the first time
that carbon-negative chemistry has reached the com-
mercial stage,” said Joe Jones, founder and CEO of
Skyonic. Skyonic Corporation has secured US$128m
funding to support the project from new investors
Cenovus Energy, BlueCap Partners, Toyo-Thai Corpora-
tion and Energy Technology Ventures. The funds will
also help support Skyonic’s other global projects, re-
search and development and operations expenses. In
addition the US Department of Energy’s National Energy
Technology Laboratory will provide US$28m towards
the project.
The retrofit plant is expected to directly capture
83,000t of CO2 from the Capitol Aggregates’ emissions.
In addition, by using this captured CO2 to make products
that would otherwise generate extra CO2, the plant will
offset an additional 220,000t/yr, once fully operational
in 2014. Skyonic is also expected to create more than
200 jobs through the plant’s construction and ongoing
operations.
Skyonic’s electrolytic SkyMine(R) technology will se-
lectively capture CO2, acidic gases and heavy metals from
the flue gas and mineralise
the captured pollutants
into safe, stable, solid prod-
ucts. Skyonic states that
its carbon capture process
does so at a lower cost than
its competitors. The plant
is expected to turn a profit
from the sale of these prod-
ucts within three years.
Upgrade for Yura
Peru: The Peruvian
industrial conglomerate Grupo Gloria plans to
invest US$217m towards upgrading its Yura ce-
ment plant near Arequipa. The plant currently has
a cement production capacity of 3.5Mt/yr and the
upgrade is expected to double production by 2016.
The project will include the installation of a new
clinker line with a capacity of over 4500t/day, a new
cement mill and bagging, palletising and loading
equipment. The work will create more than 3000
direct jobs and ~9000 indirect ones.
Construction is set to start in 2013 with the mill
complete by mid-2014 and the new clinker line
ready by the end of 2016. Grupo Gloria is targeting
the additional cement capacity in the south of Peru
and Bolivia.
NEWS THE AMERICAS
TXI posts improved results for 2012-13
US: Texas Industries, Inc. (TXI), the leading cement producer in Texas
and a major player in the Californian cement market, has reported
financial results for the quarter and year ended 31 May 2013. Net
income for the quarter was US$44.1m. Net income included income
net of tax from discontinued operations of US$28.5m. Net income for
the quarter ended 31 May 2012 was US$60.2m.
Net income for the year ended 31 May 2013 was US$24.6m and in-
cluded a pre-tax gain on the disposition of discontinued operations
of US$41.1m. Net income for the year to 31 May 2012 was US$7.5m.
“The fourth quarter certainly benefitted from the continuing
recovery of construction activity in our major markets,” stated Mel
Brekhus, CEO of TXI. “Shipments of all products reflect double digit
percentage increases compared to a year ago.”
“We also achieved two strategic milestones during the quarter,”
continued Brekhus. “The commissioning of our 1.4Mt/yr cement kiln
at our central Texas plant (Hunter) was finished late in the quarter
and we completed the acquisition of 42 ready-mix plants in east
Texas. Both events significantly improve our ability to take advan-
tage of the strong recovery under way in Texas.”
Cimpor starts imports to northern Brazil
Brazil: Portuguese cement producer Cimpor, which has been con-
trolled by the Brazilian diversified holding group Camargo Corrêa
since June 2012, has started the first exports to northern Brazil.
The first shipment of 28,000t/yr of cement reached the port
of Manaus, northwestern Brazil in July 2013, according to local
press. Cimpor’s main rivals in this region are
Brazilian sector players Votorantim Cimentos
and Joao Santos.
Camargo Corrêa’s subsidiary InterCement,
which directly owns Cimpor, plans to import
some 70,000t/yr of Portuguese cement to
Brazil in 2013. Cimpor is also targeting exports
to Bolivia amid the continuing severe economic
downturn in Portugal.
Holcim agrees Hagerstown fine
US: Holcim (US) Inc., the current owner-operator
of the Hagerstown cement plant in Hagerstown,
Maryland and St. Lawrence Cement Co., which
previously owned the same facility, have agreed to pay a US$700,000 fine
and improve emission controls at the facility to settle alleged air pollution
violations, according to the US Environmental Protection Agency (EPA). The
action against the Hagerstown plant is part of an ongoing nationwide EPA
effort to tighten pollution controls in the cement industry.
The proposed federal court consent decree requires Holcim Inc. to install
‘advanced pollution controls’ at the plant. Holcim also pledged to spend at
least US$150,000 to replace outdated environmental protection equipment.
“It has been a long-standing issue and now the company feels that it re-
ally is in its best interests to find a resolution,” said Holcim spokeswoman
Robin DeCarlo.
The Department of Justice filed a suit on behalf of EPA in 2011 accusing
Holcim and the plant’s prior owner, St. Lawrence Cement Co., of violating
the federal Clean Air Act from 2003 to 2007 by modifying the facility’s ce-
ment kiln in a way that produced ‘significant’ increased emissions of SO2.
globalcementMAGAZINE September 2013 63
NEWS THE AMERICAS
Vulcan sales up by 7% Q2
US: Vulcan Building Materials has increased its sales year-on-
year by 7% to US$696m in the second quarter of 2013 from
US$649m. The construction aggregates and building materi-
als producer said that demand for its products had followed
the recovery in private construction activity, particularly resi-
dential construction.
“Each of our operating segments reported solid growth
in second quarter earnings, contributing to improved gross
profit margin and earnings per share. We achieved these
results despite challenging, wet weather conditions that
sharply reduced June shipments in many markets, “ said
chairman and chief executive officer Don James.
Vulcan’s gross profit for the quarter rose by 25% year-
on-year to US$133m from US$106m. Its net earnings were
US$28.8m up from a loss of US$18.3m. Vulcan’s cement busi-
ness reported a rise of 11% to US$11.9m from US$10.7m.
Volumes of cement shipped rose by 20% to 0.26Mt
from 0.22Mt.
In its outlook for the rest
of 2013 Vulcan expects the
continued recovery of the
US economy and building
sector to drive demand. Ce-
ment earnings are predicted
to improve overall in 2013
due to higher shipments and
pricing as well as lower pro-
duction costs.
Fire at Lehigh plant in Union Bridge
US: 40 firefighters extinguished a grease fire in a conveyor
at the Lehigh Cement Co. in Union Bridge on the evening
of 21 July 2013.
At 19:33, fire crews from Union Bridge and four other
towns responded to the fire, according to Perry Jones,
spokesman for the Union Bridge fire company. He said
the bearings in the conveyor overheated and the grease
caught fire but that it was controlled and put out in 15 min-
utes. No injuries were reported.
Two new Brazilian orders for FLSmidth
Brazil: FLSmidth has received two new orders in Brazil. The
first is for a 3300t/day line for Pitimbu Plant, a greenfield
project by Companhia De Cimento Da Paraíba in Paraíba
state. The Danish cement plant supplier previously built a
plant at Sete Lagoas for the same client.
The second order is for an OK-33 vertical roller mill.
Cimento Itambé has ordered the mill for cement grinding
at its Balsa Nova Plant located in Paraná state. This is the
19th OK mill sold in Brazil.
“The awarding of these orders to FLSmidth is a
consequence of a high market demand and has been
given to FLSmidth in spite of great competitor interest
in the same area,” said President, Cement Division, Per
Mejnert Kristensen.
64 globalcementMAGAZINE September 2013
Pacasmayo income down nearly 22%
Peru: Cementos Pacasmayo has reported a rise in sales of 9.1%
to US$197m for the second quarter of 2013 from US$180m in the
same period in 2012. However the Peruvian cement producer’s
net profits were hit by negative exchange rate changes in the
second quarter of 2013 and fell by 21.7% to US$8.38m. Despite
the effects of the exchange rate drop, the company attributed
its increase in sales to growing domestic demand for cement by
so-called ‘self-construction’ projects.
The company’s operating profit rose by 72.9% in the second
quarter to US$27.9m from US$16.1m. Consolidated earnings be-
fore interest, tax, depreciation and amortisation rose by 60% to
US$32.8m from US$20.5m. Total cement production increased
year-on-year to 0.55Mt from 0.51Mt.
In its summary of quarterly events Cementos Pacasmayo
reported that it obtained the approval of the environmental im-
pact study in May 2013 for the construction of the new cement
plant in Piura. Construction of the plant is expected to begin in
the ‘coming months.’
New CEO for Bío Bío
Chile: Cementos Bío Bío has
appointed Iñaki Otegui as its new
CEO, effective 1 August 2013.
Otegui replaces Jorge Matus, who
has resigned after 39 years with the
company.
Itacamba plans new Bolivian plant
Bolivia: Itacamba Cement intends to build a 0.85Mt/yr cement
plant costing US$180m at Yacuses near Puerto Suarez, Santa Cruz.
According to Bolivian local media, the project will start once Presi-
dent Evo Morales approves state-owned oil company Yacimientos
Petrolíferos Fiscales Bolivianos to install a gas line. Itacamba in-
tends the new cement plant to reduce its reliance on imported
clinker from Brazil.
Currently based in the Santa Cruz region of Bolivia and estab-
lished in 1991, Itacamba operates a cement grinding plant. It is
majority owned by Votorantim (66%) and other entities including
Bolivia’s Tumpar Group. The new plant is expected to create 540
jobs when it is opened.
Hi-Vac adds inside sales manager
US: Hi-Vac Corporation, manufacturers of a broad line of environ-
mental and industrial equipment, has hired Brent Muskin as inside
sales manager. He will oversee inside sales for products sold through
contractors (X-Vac and UltraVac) as well as industrial sales (Hi-Vac
and UltraVac).
Craig Primiani, vice president of sales and market-
ing for Hi-Vac Corporation stated, “We are happy to have
someone with over 20 years of sales and management experi-
ence on the Hi-Vac team. Brent’s specific experience in small
engines and high pressure hydraulics will be very helpful in his
new position.”
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RZ_Anz_FLT26313mit.indd 1 26.03.13 08:14

NEWS THE AMERICAS
Cemex launches Cemex Global Solutions
Mexico: Cemex has launched Cemex Global Solutions, a service that the
company says ‘leverages over a century of industry-leading expertise’ to
provide customers with the best value proposition in a full range of techni-
cal services for the cement, ready-mix concrete and aggregates industries.
Cemex Global Solutions is available around the world, with ongoing
projects in several countries. By using the best practices and innovations
from the company’s Research and Development Centre in Switzerland
and extracting value from its expertise as a top cement, ready-mix con-
crete and aggregates company, Cemex Global Solutions is expected to
provide state-of-the-art technological support across the entire building
materials manufacturing process, from plant design and conceptualisation
to expanding capacity and upgrading equipment. This service reinforces
Cemex’s commitment to suiting its customers’ needs by providing them
with reliable and cost-efficient solutions.
“We have an unparalleled team of experts with experience throughout
the building materials value chain strengthened by our cutting-edge re-
search and development centre,” said Hugo Bolio, Cemex Vice-President of
Global Technology and Safety. “From feasibility studies to plant manage-
ment and optimisation, we believe that by offering integrated solutions, we
can provide our customers with more reliable and higher quality services.”
Sixth annual safety month for Lafarge North America
US/Canada: Lafarge North America put an extra focus on best prac-
tices in health and safety in June 2013 as the company celebrated its
sixth annual Health & Safety Month. Sites across the United States
and Canada held special events to highlight this year’s theme,
‘At home, at work - make the link,’ and encouraged employees to take
home concepts and best practices used at work and apply them in ways
that make sense at home, with their families and out in their communities.
Protests in Guatemala over
cement plant plan
Guatemala: Local press has indicated that Gua-
temalan residents have staged protests against
local cement manufacturer Cementos Progreso’s
plans to build a cement factory in San Juan
Sacatepéquez, 30km north west of Guatemala
City. Members of 12 local communities claim
that they were not consulted prior to works com-
mencing and they say that the cement plant will
contaminate the local environment. The protests
started in the middle of July 2013.
The cement factory will be built in the area to
serve construction of a highway known as the
‘Anillo Regional’ that will connect the depart-
ments of Guatemala, Quiché, Baja Verapaz and
Chimaltenango. The highway is expected to cost
US$19.2m and works are being carried out under
a public-private partnership, in which Cementos
Progreso is participating.
The Guatemalan president Otto Pérez inaugu-
rated the start of construction works in May 2013
and defended the project, saying that it would
bring development to the area, according to a
presidential statement. “I want to ask the local
population, which will benefit from the project, to
help us and collaborate,” said Pérez. The president
also characterised claims that the highway will
damage the environment, affect local farming
and reduce water resources in the area as ‘lies.’
 ASTM TESTING SANDS
NEWS THE AMERICAS
New plant in Dominican Republic
Domincan Republic: President Danilo Medina has inau-
gurated the Cemento Panamericano (PANAM) grinding
plant at Villa Gautier, San Pedro. PANAM executive Hydraulic & Masonry
Manuel Estrella said that the US$80m plant will create
800 direct and 2400 indirect jobs. The PANAM cement Cement Testing (C-109)
plant will increase
Dominican cement
capacity to ~7Mt/yr.
Available in Graded and 20/30
Conforms to ASTM C-778
New president The Original Ottawa Silica
for Adocem
Dominican Republic: ISO 9001: 2008
The Dominican Association of Cement Producers
(Adocem) has sworn in Carlos Gonzalez as its president
for 2013 – 2014. Gonzalez, who is also president of Cemex
in the country, joins Gabriel Ballestas of Cementos
Argos as treasurer and Jose Caceres of Cementos Cibao
as secretary.

New vice president for Ash Grove

US: Ash Grove Cement Company has announced that
8490 Progress Dr. Suite 300, Frederick, MD 21701
Stuart E Tomlinson has joined the company as its vice
president of manufactur- www.u-s-silica.com • sales@ussilica.com
ing for the Midwest region
and will be based in the
company’s home office in (800) 345-6170
Overland Park, Kansas. He
joined Ash Grove on 15
August 2013 and replaces
Edwin Pierce, who will retire on 31 December 2013.
“Stu is a cement industry veteran and he possesses more than three decades of experience,” said
Ash Grove’s senior vice president of manufacturing. “He is an industry leader and will be an impor-
tant part of the Ash Grove leadership team.”
In his new role, Tomlinson will direct Ash Grove’s cement operations in the Midwest region, which
includes four cement manufacturing plants in Chanute (Kansas), Foreman (Arkansas), Louisville
(Nebraska) and Midlothian (Texas).

VHSC launches Pozzoslag

US: VHSC Cement has announced the commercial release of
Pozzoslag 1.2, a cementitious material made using coal fly ash as a
raw material. VHSC says that Pozzoslag 1.2 is a partial replacement
to OPC, offering early set times, greater long-term strength and
enhanced concrete durability. Users are also able to reduce their
chemical additive packages and lower the total amount of cementi-
tious binder material.
“Pozzoslag 1.2 is created using a patented process that was in-
troduced into commercial operations in November 2012. This new
product uses raw fly ash as a base material to produce a cementi-
tious blend of material that meets grade 120 slag strengths based on
ASTM 989 testing protocols. Using Pozzoslag in concrete allows very
high durability at routine replacement factors in the 55-65% range,”
said Buddy Pike, company president.
Votorantim cancels IPO due to
market conditions
Brazil: Votorantim Cimentos has cancelled a
US$4.8bn initial public offering (IPO) due to
poor market conditions. According to Dow
Jones, the leading Brazilian cement producer
had initially delayed its IPO in July 2013 to
September 2013.
“The IPO continues to be the company’s
plan and we will continue to monitor the evo-
lution of the capital market conditions to be
able to resume the offer,” said chief financial
officer Lorival Luz.

globalcementMAGAZINE September 2013 67

 Contents Subscribe Ad Index
MATERIALS HANDLING
Jürgen Meszaros & Helmut Lück, SCHADE Lagertechnik

Retrofit and capacity increase for South

America’s largest bridge scraper reclaimer

The largest bridge scraper reclaimer in South America was

commissioned at Cementos Lima S.A.A (now Union Andina
de Cementos (Unacem) in Peru in 1979. It remains the largest
on the continent to this day. The equipment, with a diameter
of 108m and a reclaim capacity of 1000t/hr of limestone has
now been rebuilt within the framework of a refurbishment
programme painstakingly and jointly planned by SCHADE
Lagertechnik engineers and assembly experts and the client.

Above: The retrofit of the

bridge scraper reclaimer
Unacem S.A.A., Peru
D uring the project to upgrade the bridge scraper
reclaimer, up to 14 welders and a total of 60
fitters worked at the site in Atocongo on the modernisa-
Photo: © AUMUND.
tion and capacity increase under the direction of four
SCHADE project managers, at times in parallel. Within
two months the unit, originally sourced from another
supplier, was technically brought completely up to date.
The reclaim capacity was increased from 1000t/hr to
1200t/hr with a number of individual measures.
This rapid and successful implementation was
thanks to the thorough preparation via on-site inspec-
tions and enabled analysis of the strived-for updates in
close consultation with the customer. No less than 14
containers, with a total weight of 140t, were shipped to
South America for the refit. In order to avoid potential
interface problems, Unacem had also awarded the entire
steel construction work to SCHADE Lagertechnik.
There had already been initial contact between
Cementos Lima S.A.A and SCHADE in 2008 in relation
to the refit. In several project stages potential upgrades
were examined and checked for their practicability. In
June 2011 Unacem S.A.A and SCHADE agreed on the
scope of the technical upgrades, which were eventually
tackled in September 2012. Unacem S.A.A was formed
through the merger of Cementos Lima and Cemento
Andino and is today the largest manufacturer in Peru.
One of the most significant upgrades in the capacity
increase of the existing equipment was the replacement
of the steel rope harrow with a new, round 700m2
hydraulic harrow. This enables an enhanced homogeni-
sation of the material and ensures even charging of the
shovels compared with the previous uneven charging.
This effect is further reinforced by new, asymmetric
shovels that were optimally tailored to the available
space.
The stacking process was switched from chevron
to chevcon within the modernisation programme. The
complete chain system, including the chain guide, was
exchanged and an additional scraper chain drive was
installed. The refit measures were rounded off by replac-
ing the entire electronics as well as new hydraulics for
the related stacker.
In addition to this project SCHADE has also exhib-
ited its ability to increase the capacity of other marques’
equipment, especially on the South American continent.
This includes two projects at Loma Negra (Argentina),
one at Cementos Yura (Peru) and also at Cementos
Itambé (Brazil). The company also has many retrofit
references in other sectors that depend on large-scale
material handling equipment.

68 globalcementMAGAZINE September 2013

 Contents Subscribe Ad Index
SOUTH AMERICA
Peter Edwards, Global Cement Magazine

The countries of South America are at different stages

South American of economic development, with cement industries of

varying size and ages. Nine countries, namely Argentina,
Bolivia, Chile, Colombia, Ecuador, Paraguay, Peru, Uruguay
cement focus and Venezuela, have integrated cement facilities. These
have a combined cement industry that is the same size as
that Argentina
of Brazil, which is not covered in this review.

Argentina 12000
12,000 1212

F ollowing Spanish colonial occupation and a series10000

of dictatorships, the Argentine Republic’s civilian
10,000 1010

Cement production (Mt)

governments have presided over gradual economic 8000
8000 88

GDP/capita (US$)
advances in the past 30 years (See Figure 1). However, 60006000 66
the country experienced a severe economic crisis from
1999 to 2002. This saw it default on its foreign debt 4000
4000 44

with a lost decade of growth, the collapse of the gov- 20002000 22

ernment and widespread riots.
00 00 Above - Figure 1:
GDP/capita (red) in 2011
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
Cement industry 1 3 5 7 9 11 13 15 17 19 21 US$ and cement production
After a number of false starts Argentina’s 15 plant Year in million tonnes (blue) for
Argentina, 1991 - 2011.
strong cement industry has now become the second- 1990s. There are no further planned or ongoing major
largest in South America after Brazil. It is dominated expansion projects in Argentina at present other than
by Loma Negra, which is 100% owned by Brazil’s Loma Negra’s investment plans to 2014. GDP US$755bn
Camargo Corrêa. It has seven integrated plants and a
GDP/capita US$18,400
capacity of 7.7Mt/yr. It is investing US$400m in new Bolivia
capacity in the period 2012 - 2014. Population 42.6m
Three local producers, Cementos Avellaneda, PCR
and Cementos Artigas have a combined capacity
of 7.0Mt/yr. The only multinational in Argentina is
B olivia fully broke away from Spanish colonial rule
in 1825 but then endured ~200 coups and counter-
coups until 1982. These prevented significant political,
Area 2,780,400km2

Above: Summary economic

Holcim, with four plants and a capacity of 3.1Mt/yr. economic or social progress during this period. Bo- and geographical statistics
Although the Argentine cement industry has a ca- livia is the least socially- and economically-developed for Argentina.
pacity of 16.8Mt/yr, the country produced 10.7Mt of country in mainland South America.
cement in 2012. This is lower than in 2011, when it Despite these issues, Bolivia’s economy has devel- Below: Summary economic
made 11.6Mt and indicates a capacity utilisation rate oped over the past 20 years (See Figure 2), with GDP/ and geographical statistics
of 60%. Despite this, production is now higher than capita rising by a factor of over 2.5 in the 20 years for Bolivia.
before Argentina’s crash (See Figure 1). between 1991 and 2011. Oil discoveries in the 2000s
There have been a number of changes in the Ar- have the potential to transform the country’s prospects
gentinian cement industry in 2012 and so far in 2013. but political disputes surrounding the best course of GDP US$56.1bn
Cementos Avellaneda commissioned its 2.5Mt/yr action regarding the oil have hampered development. GDP/capita US$5,200
Olavarria plant in February 2012 and in January 2013, Many are concerned that policies will widen the gap Population 10.5m
Spain’s Cementos Molins sold a 16.1% stake in Cemen- between rich and poor despite Bolivia already having Area 1,098,581km2
tos Avellaneda to Votorantim Europe. one of the largest income disparity gaps in the world.
So far in 2013 the industry is on an upward trend
with regards to output, with substantial increases in Cement industry Below - Figure 2:
GDP/capita (red) in 2011
monthly production relative to 2012. In May 2013, the Bolivia has one of the smallest cement industries in US$ and cement production
country produced over 1Mt of cement in a month for South America, with a total capacity of 2.8Mt/yr over
Bolivia in million tonnes (blue) for
the first time since November 2011. six integrated cement plants. Bolivia, 1991 - 2011.
Looking ahead, Argentina is forecast to see eco-
nomic growth of 4.6% in 2013.1 If the past relationship 2500
2500 3.03

between cement production and GDP continues, this 2.52.5

2000
2000
should see a substantial increase in cement production
2.02
Cement production (Mt)
GDP/capita (US$)

for the rest of 2013. This should bolster the balance 1500
1500
sheets of major producers like Loma Negra, which saw 1.51.5
its profit halve year-on-year to US$43.9m in 2012. 1000
1000
1.01
Despite the implied likelihood of growth for the ce-
ment industry, there is plenty of headroom for higher 500
500
0.50.5
consumption within the country’s existing cement ca-
00 0.00
pacity. This trend has been seen for the past 20 years,
1 3 5 7 9 11 13 15 17 19 21
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011
2002

with capacity utilisation as low as 52% in the early

Year

globalcementMAGAZINE September 2013 69

SOUTH AMERICA
Below - Figure 2: Map of South America. Coloured by integrated Venezuela: 11.8Mt/yr Guyana: 0Mt/yr
cement capacity according to Global Cement Directory 2013.
The Venezuelan Government has expropriated all cement plants (apart from GDP US$6.3bn
0 Mt/yr 4 - 6Mt/yr
1 - 2Mt/yr 6 - 15Mt/yr Catatumbo) as part of ongoing re-nationalisation of major industries.
GDP/capita US$8100
2 - 4Mt/yr >15Mt/yr
1. FNC Venezuela, Monay Plant, 0.58Mt/yr. (Line 2 under construction.) Population 739,903
2. FNC Venezuela, Lara Plant, 0.5Mt/yr.
Area 214,969km2
Colombia: 13.3Mt/yr 3. FNC Venezuela, Maracaibo Plant, 0.68Mt/yr.
4. FNC Venezuela, Pertigalete Plant, 3Mt/yr.
1. Cementos de Cairo (Argos), Antioqia Plant, 0.35Mt/yr. 5. FNC Venezuela, Táchira Plant , 2.16Mt/yr.
2. Cementos de Caribe (Argos), Barranquilla Plant, 1Mt/yr. 6. FNC Venezuela, Occumare del Tuy Plant, 1.32Mt/yr.
Suriname: 0Mt/yr
3. Cementos del Valle (Argos), Puerto Isaacs Plant, 1.2Mt/yr. 7. Cementos Catatumbo C.A., Rosarito Plant, 0.75Mt/yr. GDP US$6.9bn
4. Cementos Paz del Rio, (Argos), Sogamoso Boyaca Plant, 0.5Mt/yr. 8. Invecem, San Sebastian Plant, 0.9Mt/yr. (Line 2 under construction.)
5. Cementos Rioclaro (Argos), Puerto Triunfo Plant, 1.4Mt/yr. GDP/capita US$12,600
9. Invecem, Cumarebo Plant, 0.9Mt/yr.
(0.9Mt/yr expansion announced in 2012). 10. Cerro Azul, El Pinto del Municipio Piar Plant, 1Mt/yr. Population 566,846
6. Cemex Colombia, Bucaramanga Plant, 0.11Mt/yr. Area 163,820km2
7. Cemex Colombia, Caracolito Plant, 2.17Mt/yr.
8. Cemex Colombia, Cúcuta Plant, 0.25Mt/yr.
9. Cemex Colombia, La Esperanza Plant, 0.8Mt/yr. 2 9
4 • CARACAS French Guiana: 0Mt/yr
12
10. Cemex Colombia, La Sibena Plant, 0.4Mt/yr. 14
3
10
1 2 8
11. Cemex Colombia, Tolima Plant, 0.4Mt/yr. 7
7
5
6 GEORGETOWN
12. Colclinker (Argos), Cartegena Plant, 1.35Mt/yr. •
• PARAMARIBO GDP US$3.2bn
5 6
13. Holcim (Colombia), Nobsa Plant, 2.1Mt/yr. 1 •16
4
8 9 13 • CAYENNE GDP/capita US$14,204
14. Tolcemento (Argos), Toluviejo Plant, 0.8Mt/yr. 11 10
15. Cementos San Marcos, Cali Plant, 0.2Mt/yr. 3 15 Population 236,250
16. Cementos Tequendama, 0.3Mt/yr. BOGOTÁ Area 83,534km2
QUITO • BRAZIL
1

Ecuador: 4.1Mt/yr 3

2
1. Cemento Chimborazo, Bolivia: 2.8Mt/yr
IL
BRAZ

Riobamba plant, 0.23Mt/yr. 4

1. Cooperativa Boliviana de Cemento, Industrias y Servicios (COBOCE), Irpa Irpa Plant, 0.83Mt/yr.
2. Holcim Ecuador, 1 2. ITACAMBE Cemento SA, Santa Cruz Plant, 0.2Mt/yr.
Cerro Blanco Plant, 3.5Mt/yr.
3. Fabrica Nacional de Cemento SA (FANCESA), Cemento FANCESA Plant, 1Mt/yr (Est.).
3. Industrias Guapan,
LIMA • 4. Sociedad Boliviana de Cemento SA (SOBOCE), El Puente Plant, 0.2Mt/yr.
Azogues Plant, 0.35Mt/yr. 3
5. Sociedad Boliviana de Cemento SA (SOBOCE), VIACHA Plant, 0.5Mt/yr.
2 5 6. EMISA, Ouro Plant, 0.13Mt/yr.
5 2
• LA PAZ
Peru: 10.3Mt/yr 1

3 Paraguay: 0.7Mt/yr
1. Unacem, Condorcocha Plant, 1.88Mt/yr.
2. Cemento Yura SA (Gloria), Yura Plant, 2Mt/yr. 4
1. Industria Nacional del Cemento, Puerto Vallemi Plant, 0.7Mt/yr.
1
3. Unacem, Atocongo Plant, 4.8Mt/yr. 2 2. Yguazú Cementos, Villa Hayes Plant, 0.4Mt/yr. (Under construction).
5
4. Cementos Pacasmayo, Pacasmayo Plant, 1.33Mt/yr.
CEAN

5. Cemento Sur, Coracoto Plant, 0.33Mt/yr. ASUNCIÓN • 2

13
Uruguay: 2.1Mt/yr ANCAP = Administración
O

Nacional de Combustibles,
PACIFIC

1. ANCAP, Minas Plant, 0.25Mt/yr.

10 Alcohol y Portland.
Chile: 5.5Mt/yr 4 2 2. ANCAP, Paysandu Plant, 0.31Mt/yr.
3. Cementos Artigas, Verdum Plant, 0.5Mt/yr.
1. Cemento Mélon (Lafarge), La Calera Plant, 0.85Mt/yr. 7 1
1
SANTIAGO • 5 3 6
5 14
4. Cementos Molins/ANCAP/Votorantim Cimentos,
2. Cementos Bío Bío, Antofagasta Plant, 0.73Mt/yr. 3 6 3
BUENOS AIRES • • MONTEVIDEO Trienta y Tres plant, 0.75Mt/yr. (Under construction).
3. Cementos Bío Bío, Curico Plant, 1.0Mt/yr. 89
4 5. Cementos Artigas, Minas Plant, 1Mt/yr - Est.
4. Cementos Bío Bío, Talcahuano Plant, 0.75Mt/yr. 2
15 7
5. Cementos San Juan, San Juan Plant, 0.3Mt/yr.
6. Cementos Bío Bío, San Antonio Plant, 0.3Mt/yr. 11
8. Loma Negra, L’amali Plant ,1.65Mt/yr.
7. Cemento Polpaico (Holcim), Cerro Blanco Plant, 1.6Mt/yr. 9. Loma Negra, Olavarria Plant, 1.5Mt/yr.
Argentina: 16.8Mt/yr
10. Loma Negra, San Juan Plant, 0.2Mt/yr.
CEAN

12 1. Cementos Avellaneda, San Jacinto, 2.1Mt/yr. 11. Loma Negra, Zapala Plant, 0.4Mt/yr.
S America (Excl. Brazil): 2. Cementos Avellaneda, Olavarria Plant, 3Mt/yr. 12. Petroquimica Comodoro Rivadavia SA (PCR),
TIC O

14
Plants 69, Capacity 67.4Mt/yr 3. Holcim Argentina, Capdeville Plant, 0.66Mt/yr. Comodoro Plant, 0.44Mt/yr.
N

4. Holcim Argentina, Malagueno Plant, 0.9Mt/yr. 13. Loma Negra, Catamarca Plant, 1.3Mt/yr.
ATLA

Brazil: Plants 73, 5. Holcim Argentina, Puesto Viejo Plant, 1Mt/yr. 14. Petroquimica Comodoro Rivadavia SA (PCR),
Capacity 69.2Mt/yr 6. Holcim Argentina, Yocsina Plant, 0.54Mt/yr. Pico Truncado Plant, 0.45Mt/yr.
7. Loma Negra, Barker Plant, 1.6Mt/yr. 15. Loma Negra, Sierras Bayas Plant, 1Mt/yr - Est.

70 globalcementMAGAZINE September 2013


It began with the establishment of the SOBOCE
(Sociedad Boliviana de Cemento) Viacha plant in
1928. Initially with a capacity of 65t/day, the plant has
since expanded to 0.5Mt/yr. Today SOBOCE has an
integrated capacity of 0.7Mt/yr over two plants. The
remainder of the industry is split between four cement
players, which share 2.0Mt/yr of capacity between
them. The USGS reports that Bolivia produced 2.8Mt
of cement in 2011 (See Figure 1).
In the coming years FANCESA will set up a plant at
Maragua and a new state-owned company Ecebol will
set up a 0.7Mt/yr plant in 2014.
SOUTH AMERICA
Figure 4 shows that Chilean cement production
declined after peaking in 2008 at 4.6Mt. It has since
recovered to 4.4Mt in 2011 and 4.7Mt in 2012. In the
first six months of 2013, Chile produced 2.36Mt of
cement. Averaging cement production of 393,000t/
month, Chile is on course to produce 4.72Mt in 2013,
a similar amount to 2012. The country’s economy is
expected to grow by 4.6% in 2013.2 This should enable
continued growth in cement demand in the short to
medium term.
Colombia

Chile Like Ecuador and Venezuela, the Republic of Colom-

Chile declared independence from colonial Spain
in 1810 but was only decisively victorious in 1818.
Gradually developing, its 20th Century history saw
a mixture of progressive, conservative and socialist
governments. Between 1973 and 1990 Chile was ruled
by military strongman Augusto Pinochet, who rose to
power in a coup-d’etat. He was replaced by a demo-
cratically-elected President. This has led to increased
stability and economic progress, allowing Chile to take
Chile
a leading political position in South America.
bia emerged from the break-up of Gran Colombia in
1830. The country endured a hard 20th Century, with
periods of war, political conflict and intense battles be-
tween the government and anti-government guerilla
forces, notably the Revolutionary Armed Forces of
Colombia (FARC), which has fought to overthrow the
government for almost 50 years.
Cement industry Below- Figure 5: GDP/capita
(red) in 2011 US$ and cement
Colombia’s 16 cement plants are mainly located in the
Colomiba
north and west of the country. As well as being large,
production in million tonnes
for Colombia, 1991 - 2011.

20000
20,000 5.05 8000
8000 12
12.0
7000
7000 10
10.0
4.04
Cement production (Mt)

15000 6000

Cement production (Mt)

15,000 6000
8
GDP/capita (US$)

GDP/capita (US$)

5000 8.0
3.03 5000
10000
10,000 4000
4000 6
6.0
2.02
3000
3000
4
4.0
5000
5000
1.01 2000
2000
1000
1000 2
2.0
00 0.00 00 0
0.0
1 3 5 7 9 11 13 15 17 19 21
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011

1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011
2002

2002

1 3 5 7 9 11 13 15 17 19 21
Year Year

Cement industry
GDP US$326bn
Chile has seven integrated cement (~13.4Mt/yr) the industry is fairly well de- Above left - Figure 4:
plants with a combined capacity GDP/capita US$18,700 veloped, with Mexican multinational Cemex GDP/capita (red) in 2011 US$
and cement production in
of 5.5Mt/yr. The plants are mainly Population 17.2m (4.1Mt/yr) and domestic/regional player million tonnes (blue) for Chile,
located in the centre of the coun- Area 756,102km2 Cementos Argos (6.2Mt/yr) the two main 1991 - 2011.
try close to the capital Santiago, players up the market. Holcim is also present
Left: Summary economic
with one plant in the north. Chile’s through the 2.1Mt/yr Holcim (Colombia) and geographical statistics
largest producer is Cementos Bío Bío (CBB), which Nobsa plant. Three other local players share the re- for Chile.
has 2.4Mt/yr (44% of Chilean capacity) across four maining 0.75Mt/yr of capacity. Cementera San Marcos
sites. CBB was formed in 1957 with a capacity of just started operations in Yumbo in the Valle del Cauca
GDP US$511bn
0.12Mt/yr at Talcahuano. CBB expanded in 1978 with region of Colombia in June 2012.
the acquisition of the INACESA (National Cement) Outsiders Holcim and Cemex entered the Colom- GDP/capita US$11,000
plant at Antofagasta. bian market in 1969 and 1996 respectively, However, Population 45.7m
In 1995, CBB constructed a new line at Curico. Cementos Argos, which operates a number of subsidi- Area 1,138,910km2
Also in 1995 the Talcahuano plant reached 0.75Mt/ aries, is a native Colombian group. It began operations
yr. In mid-1998 it launched a 0.5Mt/yr expansion at out of Medellín in 1934 and is the leader in cement,
Above: Summary economic
Antofagasta. The 1Mt/yr Curico plant was completed ready mix and aggregates in the country. Since 1998, and geographical statistics
by the end of the same year. the group has been international, with units in the for Colombia.
Elsewhere, Cemento Mélon has been part of Dominican Republic, Venezuela, Haiti and Panama.
Lafarge since 2000. Mélon has a single cement plant at In 2012 it acquired three cement plants in the United
La Calera, with a total capacity of 0.85Mt/yr. Cemen- States from Lafarge. These foreign plants make it the
tos Polpaico, which is a Holcim subsidiary, operates only non-Brazilian South American cement producer
the largest cement plant in the country, the 1.6Mt/yr to operate cement plant assets outside its own borders.
facility at Cerro Blanco.

globalcementMAGAZINE September 2013 71

 SOUTH AMERICA
The Colombian cement industry is set for expan-
sion in the coming years. In November 2012 Holcim
announced that it would build a second, 2.0Mt/yr
integrated cement plant at a cost of US$600m some-
where in the country. It expects to cash in on greatly
increased government infrastructure spending in the
future. Holcim expects cement demand in Colombia
to rise from ~10Mt/yr in 2011 to ~17Mt/yr by 2020,3
although demand for cement was down by 7.6% year-
on-year in the first quarter of 2013 compared to the
same period of 2012.4
Ecuador
Paraguay
Paraguay is a land-locked republic in central South
America. It gained independence from Spain in 1811.
A series of crippling wars with its neighbours took
their toll on the country for much of the 19th and 20th
century. These caused it to lose ground economically
and socially. A 35-year military dictatorship under Al-
fredo Stroessner was brought to an end in 1989.
Since then Paraguay has held regular democratic
Presidential elections that are relatively free and fair.
However, the country lags behind many of its South
American peers in key economic and social terms. It
experiences net emigration.

Below - Figure 6: Emerging from the fracturing Gran Colombia in 1830 Cement industry
GDP/capita (red) in 2011 US$ the geographically-named Ecuador occupies a small Paraguay has the capacity to produce 0.7Mt/yr of ce-
and cement production
corner of central-western South America that straddles ment at one production site. This means that it has the
Ecuador
in million tonnes (blue) for
Ecuador, 1991 - 2011. the Equator. The country, like others in the region, has smallest cement industry of the countries featured in
endured a troubled this review. Figure 7 shows that in 2011 the country
5000
5000 6
6.0 political history. In 30 produced around 0.65Mt of cement, a capacity utilisa-
4000
4000 5
5.0 years of civilian rule tion rate of ~93%.
Cement production (Mt)

4
4.0 there have been 20 This level has been broadly static since the mid-
3000
GDP/capita (US$)

3000 new constitutions and 1990s. A low of 0.47Mt was seen in 2004, which was
3
3.0
2000
2000 political protests that due to knock-on effects of Argentina’s banking crisis.
2
2.0
led to the removal of Paraguay’s
Paraguay only integrated cement plant is located
1000
1000 1
1.0 four democratically- at Puerto Vallemi close to the Brazilian border. It is op-
00 0
0.0
4000 4000 0.80.8
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011

1 3 5 7 9 11 13 15 17 19 21
2002

Cement production (Mt)

Year
3000
3000 0.60.6
GDP/capita (US$)

GDP US$156bn GDP US$41.6bn 2000

2000 0.40.4
GDP/capita US$10,200 GDP/capita US$6,200
1000
1000 0.20.2
Population 15.4m Population 6.6m
Area 283,561km2 Area 406,752km2 00 0.00
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011
1 3 5 7 9 11 13 15 17 19 21
2002

elected presidents. The country’s Year

Above left: Summary
economic and geographical
statistics for Ecuador.
Above centre: Summary
economic and geographical
statistics for Paraguay.
Above right - Figure 7:
GDP/capita (red) in 2011 US$
and cement production
in million tonnes (blue) for
Paraguay, 1991 - 2011.
economy is dominated by oil reserves, which account
for around half of export earnings in recent years.
Cement industry
Ecuador’s cement industry (4.1Mt/yr) has three
producers that each have one integrated plant: Hol-
cim (3.5Mt/yr), Industrias Guapan (0.35Mt/yr) and
Cemento Chimborazo (0.23Mt/yr). Holcim, which
entered the Ecuadorean market in 1976, also oper-
ates a 0.5Mt/yr cement grinding plant at Latacunga.
It dominates the country in terms of cement capacity
and supply.
Holcim’s integrated plant, located at Guayaquil, is
currently undergoing expansion to 5.4Mt/yr at a cost
of US$400m. The expansion process, which began
in late 2012, is likely to be completed in 2014. As in
neighbouring Colombia, Holcim is expanding in order
to benefit from future demand from infrastructure and
housing projects.
Indeed, in Ecuador in the first quarter of 2013,
cement consumption was up by 10.5% year-on-year
compared to 2012.4 The country was one of only three
on the continent that saw increased cement consump-
tion during the period.
erated by state-owned Industria Nacional del Cemento
and has the capacity to produce 0.7Mt/yr.
So far in 2013 the plant has struggled with technical
difficulties. A planned 30-day stoppage in March 2013
lasted over 75 days. Compounding this has been a sud-
den influx of Argentine cement in the south west of the
country, which the company’s president Carlos Krussel
said is being brought into Paraguay without payment
of customs duties.5 He said that more expensive
cement prices in Paraguay compared to Argentina,
were driving the imports and putting the domestic
plant at risk.
Elsewhere, Paraguay’s second integrated cement
plant is under construction at Villa Hayes. An up-
to-date 0.4Mt/yr plant will be operated by Yguazú
Cementos, itself owned by the Brazilian cement gi-
ants Votorantim and Camargo Corrêa as well as
Concremix, a Brazilian ready-mix concrete producer.
The plant is currently under construction with no
known date for completion. When this plant comes
online it could cause even more problems for Industria
Nacional del Cemento, which is considerably older
and less efficient.

72 globalcementMAGAZINE September 2013

21-22 OCTOBER 2013 Toronto, Canada

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13th
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 SOUTH AMERICA
Below centre: Summary
economic and geographical
statistics for Peru.
Below - Figure 8: GDP/
capita (red) in 2011 US$ and
cement production in million
tonnes (blue) for Peru,
1991 - 2011.
Peru Uruguay
Located on the west coast in northern South America, The Oriental Republic of Uruguay was formed around
Peru has seen economic and social advances in recent the port location of the country’s modern-day capital
decades despite constant political changes. It has grown Montevideo, which was established as a military port
strongly in terms of GDP and GDP/capita since 2002, by Spain. Its territory was claimed at different times
averaging 6.4% growth per year to 2013. It is relatively by neighbouring Argentina and Brazil following in-
well-off in the region, with a strong mixed economy dependence and the country went through political
backed up by significant mineral wealth. turmoil and a 20th Century dictatorship that only
ended in 1985. Since then, however, the country has
Cement industry seen rapid increases in political and social equality
Peru’s cement industry is one of the larger cement in- and today enjoys some of the best living conditions in
dustries in South America, with the ability to produce South America.
10.3Mt/yr of cement across five facilities.
The largest producer is Unacem, formed in 2012 Cement industry
from Cementos Lima and Cemento Andino. Today There are currently four integrated cement plants in
Unacem has two integrated plants and a total capac- operation in Uruguay, two of which are operated by
ity of 6.7Mt/yr, around 65% of the Peruvian total. The Administracíon Nacional de Combustibles Alcohol y
company, through its history as Cementos Lima (and Portland (ANCAP) and two of which are operated by
Peruvian Portland Cement before that), traces its pro- Cementos Artigas. ANCAP currently has a combined
duction history back to 1916. capacity of just 0.56Mt/yr but is currently expanding
Three other producers, Cemento Yura (2Mt/yr), with the construction of a new plant. ANCAP is one of
Cementos Pacasmayo three companies that is
GDP US$332bn (1.3Mt/yr) and Cemento GDP US$54.7bn building the new plant,
GDP/capita US$10,900 Sur (0.3Mt/yr) have a GDP/capita US$16,200 located in the south of
Population 29.8m plant each. While their Population 3.3m the country. The others
Peru
Area 1,285,216km 2 combined capacity is
Area 176,215km 2 are Votorantim of Brazil
currently dwarfed by Uruguay and Cementos Molins

7000
7000 10
10.0 16,000
16000 1.2
1.2
6000
6000 14,000
14000
1
Cement production (Mt)

8.08 1.0
12,000
12000
5000

Cement production (Mt)

5000 0.8
0.8
GDP/capita (US$)

6.06
GDP/capita (US$)

10,000
10000
4000
4000
8000
8000 0.6
0.6
3000
3000 4.04 6000
6000 0.4
2000
2000
4000
0.4
2.02 4000
1000
1000 2000
2000
0.2
0.2
00 0.00 00 0.0
0
1 3 5 7 9 11 13 15 17 19 21
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

2003
2004
2005
2006
2007
2008
2009
2010
2011
2002

1 3 5 7 9 11 13 15 17 19 21
Year Year

Above right- Figure 9:
GDP/capita (red) in 2011
US$ and cement production
in million tonnes (blue) for
Uruguay, 1991 - 2011.
Unacem, Cementos Pacasmayo more than doubled
its income in 2012 on the back of increased sales
and public infrastructure works and Yura, owned by
Grupo Gloria, is having a new 4500t/day production
line installed at a cost of US$217m. A Loesche mill
will provide additional grinding capacity for the plant
between 2014 and 2016, when the new integrated line
is expected to come online. The additional capacity will
reportedly be targeted at the south of Peru and neigh-
bouring Bolivia.
These expansions are consistent with a recent trend
towards higher domestic cement consumption due
to the construction and real-estate sectors. Cement
demand was up by 3.7% year-on-year in 2011 and
despatches were up by 15% in 2012. Despatches grew
again by 11.4% year-on-year in the first half of 2013.
The country had one of the fastest-growing economies
on the continent in 2012 and is expected to continue
growing strongly in 2013 and beyond. This is likely
to continue generating higher cement demand in the
short to medium term.
of Spain. The three firms have targeted an expected
surge in cement demand from Brazil as it builds up for
the 2016 Summer Olympic Games in Rio de Janeiro.
ANCAP will contribute 20% of the US$262m con-
struction cost.
The development of the plant in Uruguay specifi-
cally to supply markets outside the country represents
an interesting strategy. While one of the major drivers
of the project is from the expected destination country,
it implicitly appears that the other parties expect Uru-
guay to require more cement in the future.
Elsewhere, Cementos Artigas, which is owned by
Cementos Molins and Votorantim Andina of Chile,
operates a 0.5Mt/yr cement plant in Verdum in the
south west of the country. It has been active since 1997.
Cementos Artigas also operates a grinding plant in
María Orticochea y Garzón in the Montevideo region.
Venezuela
Like Ecuador and Colombia, Venezuela emerged from
the break-up of Gran Colombia in 1830. As with most

74 globalcementMAGAZINE September 2013

 Venezuela
SOUTH AMERICA
16000
16,000 12
of its neighbours, the country experienced significant 12.0
14000
14,000
political disputes in the 19th and 20th centuries al- 10
12000
10.0
12,000

Cement production (Mt)

though a sense of stability was achieved during a series 8
10000 8.0

GDP/capita (US$)
10,000
of relatively benign military dictatorships. 8000 66.0
8000
With an economy that is based largely on its 6000
6000 44.0
well-developed oil sector, Venezuela is currently ex- 4000
4000
periencing a period of renewed socialism (dubbed 2000
2000
22.0
‘21st Century Socialism’ by former President Hugo 00 00.0
Chavez). This seeks to remove the social problems 1 3 5 7 9 11 13 15 17 19 21

1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001

resulting from socialism while attacking established
capitalist conventions. While popular in some do-
mestic quarters, this trend worries external observers.
Whatever one’s political stance, however, the country
remains overly-dependent on its oil sector.
Cement industry
In line with Venezuela’s 21st Century Socialism, vast
swathes of privately-owned businesses and industrial
installations have been expropriated from private
companies in recent years. This includes the majority
of cement plants, which have been forcibly purchased
from domestic and multinational cement producers.
The result of re-nationalisation is that Fábrica
Nacional de Cementos (FNC Venezuela) now oper-
ates six integrated cement plants that have a combined
capacity of 8.2Mt/yr. Another 1.8Mt/yr is under
the control of Industria Venezolana de Cemento
(Invecem), which is also controlled by the government.
The 1Mt/yr Cerro Azul cement plant at El Pinto del
Municipio Piar, which is also a state-run operation,
began production in late 2012.
Only one cement plant, the 0.75Mt/yr Cementos
Catatumbo plant at Rosarito, remains in private hands.
This means that 94% of the country’s cement capacity
is under government control.
Prior to 2008 the cement industry scene in
Venezuela was very different, with major stakes for
Lafarge, Holcim and Cemex. France’s Lafarge owned
the Táchira and Ocumare del Tuy plants, while Mexi-
can multinational Cemex owned the Lara, Pertigalete
and Maracaibo plants. Holcim’s plants at San Sebastian
and Cumarebo were taken over by Invecem. Cementos
Andino, a domestic producer, also had its Monay plant
taken over by FNC Venezuela.
In the cases of Lafarge and Holcim, the multina-
tionals decided to remain a minority stake-holder in
the plants but for Cemex the expopriation process was
more controversial. The government targeted Cemex’s
Venezuelan assets for expropriation in April 2008 but
Cemex was of the opinion that the US$600m offered by
the government significantly undervalued the assets.
With Cemex demanding US$1.3bn, the disagreement
was finally settled at the value of Venezuela’s initial
offer in late 2011.
Expansion is currently a key element of the govern-
ment’s cement industry policy. New lines are coming at
the FNC Monay plant and the Invecem San Sebastian
plant, while the Cerro Azul plant was commissioned
recently. In October 2012 it was announced that
Iranian investors had begun construction of a new
1Mt/yr cement plant in the country.
2003
2004
2005
2006
2007
2008
2009
2010
2011
2002
Year
Above - Figure 10: GDP/
While cement capacity is on the increase, Ven-
capita (red) in 2011 US$ and
ezuela has seen varying levels of cement output in cement production in million
recent years. Production rose from 6.3Mt in 1991 to tonnes (blue) for Venezuela,
a peak of ~11Mt in 2006. It then fell off dramatically 1991 - 2011.
to just 8Mt in 2007 and has since stabilised at around
7.5-8.5Mt/yr. With US$600bn earmarked by the
government for social, economic and infrastructure GDP US$408bn
projects in the period 2013-2019,6 the demand for GDP/capita US$13,800
cement looks set to rise again. While there is major Population 28.5m
potential for significant gains, successful implemen-
Area 912,050km2
tation will be key to the future of the country and its
cement industry.
Above: Summary economic
Notes and geographical statistics
for Venezuela.
Country GDP, population and area: CIA World Factbook website.
GDP/capita: World Bank Data Indicators website. Cement production:
United States Geological Survey website. Cement plant information:
‘Global Cement Directory 2013,’ PRo Publications International Ltd.,
Epsom, UK, 2012;’ Cement company information: Company website(s).
Company results, projects and expansion news: Back-issues of Global
Cement Magazine and Global Cement website.
References
1. MercoPress website, ‘Argentine economy forecast to expand 4.6% in
2013,’ http://en.mercopress.com/2012/12/26/argentine-economy-fore-
cast-to-expand-4.6-in-2013-but-dollar-clamp-remains, 26 December
2012.
2. Market Watch website, ‘Chile sees 4.8% GDP growth in 2013,’
http://www.marketwatch.com/story/chile-sees-48-gdp-growth-
in-2013-2012-10-02, 2 October 2012.
3. Leu, A. ‘Holcim in Latin America,’ presentation at Holcim Investor
and Analyst Day 2012, http://www.holcim.com/fileadmin/templates/
CORP/doc/IR_Presentations/IaAD_2012_LatinAmerica.pdf, 2012.
4. BN Americas website, ‘Cement consumption drops in Latin America’s
largest economies,’ http://www.bnamericas.com/content_syndication/
extranet2/story.xsql?id_source=&id_noticia=621385&id_sector=5&Tx_
idioma=I&id=987770, 5 July 2013.
5. UPI Español website, ‘La industria del cemento de Paraguay pasa
por una grave crisis,’ http://espanol.upi.com/Economia/2013/05/24/
La-industria-del-cemento-de-Paraguay-pasa-por-una-grave-crisis/
UPI-63751369390500, 24 May 2013; Construcción Latinoameri-
cana website, ‘Horno de la Industria Nacional del Cemento del
Paraguay lleva tiempo sin funcionar,’ http://www.khl.com/magazines/
construccion-latinoamericana/detail/item84204/Horno-de-la-Indus-
tria-Nacional-del-Cemento-del-Paraguay-lleva-tiempo-sin-funcionar,
5 April 2013.
6. Embassy of the Bolivarian Republic of Venezuela (US) website,
‘Venezuela to invest US$600bn in social, economic and infrastructure
projects,’ 20 June 2012.

globalcementMAGAZINE September 2013 75


NEWSASIA
Sri Lankan plant to be restarted...
Sri Lanka: The State Resources and Enterprise Development
Ministry of Sri Lanka will re-establish a currently closed cement
plant in Kankesanthurai, Northern Province, in the extreme
north of the country. The plant will be restarted under the aus-
pices of Sri Lanka Cement. The ministry estimates that, with an
investment of US$11.4m, the plant can become operational
again within 12 months.
Project proposals to re-establish the factory were presented
to State Resources and Enterprise Development Minister Dayas-
ritha Tissera by Sri Lanka Cement
Corporation Chairman N.S.M. Sam-
sudeen on 26 July 2013.
According to the project pro-
posal, funds will be sought from the
Bank of Ceylon and a copy of the
project proposal was also presented
to the Bank of Ceylon by Samsu-
deen. The project aims to produce a
minimum of 12,000 x 50kg cement
bags per day, which is 600t/day, or
0.2Mt/yr.
Sri Lanka Cement said that it
could cover the project cost if it is selected as the main cement
supplier for the Northern Highway project initiated by the gov-
ernment. “The project can save US$13m/yr in foreign exchange
spent to import cement to the country and it will also generate
300 direct employment and 400 indirect employment opportu-
nities for people in Kankesanthurai”, said Samsudeen.
Sri Lanka is in the process of building a series of new highways
and toll-roads.
... and Tokyo Cement plans new plant...
Sri Lanka: The Tokyo Cement Company intends to build
a US$50m cement plant in Trincomalee, Eastern Province
Record sales in Pakistan in 2012-13
Pakistan: Domestic cement sales in Pakistan reached 25.1Mt in the
2012 – 2013 fiscal year that ended on 30 June 2013, according to data
released by All-Pakistan Cement Manufacturers Association (APCMA).
This is the first time domestic sales of cement in the country have risen
above 25Mt/yr. In 2011 – 2012 domestic cement sales stood at 24Mt.
Overall the industry despatched 33.4Mt of cement in the 2012 –
2013 year, with 8.3Mt exported. This is below the record of total cement
sales set in 2009 – 2010 of 34.2Mt with 10.7Mt of exports. Data for June
2013 showed that construction activities slowed down, following the
Pakistan general election in May 2013. Domestic cement despatches
declined by 3% to 2.21Mt in June 2013 from 2.29Mt in June 2012.
Exports fell by 9% to 0.67Mt from 0.73Mt.
A spokesman for APCMA hoped that the current fiscal year would
lead the cement industry to high productivity as the new government
is giving due importance to infrastructure and accelerated economic
growth. He added that with proper planning and prudent economic
policies, Pakistan has the capability to consume its entire installed ce-
ment production capacity of 44.7Mt/yr.
76 globalcementMAGAZINE September 2013
Contents Subscribe Ad Index
according to a top company official. The new 1Mt/yr plant will
be called the Tokyo Eastern Cement Company. The build will also
include a captive 10MW biomass power plant.
“We are currently in the process of finalising a 33-year lease
agreement with the government for the land to construct the
factory,” said Tokyo Cement’s managing director, S R Gnanam.
Tokyo Cement has received tax breaks on the investment that
will be financed by internal funds and bank loans. The company
anticipates a 10% year-on-year growth in cement demand in the
medium term in Sri Lanka.
...despite slump in
Sri Lankan sales
Sri Lanka: Sri Lanka’s ce-
ment demand will pick
up in the second half
2013, ending a slump that
began in 2012, according
to Philippe Richart, the
head of Holcim (Lanka)
Ltd. However, he added
that cement volumes
were 7-9% down year-on-year in the first half of 2013. In 2012
the firm posted revenues of US$152.9m.
“We expect the second half to be better, whereas 2012 saw a
little bit of a decline,” said Richart. “Overall we think the market
this year will be probably down by 2%.”
Tokyo Cement, another Sri Lankan firm which operates grind-
ing plants had also said demand has fallen by 7% in the first
quarter but that an improvement was expected.
Official data shows that Sri Lanka’s domestic cement pro-
duction was down by 3.4% year-on-year to 320,000t in the first
two months of 2013. Imports were down by 34% to 593,000t.
However, production picked up in March 2013 and first quarter
production was up by 0.7% year-on-year. Imports for the first
quarter also surged by 118% to 854,000t.
CCI approves Lafarge sale
India: Competition regulator the Competition
Commission of India (CCI) has given its approval to
the proposed 14% stake sale by Lafarge of its subsidi-
ary Lafarge India to Baring Private Equity Asia, saying
that the deal will not adversely affect competition in
the country.
“The combination is not likely to have an appre-
ciable adverse effect on competition in India and
therefore, the Commission hereby approves the com-
bination under... the (Competition) Act,” said the CCI in
its order on 26 June 2013.
According to the regulator, the deal will not cause
adverse competition concerns as neither Lafarge Ce-
ment nor Baring or any of its portfolio companies is
engaged in the business of manufacturing cement in
India. Lafarge and Baring entered their sale agreement
on 14 May 2013, which stated that certain actions of
Lafarge India cannot be taken without the prior writ-
ten consent of Paris Cement Investment Holdings.

China makes 1.1Bnt in first half of 2013
China: China produced 1.1Bnt in the first half of 2013, a year-on-
year increase of 9.7%, according to the latest statistics released
by the National Development and Reform Commission (NDRC).
The cement inventory of the country’s major cement producers
increased by 0.3% year-on-year to 27.76Mt. Profit for the cement
industry rose by 1% year-on-year to US$2.49bn.
Meanwhile, the government is considering a detailed plan to
eliminate outdated industrial production capacity, according to
the China Securities Journal. The plan is expected to eliminate out-
dated capacity in the cement, steel, electrolytic aluminium, plate
glass and shipbuilding sectors.
Zhu Hongren, chief engineer of the Ministry of Industry and
Information Technology (MIIT), confirmed that MIIT and the NDRC
are currently working on the plan. The plan will boost the sectors’
utilisation of existing capacity by setting industry access standards
and eliminating outdated capacity. To ease overcapacity in affected
industries, MIIT ordered in late July 2013 around 1400 companies
in 19 sectors to eliminate outdated production capacity by Sep-
tember 2013 and eliminate excess capacity by the end of 2013.
Indonesian producers announce major
expansion plans...
Indonesia: Semen Indonesia plans to invest up to US$2bn on
expansion projects by 2016, according to the Jakarta Post. The
company’s finance director Ahyanizzaman was cited as saying
that the government-owned cement producer would prepare
and invest the funds in separate stages, with around US$190m
earmarked for investment in 2013.
Semen Indonesia, which accounts for nearly 50% of the total
cement sales in Indonesia, is looking to increase its cement pro-
duction capacity to 40Mt/yr by 2017 from 30Mt/yr at present to
meet the rising demands in Southeast Asia. It plans to spend
around US$580m in 2014 and 2015, and around US$380m
in 2016.
Meanwhile, Semen Padang has announced that the
construction of its sixth factory, Indarung VI, will start by
the end of 2013. The new production unit will increase the
company’s production capacity to meet growing demand
for cement, according to Munadi Arifin, the president of
the subsidiary of state cement producer PT Gresik.
“The groundbreaking ceremony will take place soon
for the US$340m project,” said Munadi, who added that
Semen Padang’s current 6.5Mt/yr capacity was insufficient
to meet demand. Munadi said that Indarung VI will have
a production capacity of 3.5Mt/yr, bringing the company’s
capacity to 10Mt/yr. It will provide jobs for around 200 full-
time employees, helping the employment situation in the
local area.
... as nation’s cement sales growth slows
Indonesia: Indonesian cement sales growth has fallen to
7.5% at 27.8Mt for the first six months of 2013 from 25.9Mt
in the same period in 2012, according to the Indonesian
Cement Association (ASI). Year-on-year sales grew by 15%
for the January to June period between 2011 and 2012.
NEWSASIA
UltraTech profit drops by 13.5%
India: UltraTech Cement has reported a 13.5% drop in profit
after tax to US$111m for the quarter ending on 30 June
2013. The cement producer, part of the Aditya Birla Group,
offered no explanation for the decrease in profit. It did state
that the quarter saw logistics and raw materials costs rise,
linked to rises in railway freight and diesel prices.
The company’s net sales for the quarter fell by 2%
year-on-year to US$820m from US$837m. Profit before in-
terest, depreciation and tax fell by 10% to US$205m from
US$228m. Combined domestic cement and clinker sales
were 9.94Mt. In its outlook UltraTech expected business to
be challenging and dependent on housing demand and
infrastructure spending.
In its development plans UltraTech reported that it has
commissioned its 3.3Mt clinker plant in Karnataka. US$350m
has been set aside to set up grinding plants, taking the
company current capital expenditure total to US$2.25bn.
Cement production capacity is planned to rise by 10Mt/yr
by 2015 bringing the company’s total capacity to 64.45Mt/yr.
The deceleration in cement sales is expected to continue in
the second half of 2013 due to a reduction in infrastructure
development.
Reasons for slower national growth in the first half of 2013
include fewer infrastructure projects, falling commodity prices
that have affected development in resource-rich provinces and
more frequent rain, according to ASI chairman Widodo Santoso.
Sales in Java, the main driver of growth in the first months of
2013, rose by 9.2% to 15.5Mt. Meanwhile, sales outside Java rose
by 5.38% to 12.4Mt.
State-owned cement producer PT Semen Indonesia said that
the 7.5% growth in nationwide cement sales was still higher
than sales growth before 2011. Figures from the ASI show that
domestic cement sales rose 14.5% in 2012, 17.7% in 2011, 6% in
2010 and only 0.9% in 2009.
Power prices to rise in Vietnam
Vietnam: On 24 July 2013 the Ministry of Industry and Trade
hosted an online conference to discuss measures to develop and
grow the nation’s cement and steel industries in a sustainable
way. Rising electricity prices were a hot topic of discussion.
In a draft circular issued prior to the conference, the ministry
wanted higher power price from both industries, which it believes
are consuming excessive volumes of commercial electricity per
year. The potential price hike was cited as being 2-16%, a range
that could entail a range of outcomes between acceptance by
manufactuers to potentially ruinous charges.
Bui Quang Chuyen, Deputy Head of the Heavy Industry
Department under the Ministry of Industry and Trade, said that
the cement and steel industries consumed 12% of commercial
electricity in 2010, 11.6% in 2011 and 11.4% in 2012. He described
the price increase as ‘unavoidable.’
On top of this the electricity industry is suffering losses and
has no funds for further investment. A new 1000MW thermal
power plant requires expenditure of up to US$1.7bn.
globalcementMAGAZINE September 2013 77
NEWSASIA
Vietnam cement exports rise 63% in first half of 2013
Vietnam: Vietnam exported nearly 5.2Mt of cement in the first half of 2013,
a rise of 63% year-on-year compared to 3.2Mt in the same period of 2012
said the Ministry of Construction. Taiwan, Singapore, Indonesia and Cam-
bodia were the major destinations. The ministry also stated that cement
sales have grown by 27.9% year-on-year, reaching 27.9Mt so far in 2013.
Due to reduced demand at home, many cement producers have focused
on exports, said Tran Van Huynh, chairman of the Vietnam Construction
Materials Association. The cement industry expects to export over 10Mt
of cement in 2013, or 15% of the nation’s total output. Huynh added that
the Vietnamese export price was around 20% below the average global
export price.
Exports have helped reduce the June 2013 inventory to around 2.6Mt,
according to the construction ministry. The unsold volume of Vietnam
Cement Industry Corporation (VICEM) accounts for half of this amount.
There have been no changes in the price of cement in the Vietnam mar-
ket since January 2013 despite higher coal, power and fuel prices that have
pushed up production costs and caused difficulties for domestic producers.
The Vietnamese cement industry has a production capacity of 66Mt/yr and
consumption for 2013 is forecast to be in the region of 57Mt.
Almalyk to build US$250m plant in Uzbekistan
Uzbekistan: The Almalyk Mining and Metallurgical Plant (AMMP) plans to
build a US$250m cement plant in the Surkhandarya region in southern
Uzbekistan. The Government of Uzbekistan has instructed AMMP to start
negotiations with Turkey’s Dal Teknik Makina on the project’s implemen-
tation. The plant will have a cement production capacity of 1.5Mt/yr and
should be completed by 2017.
The project will be financed by AMMP with loans from the Fund for
Reconstruction and Development of Uzbekistan and Uzbek banks. Pre-
viously the plant was to be built by the national oil and gas company
Uzbekneftegaz but it failed to attract foreign partners to the project.
AMMP and Dal Teknik Makina are also collaborating on a cement plant
in the Jizakh region of Uzbekistan. The plant is due to be built by the end
of 2014.
Is Nepal self-sufficient in cement?
Nepal: Amid cement manufacturers’ claims that Nepal has become self-
reliant in terms of cement production, cement imports have actually risen
by 15.5% in the first 10 months of the country’s current fiscal year, a period
that ran until 15 July 2013.
In the review period, Nepal imported cement worth US$34.6m, against
imports worth US$30.0m in the same period a year earlier, according to
Trade and Export Promotion Centre statistics. Over the period, the country
also saw seven new cement factories commissioned or announced.
According to Aatma Ram Murarka, former president of the Nepal
Cement Manufacturers Association (NCMA), the imports went up because
of the ongoing development projects with foreign investment. “In case of
projects with foreign investment, the government has provided customs,
tax and VAT waivers on cement imports from India,” said Murarka.
Murarka said that domestic manufacturers have repeatedly demanded
that the government roll back the provision because they say that local pro-
duction can meet the market demand. “The government hasn’t reviewed it
seriously,” he said, adding that projects being undertaken by Nepali con-
tractors were, however, using domestic cement.
78 globalcementMAGAZINE September 2013
Japanese firms see improved sales
Japan: Taiheiyo Cement’s sales revenue rose by
12% year-on-year to US$1.91bn for the first quar-
ter of the 2012 - 2013 Japanese financial year that
ended on 30 June 2013. In the quarter ending on 30
June 2012 it was US$1.70bn. The Japanese cement
producer attributed the increase to rebuilding fol-
lowing the March 2011 earthquake and tsunami
disaster, increased private sector construction
investment in urban areas and favourable policies
by the Japanese government.
The company returned to a net profit, making
US$20.8m from a loss of US$54.8m in the same
period of the prior year. For Taiheiyo’s cement busi-
ness, sales of cement to external customers rose
by 10% to US$1.20bn from US$1.09bn.
Meanwhile, Sumitomo Osaka Cement has
reported that its operating profit rose by 77% to
US$38.5m in the first quarter of the 2012 - 2013
Japanese financial year that ended on 30 June
2013. In the quarter ending on 31 March 2013 it
was US$21.8m. Like Taiheiyo, the producer noted
that public-sector demand for cement was in-
creasing due to reconstruction efforts.
The company’s sales revenue rose slightly in
the first quarter of the 2012 – 2013 financial year
to US$547m from US$539m. Net profit increased
by 151% to US$25.8m.
China wants Taiheiyo plant closed
China: Taiheiyo Cement Corp. has been ordered by
the Chinese city of Nanjing to close a local produc-
tion facility by the end of 2014 according to The
Nikkei. Closing the Nanjing plant would reduce
Taiheiyo Cement’s Chinese cement output capac-
ity by 30-40%.
Nanjing cited air pollution as the reason and
issued the same mandate to local cement manu-
facturers as well. It has not said whether or not
there will be any compensation. The Japanese
firm has said that it will ask the city to reconsider.
If Taiheiyo Cement does not follow the order, the
local partner with which it has a joint venture will
likely be punished, with those in charge to be dis-
missed from the company.
Birla: US$416m for three new plants
India: Birla Corporation has announced that it will
increase cement production capacity by 4.5Mt/
yr with an investment of around US$416m over
a period of three years. Of the proposed 4.5Mt/yr,
the company plans to set up two 1.5Mt/yr facilities
at Chanderia, Rajasthan and a 1.5Mt/yr plant at
Satna, Madhya Pradesh.
The proposed expansion represents around
half of Birla’s current installed capacity, which
is 9.3Mt/yr.
 NEWSASIA
CRH will buy Sree JayaJothi Cements
India/Ireland: Following earlier speculation, Ireland’s
Cement Roadstone Holdings (CRH) has announced that
its 50:50 Joint Venture in India, My Home Industries Ltd
has reached an agreement to acquire the shares of Sree
Jayajothi Cements, a 3.2Mt/yr cement producer in south
India for Euro175m.
The investment will be financed from My Home Indus-
tries’ existing debt capacity and by equity inputs from the
joint shareholders (Euro70m). CRH’s equity interest will
amount to Euro35m.
Azerbaijani president opens new line
Azerbaijan: Azerbaijani President Ilham Aliyev has
opened a cement production line at a new cement plant
in Gazakh. The project is a joint investment between Ak-
kord Industrial Construction Investment Corporation and
the International Bank of Azerbaijan. Construction began
at the plant in 2010.
Construction of the plant has been planned in two
stages, starting with the commissioning of cement first,
followed by gypsum production. Construction work on
the cement production line was completed in March
2013. The plant has a planned clinker production capac-
ity of 2500t/day.
100% cement duty in Turkmenistan
Turkmenistan: Cement imports to Turkmenistan have
had to pay a 100% customs duty since 1 August 2013,
according to the Turkmenistan.ru news portal. The
resolution was signed by President Gurbanguly Berdymu-
hamedov in order to support domestic production and to
‘streamline’ the import of cement. A minimum customs
import duty of US$200/t will be imposed.
Chinese Resources profit up in first half
China: China Resources has reported that its net profit
rose by 80.4% year-on-year to US$148m for the first half
of 2013. Its revenue rose by 16.5% to US$1.66bn. Gross
profit rose by 29% to US$383m.
China Resources expects that its cement production
capacity will reach 76.5Mt/yr by the end of 2013. Clinker
production capacity is expected to reach 51.8Mt/yr.
Hubei Province increases output
China: Hubei Province saw cement output increase by
9.7% year-on-year to 50.71Mt/yr in the first half of 2013,
according to an official from the local statistics bureau.
globalcementMAGAZINE September 2013
79
Build something great™
Principal Mechanical
Engineer - Cement
(Australia)
Boral Cement Engineering Services (BCES) exists to
provide Project Management, process & engineering
knowledge to enable cement, lime and ash facilities to
be developed, built, commissioned and operated
effectively. Operations include cement & ash plants in
NSW and Victoria, limestone quarrying and lime
production at Marulan in NSW, and distribution depots
situated in each of the two states.
BCES provides Engineering services for Boral Cement
and, to a lesser extent, for the wider Boral Limited
Group and the joint ventures Sunstate and Fly Ash
Australia. As such it is involved in diverse engineering
and process improvement projects as well as the
provision of technical advice and investigations across
many operations and sites.
The Principal Mechanical Engineer (PME) is primarily
accountable for investigating, designing, evaluating
and controlling engineering projects and costs, and
providing effective engineering services for both Boral
Cement and Boral Limited in order to support the
Boral Purpose to be a world leader in the building
and construction materials industry. To do this, the
PME plans and controls the investigation, design
and evaluation of Mechanical Engineering projects to
ensure that the projects are delivered to the customer
within the Company's contractual obligations in respect
to safety, quality, time and performance requirements,
at optimum cost.
To be successful in this role you must have the following
skills, qualifications, experience and competencies:
• Tertiary Degree in Mechanical Engineering or
Certificate with extensive Cement industry
experience
• Minimum 10 years mechanical design and
engineering post graduation, plus 2-3 years direct
Project or Engineering management experience in
heavy industrial engineering development or similar
• Experience in the management of people
• Sound knowledge of customer and supplier relations
• Contractor management
• Ability to provide technical support and contributes to
required engineering systems, design environment,
methodologies and techniques.
• Ability to resolve complex and substantial engineering
issues and be a source of related advice on external
interfaces for others.
If you are interested in this role please visit
http://careers.boral.com.au
H64574
www.boral.com.au
NEWSASIA
Dalmia Cement to open Belgaum plant in March 2014
India: Dalmia Cement has announced details about the 2.5Mt/yr cement
plant it is currently building in Belgaum, Karnataka. Mumbai newspaper
DNA has reported that the Indian cement producer predicts that the plant
will create over 1000 jobs when it opens in March 2014. Dalmia has invested
over US$210m on the project.
“Though we have had a good presence in Tamil Nadu and Kerala, Karna-
taka has not been a great market for us so far. We have to address this state
seriously by ramping up our presence here,” said chief executive officer of
Dalmia Cement, Vipin Agarwal. He added that the Indian cement producer
intends to become one of the top three producers in the state. Currently,
the top three cement producers in Karnataka are UltraTech, Zuari and ACC.
The company’s market share through sales is about 5% from Karnataka,
compared to about 14% each from Tamil Nadu and Kerala.
Dalmia has three other cement plants in southern India, including two
in Tamil Nadu (Dalmiapuram and Ariyalur) and one in Andhra Pradesh
in Kadapa.
Star Cement starts river exports to Bangladesh
Bangladesh/India: India’s Star Cement has started exporting clinker
to Bangladesh by river. According to a report by the Times of India,
the cement producer aims to export over 50,000t/month of clinker to
Bangladesh by this route.
“Exporting clinker to Bangladesh by the river will give an edge to the
company to encounter the stiff competition it is likely to face from manu-
facturers of Southeast Asian countries, all of whom cater to 99% clinker
requirement of this country,” said a Star Cement official.
In a pilot project in 2012 Star Cement had started clinker exports to
Bangladesh by road. The company has deals with several leading cement
producers in Bangladesh to meet their clinker requirements and is plan-
ning to develop this business model.
India Cements net profit falls
India: India Cements has reported that its net profit has fallen by 73% year-
on-year to US$2.74m for the first quarter of the 2013 – 2014 fiscal year that
ended on 30 June 2013. Its net profit for the same period in the 2012 – 2013
fiscal year was US$10.1m. The Indian cement producer attributed the weak
performance to overcapacity in the south of the country, poor demand for
cement and low prices, increasing energy costs and depreciation of the
Rupee against the US Dollar.
India Cements’ sales remained stable at US$201m in the first quarter of
the 2013- 2014 fiscal year compared to US$196m of the same quarter in
the previous year. Clinker production rose by 18% year-on-year to 2.08Mt
from 1.80Mt. The combined volume of cement and clinker production rose
by 11% year-on-year to 2.65Mt from 2.38Mt. The company also reported
that its captive power plant at its Vishnupuram cement plant had been
commissioned in July 2013 and is expected to stabilise operations in the
autumn of 2013.
Yovon cement plant set for imminent commissioning
Tajikistan: A new 1Mt/yr cement plant in the Yovon district, Khatlon prov-
ince is expected to start operation in late August 2013, according to the
Ministry of Energy and Industry (MoEI). The US$100m project has been
built by the Tajikistan-China joint venture Huaxin Gayur Cement. A source
from the MoEI said that construction had ‘practically been completed.’
80 globalcementMAGAZINE September 2013
Holcim simplifies Indian dealings
India: Multinational buildings material producer
Holcim has released plans to simplify its structure
in India by merging Holcim India with its sub-
sidiary Ambuja Cements. Both of Holcim’s Indian
subsidiaries, Ambuja and ACC, have seen net
profits fall in the second quarter of 2013.
Holcim intends to increase its shares in Am-
buja to 61.39% and Ambuja will acquire Holcim’s
50.01% stake in ACC. Both Ambuja and ACC will
continue to operate as separately with their own
brands. However, the restructuring will allow for
closer back-end cooperation between the com-
panies as well as simplifying the group structure.
“This transaction further improves Holcim’s
holding structure in India, strengthens the
platform for future growth and is expected to
generate synergy benefits of US$150m/yr. These
benefits, which will be realised in a phased manner
over two years, will be shared by both companies
equally through supply chain, shared services
and fixed costs optimisation. The transaction is
expected to be neutral on Holcim’s earnings in
the first full year following the completion of the
transaction and accretive thereafter,” said Holcim
CEO Bernard Fontana.
In a two stage deal, Ambuja will first acquire,
through a purchase, a 24% stake in Holcim India
for a cash consideration of around US$600m,
followed by a stock merger between Holcim
India and Ambuja. As part of the merger, Holcim
will receive 584 million new equity shares in
Ambuja resulting in an increase of its ownership
in Ambuja from the current 50.55% to 61.39%.
The transaction is subject to Ambuja’s share-
holder and regulatory approvals in India.
Philippines: Cement sales take off
Philippines: Cement sales in the second quarter
of 2013 have increased by 8.8% to 5.35Mt from
4.92Mt in the same period in 2012, according to
data from the Cement Manufacturers Association
of the Philippines (CeMAP). CeMAP commented
that it expects the industry to grow as there is an
increase in building construction, infrastructure
projects and farm-to- market roads, which will
now be built using cement.
The increase in sales marks a return to the
growth seen in the fourth quarter of 2012 when
sales rose by 8.5%. In the first quarter of 2013
sales growth fell to 3%.
Filipino infrastructure spending is expected
to grow in 2013. The government has budgeted
around US$6.9bn, around 2.5% of the country’s
gross domestic product, for projects. CeMAP has
not yet forecast how much sales will grow by the
end of 2013.

Weston on back burner for Holcim with announcement of new terminal
New Zealand: Holcim New Zealand Ltd has announced that
it will spend more than US$80m on the construction of an
import terminal and related infrastructure that will allow
it to import and distribute bulk cement to the New Zealand
market. The terminal is expected to be operational in two to
three years’ time. The location of Holcim New Zealand’s new
import terminal is yet to be finalised and the company is investi-
gating options at a number of New Zealand ports.
Announcing the decision, Holcim New Zealand Ltd
managing director Jeremy Smith said, “This represents a
substantial commitment by Holcim to the New Zealand
building materials market. It means we will be able to
leverage off the vast resources available through the
• impact for our staff, customers and for the
Holcim Ltd worldwide supply network to ensure
that our New Zealand customers receive
cement of a quality and specification
suitable for New Zealand conditions.”
Once operational, cement im-
ported through the new terminal • Weston - New plant
will replace local production at the
company’s Westport cement plant.
ACC profit and revenue take a hit
India: Associated Cement Companies Ltd (ACC) reported declining
profit and revenue for the quarter to 30 June 2013 owing to lower-
than-expected demand, according to a company statement.
ACC’s net profit for the quarter that ended 30 June 2013 fell
by 37% compared to the same period of 2012 to US$44.3m. Sales
dropped by 3.6% year-on-year to US$473.1m. Cement sales, how-
ever, were up by 1.2% to 6.1Mt over the three month period.
Holcim Indonesia sells less amid overcapacity
Indonesia: Holcim Indonesia has reported that market oversup-
ply has caused lower cement sales in the first half of 2013 than
in the first half of 2012. Sales volumes dropped by 1.3% to 4Mt
between January 2013 and June 2013.
“The company had foreseen the contraction after a similar
dip in the first quarter, the first time after eight consecutive
quarters of growth,” said Holcim Indonesia’s president director
Eamon Ginley.
In the first quarter, Holcim Indonesia reported that its ce-
ment sales volume had declined by 1.6% to around 2Mt. Ginley
said the condition was temporary as demand would continue
to increase over the medium to long terms, citing government
and private sector investments in infrastructure and housing.
Chinese order for Loesche
China: Hebei Jintaicheng Building Materials Shareholding Co.
has ordered a Loesche vertical roller mill from Loesche Mills
(Shanghai) to grind granulated blast furnace slag.
Hebei Jintaicheng has ordered a LM 4600 CS 2 that will pro-
duce up to 90t/hr. The mill drive will have a capacity of 3150kW.
NEWSASIA
Holcim New Zealand has signalled for some years
that the Westport plant was not sustainable in
the long term. The decision also means
that the long-delayed proposal for a
new cement plant at Weston, near
Oamaru, is on hold for the foresee-
able future. Holcim will, however,
maintain ownership of its land assets
for the moment.
“We recognise that this decision has an
Westport and Weston communities,” said
Smith. “It’s one we’ve arrived at after ex-
tensively investigating a range of cement
Westport - Plant
to close
supply options and we will be working
through the implications with those who
will be impacted by the move. For the cur-
now unlikely rent economic environment, constructing
an import terminal and importing cement
is simply the most appropriate decision.”
Armenian cement demanded in Georgia
Georgia/Armenia: A total of 92,200t of cement were
exported from Armenia in the first half of 2013, almost
twice as much as in the first half of 2012. Armenia’s only
cement export partner is neighbouring Georgia.
Cement production in Armenia fell by 3.5% to ap-
proximately 180,000t during the first half of 2013,
meaning that over half of Armenian-made cement is
exported to Georgia.
UltraTech’s US$415m plant in Tamil Nadu
India: UltraTech Cement, part of the Aditya Birla Group, is
working on environmental clearance for a new US$415m
cement plant in Tamil Nadu, according to Indian media. The
project will have a cement production capacity of 5.5Mt/yr,
a clinker production capacity of 4.5Mt/yr, a 75MW captive
power plant (with additional power from diesel generating
sets of about 18MW) and a 15MW waste heat recovery facility.
The public hearing for the project was conducted in May
2013 as part of the environment impact assessment and man-
agement plan. The plant is intended to have two production
lines. The total project area is about 263 hectares with a plant
area of about 86 hectares.
The contract was signed in December 2011, the components
have been delivered and the mill is currently being installed.
Hebei Jintaicheng, a building materials processing private
enterprise founded in 2009, is located in the industrial area
of Baita County, Shahe City. The company produces and sells
ground granulated blast furnace slag. The project has a planned
output of 500,000t/yr of ground granulated blast furnace slag.
globalcementMAGAZINE September 2013 81

NEWSMIDDLE EAST & AFRICA
Oman’s Raysut making moves in Somalia,
Yemen and UAE
Oman: The board of directors at Oman’s Raysut Cement has announced
that it will give the green light to the firm’s plans for a series of expansion
moves, both at home and abroad. As part of the plan, the country’s larg-
est cement manufacturer will establish a modern state‐of‐the‐art cement
terminal inside Oman’s Duqm Port for storing, packing and distribution
of cement. The facilities will include two silos, each with a capacity of
4000t. The port plan is expected to commence operation in the second
half of 2014.
The Raysut board has also given approval for the establishment of a
modern state‐of‐the‐art cement terminal at Berbera Port in Somalia. The
construction, to be undertaken as a joint venture with local partners, will
see storage, packing and distribution of cement from three 4000t silos.
Additionally, the board approved the establishment of a grinding plant
in Mukulla, Yemen through its sister company Mukulla Raysut. Another
joint venture with a local partner, the Yemen grinding plant will have a
capacity of 0.5Mt/yr and will pack cement for the Yemeni market.
Finally, Raysut is planning to improve its Pioneer Cement Industries
plant in the United Arab Emirates. The expansion will see the installation
of an additional cement silo, a cooling system upgrade and the installa-
tion of environmental abatement systems.
“This development and expansion will have a positive impact on the
performance results and profitability of the company in the future,” said
Raysut in a statement.
RAK Cement Company starts expansion
UAE: The Ras Al Khaimah (RAK) Cement Company has launched an US$18m
expansion of its second kiln at its cement plant in Khor Khwair in Ras
Al Khaimah, UAE.
Sheikh Ahmed bin Humaid bin Mohammed Al Qasimi, chairman of the
board of the RAK Cement Company launched the new expansion. Also in
attendance was Yasser bin Ahmed bin Humaid Al Qasimi, director-general
of the Union Cement Company, along with a number of senior officials.
Sino-Zimbabwe prepares for upgrade
Zimbabwe: The Sino-Zimbabwe Cement Company has commenced its
first phase of upgrading and refurbishing at its Gweru factory. Work on
the cement mill and rotary kiln is set to increase the clinker production
capacity up to 0.2Mt/yr by the end of 2013. A second phase, also due for
completion in 2013, will upgrade warehousing and storage facilities. Fur-
ther upgrade work is planned for 2014.
“We are upgrading the capacity and efficiency of our cement mill so
as to meet growing local and regional demand. The cement mill will be
modernised with third generation technology that will immensely im-
prove our efficiency and the quality of our product. This technology is the
first of its kind in Zimbabwe,” said the company in a statement.
The Sino-Zimbabwe Cement Company is the product of a joint busi-
ness venture between a Chinese foreign direct investment partner, China
Building Material Industrial Corporation for Foreign Econo-Technical
Co-operation (CBMC), and the Industrial Development Corporation of
Zimbabwe Limited. CBMC contributed 65% of the original funding in the
form of modern technology and expertise while IDC provided land, civil
works, manpower and local knowledge. The cement plant has been in
operation since 2001.
82 globalcementMAGAZINE September 2013
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CCECC plans US$1bn for Nigeria
Nigeria: The China Civil Engineering Construc-
tion Corporation (CCECC) has released plans to
invest around US$1bn in Nigeria towards the
construction of a cement plant and other projects,
including the modernisation of a port near Lagos,
a saw mill, real estate investment and manpower
development. President of CCECC, Yuan Li, made
the announcement in conjunction with a Nigerian
delegation to China led by the Nigerian President
Goodluck Jonathan.
Hima completes bag filter upgrade
Uganda: Hima Cement has completed the instal-
lation of new bag filter technology at its Kasese
plant. The US$3.2m investment is geared towards
bringing the plant’s stack emissions in line with
global environmental standards.
“We invested significant resources to conduct
environmental impact assessments to ensure that
the plant operations met all the required environ-
mental standards for its manufacturing processes
and operations,” said Peter Robson, Hima Cement’s
Plant Manager.
Hima Cement, part of Kenya’s Bamburi Ce-
ment that in turn is a subsidiary of Lafarge,
expects the plant’s target emissions to be below
Lafarge’s industrial targets. Further testing was
completed at the end of July 2013. Project
manager Jackson Molo added that Bamburi
Cement achieved 0.01mg/m3 emissions with the
same technology at a plant in Mombasa, Kenya in
2012. The Kasese plant has a cement production
capacity of 0.85Mt/yr.
ARM profit up in first half 2013
Kenya: ARM Cement’s pre-tax profits for the first
half of 2013 have risen by 28% year-on-year to
US$11.5m, driven by a rise in cement sales. The
Kenyan cement producer has also forecast a strong
performance for the second half of 2013.
Najran closes line for maintenance
Saudi Arabia: On 10 July 2013 Saudi cement
producer Najran Cement announced that it had
shut down production line one at the plant for
scheduled maintenance. At the time of the an-
nouncement it was anticipated that it would take
25 days to complete, with completion around 4
August 2013. Najran Cement said that the shut-
down would cost US$1.3m.
The company previously announced it was
ready for trial operations on its third production
line. The new production line will have a capacity
of 6500t/day.

Mali gets plant upgrade money
Mali: China has agreed to offer Mali a loan worth around US$140m for
construction of a hydro-electric power plant and a number of other in-
frastructure projects. Among these will be refurbishment of the Diamou
cement plant and connection of this to an upgraded power grid.
HeidelbergCement launches Liberian mill
Liberia: HeidelbergCement has commissioned a new 0.5Mt/yr, US$14m
cement mill at its cement grinding plant in Monrovia, Liberia. The
German cement producer operates in Liberia through a subsidiary, Ce-
menco. It is the only cement producer in the country.
“The construction of the new cement mill in Liberia is in line with our
strategy of modernising and expanding clinker and cement capacities
in emerging markets,” said Dr Bernd Scheifele, Chairman of the Manag-
ing Board of HeidelbergCement. “In Ghana, we recently increased the
cement grinding capacity at our Tema cement plant and are currently
building a new cement mill in Takoradi. Together with our existing plants
in this region, the new mill in Liberia strengthens our coastal network
in West Africa.”
Investment in the new cement grinding facility in Liberia includes a
two-chamber 65t/hr ball mill with high-efficiency separator, filter, fan
and flow meter. The power supply of the new cement-grinding mill is
provided through a 5.7MW generator plant on a rental basis.
HeidelbergCement is currently conducting investment projects in
sub-Saharan Africa amounting to almost US$400m. They include expan-
sion projects of cement capacity of about 3Mt and of clinker capacity
of 1.5Mt.
Nigerian Army closes fake cement plant
Nigeria: The Nigerian Army has reported that a fake cement production
plant has been discovered in Ewekoro, Ogun State. According to a state-
ment made by Captain Adamu Yahya Ngulde of the 35 Artillery Brigade,
eight suspects were arrested at the site on 25 June 2013 and four cement
trucks were found.
“Based on our preliminary investigation, the suspects obtain cement
from the Dangote Cement Company and Lafarge and adulterate it with
sand dust and package it in Dangote cement bags for distribution,” said
Ngulde. The suspects and the vehicles have been detained pending
an investigation.
Results from Saudi Arabia
Saudi Cement: Saudi Cement Company has reported a 5.9% year-on-
year increase in its second-quarter net profit. It identified a rise in local
demand for cement as among the reasons for the improvement. The
company posted a second-quarter net profit of US$81.7m compared to
US$77.3m in the same period in 2012. Net profit for the first six months of
2013 was US$172.5m, a 5% rise compared to the first half of 2012.
Yanbu: Yanbu Cement Co’s first-half net profit rose by 44.7% year-on-year
to US$138.9m, thanks to higher production and sales volumes supported
by the start of its kiln line No 5 in 2012.
Southern Cement: Southern Cement Company achieved net profits
amounting to US$150.9m in the first half of 2013 compared to US$145.6m
for the same period of 2012, a year-on-year rise of 3.7%.
NEWSMIDDLE EAST & AFRICA
Sephaku reports on progress
South Africa: Sephaku Holdings has reported that
it is on schedule to commence production of ce-
ment at its associate company, Sephaku Cement,
in the first two quarters of 2014. Sephaku Cement
is a subsidiary of Nigerian multinational cement
producer Dangote Cement. In its nine-month fi-
nancial report to 31 March 2013 Sephaku reported
that construction of the US$320m Delmas grinding
plant and the Aganang clinker and cement plant
were both at an advanced stage of development
at the end of 2012.
The Delmas cement milling plant in Mpuma-
langa will receive approximately 55% of the clinker
produced at Aganang for further processing and is
on track for completion in the final quarter of 2013,
with production due to start in January 2014. The
Delmas plant will have annual cement production
capacity of 1.4Mt/yr. The Aganang plant in North
West Province will commence production in the
second quarter of 2014 with the capacity to pro-
duce 1.9Mt/yr of clinker and 1.2Mt/yr of cement
when fully commissioned.
Cimpor to increase grinding
capacity in Mozambique
Mozambique: Portuguese cement producer
Cimpor intends to increase its grinding capac-
ity in Mozambique by 220,000t/yr. Cimpor’s local
subsidiary Cimentos Mozambique has signed an
agreement to lease a grinding plant near to its
Matola cement plant. The agreement will also
allow Cimpor to increase its product range.
Higher profit for Southern Cement
Saudi Arabia: Southern Cement Co. achieved net
profits amounting to US$150.9m in the first half of
2013 compared to US$145.6m for the same period
of 2012. This represents an increase of 3.7%.
Three cement plant workers killed in
Sinai ambush
Egypt: At least three people have been killed and
17 wounded in a grenade attack upon a bus carry-
ing cement plant workers in the north of the Sinai
Peninsula. Security and medical sources reported
that suspected militants used rocket-propelled
grenades to attack the bus.
Belated Lafarge WAPCO results
Nigeria: Lafarge Cement WAPCO saw its total reve-
nue increase by 40.7% year-on-year to US$566.5m
and its net profit grow by 70.3% to US$94.2m
in 2012.
globalcementMAGAZINE September 2013 83
NEWSMIDDLE EAST & AFRICA
Dangote land purchase causes local divide Tanzania to investigate cement
Zambia: The head of Chiwala village has told a local court how four imports from Pakistan
people threatened to burn down the houses of villagers if they collected Tanzania: The Tanzanian government has formed a
money from Dangote Cement as compensation for being displaced from seven person team to investigate alleged subsidies,
their land to make way for a new cement plant development. tax evasion and the quality of cement imported
On 27 July 2013 it was alleged that Jeff Mulewa, Chiefe Mwamba, from Pakistan. Minister for Industry and Trade, Dr
Ahmed Musonda, Fridah Wamunamuna, had threatened arson over the Abdallah Kigoda, said that the team will help to un-
controversial development by the Nigerian cement firm, which is to be derstand the quality, manufacturing cost and selling
built in the Masaiti district. price of cement from Pakistan to help in creation of
Dangote management had offered US$230 per hectare for areas of fair competition in the local market.
non-agricultural land and US$550m for agricultural land. Farmers were The team comprises experts from the Ministry
reportedly split on the value, with some suggesting that they should be of Finance and Economic Affairs, the Ministry of
given over US$2800 per hectare instead. This has since led to the disa- Industry and Trade, local cement manufacturers,
greement between the farmers as to the value of the land, with alleged the Confederation of Tanzania Industries (CTI), the
threats of arson and blockages around the village to stop anyone collect- Tanzania Bureau of Standards, the Fair Competition
ing any money from Dangote. Commission and the Tanzania Revenue Authority.
In 2012, over 200,000t of cement was imported
from Pakistan to Tanzania and in 2013 over 300,000t
One dead in Dangote accident has been imported, according to Director of Policy
and Advocacy with the CTI, Hussein Kamote. Cur-
Nigeria: One worker was killed on 31 July 2013 at the Dangote rently Tanzania has a demand for cement of 4Mt/yr
Cement Gboko plant when he was hit by falling limestone, according to with a cement production capacity of 3Mt/yr.
the All Africa Media Group. The deceased labourer, Solomon Ashir, was
killed instantly.
Dangote profit up by 52%
Ashir was from the local community, which reacted angrily towards
Dangote following his death. Many were of the opinion that health and Nigeria: Dangote Cement has announced that its
safety measures at the plant had been deficient. half-year pretax profit rose by 52.1% to US$669m
Bonfires were lit on the roads used to access the plant in the hope in 2013 compared with US$$36m in the first half
of trapping key staff members in the plant and Ashir’s body was even of 2012. Dangote said that a building boom was
carried into the office of the local Assistant General Manager (AGM) in behind the rise in profit.
charge of mines. He had fled the office in fear for his life before the pro- Turnover at Nigeria’s largest listed company
testers arrived. rose to US$1.23bn during the six months to 30
Local media reported that Dangote representatives took the body to June 2013, up by 28.5% from US$905m in 2012.
the local hospital after the protesters had vacated the office. Dangote’s The company announced that it expected a
community relations manager could not be reached for comment. pretax profit of US$308m in the third quarter of
Meanwhile, Benue State Police Public Relations Officer, Daniel Ezeala, 2013 from sales of US$603m.
confirmed that the incident had taken place and said that an investiga- Meanwhile, Reuters has reported that Dangote
tion into the cause of the incident was underway. has expressed its plans to increase its cement
capacity in Nigeria to 29Mt/yr by 2015 from
19.5Mt/yr. It also said that it wants to expand to
Cemtech to build 30MW captive coal plant 55Mt/yr across Africa by 2016.
It reported that cement demand in Nigeria had
Kenya: Cemtech, the Indian cement firm owned by the Sanghi Group, is risen to 11Mt/yr during the first half of 2013, a 14%
set to build a 30MW coal power plant for its proposed cement plant in year-on-year rise compared to the same period of
West Pokot County. Construction of the plant was expected to begin on 2012. This, it said, was caused by a surge in govern-
14 August 2013, according to the Kenyan newspaper Business Daily. ment infrastructure projects.
15MW of electrical energy is in-
tended to run the operations of the
proposed cement plant. The remain- Bamburi expects better second half of 2013
ing 15MW will be sold to the Kenyan
national power grid said the National Kenya: Bamburi Cement expects a robust second half of 2013, after it saw its pretax
Environment Management Authority. profit drop by 12% in the first half of 2013. It attributed the decline to uncertainty over
The entire cement plant project is the Kenyan elections and a slowdown in its export markets.
expected to cost US$175m. The plant Bamburi, which is controlled by the French multinational cement giant Lafarge,
is due for completion in 2015 and will posted a first-half pretax profit of US$37.46m, while its turnover declined by 18%
have a cement production capacity of to US$180.8m.
1.5Mt/yr. Although centered on the “We started seeing a significant turnaround in the markets of Kenya and Uganda
Kenyan cement market, the plant will with continued signs of an improving macro-economic environment in both countries,”
also target Uganda and South Sudan. said the company. “The group is therefore strongly optimistic of a stronger second half.”

84 globalcementMAGAZINE September 2013

NEWSMIDDLE EAST & AFRICA
PPC to buy Safika Cement
South Africa: PPC (formerly Pretoria Portland Cement) has an-
nounced details of an agreement to buy a controlling stake in Safika
Cement Holdings for US$35.3m, according to a Johannesburg Stock
Exchange release.
“We are very excited to be able to add another complemen-
tary business to PPC. This is an important step in our ‘Keeping the
Home Fires Burning´ strategy. The proposed transaction is subject
to approval by the regulatory authorities as well as the conclusion
of the due diligence process,” said chief executive officer of PPC
Ketso Gordhan.
Safika is a blended cement producer that owns five blending plants
and one milling operation. It produces blended 32.5N cement under
three brands: IDM Best Build, Castle and the Spar Build-It house brand.
Concrete Institute clarifies role
South Africa: The Concrete Institute in South Africa has re-
sponded to the news item, ‘PPC steps up pseudo-association role,’
which appeared in the July-August 2013 issue of Global Cement
Magazine, regarding the newly-formed Concrete Institute and
the demise of South Africa’s Cement & Concrete Institute (C&CI).
On 6 August 2013 Bryan Perrie, managing director of The
Concrete Institute and previously the C&CI, said, “The C&CI
was a completely independent and unbiased organisation and
recognised as such by the construction industry. The C&CI was
never an association to provide services to its members nor was
it mandated to do so. Its mandate and articles empowered it to
provide services to the concrete construction industry on behalf
of its funding members. The South African Cement Producers As-
sociation (SACPA), before closing down in 1996, was responsible
for providing its members with a range of services. SACPA was
replaced by the Association of Cementitious Material Producers
(ACMP) which focused primarily on environmental, health and
safety issues.”
“The decision to close the C&CI laboratory a number of years
ago was unanimously agreed to by all four of the cement pro-
ducer members of the C&CI,” continued Perrie. “The closure of
the C&CI was precipitated by the withdrawal of funding and the
resignation from the C&CI by PPC, following which the other
funders, AfriSam, Lafarge and NPC-Cimpor were compelled to
resign as PPC’s withdrawal left a significant void in the structure
and funding of the non-profit organisation.”
“Following the regrettable and contentious closure of the
C&CI and the subsequent strong reaction from both the con-
struction industry and the academic fraternity in response to a
potential loss of services, the CI was formed. The initial funders
of The Concrete Institute are AfriSam, Lafarge and Sephaku.”
“The Concrete Institute has been created to continue pro-
viding independent, unbiased information and publications as
well as accredited and internationally-recognised training on
concrete technology to the construction industry. The Institute
is mandated to continue offering the following vital services
previously offered by the C&CI: 1. Education and training – With
the skills challenges facing the industry, this is seen as an essen-
tial requirement for the future of a qualified and suitably skilled
construction industry of the future. The Concrete Institute will
86 globalcementMAGAZINE September 2013
Ethiopia produces twice as much
cement as it needs
Ethiopia: Ethiopia has produced 12Mt of cement, dou-
ble its domestic demand, in the fiscal year that ended
on 7 July 2013, according to a report released by the
Ministry of Industry (MoI). The country’s current do-
mestic demand for cement is estimated to be around
5.4Mt/yr. The government expected a significant rise
in cement demand in its Growth & Transformation Plan
(GTP) that plans for per capita consumption of cement
to increase from 35kg to 300kg. It had predicted that
the demand would grow to 27Mt/yr, exceeding the
12Mt/yr cement production capacity of the country’s
18 plants in the 2014 – 2015 fiscal year.
Higher results for Suez amid domestic strife
Egypt: Suez Cement Company has reported that its con-
solidated revenue rose by 7% year-on-year to US$368m in
the first half of 2013 from US$343m in the same period in
2012. Despite continued energy-supply uncertainties and
increased energy prices, the Italcementi subsidiary managed
to increase its profits by controlling costs and improving
manufacturing efficiency.
Suez Cement’s recurring earnings before interest, taxes,
depreciation and amortisation (EBITDA) rose by 15% year-on-
year to US$93.3m from US$81.3m. Its net profit rose by 46% to
US$55.7m from US$38.0m.
continue offering a range of internationally-recognised courses
including Introduction to Concrete; Making Concrete Bricks
and Blocks; Mortars, Plasters, Screeds and Masonry; Concrete
Practice; Concrete Technology; Concrete Structures: Analysis
& Design; Properties of Concrete for the Structural Designer
and Constructor and the highly acclaimed Advanced Concrete
Technology course. 2. A comprehensive Information Centre
– Inherited from the renowned C&CI facility, this is one of the
largest and most respected sources of information on concrete
in the southern hemisphere and is widely used by the industry
and students as a valuable reference source for technical infor-
mation. The information centre is equipped with state-of-the art
computerised information systems and produces a number of
valuable publications. 3. Consulting – The Concrete Institute will
continue to offer invaluable advice on concrete-related issues
including on-site visits by technical staff.”
“It is worth noting that The Concrete Institute intends to
broaden its member base, not only to other cement produc-
ers but also to building and construction bodies and relevant
academic organisations with a view to facilitating greater co-
operation amongst the various built environment industry play-
ers for the promotion and unlocking of growth opportunities in
South Africa.”
“The Concrete Institute looks forward to providing the South
African construction industry with much needed services and
information,” concluded Perrie.
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Afghanistan: Pakistan-based cement manufac-
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for Afghanistan by ~US$3.00/t in order to defend
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Armenia: Vazgen Safarian, the chairman of the
Armenian Union of Domestic Producers, has said that
gas and oil price increases implemented by the country’s
sole Russian supplier on 11 July 2013 will have an adverse
effect on cement prices in Armenia. The price of cement could
increase by ~20% in the country, according to Safarian.

China: China’s cement prices rose by 0.5% week-on-week in the week

to 4 August 2013, driven by a 1.5% rise in eastern and southwestern China.

Pakistan: Local press has reported that cement manufacturers in Pakistan may
increase cement prices in response to increased electricity rates and a 1% increase
in general sales tax on the product. An anonymous associate from the All-Pakistan
Manufacturers Association (APCMA) said that prices could rise by US$0.34/bag (50kg).
The price of the paper used to make cement bags has also increased, further adding to prices for end consumers.

Indonesia: PT Indocement Tunggal Prakarsa’s products became more expensive in response to

subsidised fuel price increases in late July 2013. On 19 July 2013 a company spokesman said
that the new prices were not yet known. The company’s Portland cement currently sells for
US$6.33/bag (50kg). The government has increased the prices of subsidised fuel from
US$0.45/L to US0.64/L for premium gasoline and to US$0.54/L for solar diesel fuel.

Iran: Iranian cement exporters have increased the cement export price to Iraq by
US$5.00/t, according to the Fars News Agency, which quoted Abdorreza Sheikhan,
the chairman of the association of Iranian cement exporters. This represents a
10% increase from US$50/t at present.
Iraq, which takes 63% of all Iranian cement exports, had previously an-
nounced that it would cease importing cement from Iran on 1 July 2013.

Prices are for cement in metric tonnes, unless stated otherwise. Where a source has given a range,
the published price is the minimum value.
FOB {+ the named port of origin} = Free On Board: The delivery of goods on board the vessel at
the named port of origin (loading), at seller’s expense. Buyer is responsible for the main carriage/
freight, cargo insurance and other costs and risks.
CIF {+ the named port of destination} = Cost, Insurance and Freight: The cargo insurance and
delivery of goods to the named port of destination (discharge) at the seller’s expense. Buyer is
responsible for the import customs clearance and other costs and risks.
ASWP = Any safe world port.
Conversions to US$ from local currencies are as at the time of original publication.

globalcementMAGAZINE September 2013 87

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 Contents Subscribe Ad Index
Dr Robert McCaffrey Editor, Global Cement Magazine (rob@propubs.com)
The Last Word
We sell miracles: don’t pay us peanuts!
I t never ceases to amaze me that you can buy a tonne
of cement so cheaply. The standard worldwide price
of 42.5 cement is only $60-80/t. In a few countries it
might nudge $100/t and in some out-of-the-way spots,
generally land-locked and a long way from competition
from importers, it will peak at past $200/t. However,
for most producers, the most they will receive for their
efforts in producing this miracle material is a measly
hundred bucks - max. Take away the costs of production
(especially the ever-increasing costs of raw materials,
electrical energy, fuel, transport, labour, maintenance
and finance*) and a cement producer is lucky to man-
age a 10% margin. If there is competition in a particular
market then margins will drop below 5% - perhaps even
below 0% (and that is when the trouble starts).
Of course, if cement producers were to enjoy ‘bo-
nanza’ levels of margins of above 10%, then potential
market entrants will look greedily at the markets and
will decide that they too would like a ‘slice of the pie.’
An honest margin of 10% or below will make potential
market entrants think very seriously about risking their
money in cement. After all, you might be able to earn
more money by investing in a higher-yielding industry
altogether, like biotechnology or telecommunications.
What I want to ask in this month’s column though
is, even at a steady profit margin of 10% of the selling
price, is cement correctly priced? Does its selling price
include all of the costs associated with its production?
On the other hand, is the industry being fairly paid (or
paid enough) for making such a wondrous material?
At first glance, the list of costs above (*) seems fairly
complete, but there are other costs that are entirely absent
from the list that very many cement plants around the
world also incur. For example, just as a noisy car levies
an unpaid-for cost on those that it disturbs (you might,
after all, be willing to pay to avoid the noise, and houses
close to a noisy road are worth less than those that are
quieter), a cement plant will impose an unpaid-for cost
on its neighbours, in terms of noise, dust, odours, vibra-
tions, lorry movements, air and water quality impacts
and loss of visual amenity. These costs are not included
in the cost of the cement (unless you count land-taxes
and local taxes that would need to be distributed propor-
tionately to those most inconvenienced by the cement
plant). Air and water quality impacts are possibly yet
more controversial, since they are felt more widely and
less predictably than, for example, lorry movements.
THE LAST WORD
Maybe there should be more locally-levied environmen-
tal taxes that are then disbursed to those affected most.
Risk also has its own cost, but is risk included in
the price of cement? If your cement plant employer has
a reckless approach to risk and safety, the cost of your
injury/death will only be included in the price of the ce-
ment if the victim and their family are fully recompensed
and the company adequately (financially) punished. In
how many countries is this the case? For the unlucky
gentleman killed in a cement plant in Nigeria (see page
84) - and in many other fatalities that we have reported
in these pages over the years - we suspect that the full
cost is not borne by the cement company. It should be.
Other costs that are incurred by the cement company
but not necessarily paid-for might include the effect of
fuels and electricity on GHG levels (unless a carbon
tax is in effect) and environmental impacts of quarry-
ing (although rehabilitated quarries can be biodiversity
hot-spots, particularly for birds), amongst others. I argue
that the price of cement should be higher, reflecting all
of the costs that go into making this sophisticated build-
ing material. Producers need to be held to account for all
their costs, including ‘externalities.’
On the other had, cement is a near-miraculous mate-
rial with myriad benefits: ease of use, strength, durability,
fire-resistance, thermal capacity, reliable quality and
widespread availability. There are substitutes, but none
with all the benefits of cement. After all, would you build
a bridge out of glass or a dam of aluminium? No way!
Cement producers need to be paid fairly (more) for the
long-term benefits that cement brings to society.
However, the one factor that holds back the price
is that there is often too much cement. Markets that
are over-supplied will see producers fighting for sales
through price reductions. At the moment, it is often il-
legal to arrange to try to balance supply with demand in
order to support prices, since this will inevitably involve
collusion and cartelisation of the markets. However, a
cartel in a growing healthy market that leads to excess
profits is surely different from an arrangement that pre-
vents producers from making losses (negative margins)
in a depression. Perhaps there is a case for cement makers
to point out to law-makers that unless ‘arrangements’ are
allowed in an over-supplied and therefore loss-making
market, that companies will not make money, possibly
leading to plant closures, job losses and a reduction in
tax revenue. What do you think? rob@propubs.com
globalcementMAGAZINE September 2013 89
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