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JANUARY 2013 MAGAZINE

 INDUSTRY CHAINS
INDUST
CHAINS
UK Lafarge UK Hillhead 2012 Mining Chains Motors

CEMENT CHAINS
CEMENT CHAINS
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INDUSTRY
CADENAS PARA LA INDUSTRIA DEL CEMENTO Y CANTERA

INDUSTRY IND
IND
IN
NDUSTRY CHAINS
CHAINS CHAINS CH
80 years
years experience
experience in in supplying
supplying cement
cement industry
industry

CHAINS CHAINS CHA

80

CHAINS CH
mechanical
80 years handling
experience in
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supplying cement industry
mechanical handlingofequipment.

CHAINS
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replacements in OEM
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Bucket Elevators, Pan
Elevators, PaninConveyors
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INDUSTRY
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King Chains Corporate identity

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N CEMENT
CEMENT
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JOHN KING KING G
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For more information
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For more information on JOHN KINGS Cement and Quarry Industry
Quarry
KINGS
Industry Chains
a
Chains contact
contact us:
Cement and Quarry
sales@johnkingchains.co.uk
sales@johnkingchains.co.uk
us:
Tel: Industry
Tel: (0044)
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CHAINS
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Inc John King .
Chains (USA)
LimitedInc. chrisrobinson@johnking-chain.com
sales@johnkingchains.com
sales@johnkingchains.co.uk Tel: (0044) Tel: (001)c309-698-9250
1977-681910 h

CHAINS
John King Chains (USA) Inc. chrisrobinson@johnking-chain.com Tel: (001) 309-698-9250
TY )
John King
John King Chains (SA) (PTY)
Chains (USA)
(SA) (PTY) Ltd.
Inc. Ltd. sales@jkc.co.za
L Tel: (27)
(27) 011894-3570
chrisrobinson@johnking-chain.com
sales@jkc.co.za Tel: 011894-3570 t
Tel: (001) 309-698-9250d
S o
REG NO: FM77342
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Cadenas
John KingJohn King
Chains uLtda
(SA) South
(PTY) Ltd.America Manuel@johnkingchains.com
sales@jkc.co.za t
Tel: (27) 011894-3570
Cadenas John King Ltda South America Manuel@johnkingchains.com Tel: (56) h Tel: (56) 2517
2517 7313
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REG NO: FM77342 John King
Cadenas (Central
John Europe)
King Ltda SouthUI. Grundwaldska
America 182 85-401 Bydgoszcz PolandTel:
Manuel@johnkingchains.com Tel:(56)
(48) 2517
52 3497313
08 97
2

John King Jan 2013.indd 1 16/01/2013 09:12

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This issue’s front cover...

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JANUARY 2013 MAGAZINE

Claudius Peters Projects GmbH / Prostruc Consulting
TM
Engineers: Melbourne Cement Facilities’ silo A is a 42m-
high concrete silo, with a 30m diameter. A poorly perform-
ing screw extraction system needed to be replaced with a
more efficient airslide system. The new system features a
cone and 10 radial tunnels. The system reduces eccentric
wall loads on the silo and improves extraction efficiency. MAGAZINE
Engineers: Prostruc Consulting Engineers www.globalcement.com
Contact: Dennis E Kennedy Exclusive Official Magazine for
Tel: +613 9326 0945 Global Cement Conferences:
Email: dennis@prostruc.com.au Global CemFuels, Global Slag,
Global CemTrader, Global CemPower,
Equipment Supplier / Mechanical Concept: Global Cement India.
Claudius Peters Projects GmbH
Contact: Stephan Oehme - Sales and Technology Director The image used for this issue’s front cover is officially the runner up
Tel.: +49 4161 706 258 in the Global Cement Photography Competition. Congratulations to
Email: stephan.oehme@claudiuspeters.com the photographer, James Lauritz. ISSN: 1473-7940
Published by:
Dear Readers, PRo Publications International Ltd
First Floor, Adelphi Court
Happy New Year and welcome to the January 2013 issue of Global Cement Magazine. It 1 East Street, Epsom, Surrey, UK KT17 1BB
may be the start of a new year but it might not be a good news year for the multinational Tel: +44 (0)1372 743837 (switchboard)
cement giants. 2013 has the potential to bring further consolidation and belt-tightening Fax: +44 (0)1372 743838
to the multinationals, each of which has its own plans to sell more minority stakes and
Editor Dr Robert McCaffrey
non-core assets in order to reduce its debts. Notable sales as a result of these plans in rob.mccaffrey@propubs.com
2012 included Lafarge selling cement plants in the US, its joint-venture in the UK with
Deputy editor Dr Peter Edwards
Tarmac and Holcim selling stakes in Thailand and Guatemala as part of its ‘Leadership
peter.edwards@propubs.com
Journey’. In 2013 this trend looks set to continue with the news of another Lafarge joint
venture proposal (in Mexico), Italcementi’s ‘Project 2015,’ which in reality will see 26% Admin Margaret Masson
margaret.masson@propubs.com
of its Italian staff lose their jobs, and the worsening situation in Spain, where cement
consumption dropped by another 33% year-on-year in 2012. Subscriptions Sonal Patel
sonal.patel@propubs.com
Multinationals have also been under sustained pressure from the continued low demand
Commercial director Paul Brown
in established markets, rising fuel prices and the increasing presence of large regional
paul.brown@propubs.com
players in Africa, Asia, South America and the Middle East. If they can play their cards Mobile: (+44) (0) 7767 475 998
right, these regional players could take advantage of the multinationals’ weaknesses by
Business development Sören Rothfahl
picking up their cast-offs, both in terms of assets and market shares. Examples of this
executive soeren.rothfahl@propubs.com
include the creeping ‘Brazilian-isation’ of Portugal’s Cimpor by Camargo Corrêa as the Mobile: (+44) (0) 7850 669 169
Portuguese firm struggles for air, the advance of Dangote into African markets that are
Web editor David Perilli
currently supplied by European and Asian exports, the purchase of cement assets in the
david.perilli@propubs.com
southern US by Colombia’s Cementos Argos and even rumours that Siam Cement is The Editor welcomes editorial
looking to buy European cement assets. contributions (letters, articles etc).
For full details on article submission, please see:
Away from the multinationals, India and China, the world’s two largest cement producers, www.GlobalCement.com
are unlikely to pull any major surprises in 2013. China remains broadly closed to foreign SUBSCRIBE TODAY SEE PAGE 64
investors and has little presence in terms of subsidiaries other than in Taiwan. India, • Independent thinking and analysis
while suffering overcapacity, is expected to maintain its 76% 2012 capacity-utilisation • Best for news, prices and trends
rate in 2013. However, the less competitive Indian assets could be • Global cement news and country reports
snapped up and ‘improved’ by enterprising multinationals looking • Global cement technology
• Your own copy, on time, every issue!
for new revenue streams.
Dr Peter Edwards
We hope that you enjoy this issue of Global Cement Magazine! Deputy Editor Global Cement Magazine
is printed on Forest Stewardship Council (FSC®) certified

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GLOBAL CEMFUELS CONFERENCE & EXHIBITION papers by Wyndeham Grange, a company with ISO
12-13 March 2013, Istanbul, Turkey 14001:2004 environmental accreditation.

cemfuels
CONFERENCE & EXHIBITION 2013
2 ALTERNATIVE FUEL FIELD TRIPS!
• Cost benefits, efficiency, practical considerations
• Legislation, permits and permitting
• Health & Safety and community relations
• Details: www.CemFuels.com

World Business Cement

Council for Industry
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globalcementMAGAZINE January 2013 3

CONTENTS
Global technology, trends & AFR
6 Diary dates
PHOTOGRAPHY COMPETITION - WINNER PHOTOGRAPHY COMPETITION - RUNNER-UP

7 Melbourne Cement Facilities: Silo upgrade

8 Global Cement Photography Competition 2013
16 JAMMBCO’s Diamond HEAT-X kiln chain
WINNER: ‘PENNsuco comPlEx’,
TITaN amERIca llc
ENTRaNT: TREvoR RosEcRaNs
18 G12 - The ‘Formula 1’ of technical chains
8
couNTRY: usa

“ThE PhoTogRaPh Was TakEN fRom ThE

19 Crusader chains to the rescue at Hope

NoRThEasTERN ENd of ThE PRoPERTY aT
TWIlIghT aNd caPTuREs ThE PlaNT aNd ITs
ENoRmous REflEcTIoN. oNE caN EasIlY
sPoT ThE RaW mEal sIlo (cf sIlo), PRE RUNNER-UP: ‘SoUfiaN CEmENt ComPaNy’
hEaTER ToWER, bag housE, kIlN aNd all ENtRaNt: ali malEkzadEh
ThE coNvEYoR bElTs aRouNd ThE PlaNT. ComPaNy: kaNikavaN
CoUNtRy: iRaN

8 globalcementMAGAZINE Janruary 2013 globalcementMAGAZINE January 2013 9

20 Buying chain on price can lead to costly downtime

FANS
Global cement staff
FANS
22 BWF Envirotec - Expanding with the PM-Tec
Fan focus at Venti Oelde Left: Special transport of
ready-welded impellers
for a raw meal fan and a
filter fan dispatched for
low-stress tempering.
membrane product line
24 Fan focus at Venti Oelde
In December 2012 Global Cement Magazine visited Venti Oelde’s fan production facility in Oelde,
Germany. Established in 1930, the company is a leader in the manufacture and installation of
industrial fans and related equipment. Here we present a look at its current projects and some of
the equipment making its way to Venti’s customers in the global cement industry.

E stablished in 1930 in Oelde, Germany, Venti Oelde

plants and components are today used for collect-
ing, handling and filtering of air, vapours, gases, dust
Above: A detailed view of a
Venti-Oelde impeller. and airborne solids across a number of major indus-
tries including the global cement industry.
Below: Rotor unit for Apart from industrial fans, its manufacturing
bag filter fan, type DHRV programme includes dust collection and process gas
72P-2800/K, destined for an
African cement plant.
cleaning plants, exhaust air treatment plants, venti-
lating, heating and air-conditioning plants, recycling
Flow volume:
and waste treatment plants as well as plants for
1,633,800Am3/hr
surface technology. Maintenance, servicing, inspec-
a number of projects ready to be shipped to cement
customers around the world.
Of particular note was a rotor unit for a bag filter
fan (Type DHRV 72P-2800/K), destined for an African
cement plant and shown below. In many applications,
for example conveying of clean-gas side process air,
fans like this one, which has profiled impeller blades,
are recommended. Their design is comparable with
the wing of an aeroplane and the advantages are clear:
Better flow guidance, higher efficiency and therefore
lower energy consumption.

Fan speed: 744rpm tion, repairs as well as plant upgrading, rationalisation
Output on shaft: 3911kW and enlargement complete the available services.
In December 2012, Global Cement Magazine vis-
ited the company at its Oelde headquarters and saw
European cement
A further benefit is the reduction in noise levels
by up to 10dB in the optimum of the characteristic
zone. Cost intensive noise protection measures are
often no longer necessary. Such fans represent a very
specialist request. Above: Boring of flange connection of fan impeller.

Below: A fan being dispatched during Global Cement’s visit, destination Brazil!

26 The View from Brussels

24
Above: A high-efficiency centrifugal fan
HRV 28-400 K for a burner. Peter Herrmann,
manager of Venti-Oelde’s fan division and Inge
Teich, head of marketing, pose for the camera.

Technical data

28 European cement news

Flow volume: 16659m³/hr
Static pressure difference: 251.81mbar
Total weight: 2220 kg

24 globalcementMAGAZINE January 2013 globalcementMAGAZINE January 2013 25

ETHIOPIA ETHIOPIA
33 Southern Cement unveils new ship unloader
Peter Edwards, Global Cement Magazine Cement industry grinding plant will
450
450 3.5
3.5

The Ethiopian cement industry consists of four in- produce OPC and 400
400 3
3.0
tegrated cement plants.3 Three of these are located pozzolana Portland 350
350

Ethiopian Ethiopia is a large landlocked country in central east Africa. Synonymous with in the central area of Oromia, close to the capital cement. The plant is 2.5
2.5
Cement production (Mt)
GDP/capita (2011 US$)

poverty since the mid-1980s famine that ravaged the country, Ethiopia has 300
300
Addis Ababa, with one in the north of the country owned by six members
since experienced a step-change in economic performance, with an increase in 2
2.0

cement focus
close to the disputed border with Eritrea. With the of the Haji Moham- 250
250
cement production also seen. The country is becoming increasingly developed country’s economy relatively closed to outside com- med Ture family, who

Cement in the Americas

200
200 1.5
1.5
and has huge potential for high cement consumption. panies, there are no major multinationals with a named the plant after
150
150
stake in the Ethiopian market, although one plant its late founder Haji 1
1.0
is part owned by South Africa’s Pretoria Portland Mohammed Ture. It 100
100
Cement (PPC).5 lies completed 8km 50
0.5
0.5
50
Ethiopia is well set up geologically for cement from Dire Dawa and
production and has large limestone reserves. Poor in- was awaiting approval 00 0
0.0
1993

1
1994
1995

3
1996
1997

5
1998
1999

7
2000
2001

9
2002
2003

11 13 15 17 19
2004
2005
2006
2007
2008
2009
2010
2011

frastructure has previously prevented this from being from the Ethiopian
exploited more efficiently. Conformity Asses- Year
Ethiopia has historically had low cement consump- ment Enterprise in late 2012.11
tion, as low as 35kg/capita/yr in recent years. However, Elsewhere in the country, Derba Midroc Cement,
it is expected that this rise by a factor of nine or 10 operated by Midroc Ethiopia plc and 70km from Addis Left - Figure 2:
to 300kg/capita/yr in the coming years.6 However, Ababa, was commissioned in January 2012.12 It is cur- GDP/capita (red) and cement

34 American cement news

Above: View across Addis
Ababa, the highest capital
in Africa, rising to over
3000m in places.
GDP1 US$94.85bn
GDP/capita2 US$374 ist state, which, through further coups, uprisings,
Population1 91.2m
Integrated plants3 4 (2 projects)
Integrated capacity3 7.2Mt/yr
Below - Figure 1: Map of Ethiopia showing
Introduction
Unlike all other African lands, Ethiopia was not colo-
nised by European powers, except by Italy for a short
period during the Second World War. Its indigenous
monarchy survived throughout the colonial era, only
to be toppled by a 1974 military junta.
After taking over, the military set up a social-
drought and infighting, wrestled to control itself and
the country throughout the 1970s and 1980s. During
this time inaction and neglect of its own people by the
regime amplified the speed and severity of the 1983-
1985 famine that claimed 400,000 lives.
In 1991 a diverse opposition group, the Ethiopian
Economy
Throughout its long history, the economy of Ethio-
pia was very small, comprising extensive subsistence
farming and market-based trade. Today, its agricul-
tural sector is still the largest sector of its economy,
employing 85% of workers and creating 41% of GDP.1
Many areas of the service sector, including finance
and insurance, are currently off-limits to foreign in-
vestors, although industrial and manufacturing firms
can be owned by those abroad. However, in practice
there remains a predominance of native firms in the
industrial sector.1
Other barriers to foreign investment in the
country include the fact that all land is owned by
such a level would still be behind the global average of
390kg/capita/yr.
There has been a significant increase in cement
capacity since the early 2000s, reflected in Figure 2.
This has been due to a number of upgrade projects
that continue to come onstream. In 2011 Ethiopia
imported around 1Mt of cement.6 The government
elimitated this on 27 March 2012 when it banned
imports as a measure to protect new and forthcoming
domestic cement capacity.7
In the short to medium term, the country’s eco-
nomic growth is expected to remain strong, with
cement playing an increasing role in new roads, dams,
low-cost housing and public buildings. One such pro-
ject is the US$4.2bn, Millennium Renaissance Dam
hydroelectric project. The project began construction
in 2011 and should be completed by 2015.8 Ethiopia
has grand plans for the project and expects to be able
to use it to export power to its neighbours.
Cement plants
The city of Dire Dawa is the historical centre of the
Ethiopian cement industry and remains very impor-
production rates (blue) for
rently the largest cement plant in Ethiopia.
the Ethiopia between 1993
The opening of such a large capacity had a dramatic and 2010/2011.
effect on cement prices, with the new plant offering
the lowest cost cement on the local market. By Feb-
ruary 2012 it was reported that the plant was selling
cement at US$9.36/bag (for bulk orders) in a market
that had seen prices close to US$28.00/bag at the start
of 2011. The company imported around 1000 Volvo
trucks in order to assist with its distribution require-
ments, helping to stabilise the price of cement in the
local market.13
As well as its main cement plant Derba Midroc
Cement operates two mini vertical-shaft kiln cement
plants. The two plants each have a capacity of 300t/day
(0.1Mt/yr). They were designed by the Indian com-
pany SABOO and are located at Derba (next to the
main plant) and at Dejen, 230km from Addis Ababa.14
Messabo Cement is located in Mekelle in the
north of Ethiopia. The FLSmidth-built plant was co-
missioned in 2001 with a capacity of 2.2Mt/yr. The
company produces cement to European standards due
to its European design and claims a domestic market
share of around 30%. The plant is fuelled by fuel oil

Asian cement
major settlements and cement plants.3 People’s Revolutionary Democratic Front (EPRDF) the government, with industrial groups having to tant for the sector. Dire Dawa Cement plant, the first and a 16MW captive power plant.15
overthrew the socialist system. It drew up a consti- hold long-term lease agreements to set-up facilities. cement plant in Ethiopia was opened in 1936 with a Messabo routinely produces OPC and Portland
Eritre tution in 1994 and held free elections in 1995 Another is that, although Ethiopia’s GDP growth capacity of 60,000t/yr by occupying Italian forces.9 pozzolana cement and also has the ability to make
a for the first time. At the same time as the has averaged 9.3%/yr since 2004,2 GDP itself re- The Dire Dawa plant was acquired by the National sulphate-resistant cement and low heat of hydration
1 Ethiopian revolution, the land that forms mains in the bottom 20% of African countries, at Cement project in 2005, which changed the plant’s cement (suitable for dams and other large concrete
ETHIOPIA modern Eritrea was re-taken by rebel US$374/capita in 2011. This limits the market for con- name and upgraded the plant to 0.2Mt/yr. National forms) to order. It exports to Sudan and Djibouti, the
n

uti forces that had fought for independ-

da

sumer goods at present. Infrastructure also remains Cement is due to bring a new 1.2Mt/yr project online latter of which does not have its own cement plants.
Bahir Dar • Djibo
Su

49
• Dese ence for 30 years. relatively undeveloped, although investment is on 3km from Dire Dawa in 2013.9-10 The plant underwent expansion to 2.2Mt/yr in June
the rise. “We will start clinker trial production in October 2011 following a 1.3Mt/yr, US$126.6m upgrade by
4 2 3 • Dire Dawa Despite these poor economic sta- 2012 and cement trial production in November 2012,” China’s Hefei Cement Research and Design Institute.16
ADDIS ABABA • • Harer Somalia
tistics, Ethiopia is well positioned said Busa Assefa, chief executive of National Cement Mugher Cement, a state-owned venture, is lo-
1. Messabo Cement, 2.2Mt/yr.
for development compared to its in September 2012. He added that the trial production cated in central Ethiopia. It began production in 2007

40 Asian cement news

• Jima 2. Mugher Cement, 2.3Mt/yr.
neighbours. It has the second highest phase at the company’s new plant near Bajatu, Kebele, with a capacity of 0.7Mt/yr. Having earlier reported
• Awasa Werder • 3. Derba Midroc Cement, 2.5Mt/yr.
4. Habesha Cement, 1.4Mt/yr. (Project). population, and thus workforce, on would begin at 60% (clinker) and 70% (cement) of a sales slump at the tail end of 2011,17 the company
Sout

5. National Cement, 0.2Mt/yr. the continent1 after Nigeria and ranks installed capacity, before full operation in 2013. The commissioned a new US$94m Chinese-built cement
h Su

6. National Cement, 1.2Mt/yr. (Project)

7. Ture Dire Dawa Cement, 0.5Mt/yr. higher in the World Bank’s ‘Ease of company expects to rely on the eastern Ethiopian mar- production line in April 2012, increasing the capac-
da

lia Doing Business’ survey than all of its ket and will also export to Djibouti and Somalia.10 ity to 2.3Mt/yr.18 The company says that it is targeting
n

Dolo Oda • (Commissioning / Grinding).

5-7 Soma neighbours except for Kenya.4 Also in Dire Dawa, the Tura Dire Dawa Cement the state sector and real-estate projects to absorb its
250km
Kenya Plant will enter production in 2013. The 0.5Mt/yr new capacity.

54 globalcementMAGAZINE January 2013 globalcementMAGAZINE January 2013 55

45 Global Cement India: Preview

IRAQ IRAQ
Peter Edwards, Global Cement Magazine
Company Plant Location Established Lines Process Line 1 Line 2 Line 3 Line 4 Theoretical capacity

Middle East and African cement

Iraqi General Qaim Qaim 1989 1 Dry 3200 - - - 3200t/day 1.0Mt/yr

Iraqi cement focus Cement Co Fallujah

Kubaisa
Fallujah
Kubaisa
1978
1983
3
2
Dry
Dry
300
3200
350
3200
350
-
-
-
1000t/day
6400t/day
0.5Mt/yr
2.0Mt/yr
Kirkuk Kirkuk 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
A turbulent political history
Northern Badoosh - Old Mosul 1955 2 Wet 300 300 - - 600t/day 0.2Mt/yr
has stunted the growth of Iraq,
Cement State Co. Badoosh - New Mosul 1978 2 Dry 1250 1250 - - 2500t/day 0.8Mt/yr
a country with vast natural oil
reserves. Now that the US-led Badoosh - Ext Mosul 1983 1 Dry 3200 - - - 3200t/day 1.0Mt/yr
occupation has given way to Hammam Al Ali - I Mosul 1963 2 Wet 350 350 - - 700t/day 0.23Mt/yr
self-governance, the country Hammam Al Ali - II Mosul 1 Wet 1200 - - - 1200t/day 0.38Mt/yr
has turned up the wick on

47 Middle East and African cement news

Private Group Sinjar Sinjar 1985 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
its (re)-development. Recent
speculation surrounding the Southern Najaf Najaf 1975 1 Wet 700 - - - 700t/day 0.23Mt/yr
possible doubliing of its known Cement State Co. Al Kufa Kufa 1977-78 4 Wet 1500 1500 1500 1500 6000t/day 1.9Mt/yr
oil reserves has put Iraq in a Muthana Muthana 1984 2 Dry 2500 3000 - - 5500t/day 1.76Mt/yr
strong position to become an
Babil Hindia Barrage 1957 2 Wet 250 300 - - 550t/day 0.18Mt/yr
economic and political leader
in the Middle East. The cement Samawa Samawa 1957/1973/1986 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
industry will have an important Lafarge Bazian Sulaimania Sulaimania 2 Dry 3600 3600 - - 7200t/day 2.3Mt/yr

F
role to play in this development ormerly part of the Ottoman
(Leased from Gov.) Bazian Sulaimania 1 Dry 7000 - - - 7000t/day 2.2Mt/yr
and is seeing major investment Empire, Iraq came under control of Kerbala Kerbala 1984 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
in production capacity. the British in the early part of the 20th

49 Ethiopian cement focus

MASS Global MASS Iraq Sulaimania 3 Dry 5500 5500 5500 16,500t/day 5.3Mt/yr
Century. In 1932 it became a Kingdom
and in 1958 it declared itself as a ‘Republic,’ although
in reality a series of six military dictators ruled. Throughout its time as a cement producer, Iraq has more than just cement at that time. In 2003 the level, as Above: List of integrated
cement plants that have
The most infamous of these leaders was Saddam benefitted from its natural limestone and gypsum as measured by the USGS returned to ~2Mt/yr.3 produced cement in
Hussein, who came to power in 1979. He led Iraq into well as its oil. In addition to having a lot of limestone, Iraq, drawn from a number
a territorial conflict with neighbouring Iran that lasted it is also of unusually high quality, Cement industry - Since 2003 of sources. Not all plants are
from 1980 to 1988 and invaded Kuwait in 1990, trig- in that it has a high percentage of Following the US-led invasion in active at present.
GDP (2011 est.)4 US$138.8bn
gering the Gulf War of 1991. calcium carbonate (CaCO ). This 3 2003, UN sanctions were lifted and
Throughout the rest of the 1990s Hussein’s regime means that more cement is pro- GDP/capita (2011 est.)2 US$3501 cement capacity began to rise. Pro- Left: Summary statistics for
taunted the established western powers after US-led duced per tonne of limestone, which Population (July 2012)4 31.1m duction, as reported by the USGS, Iraq and its cement industry.

Above: The Sinjar cement sanctions against the oil-rich nation. In 2003, amid Much of Iraq’s inherent wealth is tied up in its oil, theoretically enables a more efficient Official oil reserves4 171bn barrels has risen by a factor of more than

52 Iraqi cement focus

plant dates from the late growing fears over Hussein’s access to and willing- which provides 90% of all government income.4 This process. Iraq’s limestone is also very three since 2003 to around 6.5Mt/yr Below: Map of Iraq with key
1980s. It underwent an exten- Area4 438,317km2
ness to use weapons of mass destruction, allied forces will provide a very strong source of revenue for the close to the surface, allowing low- in 2011 from a theoretical capacity settlements and
sive re-fit in 2011 courtsey of
invaded the country, toppling the Hussein regime in country’s (re)-development in future years. Speculative cost mining. Integrated plants6 19 of around 32.5Mt/yr.3 neighbouring countries.
Austroplan Austrian
Engineering GmbH.1 April of that year. results from 2011 have led the government to claim Since 2003 the Iraqi cement sec- Integrated capacity6 32.5Mt/yr Turkey
that it has the largest reserves in the world, although tor has been split into two categories. Average plant capacity6 1.70Mt/yr
Economy with ‘just’ its existing 171bn barrels, it sits 12th in the On one side are the former state-run
Below: Sporadic
• Mosul
Iran

The 10 years since the removal of Hussein have been list of oil producers and third in the list of oil reserves.1 plants and on the other side are new
GDP/capita (red)2 and ce-
characterised by economic improvement amid contin-
ment production data (blue)3 Despite this, unemployment and corruption re- private operators. Lafarge acquired two plants post- Sinjar •
for Iraq since 1982. ued violence and lawlessness. Foreign firms, especially main major barriers to fair and wide distribution of 2003 and took over the running of a third in 2008. 150km

in the oil sector, are Iraq’s increasing wealth. It remains hard to set up new Other private operators include the Al-Rawi group,
Kirkuk • • Sulaimania
4000
4000 8000
8.0 investing heavily in Iraq enterprises due to government regulations and 25% of which operates three plants and MASS Global, which
a
Syri • Qaim

56 17th Arab-International Cement Conference &

despite the risks. the population remains in poverty.2 commissioned its first kiln at Sulaimania in 2010 and
Iran

3500
3500 7.0
7000

52
Suspected outlier Since 2003, Iraq’s a second in 2011. Also under private ownership is the
3000
3000 6.0
6000 economy has steadily Cement industry - History Sinjar Cement Plant, owned by a consortium of family Kubaisa •
improved due to the re- From the start of cement production in Iraq at Badoosh members. • Rutba Faluja • • BAGHDAD
Cement production (Mt)

Jordan

2500
2500 5000
5.0
GDP/capita (2011 US$)

Kerbala • •Hindia Barrage

moval of UN sanctions in 1955 until 2003 all cement factories in the country
that had been in place were owned and operated by the government.3 After Cement industry - Reported production
2000
2000 4000
4.0
since 1990. This has al- Badoosh started production, further plants were The United States Geological Survey’s (USGS) records Najaf • Kufa
1500
1500 3.0
3000 lowed its GDP/capita to added over the next three decades by a government of Iraqi cement production in the 1990s confirm that
return to pre-sanction keen to develop Iraq’s standing as a major regional production was fairly low for a country of its size at Saud Samawa •
1000
1000 2000
2.0
levels and highlights player across a number of development indicators. around 2Mt/yr from 1993 to 2001.3 However, like
i Arab Nasiriyya•
500
500 1000 two decades of lost Iraqi This drive to develop the economy brought 15 ce- other outside parties the USGS’s access to information
ia • Basra
1.0

Exhibition - Reviewed
00 0
0.0
economic development ment plants into production in Iraq but, although the about Iraq’s internal affairs was largely restricted. Muthana •
as a result of the Hussein country’s headline capacity was fairly high, it suffered In 2002 the country reported a large increase in its
1990

1994

1998

2002

2010
1982
1984
1986
1988

1992

1996

2000

2004
2006
2008

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Kuw

regime’s hostile relation- from severe overcapacity. The country was breifly a ce- cement production to nearly 7Mt. However, it is now
Year ship with the west. ment exporter in the mid 1980s.5 known that the Hussein’s regime was lying about a lot
ait

54 globalcementMAGAZINE January 2013 globalcementMAGAZINE January 2013 55

AUCBM 2012 REVIEWED

Robert McCaffrey, Editor, Global Cement Magazine

17th Arab International Cement Conference and

AUCBM 2012 REVIEWED
Regulars and comment
Exhibition - AUCBM Dubai 2012 - Reviewed

62 A trader’s view
7 8
The 17th Arab International Cement Conference and Exhibition, organised by the Arab Union for Cement and Building
Materials (AUCBM), has been successfully held at the Dubai World Trade Centre in Dubai, UAE. Over 650 delegates
attended the event, which also featured nearly 140 exhibition booths in what was one of the largest - and certainly best inefficiency. He pointed out that there are a number cement capacity outside of China),
organised - cement exhibitions ever held in the Middle East. The next AUCBM meeting will take place in Marrakesh. of different adjustment options in a VRM that allow but that there are no member
you to tailor your particle size distribution (and water companies in the Middle East (or
demand) to customer demands. However, using par- Australia). Companies that sign up

T
9
1: Anis Haider of ITECA, right he conference and exhibition took place at the Aimo Haack of ThyssenKrupp Polysius spoke ticle image analysis, the sphericity of cement particles to the CSI are required to comply

63 Global cement prices

being visited by Ali Riahi of
Scantech.
2: David Hughes, left and
Klaus-Martin Rupp manning
the Andrew Webron stand.
3: Cemengal’s display Moisés
Nuñez Rodriguez, centre, and
Fernando Dueñas Pozo, right
in discussion with a visitor.
large and modern Dubai World Trade Centre,
which was well-serviced by good transport links and
on-site hotels. The event took place over two and a half
days, such was the large number of presentations that
had been offered to the organisers. The exhibition, fea-
turing nearly 140 exhibition stands, was of very high
quality, with very smart exhibition stands and carpet-
ing, and regularly-served fresh coffee. The exhibition
was busy for the first two days of the event.
about cement grinding with the Polycom high pres-
sure grinding roll system, allowing a reduction in
specific electricity costs. Aimo suggested that the
Polycom system has only 46% of the energy consump-
tion of a ball mill (a vertical roller mill has an energy
consumption of around 53% of a ball mill). The Poly-
com grinding system is best teamed-up with the Sepol
high-efficiency separator.
is similar for ball mill and VRM-produced cements,
apart from for particles above 50 microns, but which
have no influence on strength development.
In a ball mill, gypsum is dried and converted into
reactive hemihydrate, necessary as a setting regula-
tor. The lower mill temperature and shorter residence
time of cement in a VRM will result in a difference in
gypsum performance, but again there are a number
of measures that can be taken to optimise the result-
ant cement, for example, using a little more gypsum,
adding a small amount of hemihydrate, increasing the
mill exit temperature or reducing the moisture content
with the organisation’s charter within
three years of signing up.
The first priority is to eliminate fatalities from the 7: A busy coffee break provided
industry. In fact, 56% of industry fatalities involve ideal networking opportunities.
moving vehicles, 10% with falls from height and 8%
involve being hit by moving machinery.
The second priority for the CSI, to reduce CO2
emissions, will be brought about by improving energy 8: A very busy MVW Lechten-
efficiency, the use of alternative fuels, clinker substi- berg exhibition stand!
tution and through the use of Carbon Capture and
Sequestration (CCS).
Wilfred Zieri of A TEC, who stated as his hobby

64 Subscription form for Global Cement Magazine

1 2
4: Sebahattin Akbas, left, Given that there were 47 papers - of only 20 min-
of the mill air supply. Thomas effectively dispelled the
VRM myths in his excellent paper.
John Dicom of FLSmidth stepped up to the mi-
crophone to speak about automation technologies to
enable an intelligent collaborative environment (ICE).
Remote locations, lack of skilled personnel, rising
energy costs and intense competition are among the
3 most pressing concerns for the global cement industry,
according to John Dicom.
ICE allows remote access to plant information, in-
Dispelling VRM myths cluding performance monitoring, asset management,
9: Intensiv-Filter’s new owner,
‘alternative fuels,’ spoke about his company’s ReduDust Himenviro exhibited, left to
solution for excess volatiles such as sulphur, chlorine right Vidhan Sharma, Rajeev
and potassium. A TEC and Holcim have jointly de- Sood and Markus Schröder.
veloped a process to wash the dust to create a brine,
which can then be precipitated, oxidised and neutral-
ised (and - expensively - crystallised) to create pure
enough potassium chloride salts that could be sold as a
base product (at Euro300/t) for fertilisers. A pilot plant
10: KIMA was well represented
at this year’s AUCBM.
has been completed, as well as designs for a full scale
plant which would cost around Euro10m.

65 The Last Word

welcoming visitors from
Egypt to the Möllers stand.
5: Eduardo Tena Recalde,
right and Alejandro Corcuera
Rodriguez of Aceros y Sumin-
istros pose for the camera.
6: Haver & Boecker’s Claus
utes each - spread over the course of the two and a half
days of the conference, Global Cement Magazine here
reports on a few of the highlights of the conference.
The first speaker, Tareq Samaha from RAK Com-
pany for White Cement, told the audience that there
was a huge oversupply in the UAE, with around 30Mt/
yr of cement production capacity, but with demand
only amounting to 10Mt in 2012. “Despite the contin-
ued oversupply, UAE real estate has been recovering
Thomas Fahrland of Loesche next sought to dispel
some of the myths surrounding the quality of cement
produced by vertical roller mills. It was said, when
VRMs were first introduced into the cement industry
in the early 1990s, that the cement they produced
would have a higher water demand, a retarded set time
and a lower compressive strength due to a steeper par-
ticle size distribution, different particle shapes and due
to gypsum dehydration.
process control and optimisation and predictive main-
tenance. The ICE centre in Denmark collects in plant
information and can benchmark plants against each
other in real time, as well as feeding back to the plants’
advanced information about the performance of the
cement plant and its equipment. 140 already plants use
the system.
Cement Sustainability Initiative
Energy matters
Uwe Maas for ThyssenKrupp Polysius pointed out that
11: Andreas Renetzeder, right
the use of an intermediate crusher in a clinker cooler
and Ruggero Baldo of Scheuch
can raise the temperature of the exhaust air by 30-40°C, smile for the camera.
while simultaneously lowering the clinker tempera-
ture. Uwe also mentioned the Prepol Step Combustor,
for the use of alternative fuels: feed screws push fuels
onto an ignition table where they are ‘lit’: the materials
then cascade down an inclined grate, with a residence

56
Ohlmeyer, far left, in discus- 12: Shakespeare Foundry was
sion with visitors from the crisis, thanks largely to increased tourism, Thomas showed that there is more fine (over- Philippe Fonta of the WBCSD stated that the Cement time of around 15 minutes, using pneumatic transport. out in force this year from both
and colleague Alan the UK and Egypt.
as well as an Arab-Spring induced demand for stable ground) material in cement produced in a ball mill Sustainability Initiative now represents one third of the The first installation will be in spring 2013 and we look

66 Advertiser Index
Arbotante, right.
safe-havens in the Arab world.” system, due to the high number of impacts and the mill world’s cement production, (two thirds of the global forward to the first results.

4 5 6 10 11 12

24 globalcementMAGAZINE January 2013 globalcementMAGAZINE January 2013 25

4 globalcementMAGAZINE January 2013

 18-19 FEBRUARY 2013 MUMBAI, INDIA

gl bal
2nd Call for papers,

cement
A world-class
event for India’s exhibition information
world-class and further details at
cement industry!
www.cement-India.com
CONFERENCE • EXHIBITION • INDIA 2013
The first Global Cement Conference in India was organised in Mumbai
in 2004 and was an outstanding success. After a gap of nine years, the Gateway to
event will again take place in a world-class venue in Mumbai, the ‘city
of HQs.’ India’s cement production capacity is expected to reach 300Mt
India:
within a decade and India is clearly the biggest and best market for Cement for
cement equipment and services in the world right now. If you sell - or
want to sell - to the Indian cement industry, don’t miss it! the future
Representatives of the following companies and organisations have already expressed their
interest in attending the Global Cement Conference India 2013: Main themes:
ABG Cement Limited; Abhijeet Cement Ltd; aixergee Process Optimization; Alfer Engineering; American Air Filter Alternative fuels
Malaysia; Analec; Andrew Webron Ltd; Aranca Mumbai; Bee Chems; Behre Dolbear Management Consulting; Berkely
Petrochemicals Private Ltd; Bharat Petroleum; Billerud; Boral Cement; C3S, Inc.; Cafla International Ltd; Cal.Me s.p.a.; Alternative raw materials
Caribbean Cement Company Limited; Católica Lisbon School of Business and Economics; Cega Yapi Kimyasallari San.
Tic. Ltd Sti; Cementis; Cemex; Cemex UAE; Christian Pfeiffer Pvt. Ltd.; Coromandel Infotech India Ltd; CTP Team S.r.l. Technology advances
(Bedeschi Group); Datta Sai Enterprise; DCL, Inc.; DG Khan Cement Company; Druk Cement Company Pvt Ltd; Durag
GmbH; EAB Elektroanlagenbau Reinhausen GmbH; Enam Securities; EnviroCare International, Inc.; Espandar Cement Increasing profitability
Investment Co.; Eurodur GmbH; Evonik Fibres GmbH; FAIG Fundição de Aço Inox Ltda; Farasat Gostar Hoor; FCT-
ACTech; Fives FCB; FLSmidth Private Limited; Fosroc International Ltd; Frigmaires; Fuchs Lubritech; Geoprojet; Golder Increasing production
Associates; Hayba Trading; HEKO Ketten GmbH; HEM Technologies; Holcim; Holcim Group Support Ltd.; Hotwork;
Isaksson-Taylor; J K Lakshmi Cement Limited; KHD Humboldt Wedag Pvt Ltd; Klüber Lubrication München KG; Kohat
Cement Company Ltd; KTT Company; Kuwait Cement Company; LV Technology Public Co. Ltd; Lafarge Cement Sdn.
Bhd. Langkawi Plant; Larestan Cement; Lehigh Hanson Materials Ltd.; Lilanand Magnesites Pvt Ltd.; Lubrication Engi-
neers International AG; Lucky Cement Limited; Madras Cements Ltd; Mahaphant Fiber Cement PCL; Maruti Cements
Who should attend?
Ltd; Maxcem Inc.; Meghalaya Cement; Mirdha Group; Muller Beltex b.v.; MVW; NCB; NLSupervision; Oceania Impex
Australia Pty Ltd; Oman Cement Company SAOG; Optibelt Asia Pacific; Pennco Cement Industries Pvt Ltd ; Penta Engi-
cement producers
neering; Qassim Cement Company; Ramco Systems Limited; Ras Al Khaimah Co. For White Cement & Construction Ma-
terials; Sagar Cements Limited; Schenck Process GmbH; Sharada Ceramics Pvt Limited; Shivam Cement; Siemens AG;
cement and concrete users
Sinoma-Tec; SKF; Sparta Cement & Infra Limited; Sri Lanka Standards Institution; Steag Power Minerals; Stoncor Middle
East; Sumitomo Osaka Cement co; Sverak; Tabuk Cement Company; ThangLong Cement Stock Co.; The University of
traders and shippers
Mosul; ThyssenKrupp Industries India; Titan Cement; Tracim Cement; Ultratech Cement Ltd; Union Cement Norcem
Co.; Union Continents Holding; United Cement Company (Calabar); United States Gypsum Company; Universiti Sains equipment suppliers
Malaysia; University of Gujrat; Untha Shredding Technology; Utility Engineers; VDB International; Vega Industries; WR
Grace; Welding Alloys Polska Sp. z o.o.; Zawawi Minerals LLC; Zwick Asia Pte Ltd
Companies from the following
countries have expressed their in-
Contact Paul Brown for terest to attend the Global Cement
exhibition opportunities
India conference and exhibition:
paul.brown@propubs.com
Tel +44 776 74 75 998
Australia; Austria; Belgium; Brazil;
Canada; China; Cyprus; Czech
Republic; Egypt; France; Ger-
many; Greece; India; Iran; Iraq;
Italy; Jamaica; Japan; Jordan;
Kuwait; Libya; Malaysia; Mexico;
Morocco; Nepal; Netherlands;
Nigeria; Oman; Pakistan; Philip-
pines; Poland; Portugal; Saudi
Arabia; Singapore; Spain; Sri
Lanka; Sweden; Switzerland;
Thailand; Turkey; Ukraine; United
Arab Emirates; United Kingdom;
United States; Vietnam

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cement MAGAZINE

India Jan 2013.indd 1 16/01/2013 09:11

 Contents Subscribe Ad Index
DIARY DATES
2nd Global Cement India Conference and Exhibition UNITECR 2013
18-19 February 2013, Mumbai, India 10-13 September 2013, Victoria, British Columbia, Canada
www.Cement-India.com www.unitecr2013.org

7th Global CemFuels Conference 8th Global Insulation Conference & Exhibition
12-13 March 2013, Istanbul, Turkey - See below. 23-24 September 2013, Aachen, Germany
www.CemFuels.com www.GlobalInsulation.com

54th IEEE-IAS/PCA Cement Conference 7th International VDZ Congress 2013

14-18 April 2013, Orlando, Florida, USA 25-27 September 2013, Düsseldorf, Germany
www.ieeepcaconference.org www.vdz-online.de

BAUMA 2013 13th Global Gypsum Conference & Exhibition

15-21 April 2013, Munich, Germany 21-22 October 2013, Toronto, Canada
www.bauma.de www.GlobalGypsum.com

POWTECH 2013 12th TÇMB International Technical Seminar & Exhibition

23-25 April 2013, Nuremberg, Germany 8-10 October 2013, Antalya, Turkey
www.powtech.de www.tcma.org.tr

2nd Global CemTrader Conference 9th Global Slag Conference & Exhibition
9-10 May 2013, London, UK 12-13 November 2013, Dubai, UAE
www.CemTrader.com www.GlobalSlag.com

2nd Global CemPower Conference

4-5 June 2013, London, UK Links to all events: Full 2013 Media Book:
www.CemPower.com www.Cement-Events.com www.propubs.com/advertise

Istanbul, Turkey · 12-13 March 2013

gl bal
7th ALTERNATIVE FUELS

cemfuels
FOR CEMENT AND LIME

Details: www.CemFuels.com
CONFERENCE • EXHIBITION • AWARDS 2013
Attend this popular international
conference to share information on
Featuring TWO the latest state-of-the-art in the use
alternative fuel of alternative fuels (AF) in the cement
field trips! and lime industries.

Main themes
· Legislation
· Permits and permitting
· Safety and health
· Practical considerations
· Combustion efficiency
· Cost benefits
· Community relations

Organised by:
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cement
TM

MAGAZINE
 Contents Subscribe Ad Index
Prostruc Pty. Ltd., Australia
Melbourne Cement Facilities: Silo upgrade
75% of the cement supplied into Melbourne’s
expanding skyline and infrastructure
development comes from Melbourne Cement
Facilities’ (MCF)120,000t Port Melbourne
Terminal. Silo A has a 40,000t capacity and is
30m in diameter and 42m tall. Its only access is
via a 2m x 2m door at ground level.
T he silo’s original configuration included a flat
floor and the silo was built with a central diamet-
ric rotating screw extraction system. This delivered
product to a central cement pump in the reclaim pit
underneath the silo. After 4Mt was reclaimed from the
silo, the system passed its use-by date and was failing
to cope with demand. Maintenance was becoming in-
creasingly difficult.
MCF investigated a number of options to upgrade
the system before selecting a proposal based on
Claudius Peters’ Expansion Chamber principle. The
principle had been applied in smaller silos but not in
the proposed configuration and not in a 30m diameter
silo. Its application, in the case of Silo A, is a world first
presenting a number of engineering challenges.
The system required 10 radial tunnels and a 10m-
high 60° central cone, all on a floor, which slopes 10°
towards the tunnel sides and 10° towards the centre of
the silo. The tunnels start 5.4m high at the perimeter of
the silo and taper vertically and horizontally towards
the cone.
The whole floor, including inside the tunnels, is
covered with airslides, which are air fed by three blow-
ers, located in the access tower, through 7km of piping.
Banks of airslides are selectively and symmetrically
activated via a control system to cause fluidised ce-
ment to flow down the floor slope into the cone and
laterally into the tunnels via slots at floor level. The
tunnels and cone fill with cement and the level is con-
trolled via sensing the pressure on the airslides in the
cone. A venting system removes aeration air from the
upper cone area. Cone and tunnel linings relieve the
outlet area from the pressure of stored cement. Use
STORAGE
of the area inside the cone and tunnels results in reli- Above: Prostruc engineers
working on Melbourne Cement
able discharge under de-pressurised conditions and Facilities’ Silo A upgrade.
minimises loss of volume in the silo. Fluidised cement
feeds into a hopper below the floor and to the original
cement pump.
Prostruc engineers assisted MCF with the selection
process to grant the mechanical equipment supply
contract to Claudius Peters. Subsequently Prostruc
was engaged by MCF to design all structural works,
prepare shop details, document piping and was also
appointed as the project manager for all civil and me-
chanical contract works.
Prostruc engineers were required to design the Below left: Melbourne
structures to withstand eccentric pressures and trac- Cement Facilities supplies
75% of Melbourne’s cement
tions caused by the storage and mobilisation of cement,
through its 120,000t Port
40m below the top of the silo. In addition the company Melbourne Terminal.
filtered ideas of roof access for construction, steel
structure options and pre-cast options. Prostruc engi-
neers determined that the structures could efficiently Below centre: Laser Scan of
be built via the 2m access door using a composite con- the emptying degree.
struction of steel and sprayed concrete.
All works are complete and the silo runs trouble
free. Reclaim capacity is doubled and restricted only
by the existing outlet pipe configuration. Below: Completed silo bottom
with staff shown for scale.
globalcementMAGAZINE January 2013 7
 Contents Subscribe Ad Index
PHOTOGRAPHY COMPETITION - WINNER

WINNER: ‘Pennsuco Complex’,

Titan America LLC
ENTRANT: Trevor Rosecrans

COUNTRY: USA
“The photograph was taken from the
northeastern end of the property at
Twilight and captures the plant and its
enormous reflection. One can easily
spot the raw meal silo (CF Silo), pre
heater tower, bag house, kiln and all
the conveyor belts around the plant.

8 globalcementMAGAZINE Janruary 2013

PHOTOGRAPHY COMPETITION - RUNNER-UP

RUNNER-UP: ‘Soufian Cement Company’

ENTRANT: Ali Malekzadeh
COMPANY: Kanikavan
COUNTRY: Iran

globalcementMAGAZINE January 2013 9

PHOTOGRAPHY COMPETITION - COMMENDED

COMMENDED: ‘Portlandcement and

Limeplant, Vils, Tyrol’
ENTRANT: Tobias Jentsch
COMPANY: Schretter & Cie GmbH & Co KG
COUNTRY: Austria

10 globalcementMAGAZINE Janruary 2013

PHOTOGRAPHY COMPETITION - COMMENDED

COMMENDED: ‘Ash Grove Cement,

Leamington, Utah, USA: Cement plant pre-
heater down-comer cooling tubes that have
since been replaced with a
Conditioning Tower.’
ENTRANT: Lars Hansen
COUNTRY: USA

COMMENDED: ‘Pennsuco Complex’,Titan America LLC

ENTRANT: Trevor Rosecrans
COUNTRY: USA

globalcementMAGAZINE January 2013 11

PHOTOGRAPHY COMPETITION - COMMENDED
‘Santiago De Chile, Centenary Bridge’ ‘Fresh Clinker’
Thomas Wedderwille, NUMA, Chile Tina Stache-Cakiroglu,
HC Trading, Turkey

‘World within a world’

‘Nesher Cement at night’ Mick Britton, Southern Lime
Benjamin Angeled, plant, Calera, USA
Nesher Cement, Israel

‘Lafarge Exshaw Plant’

Jason Betke, Lafarge Canada, Canada

12 globalcementMAGAZINE Janruary 2013

PHOTOGRAPHY COMPETITION - COMMENDED
‘My Home Industries’
P Sreedhar, My Home Industries, India

‘Pennsuco Complex’, Titan

America LLC
Trevor Rosecrans, USA

‘Water Mirror, Votorantim Cimentos’

Rodrigo Machado Ferronato, Dynamis
Mecânica Aplicada Ltda, Brazil

‘Melbourne Cement Facilities’

James Lauritz, PROSTRUC
Consulting Engineers, Australia

globalcementMAGAZINE January 2013 13

 THE PFEIFFER MVR MILL
NOT JUST BIGGER – BETTER

Active redundancy
Up to 6 grinding rollers and 6 drive modules: mill operation continues
even if one roller or one drive module is under maintenance.

Hydraulic system for operation and maintenance

Parallel grinding gap

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Phone: +49 631 4161 0
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GPSE Jan 2013.indd 2 16/01/2013 09:11


CHAINS
JAMMBCO
JAMMBCO’s Diamond
HEAT-X kiln chain
Since 1973 JAMMBCO has
been a leading consulting
source and provider of
specialised and patented
hardware for the cement
and pulp and paper
industries. It is dedicated
in efficiently optimising
the heat recovery from
rotary kilns with high-
quality wear performance
products. JAMMBCO has
installed products in over
250 plants worldwide and
has continued to develop
innovative products for
the future.
Right: JAMMBCO stainless
steel and carbon steel round
link kiln chains.
Right: JAMMBCO heat ex-
change round link kiln chain.
Right: JAMMBCO heat ex-
change round link kiln chain.
Right: Different sizes of
Diamond HEAT-X kiln chain.
16 globalcementMAGAZINE January 2013
Contents Subscribe Ad Index
J
AMMBCO offers a range of kiln
chains to the global cement in-
dustry, including round and oval
link chains. JAMMBCO’s quality
products have been utilised in over
250 kilns worldwide over the past
40 years. It focuses on optimising
the efficiency of kilns through the utilisation
of its chains and acquired industry knowl-
edge. JAMMBCO is able to supply over 50
grades of kiln chain in a variety of sizes.
JAMMBCO’s products and kiln chain
systems have been granted the title of ‘Green
Energy Projects,’ by several governments
globally. This is because its products sub-
stantially reduce the carbon footprint of the
calcining processes.
The company also offers quick lead-
times to meet producers’ kiln maintenance
requirements and deadlines. It is important
to preserve the chain system at its optimal
kg/t (lbs/t) ratio for a maximum heat trans-
fer coefficient. JAMMBCO’s cast proprietary
austenitic manganese kiln chain can be modified to The use of the HEAT-X strand kiln chain in wet
withstand the harsh environment of any kiln. kilns can easily increase production by 15-20%. In ad-
JAMMBCO has recently installed chain systems dition, the system can reduce fuel usage by an average
in kilns with first and second stage pre-heaters, which rate by 0.5–1.2 MBTU/t of product.
have been extremely successful. For
example, this chain system is able to
reduce the exit gas temperature on
average by 40°C and increase the
production by a minimum of 5%.
HEAT-X kiln chain
JAMMBCO’s reputable offering is
the patented Diamond HEAT-X
chain design. This superior chain
design reduces the creation of dust,
thereby retaining more product
within the kiln and thus increasing
production.
 State of the LindnerART:
Reduce to the max
Michael Hofer
Sales Manager

We reduce everything. Almost everything. But never our know-how.

You can profit from this too, because you are in good company
among our numerous renowned customers worldwide.
More than 1.000 shredders and plants for processing refuse
derived fuels sold – they speak for themselves.

L
NA
RIGI
O
%
100

The Brand for Cutters

• for Lindner, MeWa, Untha, Vecoplan,

Weima and others
• in stock
• good value
• Made in Germany

Grindermax GmbH
D-97877 Wertheim
info@grindermax.de www.grindermax.de

Lindner-Grindermax Jan 2013.indd 1 16/01/2013 09:10


CHAINS
pewag
G12 - The ‘Formula 1’ of
technical chains
Above: Smart profile. The
intelligent distribution
of material improves the
performance of the chain
(such as fatigue resistance
and bending stiffness) sig-
nificantly. This improvement
was achieved by optimising
the material use in the core
area (blue) and a reduction
of material in less relevant
areas (marked in red).
Right: Optimised
characteristics. The D-shaped
profile (above) gives the
chain an up to 16% higher
modulus compared to a
round steel chain (below)
with the same cross-section.
This reduces the maximum
stress in the chain, high-
lighted by the lack of red
areas in the D-shape chain.
18 globalcementMAGAZINE January 2013
S ince the first documented references to a
forging plant in the year 1479 in Brückl,
Austria, the pewag group became one of the
world’s leading chain manufacturers. Today’s
success is based on excellent quality and state-
of-the-art technology.
The range of products includes snow chains,
forestry chains, hoist and conveyor chains, do-it-your-
self products, engineering, slings and lashing chains as
well as tyre protection chains. Modern chain plants in
Europe, and soon in the US, enable pewag to provide a
wide range of top quality products.
pewag winner pro
The universally-applicable pewag winner pro chain
system differs from the conventional round steel by
having a D-shape profile. This D-shape allows an opti-
mised distribution of material, leading to an increased
performance of the chain at any
given diameter.
Contents Subscribe Ad Index
pewag has been at the core of chain
innovation for over 500 years and was the
first to introduce a G12 chain system. The
unique and intelligent profile of pewag’s
G12 chains, called pewag winner pro,
means that given weights can always
be lifted or secured with a smaller chain
dimension compared to other grades.
With its G12 chains pewag shows that
chain size matters - whether for lifting,
lashing or for special solutions.
The higher Working Load Limits (WLL) of the
pewag winner G12 programme (50% more compared
to G8 programmes) allow significant weight reduc-
tion. Reducing the weight of the chain sling makes
the assembly easier and also improves the usability for
the end-user. Additionally, the profile improves the
bending resistance of the chain. This is essential when
loading the chain over a corner.
 Based on the intelligent material use, the major
characteristics of the chain, such as fatigue resistance
and bending resistance, are improved remarkably, es-
pecially when comparing the same cross-section of the
profile chain versus the round steel chain. In order to
reach the best mechanical performance, the material
use was optimised in effective areas and reduced in less
relevant areas.
The bending resistance is also optimised by the new
shape. The section modulus, which is important for
preventing undesirable bending deformation, is up to
16% higher with the profile chain compared to round
steel chain with the same cross-section. Therefore the
maximum stress in the chain is reduced.
The load capacity of the G12 chains is 50% higher
than with G8 chains and 20% higher compared to G10
chains. This allows a significant weight reduction and
the chain’s handling is improved tremendously.
The pewag winner pro, representing the
‘Formula 1’ of technical chains, is avail-
able in a wide range of variations, for
lifting and lashing as well as many other
applications. For complete traceability all
chains and components are stamped with
an identification mark. With that the whole
production process can be tracked.
MENT CE
Contents Subscribe Ad Index
CHAINS
John King Chains Ltd

Crusader chains to the rescue at Hope

DUSTRY IN
hains Corporate i
John King Chains Ltd is one of the oldest chain producers in the world. Although it was originally

J K denC
a designer and manufacturer of mechanical handling equipment for mining, cement and steel,

AINS
it has refocused on the manufacture of heavy and specialised conveyor chains since the 1990s.

ohn ing
CH
John King’s tradition was in the manufacture of cast link chains in irons and steels and although
cast link chains remain an important part of the programme, the company additionally produces
engineering class, welded steel and forged fork link chain. This allows John King to offer the
widest product range of any such chain manufacturer.

MENT
Case study - Hope Cement Works, UK
I ts tradition in the manufacture of chain conveyors

MENT
and elevators allows John King a unique insight into
the design and selection of chain ‘running gear.’ Its
ability to select the correct chains for the application,
up-rate existing chains to enhance performance and
The first conversion was carried out at a UK cement
plant and the experience speaks for itself. The cement
plant at Hope, Derbyshire, UK, now owned by Mittal
Investments Ltd, operates a clinker transport conveyor

USTRY
service reliability and assist in problem solving is an to deliver clinker to a main store. The casing size is
essential element of the service that it provides. This 800mm with chain centres of 4.0m. This conveyor has

USTRY
added value has been well received in the market and a design capacity of 200t/hr.

MENT
has allowed John King to form strong alliances with Originally the system employed a double-strand
many cement producers around the world. forged chain with flight at every pitch point. The abra-
A good example of this can be seen in the John sive nature of the clinker at Hope saw high wear rates

AINS
King Crusader range of high capacity drag chains. This to the assembly and the necessity for regular replace-
option, made from welded steel, was developed as an ment and ongoing maintenance. This was considered

EMENT
AINS
USTRY
EMENT CCC
alternative to the traditional cast manganese drag links inadequate and uneconomical.

CEMENT
that are found in many cement clinker drag convey-
ors. It is noted that all types of cast drag link chains
encountered in Europe, North America and elsewhere
typically including JKT, JKD, SD and JKS types, can be
converted to Crusader by John King. This is particu-
“John King Chains approached me with a view
to presenting an alternative,” explains Trevor Shaw,
Mechanical Engineer at Hope Works. “Its proposal
was a radical departure from the current system in
being a single strand. The design in its simple and ro-

AINS
larly beneficial in areas that are abrasive and/or hot. bust construction was exactly what I considered was Below: A John King Chains

NDUSTRY
ENT II
IN
Crusader type chain, like

NDUSTRY
The Crusader series’ fabricated construction chain needed. This chain has given me over six years of reli-
that now installed at Mittal

NDUSTRY
follows the same format as John King welded steel able performance in a very challenging application.”
Investment’s Hope Works.
chain with crank link profile and circumferentially-
welded bush. It features optimum materials
and heat-treatment to ensure good resistance
to shock-loading and long service. The plates

USTRY
are from an alloy steel with through-hardening.

HAINS CCC
The pin and bush are also direct-hardening alloy

HAINS
CHAINS
steels through-hardened. The chain pin is addi-
tionally subject to secondary surface induction
hardening to provide it with both a high core
strength and a surface armour plating for wear-

INS
resistance. Square-edged wing and link plate
combined with ‘plough’ style dredging edges
ensure increased efficiency for conveying and
transportation of a deep bed of material.
The key to the Crusader range’s exceptional
wear performance is a matrix of hard facing on

EMENT
all wearing surfaces. Typical hardness values of
60Hrc are realised and with heavy weld bead
gives the chain excellent sliding wear resistance
in both hot and cold clinker applications.

globalcementMAGAZINE January 2013 19


CHAINS
FB Chain
Buying chain on price can
lead to costly downtime
C onveyors are one of the most widely used pieces
of equipment in cement processing plants. But
when something goes wrong and a conveyor system
unexpectedly stops operating, substantial costs are
often incurred which directly impact on the user’s
bottom line. And, while an effective conveyor main-
tenance plan will go some way towards preventing
failure and helping to keep breakdowns to a minimum,
unplanned and costly conveyor downtime remains an
issue that plant engineers have to contend with on a
regular basis.
One of the most common causes of conveyor fail-
ure is chain malfunction. “Chains, bearings, and other
moving parts are exposed to high levels of friction
which causes wear and tear and leads to problems,”
says Peter Church, managing director of FB Chain Ltd.
Choosing a chain that offers high levels of reli-
ability is, therefore,
essential. But, Peter
Church believes,
too many engineers
base their chain
selection choices on
price alone.
20 globalcementMAGAZINE January 2013
Contents Subscribe Ad Index
“These days more and more purchase decisions
are made purely on short term financial considera-
tions. Buyers seem less interested in product integrity
– which, for a highly stressed item such as chain, is
perhaps surprising,” he says.
“In many ways,” he continues, “Buyers have be-
come more professional and companies now employ
sophisticated purchasing techniques. But unfortu-
nately there are lots of businesses out there that still
believe that, when it comes to chain, there is little to
choose between the products that are currently on the
market. Nothing could be further from the truth”.
Church continues, “While it is hard to tell one
make of chain apart from another by simply look-
ing at it, the material, the quality of press tooling,
heat treatment processes as well as ancillaries such as
corrosion resistant coatings and lubrication will all
influence a chain’s product quality and performance.
The money that an engineer may save his or her com-
pany by selecting cheaper, inferior quality chain, is
insignificant when compared to the cost of the disrup-
tion to the plant and the lost production time that a
prematurely-worn conveyor chain causes.”
210x297_GlobalGypsum_C2.indd 1 09.10.12 13:55
 Contents Subscribe Ad Index
FILTRATION
BWF Envirotec

BWF Envirotec: Expanding with the

PM-Tec membrane product line

Airborne fine dust is detrimental to human health to a considerable extent and is particularly
high in conurbations and industrial zones. Primary fine dusts particularly occur during industrial
combustion processes such as at cement works, waste incineration plants, power plants and
the metalworking industry. By using effective filter media to combat all types of dust, industrial
filtration makes a valuable contribution to keeping the air clean.

F or more than 40 years BWF Envirotec has produced

innovative filter media for industrial filtration ap-
plications. The company is now extending the product
portfolio with the new PM-Tec product line and is of-
fering new filter media specifically used in filtration of
minute dust particles.
The name for the new product line originates in
the term ‘particulate matter,’ which was coined at the
end of the 1980s by the US Environmental Protection
Agency (EPA) when it introduced the so-called PM
standard, a classification for the measurement of fine
dust. This fine dust categorisation is now used interna-
tionally for classification of fine dust.
Continuous process chain for highest quality
The new PM-Tec product line represents the highest
demands on a filter medium for industrial filtration.
BWF Envirotec combines first-rate carrier media
consisting of needlona® needle felt or fibreglass fabric
with a high-efficiency ePTFE membrane and decades
of experience in filter medium production in the new
product line.
The continuous in-house process chain, start-
ing with the manufacture of needlona filter media,
including the laminating process to finishing of com-
plete filter bags, guarantees the high quality standard
of PM-Tec.
PM-Tec: Filter medium with an ePTFE
membrane for extremely low emissions
The product line consists of a carrier medium on
which an ePTFE membrane is laminated. The mem-
brane, which is produced from polytetrafluorethylene,
possesses characteristics that are optimally suited for
use in industrial fine dust filtration.
Dust on the raw gas side that impinges on the
filter medium is already retained on the surface and
cannot penetrate into the carrier medium. Owing to
the smooth and anti-adhesive surface, the particles do
not embed themselves in the carrier medium but ac-
cumulate on the surface of the filter medium instead.
They are subsequently almost completely cleaned away
during the dedusting process in the filtration system.
BWF Envirotec gives utmost priority to the latest
state-of-the-art and ideal characteristics of the indi-
vidual components in the new PM-Tec product line.
The membrane structure is characterised by optimum
orientation and fineness of the fibrils, in addition to
a uniform pore size. A low surface tension, which
reduces the adhesion of fine dusts in addition to a tem-
perature resistance of up to 288°C, ensures optimum
filtration properties.
During the production process BWF Enviro-
tec has perfected the manufacture of filter media.
Consequently, in-line quality controls and constant
air permeability monitoring are performed during
the laminating process. The membrane-compatible
presentation of the filter media during the entire pro-
duction process ensures maximum quality. The most
demanding emission requirements can be fulfilled by
appropriate sewing and sealing technology during the
manufacturing process.

22 globalcementMAGAZINE January 2013


Extremely low and stable differential pressure
behaviour, constant gas volumetric flow, long service
lives, low maintenance expenditure and utmost reli-
ability further characterise the PM-Tec product line
from BWF Envirotec.
needlona® needle felt or fibreglass fabric as
the carrier medium
The new PM-Tec product line for fine dust filtration is
available with two different carrier media.
1. Fibreglass fabric offers high temperature resistance
and is therefore encountered as a carrier for the ePTFE
membrane in many industrial applications.
The pre-requisite for many years of successful use is
a moderate gas composition and low mechanical stress
of the fibreglass fabric during operation in addition to
a specifically-adapted pretreatment of the fabric dur-
ing manufacture.
2. Under aggressive conditions of use, a carrier me-
dium made of a customised needlona® needle felt can
be selected. This withstands the chemical and mechan-
ical demands for a longer period than the fibreglass
and therefore achieves longer service life.
BWF Envirotec supplies the new product line as
material from the roll for manufacturers of filter bags
FBChain_CC_131pxx185px.pdf 1 01/08/2012 16:08
Find out more by visiting
MY
K
FB www.conveyorchain.co.uk
Manufacturer of
quality Conveyor Chains
FILTRATION
and as made-up filter bags for manufacturers or opera-
tors of industrial dedusting plants.
All-round customer care
PM-Tec finds applications in all industrial dedusting
plants where very fine dust occurs in the production
or manufacturing process. For instance, in the cement
industry, waste utilisation plants, power plants, in
the chemical and pharmaceutical industry and in the
metal or plastics processing industry.
Which filter medium is used for which dedusting
process is specifically determined at BWF Envirotec
for each customer order. Taking into account the op-
eration-specific characteristics of the filtration system
and with emphasis on the most economical solution,
BWF Envirotec recommends the right filter medium
for each specific application from the wide array of
products in the PM-Tec product line.
The PM-Tec filter medium, whether made of
fibreglass fabric or needlona® needle felt such as
polyphenylene sulphide, polytetrafluorethylene or
polyester, therefore guarantees extremely low emission
in the filtration system. The company’s comprehensive
service portfolio ensures that PM-Tec filter media are
always in perfect condition at all times, which is why
complete installation of PM-Tec filter bags, preventive
inspection and maintenance and filter bag inspection
form part of its scope of service.
 Contents Subscribe Ad Index
FANS
Global Cement staff

Fan focus at Venti Oelde

In December 2012 Global Cement Magazine visited Venti Oelde’s fan production facility in Oelde,
Germany. Established in 1930, the company is a leader in the manufacture and installation of
industrial fans and related equipment. Here we present a look at its current projects and some of
the equipment making its way to Venti’s customers in the global cement industry.

E stablished in 1930 in Oelde, Germany, Venti Oelde

Above: A detailed view of a
Venti-Oelde impeller.
Below: Rotor unit for
bag filter fan, type DHRV
72P-2800/K, destined for an
African cement plant.
Flow volume:
1,633,800Am3/hr
Fan speed: 744rpm
Output on shaft: 3911kW
plants and components are today used for collect-
ing, handling and filtering of air, vapours, gases, dust
and airborne solids across a number of major indus-
tries including the global cement industry.
Apart from industrial fans, its manufacturing
programme includes dust collection and process gas
cleaning plants, exhaust air treatment plants, venti-
lating, heating and air-conditioning plants, recycling
and waste treatment plants as well as plants for
surface technology. Maintenance, servicing, inspec-
tion, repairs as well as plant upgrading, rationalisation
and enlargement complete the available services.
In December 2012, Global Cement Magazine vis-
ited the company at its Oelde headquarters and saw
a number of projects ready to be shipped to cement
customers around the world.
Of particular note was a rotor unit for a bag filter
fan (Type DHRV 72P-2800/K), destined for an African
cement plant and shown below. In many applications,
for example conveying of clean-gas side process air,
fans like this one, which has profiled impeller blades,
are recommended. Their design is comparable with
the wing of an aeroplane and the advantages are clear:
Better flow guidance, higher efficiency and therefore
lower energy consumption.
A further benefit is the reduction in noise levels
by up to 10dB in the optimum of the characteristic
zone. Cost intensive noise protection measures are
often no longer necessary. Such fans represent a very
specialist request.

24 globalcementMAGAZINE January 2013

 FANS

Left: Special transport of

ready-welded impellers
for a raw meal fan and a
filter fan dispatched for
low-stress tempering.

Above: Boring of flange connection of fan impeller.

Below: A fan being dispatched during Global Cement’s visit, destination Brazil!

Above: A high-efficiency centrifugal fan

HRV 28-400 K for a burner. Peter Herrmann,
manager of Venti-Oelde’s fan division and Inge
Teich, head of marketing, pose for the camera.

Technical data
Flow volume: 16,659m³/hr
Static pressure difference: 251.81mbar
Total weight: 2220 kg

globalcementMAGAZINE January 2013 25


VIEWPOINT
Koen Coppenholle Chief Executive of Cembureau, the European Cement Association
The View from Brussels
O n 5 December 2012, the European Commission pre-
sented new proposals in the area of state aid, amongst
which was a proposal to exempt aid for innovation from
the obligation of prior notification. So far, such exemption
has only applied to research and development aid.
With its proposal, the commission aims to facilitate aid
mechanisms that contribute to growth, employment and
competitiveness in Europe. It fits within the commission’s
overall goal to integrate competition policy with policies
in other areas such as competitiveness, research, the envi-
ronment, cohesion and thus create a true industrial policy
for Europe. The commission also emphasises that the pro-
posal should improve the efficiency of public spending by
ensuring that aid is proportionate, targeted and does not
give rise to unjustified relocation of economic activities
between member states.
The commission’s announcement ties in well with
the topics discussed at a meeting of the Competitiveness
Council in Brussels on 10-11 December 2012, where
ministers have agreed on an update of industrial policy
and its contribution to growth and economic recovery.
In their conclusions, ministers reiterated the major
contribution that EU manufacturing industries can make
to recover from the economic crisis and emphasise four
pillars which, in their view, need urgent attention: (i)
stimulate investment in innovative and new technologies;
(ii) allow EU companies to derive maximum benefit from
the internal market and international markets; (iii) im-
prove access to finance and; (iv) increase investment in
people and skills.
In a background note to the Competitiveness Council
meeting, the Cyprus Presidency recognises that European
industry faces weak demand and high costs whilst being
under pressure to innovate and maintain its competitive
edge. It puts two questions to the member states, both
aiming at soliciting views on how state aid should be
26 globalcementMAGAZINE January 2013
Contents Subscribe Ad Index
designed to support growth, competitiveness and employ-
ment in a global context.
It is clear that growth in Europe will come from an
integrated combination of policy measures. The Com-
petitiveness Council Conclusions underline the need to
translate research into industrial advantage to cover the
entire value chain and to include traditional industrial
sectors into the Horizon 2020 programmes.
In addition, appropriate attention needs to be given to
combined public-private funding instruments that allow
industry to expand innovation based on well-tested tech-
nologies while allowing for an economically justified rate
of return. To that effect, it is important to involve financing
companies, alongside industrial players, within the debate
on the role of state aid for growth and competitiveness, as
they will be able to develop innovative financing schemes
that will allow public funding to remain proportionate and
focused on its key role of eliminating market failures.
It is further of utmost importance that the administra-
tion and enforcement of state aid rules allows potential
beneficiaries, along with private financing partners, to
obtain predictability on how public funding fits into the
investment plan. The exemption from notification for
research, development and investment funding, which
remains within clearly set limits, is certainly a step in the
right direction.
Lastly, it is encouraging to note that the discussion also
focuses on how state aid rules can contribute to employ-
ment. State aid guidelines on increasing employment
skills are already in place but a more thorough reflection is
needed on how industry and policymakers can join forces
to increase the attractiveness of some professions that suf-
fer from a chronic shortage of young talent, such as the
engineering profession, a talent which is essential in order
to maintain a strong industrial base in Europe.
VABH_adv_A4_2011_01.indd 1 20-9-2011 10:19:55
NEWSEUROPE
Lafarge Tarmac JV appoints key staff
UK: Lafarge and Anglo American have announced the comple-
tion of a 50:50 venture which combines their cement, aggregates,
ready-mix concrete, asphalt and asphalt surfacing, maintenance
services and waste service businesses in the UK. The joint ven-
ture will be known as Lafarge Tarmac and began trading on 7
January 2013. The Lafarge Tarmac combination is expected to
generate savings of Euro74m through improved operational,
logistical and purchasing efficiencies and the introduction of
value-added products across a wider geographic area.
Completion of the Lafarge Tarmac joint venture follows final
clearance from the UK Competition Commission, based on the
completed sale of a portfolio of Tarmac and Lafarge construction
materials operations in the UK, which also occurred on 7 Janu-
ary 2013. The agreed sale of Tarmac’s 50% ownership interest in
Midland Quarry Products is subject to a right of pre-emption in
favour of Hanson Quarry Products Europe Limited. As a result of
this the completion of this transaction is pending.
“We have successfully united two high quality and comple-
mentary UK businesses to create the leading UK construction
materials company with high quality assets, two experienced
management teams and a portfolio of well-recognised, in-
novative brands,” said Cynthia Carroll, Chief Executive of Anglo
American.
“The closing of this transaction and the creation of a new Brit-
ish construction materials champion reinforce Lafarge’s ongoing
commitment to the UK market and its efforts to continuously
improve its offering to customers, as well as playing a full role in
developing the infrastructure needed for a growing economy,”
said Bruno Lafont, Chairman & Chief Executive of Lafarge.
In November 2012 Lafarge and Anglo American appointed
the chairman, chief executive office (CEO) and CFO of their joint-
venture in the UK. Jamie Pike was appointed as non-executive
Chairman, Cyrille Ragoucy as CEO and Guy Young as CFO of the
joint-venture.
Holcim to slash European management
Switzerland: As part of its on-going ‘Leadership Journey’ Swiss mul-
tinational cement producer Holcim has announced that it will be
reducing its management structure in Europe to cope with lower lev-
els of construction activity in the region. The group says that proposed
measures and existing ones will lead to annual cost savings of at least
Euro99m, a better capacity utilisation rate and a more efficient alloca-
tion of capital expenditure.
The additional cash costs for restructuring in the fourth quarter
of 2012 will amount to approximately Euro83.8m including site res-
toration costs. Write-offs of property, plant and equipment will total
Euro339m and will be charged in the fourth quarter of 2012. Consul-
tation procedures with regards to impact on personnel have been
initiated in some group companies.
The restructuring accelerates the implementation of the Holcim
Leadership Journey. The major part of the anticipated cash costs of
Euro166m to realise the Holcim Leadership Journey will be incurred
in 2012. The group’s dividend payout potential for the 2012 financial
year (pre-write-offs) remains. The board of directors will propose the
level of the payout at the end of February 2013, as part of the year-end
financial statement to be submitted to the annual general meeting.
28 globalcementMAGAZINE January 2013
Contents Subscribe Ad Index
Jamie Pike, aged 57, is the non-executive chairman of Lupus
Capital, a leading international supplier of building products to
the door and window industry, RPC Group, a leading interna-
tional supplier of rigid plastic packaging and MBA Polymers, a
private US plastics recycling business. He was chief executive of
Foseco, an international business serving the foundry and steel-
making industries, until its acquisition by Cookson Group in
April 2008. He led the buy-out of Foseco from Burmah Castrol in
2001, which culminated in flotation on the main market in 2005.
His early career was as a consultant with Bain and Co and
A T Kearney before joining Burmah Castrol in 1991. He rose to
chief executive of Burmah Castrol Chemicals before leading the
Foseco buy-out. Pike was educated at the University of Oxford,
holds an MBA from INSEAD and is a member of the Institute of
Mechanical Engineers.
Cyrille Ragoucy, aged 56, is currently senior vice president
for Health and Safety at Lafarge. From 2005 to 2009 he was
CEO and regional president for Lafarge’s cement operations in
China (Lafarge Shui On Cement) where he was responsible for
25 plants and 10,000 people. Between 1999 and 2005 he was
regional president for Aggregates, Concrete, Asphalt and Pav-
ing for Lafarge in Eastern Canada. Ragoucy joined the Lafarge
group in 1998 as vice president Cement Strategy for Lafarge
North America.
Guy Young, aged 43, has been CFO of Tarmac since 2010 with
responsibility for Tarmac’s financial, IT and legal operations as
well as the pre-integration planning for the joint venture. Guy
has been with Anglo American for 15 years in a variety of roles,
including CFO of Scaw Metals, Group Procurement and within
the CEO’s Office. Guy was educated at the University of Cape
Town and qualified as a chartered accountant after undertaking
articles at Deloitte.
Joint venture for Lagan and Quinn
Ireland: Quinn Building Products and Lagan Cement
Group have signed a memorandum of understand-
ing that could lead to a joint venture (JV) between the
two groups.
The businesses that will become part of the proposed
JV are the combined cement and building products busi-
nesses based in Ballyconnell, Derrylin, Kinnegad, Belfast,
Cork and Benelux. Quinn Therm, Quinn Litepac, Quinn
Tarmac and Lagan Sand are not included in this proposal.
Commenting on the proposed JV the CEO of Quinn
Manufacturing Group Paul O’Brien and the CEO of Lagan
Cement Group Jude Lagan said, “By combining two stable
Irish businesses the proposed JV will create a sustainable
independent cement manufacturer that can continue to
support its customers on a competitive basis.”
The joint venture discussions are likely to take up to
three months to complete and will involve the develop-
ment of a business plan to combine the Quinn/Lagan
cement and building products operations.
“While it is the intention of both parties to conclude a
JV agreement, no certainty can be assumed prior to the
completion of these discussions and the relevant Com-
petition Authority approvals,” said a joint statement.
 NEWSEUROPE
Quinn opts for SRF at Ballyconnell
Ireland: Quinn Manufacturing has announced a Euro15m
investment to upgrade its Ballyconnell cement plant, which,
when completed, will facilitate the use of alternative fuels.
The plant will be adapted to use solid recovered fuel (SRF), a
move that will help to bring Quinn Cement’s cost of production
more into line with its Irish and other European competitors.

Minister visits Lafarge following upgrade

UK: A Lafarge cement plant in Cookstown, County Tyrone,
Northern Ireland has invested Euro6m in new equipment and
an apprenticeship scheme.
Northern Ireland Enterprise Minister Arlene Foster visited the
plant, where she met employees and saw a refurbished electro-
static precipitator that will reduce overall dust emissions. She
was also told about the Cement Kiln Dust (CKD) project, which
has reduced some 8000t/yr of landfilled waste to almost zero.
Further plans for the Cookstown Works were also showcased,
including a future upgrade of a central control room and the
apprenticeship scheme, which saw two new apprentices join
the works team in 2012. A further two apprentices will join the
team in 2013.
The minister said that Lafarge’s investment demonstrates its
confidence in its workforce. “This is a difficult time for the con-
struction industry and it is therefore particularly pleasing to see
that the company is investing in its future by upgrading its cur-
rent facilities and creating opportunities for apprenticeships,”
said Foster.
The investment in the Cookstown Works comes at a time
when Lafarge is merging its UK building materials business in-
terests with those of Tarmac Buxton. This has necessitated the
sale of the French giant’s Hope Works in Derbyshire, England.

New CEO for FLSmidth

Denmark: Danish cement plant manufacturer FLSmidth has
announced that Jørgen Huno Rasmussen, aged 60, group chief
executive officer (CEO) of FLSmidth since 2003 has decided to
retire in the middle of 2013 after 10 years of service. Thomas
Schulz will be appointed new group CEO and is expected to
take up his new position no later than 1 June 2013.
Schulz, aged 47, is a German citizen and has been part of
Sandvik (Svedala Industries) since 1998, currently as President of
Sandvik’s Construction business area and member of Sandvik’s
Executive Management Group, based in Sweden. From 2005 to
2011 Schulz was based in Germany, Sweden and Singapore as
president of Construction and senior vice president of Mining
and Construction. Schulz holds an MSc and PhD in Engineering
from the Technical University of Aachen, Germany with a dis-
sertation in mineral mining and quarrying.
“On behalf of the board, I wish to express my sincere grati-
tude to Jørgen Huno Rasmussen for his decisive contribution
to the successful turnaround and development of the FLSmidth
Group and for his dedicated leadership over 10 years. I am sure
Thomas Schulz will prove to be a worthy successor and look
forward to welcoming him to FLSmidth,” commented chairman
of the board of FLSmidth, Vagn Ove Sørensen.

globalcementMAGAZINE January 2013 29

 H H H CF D D :8  5 6
NEWSEUROPE
GIK
Eurocement (INTERNATIONAL)
expects 8-10% growth in 2013 TRADE
FLSmidth getsLIMITED
Kaluga contract expansion
LARKRISE, 5 MANOR WALK, WEYBRIDGE, SURREY KT13 8SD, ENGLAND.
Russia: Eurocement Group expects cement product consump-
TELEPHONE: +44-1932-856243 / 820026
Russia: The Danish cement plant manufacturer FLSmidth
tion to haveFAXgrown by +44-1932-856244
NO.: 12% in Russia in 2012 and to grow by has won a contract worth approximately Euro27m from the
8-10% in 2013, accordingPHONE:
EVENING to its president Mikhail Skorokhod.
+44-1932-843099 Russian company Kaluga Cement Plant LLC to supply additional
“We expect cement
E-Mail: product consumption to reach 64Mt
GIK@BTINTERNET.COM equipment for its cement plant currently under construction in
MOBILE:
in 2012, compared +44-in
to 56Mt 7768 -361540
2011. There will be growth of VAT No.ofGB
the Kaluga province, 300km southwest 409 8508
Moscow. 32
The contract
over 12%. ThisWWW.GIKINTERNATIONAL.CO.UK
is very significant growth and all construction is an extension of the contract that FLSmidth won in 2011 from
complex needs in Russia are covered by high quality cement Kaluga for the supply of a complete cement plant.
WEfrom
ARE A MAJOR
Russian SUPPLIER
manufacturers, OF SPARES
” he said. AND EQUIPMENT
Cement production is TO THE
“The awardCEMENT INDUSTRY.
of this order to FLSmidth underlines the strength
HERE WE LIST SOME OF THE ITEMS WE ARE ABLE
forecast to soon rise to 70Mt, the highest output in the post- TO SUPPLY:
of our good relations with the customer and the value of our
Soviet period, according to Skorokhod. long-standing local presence in Russia,” said Group CEO Jørgen
ABB DRILLING EQUIPMENT LUHR FILTER
AERZEN MACHINES
Skorokhod DUNLOP/BTR
estimated that the rise in cement prices over BELTING
Huno Rasmussen. “The order isLURGI also a good example of the gen-
ALFA LAVAL
the ‘past few years’ was comparable to theELE rise in the cost of MILLTRONICS
eral signs of a positive development in the cement market.”
ALLDOS
natural monopoly services and tariffs, from ELECTRICAL
7% to 15% per ITEMS PIV
ANTON
year. HePILLER
predicted that the price of cementENDRESS
would also fallAND
by HAUSER POLLRICH
ARL ERWIN SICK Spanish consumption ALL TYPESto
continues OF PUMPS
plummet
ATLAS COPCO
this range as new capacity comes on line. ALL TYPES OF FILTERS REMA TIP TOP
AUMA FISONS Spain: Cement consumption inROTEX Spain closed 2012 with a drop
AUMUND CHAINS HARTMANN AND BRAUN of 33% year-on-year, the fifthSAACKEdouble-digit decline in a row,
AVELING
Italcementi BARFORDto shed 26% of Italian HAUSHAN
staff SCHENCK
according to data from the country’s association of cement
BEUMER HAUSHERR DRILLING SCHEUCH
BAUER
Italy: The Italian cement maker Italcementi HAZEMAG
has prepared a producers Oficemen. SEW
BBCplan to reorganise its activities in Italy, toHEKObe implemented SIEMENS
Oficemen expects that the demand will also shrink by 20% in
BEARINGS
in 2013 and 2014. It envisages layoff schemes HERION for up to 665 2013, until it reaches the levelsSOLYVENT
similar to thoseVENTEC
in Morocco and
BOGE HIBON STAHL
CATERPILLAR
employees.
HPI TEREX
Ecuador. Spanish cement consumption was at a 48-year low
CLARKE VME
At present the company employs 2500 staff, HYDAC of whom two- after the first half of 2012. UNTERTAGE
COMPRESSOR
thirds are employed SPARES INGERSOLL
at its production sites. The remainderRAND Meanwhile, the Spanish cement VAGand ARMATUREN
building materials pro-
CONVEYOR BELTING
work at the company’s headquarters in Bergamo. KSB VENTOMATIC
ducer Sociedad de Cementos y Materiales de Construccion de
ALLThe TYPES OF CRUSHERS LINCOLN HELIONAndalucia, controlled by Portuguese
plan, dubbed ‘Project 2015,’ aims to rationalise the in-
VOITH cement group Cimpor, is
DE LIMON FUHME LOUISE VOLVO
dustrial and distribution structure of the group and reorganise negotiating the lay-off of 35 staff with its employees and trade
AND MANY
the central MORE..
structures .WE SUPPLY
and commercial ALL TYPES
network. The planOF EQUIPMENT
aims FROM
unions. The THE FACTORY
proposed TO HEAVY
move will affect 25 staffEQUIPMENT.
at its plant in
IFtoYOU HAVE ANY ENQUIRIES
reduce costs by around Euro40m/yr. FOR ABOVE ITEMS PLEASE CONTACT US ANYTIME, WE WILL
Cordoba and 10 employees at a factory in Niebla. BE HAPPY TO QUOTE.

Visiting cement equipment

Visiting cement equipmentsuppliers
suppliersininthe
theBeckum
Beckum area?
area? Seeking
Seeking comfortable
comfortable accommodation?
accomodation?

Hotel-Restaurant
Hotel Alt ALT Vellern
VELLERN
Hotel-Restaurant AltVellern
Hotel-Restaurant Alt Vellern
Dorfstrasse 21
Dorfstraße 21
D-59269
D-59269 Beckum
Beckum

Tel +49(0)2521
Tel +49 (0) 25218717-0
8717-0
Fax +49 (0)2521
Fax +49 (0) 25218717-58
8717-58

http://www.alt-vellern.de/
http://www.alt-vellern.de/
If you are visiting Germany’s cement engineering centre in the Beckum-
If you are visiting Germany’s cement engineering centre in the Beckum-
Oelde-Ennigerloh area, the Alt Vellern offers stylish, modern and comfortable
Oelde-Ennigerloh area, the Alt Vellern offers stylish, modern and comfortable
accommodation at most reasonable rates. Each room in the hotel’s extension
accommodation at most reasonable rates. Each room in the hotel’s extension
has
hasaashower
showerand andWC, telephone and
WC, telephone andsatellite
satelliteTV.
TV.
TheTheHotel-Restaurant
Hotel-RestaurantAltAltVellern
Vellernis is
located
locatedjustjust
a a
few
few minutes
minutesaway
awayfrom
fromthe
themajor
majorequipment
equipmentsuppliers
suppli-
for
ersyour cement
for your plant,plant,
cement yet is yet
located in peaceful
is located and
in peaceful
pleasant surroundings. Enjoy our quality cuisine
and pleasant surroundings. Enjoy our quality cuisine in our
traditional and delightfully
in our traditional cosy Münsterland
and delightfully restaurant,
cosy Münsterland
built in 1686.
restaurant, Foringuests
built 1686. arriving
For guestsby arriving
car, we offer
by car,ample
we
parking
offer amplefacilities.
parking facilities.
Helmut
HelmutStichling
Stichlingandandfamily
familylook
lookforward
forward to to
your
your
visit in the near future.
visit in the near future.

Buzzi purchases more of Dyckerhoff
Italy/Germany: German cement maker Dyckerhoff has
announced that its parent company, Italy’s Buzzi Unicem,
has agreed to buy additional ordinary and preferred
shares in it, raising its total share capital in the firm by
3.6% to 96.6%.
The German company did not reveal the value of the
transaction but specified that during the current fiscal
year and including the most recent agreement Buzzi
Unicem had bought shares in it for some Euro71.7m.
As a shareholder of at least 95% of Dyckerhoff, Buzzi
Unicem is entitled, under German law, to start a ‘squeeze-
out’ procedure for the remaining shares that it does not
already own. However, it has not yet made any final deci-
sion on such a move, according to Dyckerhoff.
New line proposed at Volskcement
Russia: Volskcement, a Russian asset of Switzerland’s Hol-
cim, is set to invest US$488m at the Volskcement plant
in Saratov Region to build a new cement production line.
Contract extension for Loesche
Turkey: Askale Çimento Sanayii T.A.S. is currently erecting
a new 4000t/day clinker production line in Gümüshane,
Turkey, for which it has decided in favour of two Loesche
vertical roller mills.
On 18 September 2012, Loesche secured an additional
contract for the supply of a Loesche LM 56.3+3 type mill to
grind cement with production rates of up to 230t/hr and
finenesses of up to 4600cm2/g (Blaine).
New Brazilian directors for Cimpor
Portugal: Cimpor has appointed Luiz Roberto Ortiz Nasci-
mento and André Pires Oliveira Dias as directors. The move
follows the resignations of Erik Madsen and Walter Schalka.
Ortiz Nascimento, 62, is from Brazil and holds a degree
in economics from Mackenzie University in São Paulo. He
became the CEO of construction and trade at Camargo Cor-
rêa, the owner of Cimpor, in 1992. Oliveira Dias, aged 31 and
also from Brazil, holds a degree in Business Administration
and International Business from the American Interconti-
nental University in London. He has worked at Camargo
Corrêa since joining its trainee programme in 2005.
Anzeige_ruhrwissen_net_Global_Cement_01_2012.pdf 1 14.12.2011 23:38:24
IT ruhrwissen.net
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NEWSEUROPE
Concretus looking at Akmene stake
Lithuania: Concretus Materials is planning to buy up to 51% of
shares in the cement manufacturer Akmene Cement. According to
the regulator Concretus Materials applied to the Lithuanian Compe-
tition Council on 27 December 2012 for approval of the deal.
The Mexican cement giant Cemex owns a 33.95% stake in
Akmenes Cementas. Other shareholders included Simonas Vytis
Anuzis with 13.67%, Olius Danyla with 13.55%, Arnoldas Mituzas
with 12.76% and Edmundas Montvila with 9.8%.
Akmenes Cementas is currently implementing a modernisation
project, worth Euro101m, moving to a dry production process. The
company expects to complete its new production line in mid-2013.
The producer’s annual revenue rose year-on-year by 37% in
2011 to Euro63.1m as cement sales increased by 19% to nearly
984,000t/yr. In 2011 Lithuania remained its biggest market, account-
ing for 55% of the total sales. Akmenes Cementas’ cement plant is
located in Naujoji Akmene, in north-western Lithuania.
Serbian unit shows off investment
Serbia: The Serbian unit of Swiss cement producer Holcim said
that it has invested more than Euro10m in environmental protec-
tion projects in the country in the past 10 years. The company has
put over Euro100m into its Serbian operations since 2002, Holcim
said in a statement published following a tour of environmental
protection officials around its cement factory in Novi Popovac.
Holcim showed off the plant’s environmental management
system and its use of waste fuel from Ecorec, another Holcim
subsidiary, to representatives of the association of Serbian
municipalities.
Moldavian contract for Fives FCB
Moldavia: On 14 November 2012 Fives FCB signed an order with
Imsat Ceprocim Engineering company, a member of SNEF group,
for the supply of a TSV™ 3000 HF type dynamic classifier and a
water injection system to equip an existing ball mill of the Rezina
cement plant in Moldavia (Lafarge group).
The three ball mills installed in Rezina cement plant are cur-
rently operating in open circuit. The equipment supplied by Fives
FCB will allow the plant to increase the quality of the cement
produced and allow it to expand into other, higher-quality types
of cement, while allowing substantial electrical energy savings
thanks to the conversion in close circuit of one of the ball mills.
ruhrwissen.net
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D-44720 Bochum www.ruhrwissen.net
"If we can‘t do it, you don‘t need it"
 NEWSEUROPE
Italcementi investing in Devnya
Bulgaria: Italian cement group Italcimenti will install a new
4000t/day cement production line at its Bulgarian subsidiary
Devnya Cement. The company is investing Euro160m and the
completion date is scheduled to be 2015.
Eurocement to invest in Sverdlovsk
Russia: Eurocement Group plans to invest around US$388m
towards building a 1.3Mt/yr plant in the Sverdlovsk Region,
according to the region’s government. The project at the
Nevyansky Tsementnik plant is expected to be finished by
2015. According to Eurocement, the plant will create around
1000 jobs for the construction and around 400 jobs for the
operation of the line. Eurocement will invest its own and bor-
rowed funds into the construction.
New mercury gas analyser from SICK
UK: In anticipation of tighter regulations for mercury emis-
sions, SICK has developed the new MERCEM300Z mercury
measuring system, a high-accuracy continuous-flow gas ana-
lyser for emissions down to the 0–45µg/m3 range from a wide
range of combustion sources.
According to SICK, the patented gas spectrum of the
MERCEM300Z rapid monitoring system offers superior per-
formance with better long term, drift-free accuracy and lower
running costs. The system requires minimal maintenance, is
self adjusting and uses no chemical consumables.
“Awareness of the pollution caused by mercury and its
compounds in combustion emissions is increasing in the
UK and Europe,” explained John Exford, Process Automa-
tion Division Manager, SICK (UK). “From power generation,
cement kilns and hospital waste to crematoria, the need
to tighten up on mercury will be very important in 2013,
when the EU will be following the United Nations’ lead in a
world-wide treaty.”
7th International VDZ Congress 2013
Process Technology of Cement Manufacturing
Please note the above mentioned dates in your calendar. We are looking forward seeing
you in Duesseldorf in 2013!
Organiser:
VDZ
P.O. Box 30 10 63 Tannenstrasse 2
40410 Duesseldorf, Germany 40476 Duesseldorf, Germany
Alternative fuel use hits 40% in UK cement
UK: The UK Mineral Products Association (MPA), which looks
after the interests of the cement industry, among others, in
the UK and two of its constituent bodies, the British Lime As-
sociation (BLA) and the British Marine Aggregate Producers
Association (BMAPA), have published their latest Sustainable
Development (SD) Reports. The MPA’s SD reports aim to fur-
ther improve the quality and reporting of sustainability data
to achieve more transparency and better communication of
sustainability.
With reference to cement, the report highlights that 40% of
fuel used for cement manufacture comes from waste-derived
sources. It also reports further improvements in industry
health and safety, new policies and initiatives to improve the
safety of vulnerable road users, continuing reductions in in-
dustry CO2 emissions and improving biodiversity and nature
conservation efforts.
Nigel Jackson, Chief Executive at the MPA, said, “Against the
continuing difficult economic backdrop, which sees the indus-
try now operating at the same market levels as in the mid 1960s,
these reports demonstrate the industry’s continuing commit-
ment to sustainable development, illustrate the progress we
have made and set out the challenges we still face. Our aim is to
rise to these challenges and deliver sustainable development.”
B&W Mechanical Handling is ‘SAMSON’
UK: B&W Mechanical Handling Ltd, a UK company and part
of the German Aumund Group, became SAMSON Materials
Handling Ltd on 1 January 2013.
The company said that the progression is a reflection of the
success that its SAMSON equipment has enjoyed worldwide.
The SAMSON range has played an important role in its bulk
materials handling projects in industries such as mining and
minerals, cement, environmental, ports and terminals, biomass,
steel, power and agriculture. SAMSON will launch a new range
of engineered products during 2013.
Save th
e date!
25 - 27 September 2013, Duesseldorf, Germany
Contact:
Sybille Matthäi-Yaptinchay
Tel.: +49 (0) 211 45 78 - 342 info@vdz-congress.org
Fax: +49 (0) 211 45 78 - 296 www.vdz-congress.org
 Contents Subscribe Ad Index
SHIPPING
Global Cement staff / Van Aalst Bulk Handling B.V.

Southern Cement unveils new ship unloader

Ipswich, UK-based Southern Cement has recently invested in
a new ship unloader from Netherlands-based Van Aalst Bulk
Handling to streamline its cement product supply chain into the
UK. The new unloader removes dependence on a sub-contractor
and will help the company develop its market.

S outhern Cement, which is based at the Port of

Ipswich and was established 10 years ago, imports
around 0.16Mt/yr of bulk and bagged cement products
rial is de-dusted inside one of the two transfer vessels.
The cleaned air is released into the atmosphere, while
the material drops down into the transfer vessel.
to building firms across the UK. The business, part of Once a transfer vessel has been filled in this way, its
the Spanish-based Cementos Portland Valderrivas contents are conveyed to the storage by means of com-
(CPV) group of companies, imports its products into pressed air. During emptying transfer vessel No. 1, the
the UK via ship at Ipswich. second transfer vessel is filled. All of the unit’s equip-
Southern Cement now uses a mobile ship unloader, ment is sized for a designed unloading capacity of
a Van Aalst VASS/5.000/225/D, to transfer cement 225t/hr of grey cement.
from the ship’s storage compartments so that it can be All unloading equipment is fitted onto a mobile
transferred to silos at the port. trailer, which is suitable for travel over public roads as
This task was previously sub-contracted to another well as the dock area. Normal road trucks can be used
company but now Southern Cement has invested in its to pull the machine from point to point.
own mobile ship unloader, which enables it to carry
out transfers itself. This makes for a more rapid and Parameters
reliable process. Vessels can now be efficiently and The main approximate particulars of the ship unloader
promptly unloaded as they arrive at port. are as follows:
“As we bring in our products from abroad, it is vital
for the business that every aspect of the import process Length: 13.5 m
runs as efficiently as possible,” said Southern Cement’s Width: 3.0m
operations manager Dean Wessels. “Sub-contracting Height: 4.4m
the transfer of cement from ship to silo meant reliance Weight: 40t
on a third party, but purchasing our own equipment to Installed power: 550kW
do the work ourselves adds a new level of reliability to Power consumption: 440kW
our supply chain, which is naturally passed on to our
customers.”

Technical details
The pneumatic ship unloading equipment is of the
type VASS/5.000/225/D and is designed to discharge
cement from sea-going bulk carriers of 5000 dwt. The
unit is able to convey the unloaded cement pneumati-
cally to a storage facility, which is situated adjacent to
the docks, through a pipeline.
After the cement has been discharged from the
hold of a ship, the mixture of suction air and mate-

Above: Southern Cement employees stand in front of the new

Van Aalst mobile installation. From left to right:
Mike Marler (general manager), Terry Day (commercial manager),
Dean Wessels (operations manager).
Left: The mobile ship unloader in transit.

globalcementMAGAZINE January 2013 33

 NEWS THE AMERICAS
Contents Subscribe Ad Index

JV for Lafarge and Elementia in Mexico Molins sells South American stakes
Mexico: The French building materials giant Lafarge has an- Argentina/Uruguay: Spain’s Cementos Molins has sold
nounced a joint venture with new Mexican cement player 10.61% of its Argentina-based unit Cementos Avellaneda to
Elementia on 8 January 2012, only a day after announcing that Votorantim Europe for US$59.6m.
its UK jointMATERIAL
venture with FLOW Tarmac received PROBLEMS?competition commis- Following the deal Cementos Molins retains 51% in the
sion approval. The Thenew WTW jointGroup
venture can formed help!
will be held 47% by company and Votorantim Europe, part of Brazilian group
With
Lafarge and heldguaranteed
53% by Elementia, extractionwhich will andfully
flow consolidate Votorantim, holds 49%. The Spanish firm also transferred
the venture’s financial results. a 12.61% stake in its Uruguayan-based unit Cementos
Rotary Bin Discharger (BinE (BinEXX)
The dealOurwill mostseeversatile
Lafargeand contribute its two Mexican plants
flexible discharge Artigas to Votorantim Europe for Euro19m, keeping 49% in
at Vito andsystem
Tula, which
for use have
on FGD,a combined capacity of just under
wet, rock gypsum, the subsidiary and its partner raised its stake to 51%.
limestone, clay, iron ore, etc…
1Mt/yr. Elementia will contribute its cement
Available in diameters from 2 to 6 meters WTW Engineering
MATERIAL
plant project, a 1Mt/yr
for flow rates from FLOW
installation,
0.5 to 1,000 PROBLEMS?
which
t/h. is
Peru
Przemysłowe sales
Maszyny i Urządzenia
strong in first 11 months
Sp. z o.o.
The WTW Group
currently undergoing construction in the cen- can help! ul. Tarnogajska 18
50−512 Wrocław, Poland
With guaranteed extraction and flow
tre of Mexico. Peru:
Fax: +48 Cement
(0) 71 782 50production
Phone: +48 (0) 71 782 50 20
21 in Peru reached 8.98Mt in the first 11 months of 2012,
A Lafarge press release stated that the
Rotary Bin Discharger (PlanE
(PlanEX) X) aE−mail:
riseinfo@wtw−engineering.com.pl
of 16.7% compared to the same period in 2011, according to figures from
www.wtw−engineering.com.pl
The PlanEX has the sameRotary Bin Discharger
function as the (BinE
(BinEXX)
combinationin between
BinEX, but is availableOur most versatile
diameters
Lafarge
from and
and Elementia
6 toflexible discharge the national cement association Asocem. Production in October 2012 alone
12 meters.would ‘significantly’
system for use strengthen
on FGD, wet, its rock
position
gypsum, reached a record 926,623t.
in Mexico. limestone,
Available
clay, iron ore, etc…
The transaction,
in diameters
which involves no
from 2 to 6 meters
Cement shipments within the country reached 8.76Mt to the end of Novem-
Truck Unloading Station WTW Engineering
MHC Engineering
cash and isforsubject
flow rates
(TUS) to regulatory
from 0.5 to 1,000 approvals,
t/h. is ber
Maszyny2012, growing by 16.6% compared to the same period of 2011. Meanwhile,
i Urządzenia
Fördertechnik
Przemysłowe
GmbH
Sp.21z o.o.
v.−d.−Wettern−Str.
expected to close in the second half of 2013,
This custom designed machine allows cement
ul. Tarnogajska
D−51149
50−512
exports
Cologne,
Wrocław,
Phone: +49 (0) 2203
18 Germanyin the January-November 2012 period grew by 200% year-on-
Poland
36825 0
clients to receive bulk materials directly
pursuant to the into start
their up of theThere
process. new is plant.
no need for year
Phone:
Fax: to
+48
+49
Fax: +48
E−mail:
(0)173,198t.
(0) 71 36825
2203 782 5029
(0) 71 782 50 21
20
info@mhc−engineering.de
Rotary Bin Discharger (PlanE
(PlanEX) X)
expensive civil work, front end loaders, Cement producers active in the country are making the most of the current
E−mail: info@wtw−engineering.com.pl
www.mhc−engineering.de
www.wtw−engineering.com.pl
The PlanEX has the same function as
continuous the
manpower or other conveying
BinEX, but is available insystems.
diameters from 6 to
demand in the market. Cemento Andino and
12 meters. Cementos Lima agreed to merge in July 2012,
WTW Americas Inc.
Chain Conveyors (TKF) P.O. Box 1536 Stn Main giving rise to the largest player in the local mar-
Our design of heavy duty, TruckdustUnloading
and gas Station
tight, explosion− Peterborough,
MHC ON K9J 7H7
Engineering
MATERIAL
proof Chain ConveyorsMATERIAL
FLOW (TUS)
are the PROBLEMS? FLOW
most reliable and PROBLEMS?
Canada
Fördertechnik
Phone: +1 705 749
v.−d.−Wettern−Str.
GmbH
21 3544
ket, with an installed capacity of some 7.6Mt/yr of
durable system available This
The WTW Group inThe custom
any WTW designed
industry.
can Sticky,machine
Group
help! canallows
help! D−51149
Fax: +1 705
E−Mail:
740 1775
Cologne, Germany
info@wtwamericas.com
cement. At the same time, Mexican cement pro-
Phone: +49 (0) 2203 36825 0
clients
hot (up to 750° C), abrasive to receive
materials suchbulk
as materials directly
With guaranteed With guaranteed
extraction
into their process. and extraction
flow and flow
www.wtwamericas.com
Fax: +49 (0) 2203 36825 29 ducer Cemex is building a new US$230m, 1Mt/yr
synthetic gypsum, filter dust and clinker areThere is no need for E−mail: info@mhc−engineering.de
easily conveyed from 0 expensive
to 1,000 t/h, civil
onwork,
singlefront
or end loaders, www.mhc−engineering.de
Kochi preparations
production facility in Peru.in ‘full swing’
double
Rotary strandBin chains
Discharger from continuous
Rotary 0.25Binto
(BinE
(BinEX ) 2manpower
XDischarger
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loss in the January-September 2011 period.
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MHC Engineering China MHC Engineering China
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Truck Unloading Station
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AmericasGmbH
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Chain Conveyors
rations to meet anyrations (TKF) (TUS)
application.to meet The any arms application.
of
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Beijing 101100, P.R. China v.−d.−Wettern−Str.
Beijing 101100, P.R. China
the second by Knauf in Uzbekistan.
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Peterborough,
D−51149
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ON K9J
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8952 8443
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materials
+86 (0) 10 8952 8443
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+49 (0) 2203 8143 0 US$55.6m in the third quarter of 2012, com-
and can be supplied andwith canrails, be supplied
a festoonwith rails,E−Mail: a festoon
michael_kxl@126.com
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system, include an integrated
Knauf to invest in Macedonia
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E−Mail: info@wtwamericas.com
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weigh feeder.
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of 2011. For the January-September period its
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unlimited. filter dust and clinker are or other conveying
easily conveyed from 0 systems. to 1,000 t/h, on single or losses amounted
Macedonia: to US$45.7m,
Knauf Radika, compared to a
the Macedonian
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sameKG,
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is setofto2011.
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Sweeping
Auger (SAS) Auger (SAS) Ltd.
WTW Americas
254 Nadine StreetInc. arm of Germany’s Knauf in-
designed Chain
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silosis and
designed (TKF)
bunkers for silos and bunkers
254 Nadine Street
Robertville Industrial Park MHC
P.O. Box 1536
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with design of heavy Bunkerduty, dust
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Unit 17 ON K9J
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ers up to 25 diameters
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1709 Roodepoort
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in
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Johannesburg
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Phone: 309,
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info@wtwamericas.com Macedonian Economic Chamber. It said that
globalcement
hot (up dust,to 750° C),the abrasive materials Phone: +27
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10 691
89521250
E−mail: michael_kxl@126.com
info@wtw−sa.co.za
8143 34
the Debar-based company hasMAGAZINE January 2013
so far invested
and pellets
can be discharged through it.can be discharged through it. E−mail: info@wtw−sa.co.za E−Mail:
www.wtwamericas.com
easily conveyed from system,0 to VFD 1,000ort/h, can oninclude
single or anwww.wtwamericas.com
integrated www.mhc−engineering.cn
Euro30m in the upgrade and expansion of its
double strand chains weigh fromfeeder. 0.25 to 2 meters
Bunker in width.
distance can be
production capacities.
Sinoma Jan 2013.indd 1 16/01/2013 09:09
NEWS THE AMERICAS
Environmentalists could sue over EPA cement standards
US: Washington-based news agency InsideEPA has reported that It also proposed to extend the compliance deadline for the air
environmentalists may be preparing to sue the US Environmen- toxics standards from 2013 to 9 September 2015. Both measures
tal Protection Agency (EPA) over its revised emissions limits for were sought by the cement sector, which argued that the 2010
the cement sector because the rules largely adopt weaker limits rules were too stringent.
and extended compliance deadlines, which had been sought by Environmental groups, including Earthjustice and the Natural
the industry. Critics warn that the ruling will create more toxic air Resources Defense Council, filed comments criticising the pro-
emissions and criteria pollutant emissions that pose significant posal as unlawfully weak under the Clean Air Act and opposing
risks to public health. the changes.
“By the EPA’s own numbers, that delay will cause between It now looks likely that the revised cement rules will prompt a
1920 and 5000 Americans to die prematurely from exposure to lawsuit from these and other environmental groups given their
cement plants’ soot pollution. The rules will also allow cement warnings in written comments that the proposed version was
plants to pump an additional 15,000kg of mercury into the envi- unlawful under the Clean Air Act.
ronment,” said one environmentalist quoted by Inside EPA, citing In contrast, the Portland Cement Association (PCA) President
the EPA’s data. Greg Scott has welcomed the rules, saying that they “Will pro-
The EPA had faced a 20 December 2012 consent decree vide PCA members and the cement industry the additional time
deadline to issue the rules, which revise its national emission needed for compliance with the revised standards. Such time
standards for hazardous air pollutants (NESHAP) air toxics limits is essential to properly complete the planning, engineering,
and new source performance standards (NSPS) criteria pollutant permitting, testing and construction of the various new technol-
controls for the sector. The rules address a cement sector push ogies that will be necessary to implement the revised standards.”
for reconsideration of the NESHAP and NSPS as set in 2010, in He added that the rules, while now achievable, were still ‘ex-
addition to a federal appeals court ruling partly remanding the tremely challenging,’ mitigating fears that the industry could sue
2010 rulemaking to EPA. over their implementation.
In June 2012 the EPA proposed to revise the rules by weaken-
ing the particulate matter (PM) limit for new and existing kilns.
Davenport’s quarry moves back
Votorantim preparing IPO US: Lafarge North America is seeking permits needed to ex-
Brazil: Brazil’s biggest cement producer, Votorantim Cimentos, pand its quarry operation near Buffalo, New York. According
is preparing an initial public offer (IPO) to raise US$3bn. to a notice from the Rock Island District of US Army Corps of
Votorantim is looking to acquire new assets in North Amer- Engineers, Lafarge is planning to expand its quarry operation
ica, Africa and South America. The proceeds from the IPO, the to a 71.7 acre area of the company’s property just north of its
biggest for Brazil since Banco Santander Brasil in 2009, would existing quarry.
go into funding its expansion plans. The project would include rerouting a stream and the ex-
The cement unit of Brazil’s Grupo Votorantim, controlled by cavation of an area of wetland, which would be mitigated by
the Ermirio de Moraes family, completed a swap of its 21.2% expanding the area and establishing native wetland plants.
stake in Cimpor Cimentos de Portugal in June 2012. Votoran- The expansion is part of the natural progression of the
tim Cimentos has hired Banco Itau BBA and JPMorgan Chase & quarry and will not affect the operations of the Davenport
Co to manage the deal and will include other banks. cement plant, according to company spokeswoman Joelle
Lipski-Rockwood. “This is part of the natural process as our
New board member for Monarch cement quarry grows in size,” she said.
The company hopes to begin the stream relocation pro-
US: On 7 December 2012, The Monarch Cement Company ject in the spring of 2013 and begin quarrying the area in the
elected Steve Sloan to serve on the board effective immedi- spring of 2014. The public is allowed to comment on the pro-
ately to fill the unexpired term of independent director Richard ject as part of the permit process.
N Nixon, who resigned effective as of 31
October 2012.
Brazilian demand up in 2012
Sloan, aged 51, moves to the board of
the cement firm with 17 of years experi- Brazil: Demand for cement rose by 8.5% year-on-year to 45.2Mt in the January to
ence in the aggregate and ready-mixed August 2012 period. The demand has been attributed to brickwork made from cement
concrete industry. He has served for blocks and cement walls in booming social housing projects.
many years as the President and CEO of Cement demand in Brazil rose by 8% year-on-year in 2011 to 65Mt. Industry experts
Midwest Minerals, Inc, headquartered in estimate that the use of cement systems may grow from its current level of 22% to
Pittsburg, Kansas. His current responsi- 50%. Subsequently, cement producers are increasing their capacity. Brazil’s cement
bilities include oversight of the financial, capacity was estimated at 78Mt/yr at the end of 2011 and is forecast to rise by 40% to
production, sales and regulatory af- 111Mt/yr in 2016.
fairs of Midwest Minerals’ ready-mixed Meanwhile, Holcim is spending US$710m to increase its capacity from 1.2Mt/yr to
concrete plant and 19 aggregate 3.6Mt/yr. Queiroz Galvao is currently building a cement plant in São Luis in collabora-
quarry operations. tion with the Cornelio Brennand group and is said to be planning five more plants.

36 globalcementMAGAZINE January 2013

IEEE Jan 2013.indd 1 16/01/2013 09:08
NEWS THE AMERICAS
New president for PCA
US: Gregory M Scott has become the president and chief execu-
tive of the Portland Cement Association (PCA), effective from 2
January 2013. Scott joined the PCA in January 2012 as the senior
president of government affairs and was promoted to president
in September 2012.
Scott holds a background in trade association leadership
with legislative campaigns on federal transportation, environ-
mental and energy issues. Most recently he served as executive
vice president and general counsel for the National Petrochemi-
cal and Refiners Association (NPRA) in Washington, DC. Prior
to joining the NPRA, Scott served as vice president of National
Strategies, Inc, a trade association representing CEOs of Fortune
100 firms on corporate finance and tax issues.
He began his career serving on the staff of Senator Timothy
E Wirth. From 1991-2008 Scott was a partner/member of Kelley
Drye Collier Shannon, where he gained extensive expertise in
petroleum refining and motor fuel marketing as well as legisla-
tive and regulatory issues.
Scott received his Bachelor of Arts degree from Colorado
College in Colorado Springs and a law doctorate from the Ameri-
can University’s Washington College of Law in Washington, DC.

Cemex announces Water Project

Mexico: Cemex has announced that it has developed a meth-
odology to standardise water measurement and management
across all of the group’s operations. The methodology will be
rolled out to all of the businesses in the countries in which
Cemex operates in order to minimise the company’s water foot-
print and increase its water efficiency.
The ’Water Project’ is the result of a three-year partnership
between Cemex and the International Union for Conservation
of Nature (IUCN) on the improvement and efficiency of water
management in the cement, ready-mix concrete and aggregates
sectors of the building materials industry.
The roll out of the methodology will start in 2013 and will
focus initially on measuring the company’s water footprint.
It will secondly focus on defining actions to increase its water
efficiency and reduce its water usage. The three-year partner-
ship has so far leveraged important findings from data collection
to minimise Cemex’s water footprint and increase efficiency.
“Sustainability is embedded in Cemex’s business strategy
and day-to-day operations,” said Luis Farias, Cemex’s senior vice
president of energy and sustainability. “Under existing climate
change scenarios, it is predicted that almost half of the world’s
population will live in areas of high water stress by 2030.”
“Therefore, it is our responsibility to ensure that efficient water
management plays an important role in our business. As Cemex
strives to minimise its environmental footprint, partnering with
IUCN helps our company to reduce risk, be good stewards of
the environment and ensure we provide the greatest value for
our stakeholders.”

cbi
brazil & latam

V Brazilian Cement And Lime Conference

cement business & industry

Sheraton WtC ♦ SÃo paulo, brazil ♦ February 27-28, 2013

The joint V Brazilian Cement & Lime Conference and Cement Business & Industry (CBI) Brazil and Latam 2013
Conference, which will be hosted in São Paulo on February 27-28, 2013, will create a new platform connecting the
cement industry, analysts, technologists and other stakeholders from Brazil, Latin America and all parts of the world.
The program will take a dual-track business and technical approach to issues around:
■
Brazil and Latin American cement – an unstoppable force?
■
Cement and fuel trading – still going strong or a waning force?
■
Innovation - technical, business and the human capital equation
■
Alternative fuels and the environment - new developments
■
The efficient enterprise -- designing for performance
■
The new cement plant -- tools of the trade
■
Strategy and finance -- opportunities, consolidation and what is next?

GMI
For attendance, speaking opportunities or general questions
about the conference please contact the CBI Client Service
GLOBAL team at sales@gmiforum.com or via phone at +1-203-516-7424.
 SAVE THE DATE! September 10–13, 2013
13th Biennial Worldwide Congress on Refractories

Unitecr 2013
The Unified International Technical Conference on Refractories
The Fairmont Empress and Victoria Conference Centre Victoria, BC, Canada

UNITECR’13 feature Gilles Michel, Chairman and CEO,

IMERYS as the keynote speaker; and Tom Vert, General
Manager Primary Manufacturing, ArcelorMittal Dofasco
and Charles E. Semler, President/Consultant, Semler
Materials Services as Plenary Speakers.

Topics include:
– Cement & Lime Refractories – Refractories for Waste-to-Energy Processing & Power
– Advanced Testing of Refractories – Energy Savings through Refractory Design
– Advanced Installation Techniques & Equipment – Nonoxide Refractory Systems
– Monolithic Refractories – Refractories for Chemical Processes
– Iron & Steel Making Refractories – Developments in Basic Refractories
– Raw Materials Developments & Global Raw Material Issues – Global Education in Refractories
– Refractories for Glass – Refractories for Nonferrous Metallurgy
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Siam City to restart closed kiln Lafarge to sell South Korean unit
Thailand/Cambodia: Owing to strong demand for ce- South Korea: French cement maker Lafarge is looking to sell its con-
ment in Thailand and the wider Far East region, Siam City trolling stake in its South Korean subsidiary Lafarge Halla Cement Co,
Cement (SCCC) has announced plans to re-open one of according to South Korean online media Edaily. The French company,
the two clinker lines that it shut down in 2008, according which controls about 90% of its Seoul-based unit, expects to raise
to local press. around US$651m in proceeds from the divestment, for which it has
With the re-opening of the clinker factory in October picked Lazard and HSBC’s South Korean arm.
2013, SCCC’s production capacity will rise by at least Lafarge, which has been offloading non-strategic assets in a drive
1.4Mt/yr, or 10% of its current capacity, according to the to push its debt below US$13bn from US$16bn, has not commented
company’s managing director Philippe Arto. on the report. The move follows the announcement in November
SCCC shut down the two plants, which had total 2012 that Lafarge and Anglo American would sell a portfolio of its UK
capacity of 2.25Mt/yr, in 2008 because of an increase in operations to Mittal Investments for US$439m, and the sale of two
production costs and a decline in demand for cement. of Lafarge’s cement plants in North America to Eagle Materials for
However, the company has recently seen strong growth US$446m in September 2012.
in demand. In 2013 it targets year-on-year growth of at
least 5%, following an increase in both public and private
sector projects. Jaypee nears end of Gujarat assets sale
Meanwhile, the company’s board of directors has said that it will India: The talks between Jaypee Group and Aditya Birla
consider a plan to invest in Cambodia early in 2013. The company has Group regarding the sale of the former’s Gujarat based
been working on the plan since 2010. “Our board of directors will make cement units have at last moved to the final stages,
a decision on this plan in 2013. This would be our first investment out- according to local media. It was reported that valua-
side Thailand,” said Arto at the end of 2012. tions of the deal, which had already resulted in failed
If the plan is approved, SCCC will set up a cement plant in Cambodia acquisition attempts by others, have continued to
via a joint venture with a local partner. “We are interested in investing cause delays.
in Cambodia because we have a more-than 40% share in the cement Birla has been negotiating the cost of Jaypee’s Gu-
market in the country,” said Arto. jarat cement units with the aim of paying a total of
SCCC’s sales in the first nine months of 2012 climbed by 10.8% to US$800m. The reports say that Birla had offered to pur-
US$653.8m from US$590.5m in the same period of 2011 due to grow- chase the units at US$160/t of installed capacity. This is
ing demand. However, its net profit dropped by 5.3% to US$94.1m from significantly lower than the US$200/t paid during deals
US$99.3m due to rising energy costs. between Holcim and ACC.

Iranian production up again Boral to close kiln in favour of clinker imports

Iran: Iranian cement production surpassed
49.14Mt in the first eight months of the current
Iranian calendar year which began on 20 March
2012. The figure is 6% higher than in the same
period of 2011, according to the IRIB News
Agency. Iran also exported over 9.38Mt of ce-
ment and clinker over the same period, a 30%
increase compared to the same period of 2011.
Some 8.25Mt of cement and 1.14Mt of clinker
were exported during the same period. Iraq,
central Asian countries, the United Arab Emir-
ates and Afghanistan were its main customers.
Iran’s cement production capacity currently
stands at 86Mt/yr, according to the Iranian presi-
dent Mahmoud Ahmadinejad. He said that the
country currently produces some 76Mt/yr.
“Six years ago Iran was dependent on import-
ing cement and nobody would believe that one
day the country could become an exporter in the
field. However, as we see today, Iran has become
one of the world’s greatest cement producers
and exporters,” said Ahmadinejad.
In August 2012 Iran’s Industry, Mine and
Trade Minister Mehdi Ghazanfari said that the
country’s cement production capacity would
reach 110Mt/yr by 2015.
Australia: Building products maker Boral is cutting 90 jobs as it reduces some
manufacturing at a cement plant in Geelong, Victoria, in favour of imports.
About 90 staff at the Waurn Ponds cement plant will be affected by the sus-
pension of clinker production. Boral intends to import clinker due to the high
Australian dollar and low shipping costs and use the plant as a clinker grinding
facility only. It is thought that the kiln will be shut down by April 2013.
The Australian Workers’ Union (AWU) said that it will work with the company
to try to save as many jobs as possible. Talks will be held with the workers over
coming weeks to explore all options, to avoid or mitigate job losses and to
organise redundancies or redeployment within the company.
“A continued low level of demand associated with the downturn in Aus-
tralian building and construction activity is also adversely impacting the
profitability of Boral’s cement business, where high fixed cost manufacturing
assets continue to be under-utilised,” said Boral’s CEO Mike Kane in a state-
ment. “Across all of our businesses we need to ensure that we are aligning our
domestic production with demand levels and that our cost structures are glob-
ally competitive and can be sustained through the cycle.”
Siam Cement to build Myanmar plant in 2013
Myanmar: Siam Cement Group (SCG), Thailand’s largest cement company, has
announced that it will build a cement plant in 2013 in Myanmar’s Taninthayi
region, according to country manager Soontornpol Veerapravati. “SCG is plan-
ning to manufacture its main products in Myanmar and will open four retail
stores in Yangon, Mandalay, Nay Pyi Taw and one other major city. It will also
expand its outlets in other locations,” said Soontornpol.

40 globalcementMAGAZINE January 2013

 NEWSASIA TRUE POTENTIAL TO
INCREASE YOUR PROFITS.
With
First cement plant project for McNally Bharat TM
THE PHLAUER HIGH
India: McNally Bharat Engineering Company Ltd (MBEL), a Williamson Magor PERFORMANCE MIXER - THE
group company, has booked an engineering, procurement and construction ULTIMATE PERFORMER FOR
(EPC) contract worth US$133.5m from ACC Ltd to set up a 9000t/day brown-
field cement facility at its existing plant at Jamul, Chhattisgarh. The deal was
COLORED CEMENT PRODUCTS
announced by Deepak Khaitan, chairman of MBEL, at a press conference in
the city on 17 December 2012. The plant will be set up with technology from PHLAUERTM mixers are not a knock off of
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”This order is a major milestone for us as it flags up MBEL’s entry into the
specifically using an old principle in a new
way that produces fantastic results,
cement plant construction business,” said Khaitan. “This will open up opportu-
predictable, repeatable, reliable.
nities for MBEL as EPC for working in the Indian cement industry.”
The company has also opened offices in South Africa to carry out engineer-
ing contracts in Africa. ”Our emphasis will be able to expand our footprint
globally,” said Khaitan.

Xinjiang: Production up but profit down

China: The Xinjiang Uyghur Autonomous Region in north west China pro-
duced 35.1Mt of cement in the first 10 months of 2012, a year-on-year increase
of 24.8%, according to the local statistics bureau.
From 1 January 2012 to 31 October 2012, Xinjiang saw the output value
of its cement industry come to US$1.93bn, a year-on-year increase of 0.9%.
• ACCURATE MIXING TO Cv 5 IN
However, the industry earned just US$170m in profit, a year-on-year decline
ONE MINUTE means color is always
of 58.6%.
the same, around the tile, bag to bag,
The region’s government says that the region’s cement production capacity batch to batch. (Patented rotor)
is likely to exceed 90Mt/yr in 2013.
Meanwhile, Japan’s Taiheiyo Cement Corp. has announced that it has agreed • AGGRESSIVE SHEAR DEVELOPS
with a Chinese chemical maker to set up a 1.2Mt/yr cement plant in Xinjiang. EVEN NON-SANDED STREAK
The joint venture, to be known as Xinjiang Tianye Taiheiyo Building Material FREE. Shear makers work in a
Company, will start cement production in November 2014. notched path in the rotor. An exclusive
The new company will be owned 40% by Taiheiyo Cement (China) Invest- feature is that the rotor is compensated
ment Corp., a Beijing-based unit of Taiheiyo Cement and 60% by the Chinese to retain the same mixing action.
partner, Xinjiang Tianye (Group) Company.
• SAVE PIGMENTS 5 TO 20%.
Civil unrest in Assam delays Bhutan plant
• LOAD AUTOMATICALLY AND/OR
Bhutan/India: On-going civil unrest in the Indian state of Assam is delaying OVER THE SIDE. Less space required.
the construction of a US$173m plant being built in Chengkari in south-east
Bhutan. The project is facing delays partly due to disorder in Assam that has • SEALED MACHINE—REQUIRES
impacted upon its supply channels. DUST COLLECTION ONLY FOR
In addition, a severe shortage of Indian rupees in Bhutan, due to a rise in MANUAL LOADING. With the plenum
aggregate demand for the currency and limited supply, has had an impact on connection, this reduces material in dust
collector
the project as most of the materials for the projects are sourced from India.
The Indian government is providing US$54.6m towards the project in financial
• VARIETY OF DISCHARGES
support. The project is expected to commence operation in May 2013, which,
if met, would represent a delay of nearly 15 months. Clinker production is ex-
• LOW HORSEPOWER AND LOW
pected to commence soon.
MAINTENANCE.
The project is being implemented by Dungsam Cement Corporation Lim-
ited, which is a wholly-owned subsidiary of Druk Holding and Investments, an • LOW INVESTMENT
investment arm of the Royal Government of Bhutan. The plant will have pro-
duction capacity of 1Mt/yr for clinker and 1.36Mt/yr for cement. • CUSTOMIZED FOR YOUR EXACT
NEEDS INCLUDING THE HOPPERS
Another Tajik project & CONTROLS. AR400 Wear Parts.
.
Tajikistan: The Tajikistan government has announced that the Tajikistan
Aluminum Company (TALCO) will build a 3Mt/yr cement plant costing over A & J Mixing International Inc.
US$600m in a joint venture with China National Building Material Company www.ajmixing.com
(CNBM). The new plant will be built in Khatlon province in the south of the 800-668-3470
country. The plant is expected to be operational by the end of 2013, creating 1-905-827-7288
5000 new jobs.
8-2345 Wyecroft Road
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globalcementMAGAZINE January 2013 41
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NEWSASIA
Iranian cement sold in Pakistan Adelaide Brighton buys 30% of Cementir Holding unit
Pakistan/Iran: Iranian cement is being sold in- Australia: Australian building materials producer Adelaide Brighton will buy
formally in Quetta and other parts of Balochistan a 30% stake in a Malaysian white clinker and white cement producer, Aalborg
at below the price of locally-produced cement. Portland Malaysia (APM) for US$29.7m. APM is owned by Aalborg Portland
A cement producer quoted by the Pakistani A/S, a subsidiary of Italian entity Cementir Holding. The deal also secures
newspaper Dawn said that Iranian cement was a 10 year supply agreement with APM and continues Adelaide Brighton’s
selling up to 30% below the price of locally- efforts to access raw material given its ‘maxed-out’ production capability.
produced cement. “The high dollar, rising power costs, the carbon tax and increasing labour
The producer added that cement smuggled costs make building a new plant in Australia too high in terms of capital
from Iran started arriving in Pakistan in early No- expenditure costs,” said Adelaide Brighton’s chief financial officer Michael
vember 2012. The local industry pays US$15.5/t Kelly. He added that Adelaide Brighton needs to secure imports and that the
of cement in federal excise duty and sales tax. No acquisition provides a strategic position in Asia for the company.
duties are paid on the illegally-imported cement APM is also considering a US$18.6m expansion of the plant to increase
from Iran. white clinker production capacity from about 2015. Imports of cementitious
The All Pakistan Cement Manufacturers Associa- products, including grey and white clinker, cement and blast furnace slag
tion (APCMA) chairman Aizaz Mansoor Sheikh said are expected to increase from approximately 1.6Mt/yr in 2012 to more than
that his members are performing quality checks on 2Mt/yr in 2016.
Iranian cement. The APCMA also intends to raise
the issue with the Pakistan government. Semen Gresik sets aside US$400m capex
Keeping in view the production capacity of local cement
manufacturers, he said the APCMA would take up the matter Indonesia: State-owned cement firm PT Semen Gresik has set
with the government besides suggesting imposition of import US$400m aside for capital expenditure for its corporate busi-
duty to safeguard the local industry. ness activities in 2013, according to its president director. “The
Iraq and Afghanistan are two principal markets for cement expenditure will be used to carry out a number of corporate
export from Pakistan, constituting 50% of the country’s total business activities such as continuing the company`s transfor-
exports of 9Mt/yr. Annual exports to South Africa and India are mation into a holding firm, namely PT Semen Indonesia Tbk,”
800,000t/yr and 600,000t/yr respectively. Due to US sanctions said Dwi Soetjipto.
on Iran and devaluation of Iranian currency, surplus Iranian ca- He said that the other corporate activities included the inte-
pacity has posed direct threat to Pakistani cement in these two gration of Thang Long, a Vietnamese firm it had acquired, into
markets. the Semen Indonesia holding company and the construction
At the inauguration of a cement plant in the Esfahan’s Na’in of two new factories in Rembang in Central Java and Padang in
Township on 4 December 2012 Iranian president Mahmoud West Sumatra.
Ahmadinejad placed his country’s cement production capacity “PT Semen Indonesia holding name is expected to have been
at 86Mt/yr. Iran produced 66Mt in 2011 and after international approved by the ministry of law and human rights in January
economic sanctions its local capacity utilisation is estimated to 2013 while its subsidiary PT Semen Gresik would follow in March
be 50%. Iran plans to export 12Mt of cement in the current Per- 2013,” he said.
sian calendar year.

Commerce & Industry Minister batting for cement firms

Indonesia’s sales up in November
Indonesia: Indonesia’s cement sales in Novem-
ber 2012 rose by 17% compared to November
2011, a faster pace than the previous month,
according to data from the country’s biggest
cement firm, PT Semen Gresik.
The sales of 5.23Mt were up by 0.9% com-
pared to October 2012. More than 55% of sales
were on the main island Java, with the Molucca
islands and Papua posting the highest annual
sales growth at 95%.
Between 1 January 2012 and 30 November
2012 sales surged by 15% year-on-year, ac-
cording to data from the Indonesian Cement
Association (ASI). In the first 11 months of 2012
sales rose to 49.9Mt, compared to 43.4Mt in the
same period of 2011. Over the 11 months, Java
took 55% of cement, Sumatra took 22% of the
total and Sulawesi and Kalimantan each took
7.4% of the total.
India: On 18 December 2012 The Commerce and Industry Ministry of India said
it would take up with the Competition Commission of India (CCI) the issue of
cement companies beingpenalised for ‘idle excess capacity.’
“On the issue of getting penalised for idle excess capacity, your explanation
that it is the result of a sluggish demand due to economic slowdown has merit,”
said Minister of State for Commerce and Industry S Jagathrakshakan, who was
speaking at a Cement Manufacturers’ Association (CMA) function.
“I will certainly raise this issue at appropriate levels and also with the Compe-
tition Commission of India (CCI),”
On 21 June 2012 the CCI slapped a record US$1.1bn on 11 cement makers.
The tribunal has started the hearing and during the last proceedings on 6 De-
cember 2012 asked the cement firms to raise their common issues on 29 January
2013, the next date of hearing.
On concerns over cheap imports, Jagathrakshakan said that the issue of zero
duty on import of cement would be taken up with the Finance Ministry. Also, he
said, the issue of higher state levies would be addressed.
“On the tax front, I share your concern about higher state levies, royalties and
the zero import duty. As you are aware, these issues pertain to the state govern-
ments and to the Ministry of Finance, I will certainly take it up with them,” he
said. At present, there is no duty on cement imports which affects the interest of
domestic players. State-level taxes are 12-15%.

42 globalcementMAGAZINE January 2013


Sree Jayajothi attractive to multinationals
India: On 2 January 2013 it was reported that CRH had expressed
interest in purchasing a stake in Sree Jayajothi Cements, which
operates in Andhra Pradesh, from Shriram Group. Indian invest-
ment group Shriram took control of Sree Jayajothi in 2012 and
it has been reported that private equity giants Blackstone and
KKR are also in separate preliminary talks with Shriram about
its stake in the cement manufacturer. It was also reported that
Switzerland’s Holcim Ltd was interested in purchasing the stake.
Shriram EPC, which lacks expertise in running a cement busi-
ness, had been scouting for partners to improve production and
efficiency of its cement plant. The plant currently utilises only
60% of its capacity as supply exceeds demand in south India.
A partner will also fund its plans to build an integrated unit to
produce different types of cement along with a captive power
NEWSASIA
plant. Jayajothi has approvals for mining in areas with indicated
reserves of 80Mt of limestone. Additional approvals for a further
180Mt are also expected.
Lee said that CRH is interested in expanding its presence in
India, but declined to comment on speculation surrounding
Sree Jayajothi specifically. He said that CRH was looking at In-
dian opportunities on a continual basis and that it was keen to
expand its presence there.
CRH pulled back from a potential acquisition in India in 2012
but already has a joint venture in India with cement maker My
Home Industries.
However, it is thought that the valuation of the stake could
be off-putting for both firms. The overcapacity in southern India
is also likely to be a factor that may prolong the progress of
any sale.

Taiwan and CNBM

expand cooperation
Taiwan/China: Taiwan Cement
Corp. signed a strategic part- SYNTRONICS
nership agreement with China
National Building Material Co. Manufacturer of AD*STAR®
(CNBM) on 3 January 2013 to Polypropylene Block Bottom Valve Sack
expand cooperation between
the two companies.
According to Taiwan Ce-
ment, the cooperation will
include information exchange,
production capacity expansion
in regional markets, research
and development of high-
quality cement and innovation
of production technologies.
Taiwan Cement also said
that the two sides would step
up technology exchanges and
sharing of experience as well
as the joint development of
technology in the environ-
mental protection field.
The Packaging Solution For Cement, Chemical, Sand,
Taiwan Cement Chairman Agro and all free flowing goods.
Koo Cheng-yun and several
of the company’s executives, AD*STAR® Sack is made of polypropylene which is environment friendly degradable
including senior vice president thermoplastic polymer.
Edward Huang, signed the When incinerated or put to waste it does not pollute air, soil or water with toxic residues.
Empty sacks can be reused and recycled.
agreement in Hong Kong with
Polypropylene is liable to chain degradation from exposure to heat and UV rediation such as that
CNBM’s Chairman Song Zhip- present in sunlight
ing and CEO Thomas Cao. Syntronics is a socially responsible entity which is committed to an Eco-Friendly green foot print
future. Syntronics offers complete packaging solution for free flowing goods which are
biodegradable and environment friendly.
Ambuja expands
India: Ambuja Cements has an- IS
nounced a capacity expansion eco 9001:2008
R E G I S T E R E D
at its Sankrail grinding unit in
West Bengal. The US$59.8m
project would expand the SYNTRONICS LIMITED
plant to 2.4Mt/yr. Mandviwala Chambers, Talpur Road, Karachi - 74000, Pakistan.
Tel: +92 21 3242 8678-79 Fax: +92 21 3242 0996
Email: info@premiergrouppk.com Website: www.syntronics-adstar.com
globalcementMAGAZINE 43
S AV E P E O P L E S AV E T R E E S S AV E O U R P L A N E T
NEWSASIA
Vietnam to spend US$40m/yr to reduce cement firm debt Asian cement news in brief
Vietnam: Vietnam’s Finance Ministry has announced that it will spend US$30- India: Mangalam Cement Ltd, a BK Birla
40m/yr on settling foreign debts for local cement producers until 2018. Group company, has announced that it will
State-owned producers Dong Banh, Thai Nguyen, Tam Diep and Hoang Mai will complete its expansion projects in 2013. The
all receive preferential interest rates for domestic loans and guarantees for for- company will increase its clinker capacity
eign loans. The total debt of these four projects is US$229m. from 1.5Mt/yr to 2.2Mt/yr and is also setting
According to the ministry’s recent report to the prime minister, the total up a 1.25Mt/yr grinding unit at its existing
amount of government-guaranteed loans reached US$1.37bn in 2011. Hoang plant site at Morak, Rajasthan, at a total cost
Mai and Tam Diep have been given capital to pay back their loans. However, Tam of US$92.5m.
Diep has had difficulties paying back its debts. Dong Banh and Thai Nguyen, According to sources close to the clinker
which have been advanced capital for their first period of payment, still have plant expansion is likely to be completed
troubles dealing with their foreign debt. by April 2013 while the grinding unit will be
The Dong Banh cement plant, which has a total investment of US$61.4m, was ready in October 2013.
forced to close in the first quarter of 2012 after two years in operation and a
loss of US$9.44m. By 2018 the plant’s debts with interest could reach US$28.8m. Azerbaijan: Norm has announced that the
The Thai Nguyen cement plant suffered a loss of US$3.69m after one year and 2Mt/yr Gizildash cement plant will start op-
was still running at below 60% of its capacity. It must operate from 80% capacity eration in the last quarter of 2013.
to earn a profit. As of March 2012 Ha Long cement plant had incurred debts of “With a cement production capacity of
about US$58.3m. Although the company borrowed US$96m to pay its debts, the 2Mt/yr it will not only be the largest in the
company’s liabilities for the period of 2012-15 still amounted to US$57.5m. region, but also the only plant producing API
According to the Vietnam National Cement Association, local cement mak- standard cement,” said Norm’s general direc-
ers are predicted to continue facing a lot of difficulties as the real estate market tor Hasan Yalcinkaya. Yalcinkaya added that
remained gloomy with few signs for recovery. Exports are not seen as an effec- the plant will hire 400 people, with another
tive solution to the problem as local cement producers cannot lower prices of 100-150 people to be engaged in mining.
their products any further to compete with foreign rivals. Analysts predict that
a cement surplus will persist if the government does not take drastic measures China: China Resources Cement (CRC) has
including stimulating demand and a review of current cement plant projects. announced that it has agreed to acquire
a 100% equity stake in Hainan Wuzhishan
Dajiangnan Cement Limited for a total of
Chinese cement updates US$8.4m. Hainan Wuzhishan Dajiangnan
operates a 0.6Mt/yr cement grinding line
China: The chairman of West China Cement, Zhang Jimin, has said that West in Maoyang Town, Wuzhishan City, Hainan
China’s production capacity reached 23Mt/yr in 2012. Zhang added that the Province. CRC says that the acquisition will
group plans to invest US$321m through mergers and acquisitions to increase expand the strategic locations of its business
production capacity to 30Mt/yr by 2015. and strengthen its position in Hainan.
Hebei Province-based cement producer Tangshan Jidong Cement has said
that the company plans to set up a joint-venture (JV) with two cement firms in India: PC Abraham has been appointed as
Mizhi County, Shaanxi-province. The JV will build a 2000t/day cement-clinker the managing director of Loesche India. He
production line to expand the local cement market. Jidong Cement will pay took the post at the start of October 2012.
US$15.7m for a 61% stake in the JV, which will have a registered capital of Abraham joined Loesche India in 1995 and
US$25.7m. has been working as executive director of
China Resources Cement Holdings, the largest cement producer in South the technical department. Under his leader-
China, said that its investment subsidiary will set up a JV with a local cement ship, Loesche India established a technical
company in An’shun City, Guizhou province. The JV will have a registered capi- field service department. He was also re-
tal of US$45m. China Resources Cement will invest US$28.1m in cash to hold a sponsible for growth in the company’s after
62.5% stake in the JV while in the first phase, the An’shun company will take a sales business.
37.5% stake by providing properties and other assets worth US$17m. After com-
pletion, China Resources Cement will spend US$7.86m buying a 17.5% stake in Thailand: Holcim Ltd has reduced its share-
the JV from the An’shun company, increasing its stake in the JV to 80%. holding in Siam City Cement Company Ltd
(SCCC) from 36.8% to 27.5%. The shares have
been purchased by Bangkok Broadcasting
Fuel problems slow Tajikcement and Television, a Ratanarak Group company,
Tajikistan: Tajikcement has reported lower production for the first 11 months of which will increase its shareholding in SCCC
2012 due to a shortage of natural gas. to 47%.
“Natural gas is the main fuel for the factory. Partial interruption in the supply
of gas caused a decrease in cement production. The factory produced 190,500t China: Jiangsu Province in eastern China saw
of cement in January to November 2012, which is a 60,000t decrease compared cement output rise by 10.9% year-on-year to
to the same period in 2011,” said a source quoted by local press. Gas supplies to 138.6Mt in the first 10 months of 2012, ac-
the plant in Dushanbe have been interrupted several times in 2012. cording to the local statistics bureau.

44 globalcementMAGAZINE January 2013

 Contents Subscribe Ad Index
Global Cement Magazine staff
Sunday 17 February 2013
18.00-20.00 Registration opens. Drinks and network-
ing in the Global Cement India exhibition area
Monday 18 February 2013
09.00 Conference introduction and welcome
Robert McCaffrey, conference convenor
Session 1: Global overview
09.10 ‘Global cement: current status and future trends’
Dr Robert McCaffrey, Global Cement Magazine
09.30 ‘Overview of global cement: Supply/demand, key
trends, strategic raw materials and freight impact’
Charles Zeynel, ZAG International
Session 2: Grinding advances and optimisation
10.00 ‘Energy Audit of cement plants: Methodology,
directions of energy consumption and energy saving
potentials’ Michael Chayka, GCE Group
10.20 ‘Operation results with the first MVR mill in-
stalled in India’ Caroline Woywadt, Gebr. Pfeiffer
10.40 Global Cement India Speed-Meet Session 1
Bring at least 10 business cards for this intensive
networking session
11.10 COFFEE AND NETWORKING
Session 2 Continued: Grinding advances
and optimisation
11.40 ‘Improving performance of vertical roller
mills using advanced process control and real-time
optimisation’ Steve McGarel, Loesche GmbH
GLOBAL CEMENT INDIA
Global Cement India : Preview
The 2nd Global Cement India Conference &
Exhibition will take place at the Vivanta by Taj-
President Hotel in Mumbai on 18-19 February
2013. The conference returns to India after an
absence of nine years and will bring the best
speakers from India and from around the world
together in one place for high-level technical
exchange, networking and business. Here we
highlight the conference programme and the
event’s exhibition area.
12.00 ‘Successful implementation of MYTOS on-line
particle size analysis for cement grinding optimisation’
Axel Pankewitz, Sympatec GmbH; Claude Simon,
Buzzi Unicem Cimalux; Christoph Gernet,
Spenner Zement
12.20 ‘More than just condition monitoring: Case stud-
ies on how to improve the reliability of vertical roller
mills’ Sebastian Muschaweck, Horst Brodherr and
Franz Muschaweck; DALOG Diagnosesysteme GmbH
12.40 ‘Improve performance of your roller press rolls by
innovative super-conditioning solutions’ Prashant Garg,
Diffusion Engineers Ltd
13.00 LUNCH
Session 3: Production enhancement
14.00 ‘Improving equipment availability and reliability
using the PI System for cement plants’ Lalit Pokharana,
Aditya Birla
14.20 ‘Oxygen-enhanced cement and lime production -
How it works and when you should consider it’
Larry K Farmer, Air Products
14.40 ‘Benefits of oxygen-enhanced combustion in
clinker production: Technology and results’ Siegfried
Schemberg and Joachim von Schéele, Linde AG; In-
dranil Mukherjee, OC India Ltd
15.00 ‘Calorific energy savings by using air blasters on
preheater towers’ Alvaro Chacon, Martin Engineering
15.20 ‘The new evolution in open gear lubrication’
Mark Pobjoy, Fuchs Lubritech
15.40 COFFEE AND NETWORKING
globalcementMAGAZINE January 2013 45
GLOBAL CEMENT INDIA
Exhibitor List as at 15 January 2013 Session 3 Continued: Session 5: Alternative fuels in India
Production enhancement
1. Golder Associates 11.40 ‘The production and advantages of using high
2. Sympatec/Mühlen Sohn 16.20 ‘The theory and applica- grade solid recovered fuel from municipal solid waste in
3. Martin Engineering tion of acoustic cleaners within the cement industry’ David Hooper, Entsorga
4. DCL Bulk Tech key process areas of the cement
5. BMH Technology Oy manufacturing industry and 12.00 ‘The new Cemex alternative fuel offering’ Neville
6. Claudius Peters (India) Pvt. Ltd related power generation plants’ Roberts, Cemex energy business development director
7. Enexco/BEUMER Alex Bergus, Primasonics
8. ITECA Socadei 12.20 ‘The FuelTrack approach to alternative fuels in the
9. Himenviro 16.40 ‘Corrosion control im- Indian cement industry’ Karl Menzel, Vecoplan Fuel-
10. Thorwesten Vent proves cement plant profits and Track GmbH
11. Carl Bechem Lubricants India safety’ Linas Mažeika, 3L&T
12. 3L&T Inc. Inc. 12.40 ‘Experience in RDF production from municipal
13. Scantech International solid wastes: The Aymer Project, Rajastan’ Dirk Lech-
14. Ambiz Corporation Pvt. Ltd. 17.00 ‘Implementing waste heat tenberg, MVW Lechtenberg; Tecpro Systems, India
15. DALOG Diagnosesysteme GmbH recovery in Indian cement plants
16. Fuchs Lubritech GmbH - Challenges and successes’ 13.00 ‘Petcoke as an alternative fuel in cement industry’
17. Wieland Lufttechnik GmbH Jayanta Saha, Suchismita Bhat- Srinivasan Raman, Essar Oil Limited
18. Gambarotta Gschwendt Srl tacharya, Penta India
19. MVW Lechtenberg & Partner 13.20 LUNCH
20. Available 17.20 ‘Results and benefits of on-
21. Available line analysis for plant operations Session 6: The Indian cement industry and
22. HGH Systèmes Infrarouges as implemented at Jayajothi Ce- the environment
ment India’ Anis Haider, Iteca
14.20 ‘How to increase your profitability by being more
17.40 DRINKS AND NETWORKING sustainable’ Jim O’Brien, CSR Consulting

19.00 GALA DINNER - Strictly by ticket only
Tuesday 19 February 2013
Session 4: Supplementary cementitious materials
and fly ash use
09.00 ‘Supplementary cementitious materials’
P K Ghosh, Ercom
14.40 ‘Accessing land and enhancing sustain-
ability in India using biodiversity and integrated design
techniques’ Chris Davenport, Golder UK; Hitesh
Kaushik, Golder India
15.00 ‘Industrial pollution control through dust suppres-
sion technology’
Saibal Kumar Mitra, F. Harley & Co. Pvt. Ltd

09.20 ‘Hurdles for higher usage of cementitious mate-
rials in concrete and cement’ Subray Hegde, Reliance
Cement Company Pvt. Ltd.
09.40 ‘Potential export of fly ash from India - Logistical
challenges and quality issues’ Thomas Duve and Peter
Brennan, STEAG Power Minerals GmbH
10.00 ‘Up to 30% fly ash in PPC through specific cement
strength enhancers’ Laurent Guillot, Cement Technical
Director, CHRYSO
15.20 ‘Advantages of vacuum cleaning solutions in a ce-
ment plant’ Gerd Borrmann, Wieland Lufttechnik
15.40 COFFEE AND NETWORKING
16.10 ‘Three years operating experience with P84 filter
bags’ Ashish Bhaiya, Evonik Degussa India Pvt Ltd;
Georg Rathwallner, Evonik Fibres GmbH
16.30 ‘Cylindrical bag filters – A novelty for coal grind-
ing safety’ Vincent Grosskopf, Thorwesten Vent GmbH

10.20 ‘New system to separate unburned and coarse
particles from fly ash’ S N Shenoy, Claudius Peters
(India) Pvt. Ltd.
10.40 Global Cement India Speed-Meet Session 2
Bring at least 10 business cards for this intensive
networking session
16.50 ‘Long filter bag technology in air pollution
equipment’ M K Raghu, FLSmidth
17.10 Concluding remarks
Dr Robert McCaffrey, conference convenor
17.15-19.00 DRINKS AND NETWORKING

11.10 COFFEE AND NETWORKING Programme subject to change.

46 globalcementMAGAZINE January 2013


Contents Subscribe Ad Index
Nigeria hits overcapacity
Nigeria: Since mid December 2012 a number of stories have
emerged from Nigeria concerning the oversupply of cement in
the country, which was once a heavy cement importer. Import-
ers and local producers, which have added vast new capacities
in the past 10 years, are disputing the causes of the oversupply,
with each blaming the other for stockpiles at cement plants.
Lafarge and Dangote end 2012 with 1.5Mt
Nigeria: Two major Nigerian cement producers, Dangote and
Lafarge WAPCO, ended the 2012 calendar year with 1.47Mt
of unsold cement and clinker. Figures obtained from the two
manufacturers show that Dangote had unsold stock of 950,000t
while Lafarge had 520,000t.
“At Lafarge, the situation is bad. We have 300,000t of unsold
cement and 220,000t of clinker in our silos across our three
plants (Sagamu, Ewekoro I and Ewekoro II). Before these pileups,
we used to load 10 trucks per day but now there are no sales
and loaded trucks have nowhere to go. As a result we are los-
ing 800t/day,” said Lanre Opakunle, plant manager at Lafarge
Ewekoro II.
Commenting on why the price of cement remained high in
Nigeria despite the glut, Opakunle said that manufacturers are
coping with rising energy inputs and high haulage costs. Fuel
costs account for 31% of production cost in Nigeria compared to
less than 10% in China.
Cement manufacturers have hit back at Ibeto Cement Com-
pany over its resolve to continue to import cement into Nigeria,
despite the capacity of local manufacturers to meet demand.
A statement by Dangote Cement’s head of corporate com-
munications Anthony Chiejina said that Dangote and Lafarge
WAPCO Cement were worried about the glut created by, accord-
ing to him, importers.
Cement manufacturers, under the aegis of Cement Manufac-
turers Association of Nigeria (CMAN), have also said that unless
the federal government fulfils its promise of halting importation
the cement sub-sector of the economy might go into serious
decline, with inventories building up at plants and reduced
production. Cement producers are strongly lobbying for the
development of concrete roads in Nigeria.
CMAN chairman, Joseph Makoju, said that the domestic ce-
ment production level of 18.5Mt/yr was being threatened. “The
target of 18.5Mt/yr represents just 65% of the present total
installed capacity of the industry,” he explained. “Between 2002
and May 2012 a total of US$6bn in new investment was made
Misery for Misr Beni Suef over fuel and prices
as strikes and protests cripple production
Egypt: Production at Misr Beni Suef’s cement plant was stopped
for the second time in two months on 6 - 9 December 2012 due
to shortages of natural gas. The company has reported that the
lack of fuel has led to a loss of approximately US$16.5m and that
it may lead to the dismissal of some of its workforce if further
shortages arise. The company has also been hit by a drop in ce-
ment prices amid the continued political turmoil in Egypt.
Misr Beni Suef’s managing director Farouk Moustafa said
NEWSMIDDLE EAST & AFRICA
by local manufacturers, while the ongoing expansion and new
plants are estimated to have cost another US$3.5bn. Due to
continuous rapid growth the nation no longer requires cement
imports as local demand is being effectively met.”
According to the plant manager at Lafarge’s Ewekoro cement
plant, Lanre Opakunle, 50% of Lafarge’s Shagamu plant had been
shut down. The Ewekoro plant has reportedly been running on
a skeletal staff to prevent it from being closed completely. The
manufacturers stress that, if the cement glut continues, it may
force ‘hundreds of thousands’ of Nigerians out of jobs.
Dangote to close plant due to cement ‘glut’
Nigeria: On 7 December 2012 it was announced that the
4Mt/yr Dangote Cement plant in Gboko, Benue State, was due to
shut because of a ‘glut’ of cement in the Nigerian market.
The move was necessary because of the increase in local pro-
duction of cement and also the continued import of subsidised
cement into the country, according to the group’s head of corpo-
rate communication Anthony Chiejina.
The total supply of cement to the Nigerian market at the end
of November 2012 was a record 11.4% higher than by the same
point in 2011. Chiejina said it was disheartening to note that
despite the glut in the local cement market, cement imports,
though reduced, had continued, thus calling into question the
rigorous implementation of the backward integration policy,
which was introduced to encourage local production.
Explaining why the Gboko plant should be shut, Chiejina said,
“With the dumping of subsidised imported cement in the south-
eastern market there is no way that our Gboko Cement plant can
survive. The inventory of finished products is beginning to build
up at our plants. Don’t forget that projects from our investments
of about US$1.8bn in additional capacity are already on stream,
with lines three and four at Ibese and line four at Obajana, com-
ing on stream early in 2012.”
Chiejina said that other Nigerian manufacturers are also ex-
periencing the same problem of low sales and high inventory.
He advised that the government should vigorously implement
the provisions of the cement backward integration policy, which
he said is needed to protect local manufacturers from dumping.
Chiejina said that he wants the government to consider the total
ban on cement imports, in view of the fact that local produc-
tion now surpasses demand for cement and in the interim also
increase duty and levy on imported cement to the maximum
permissible level.
that the company had sent a letter to the Egyptian President
Mohamed Mursi seeking a solution to the gas supply problem.
However, supplies restarted before any reply was received.
Meanwhile, Ezzeldin Abu Awad, the head of the Cement
Traders Society, has said that the current strikes and protests in
Egypt have decreased cement production by about 50%.
In comments to the Al-Ahram newspaper he added that
the actual demand for cement under the infrastructure project
agreements between the Egyptian government and construc-
tion firms stands at only 40% of capacity.
globalcementMAGAZINE January 2013 47
NEWSMIDDLE EAST & AFRICA
PPC expands into Rwanda with Cimerwa
Rwanda/South Africa: The major South African cement pro-
ducer Pretoria Portland Cement (PPC) has purchased a 51%
stake in the Rwandan firm Cimerwa for US$69.4m in cash. The
deal is in line with PPC’s vision of making 50% of its revenue out-
side South Africa itself in the coming years. The deal comes after
a similar deal between PPC and Ethiopia’s Habesha Cement, of
which it has bought a 27% stake.
“This transaction is a further step in our commitment to invest
in sub-Saharan Africa and we are very confident about Rwanda,”
said PPC’s CEO Paul Stuiver. “The Cimerwa plant is located in a
challenging but very strategic region in East Africa, which cur-
rently lacks significant cement production capacity.”
Cimerwa, in south-west Rwanda, has been the only cement
producer in the country for 28 years. It has the capacity to make
0.1Mt/yr of cement but is currently undergoing a 0.6Mt/yr ex-
pansion project that is due to be commissioned in 2014.
Cement demand in Rwanda is estimated at 0.35Mt/yr but,
based on the region’s positive economic outlook, regional ce-
ment demand is projected to increase to 1Mt/yr in the next
New mill in for HeidelbergCement in Ghana
Ghana: HeidelbergCement has commissioned a new cement
mill with a capacity of 1Mt/yr at its Tema cement grinding plant
in Ghana. The project has cost Euro16m.
“The commissioning of the new cement mill is part of our
strategy of focusing on expanding our clinker and cement ca-
pacities in attractive growth markets. In addition to Asia and
Southern Province matches 2011 in Q4
Saudi Arabia: Saudi Arabia’s Southern Province Cement Co re-
ported on 31 December 2012 that its fourth-quarter net profit
stayed flat compared to the same period of 2011 at US$67.5m.
The Kingdom’s second-largest cement producer said that cement
demand was high in Saudi Arabia and that its factory was run-
ning at optimum capacity.
Production restarts at Hofuf plant
Saudi Arabia: Saudi Cement Company has announced that
clinker production from kilns 1, 2 and 3 at its Hofuf plant resumed
on 22 December 2012 with capacity of 1325t/day. Production
from these kilns will be used to support clinker inventory for
meeting rising demand.
Savannah under fire from established firms
Kenya: Industry newcomer Savannah Cement is under fire from
established players in East Africa, which are seeking to prevent
it enjoying favourable terms in the Athi River Export Processing
Zone (EPZ). Complaints have been made by 10 producers from
Kenya, Uganda and Tanzania.
They also complain that Savannah is selling more than its al-
located 20% of the local market, a claim that Savannah disputes.
“Cement makers have been lobbying intensely to ensure that
we don’t get the 20% of the local market provided for in the EPZ
Act,” said Savannah’s chairman Benson Ndeta.
48 globalcementMAGAZINE January 2013
decade. “Combined with our recent investment in Ethiopia,
the Cimerwa transaction will increase PPC’s revenue outside of
South Africa to more than 30% by 2015-16,” added Stuiver.
“Rwanda looks like an attractive market to build capac-
ity, with robust gross domestic product growth expectations,
a large supply deficit in the cement market and challenging
logistics for importing cement,” said Ross Heyns, an equity ana-
lyst at Kagiso Asset Management. However, Heyns said that it
appeared that PPC had paid a fairly hefty price for the asset.
“After raising the additional US$104m of debt and expand-
ing the plant’s capacity to 0.7Mt/yr, the US$69.4m that they
are paying for 51% of Cimerwa implies a total valuation for
the business (including debt) of US$400/t of cement capacity,”
he said.
PPC’s desire to expand to more locations outside of South
Africa is in part due to the current overcapacity in that market.
The country has a capacity of 16Mt/yr but is only likely to pro-
duce 11Mt in 2012. This overcapacity will not be helped when
the 2.6Mt/yr Sephaku Cement plant, backed by Nigeria’s Dan-
gote Group, comes online in 2013.
Eastern Europe, these include, in particular, the countries of
sub-Saharan Africa,” said Dr Bernd Scheifele, chairman of the
managing board of HeidelbergCement. Schiefele added that
HeidelbergCement announced the construction of a new clinker
plant and a new cement grinding installation in the neighbour-
ing country of Togo in September 2012.
Work halted at Zambezi Portland
Zambia: Cement production stopped at Zambezi Portland
Cement in Ndola in December 2012 due to a dispute over the
company’s shareholder structure, according to local press.
A senior source at the cement producer said that manage-
ment officials were locked out of the plant on 24 December
2012. He added that the halt in operations was due to ongoing
issues regarding the ownership of Zambezi Portland Cement.
Further checks by the newspaper revealed that the plant had
been surrounded by security personnel. Zambia Portland Ce-
ment has a production capacity of 1300t/day.
Liberia drops tax on cement
Liberia: President Ellen Johnson Sirleaf of Liberia has sus-
pended tariffs on cement, saying that the move was in the
interest of national reconstruction and development.
Under Executive Order No. 46, titled ‘Re-Instituting the
Suspension of the Protective Tariff on Cement,’ the Liberian
government has repealed a US$2 protective tariff per 50kg
bag of Portland cement imposed under the Revenue Code of
Liberia, tariff No. 25.23. The mandate added that the need still
exists to encourage local industries to supply cement to the
general public at reasonable prices.
Liberia currently has one cement grinding plant, the
Liberia Cement Corporation, a subsidiary of Heidelberg-
Cement, which employs 63 people. In 2012 Nigerian cement
producer Dangote announced plans to build a US$35m plant
in the country.
 Contents Subscribe Ad Index
ETHIOPIA
Peter Edwards, Global Cement Magazine

Ethiopian Ethiopia is a large landlocked country in central east Africa. Synonymous with
poverty since the mid-1980s famine that ravaged the country, Ethiopia has
since experienced a step-change in economic performance, with an increase in
cement focus cement production also seen. The country is becoming increasingly developed
and has huge potential for high cement consumption.

Above: View across Addis

Introduction Other barriers to foreign investment in the coun- Ababa, the highest capital
Unlike all other African lands, Ethiopia was not colo- try include the fact that all land is owned by the in Africa, rising to over
nised by European powers, except by Italy for a short government, with industrial groups having to hold 3000m in places.
period during the Second World War. Its indigenous long-term lease agreements to set-up facilities. An-
monarchy survived throughout the colonial era, only other is that, although Ethiopia’s GDP growth has
to be toppled by a 1974 military junta. averaged 9.3%/yr since 2004,2 GDP itself remains
After taking over, the military set up a social- in the bottom 20% of African countries, at
ist state, which, through further coups, uprisings, US$374/capita in 2011. This limits the market GDP1 US$94.85bn
drought and infighting, wrestled to control itself and for consumer goods at present. Infrastructure 2
GDP/capita US$374
the country throughout the 1970s and 1980s. During also remains relatively undeveloped, although
Population 1 91.2m
this time inaction and neglect of its own people by the investment is on the rise.
Integrated plants 3 4 (2 projects)
regime amplified the speed and severity of the 1983- Despite these poor economic statistics,
1985 famine that claimed 400,000 lives. Ethiopia is well positioned for development Integrated capacity 3 7.2Mt/yr
In 1991 a diverse opposition group, the Ethiopian compared to its neighbours. It has the sec-
People’s Revolutionary Democratic Front (EPRDF) ond highest population, and thus workforce, Below - Figure 1: Map of Ethiopia
overthrew the socialist system. It drew up a constitu- on the continent1 after Nigeria and ranks showing major settlements and
tion in 1994 and held free elections in 1995 for the first higher in the World Bank’s ‘Ease cement plants.3
time. At the same time as the Ethiopian revolution, the of Doing Business’ survey than Eritr
land that forms modern Eritrea was re-taken by rebel all of its neighbours except for ea
forces that had fought for independence for 30 years. Kenya. 4 1
ETHIOPIA
n

Economy
uti
da

Bahir Dar • Djibo

Su

1. Messabo Cement, 2.2Mt/yr.

Throughout its long history, the economy of • Dese
Ethiopia was very small, comprising extensive 2. Mugher Cement, 2.3Mt/yr.
subsistence farming and market-based trade. 4 2 3 • Dire Dawa
ADDIS ABABA • • Harer Soma
Today, its agricultural sector is still the largest 3. Derba Midroc Cement, 2.5Mt/yr. lia
sector of its economy, employing 85% of work-
ers and creating 41% of GDP.1
4. Habesha Cement, 1.4Mt/yr. (Project). • Jima
• Awasa Werder •
Many areas of the service sector, including 5. National Cement, 0.2Mt/yr.
Sou

finance and insurance, are currently off-limits

th

6. National Cement, 1.2Mt/yr. (Project)

Su

to foreign investors, although industrial and

da

manufacturing firms can be owned by those alia

n

7. Ture Dire Dawa Cement, 0.5Mt/yr. Dolo Oda • om

abroad. However, in practice there remains a (Commissioning / Grinding). 250km 5-7 S
predominance of native firms in industry.1 Kenya

globalcementMAGAZINE January 2013 49

 ETHIOPIA
450
450 3.5
3.5 Cement industry in September 2012. He added that the trial production
400
400 The Ethiopian cement phase at the company’s new plant near Bajatu, Kebele,
3
3.0
350
350 industry consists of would begin at 60% (clinker) and 70% (cement) of
2.5
2.5 four integrated ce- installed capacity, before full operation in 2013. The

Cement production (Mt)

GDP/capita (2011 US$)

300
300
ment plants.3 Three company expects to rely on the eastern Ethiopian mar-
250
250 2
2.0 of these are located ket and will also export to Djibouti and Somalia.10
200
200
in the central area of Also in Dire Dawa, the Tura Dire Dawa Ce-
1.5
1.5
Oromia, close to the ment Plant will enter production in 2013. The
150
150
1
1.0 capital Addis Ababa, 0.5Mt/yr grinding plant will produce OPC and
100
100 with one in the north pozzolana Portland cement. The plant is owned by six
50
0.5
0.5 of the country close members of the Haji Mohammed Ture family, who
50
to the disputed border named the plant after its late founder Haji Moham-
00 0
0.0 with Eritrea. With the med Ture. It lies completed 8km from Dire Dawa and
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
1 3 5 7 9 11 13 15 17 19
country’s economy was awaiting approval from the Ethiopian Conformity
Year relatively closed to Assessment Enterprise in late 2012.11
outside companies, there are no major multinationals Elsewhere in the country, Derba Midroc Cement,
with a stake in the Ethiopian market, although one operated by Midroc Ethiopia plc and 70km from Addis
Above - Figure 2:
plant is part owned by South Africa’s Pretoria Portland Ababa, was commissioned in January 2012.12 It is cur-
GDP/capita (red) and cement
production rates (blue) for Cement (PPC).5 rently the largest cement plant in Ethiopia.
the Ethiopia between 1993 Ethiopia is well set up geologically for cement The opening of such a large capacity plant had a
and 2010/2011. production and has large limestone reserves. Poor in- dramatic effect on cement prices, with the new plant
frastructure has previously prevented this from being offering the lowest cost cement on the local market. By
exploited more efficiently. February 2012 it was reported that the plant was selling
Ethiopia has historically had low cement consump- cement at US$9.36/bag (for bulk orders) in a market
tion, as low as 35kg/capita/yr in recent years. However, that had seen prices close to US$28.00/bag at the start
it is expected that this will rise by a factor of nine or of 2011. The company imported around 1000 Volvo
10 to 300kg/capita/yr in the coming years.6 However, trucks in order to assist with its distribution require-
such a level would still be behind the global average of ments, helping to stabilise the price of cement in the
390kg/capita/yr. local market.13
There has been a significant increase in cement As well as its main cement plant, Derba Midroc
capacity since the early 2000s, reflected in Figure 2. Cement operates two mini vertical-shaft kiln cement
This has been due to a number of upgrade projects plants. The two plants each have a capacity of 300t/day
that continue to come onstream. In 2011 Ethiopia (0.1Mt/yr). They were designed by the Indian com-
imported around 1Mt of cement.6 The government pany SABOO and are located at Derba (next to the
eliminated this on 27 March 2012 when it banned main plant) and at Dejen, 230km from Addis Ababa.14
imports as a measure to protect new and forthcoming Messabo Cement is located in Mekelle in the
domestic cement capacity.7 north of Ethiopia. The FLSmidth-built plant was co-
In the short to medium term, the country’s eco- missioned in 2001 with a capacity of 2.2Mt/yr. The
nomic growth is expected to remain strong, with company produces cement to European standards due
cement playing an increasing role in new roads, dams, to its European design and claims a domestic market
low-cost housing and public buildings. One such pro- share of around 30%. The plant is fuelled by fuel oil
ject is the US$4.2bn, Millennium Renaissance Dam and a 16MW captive power plant.15
hydroelectric project. The project began construction Messabo routinely produces OPC and Portland
in 2011 and should be completed by 2015.8 Ethiopia pozzolana cement and also has the ability to make
has grand plans for the project and expects to be able sulphate-resistant cement and low heat of hydration
to use it to export power to its neighbours. cement (suitable for dams and other large concrete
forms) to order. It exports to Sudan and Djibouti, the
Cement plants latter of which does not have its own cement plants.
The city of Dire Dawa is the historical centre of the The plant underwent expansion to 2.2Mt/yr in June
Ethiopian cement industry and remains very impor- 2011 following a 1.3Mt/yr, US$126.6m upgrade by
tant for the sector. Dire Dawa Cement plant, the first China’s Hefei Cement Research and Design Institute.16
cement plant in Ethiopia was opened in 1936 with a Mugher Cement, a state-owned venture, is lo-
capacity of 60,000t/yr by occupying Italian forces.9 cated in central Ethiopia. It began production in 2007
The Dire Dawa plant was acquired by the National with a capacity of 0.7Mt/yr. Having earlier reported
Cement project in 2005, which changed the plant’s a sales slump at the tail end of 2011,17 the company
name and upgraded the plant to 0.2Mt/yr. National commissioned a new US$94m Chinese-built cement
Cement is due to bring a new 1.2Mt/yr project online production line in April 2012, increasing the capac-
3km from Dire Dawa in 2013.9-10 ity to 2.3Mt/yr.18 The company says that it is targeting
“We will start clinker trial production in October the state sector and real-estate projects to absorb its
2012 and cement trial production in November 2012,” new capacity.
said Busa Assefa, chief executive of National Cement

50 globalcementMAGAZINE January 2013


Mugher is currently in the process of tendering a
new US$32.2m burner system upgrade, for which it
has identified two potential Chinese suppliers. The
contract is to convert the heavy furnace oil system to
a coal fired one.19
This is not the first time that the contract has been
tendered. Mugher originally awarded a US$28m con-
tract for the job but to Chinese firm Hefei Cement
Research Design Institute (HCRDI) but, “The com-
pany increased the bid by around US$11m after we
had already awarded it,” said Mekonnen Zergaw, CEO
of Mugher, by way of explanation.
Cement plant projects
Habesha Cement is in the process of constructing a
1.4Mt/yr cement plant at Holeta in Oromia State.20
The company building the plant was incorporated in
2008 and secured the first 30% of the necessary funds
by selling shares in 2008 and 2009. In October 2010 it
signed a deal with Northern Heavy Machinery Group
of China.21
At the same time it was anticipated that the plant
would receive the remaining 70% financing required
to move ahead with the project from the Development
Bank of Ethiopia, but devaluation of the Birr meant
that the funds were no longer sufficient. This loan was
eventually secured in September 2011.21
Originally set to be in production by the close of
2012, the plant’s ‘foundation stone’ was laid in May
2011.20 Construction was in early stages in the summer
of 2012, with production likely to be in 2014 barring
any further delays. These are now less likely since the
acquisition of Habesha shares by South Africa’s PPC
and the South African International Development
Corporation (IDC) in July 2012.22
“We have been discussing with PPC and IDC for
the past year about the possibility of them investing
in our company,” said Gizaw Mariam, chairman of
the board of directors at Habesha, at the time. “We
are happy now that they have decided to secure a 47%
stake and become our valued shareholders.”
Eventually Habesha plans to develop the plant into
the largest cement facility in Ethiopia, with a capacity
of 2.8Mt/yr.20
Cement plant rumours
In 2010 India’s Birla Cement Corp. attempted to enter
the Ethiopian cement plant construction scene when it
submitted a bid to the Habesha Cement company for
construction of the plant at Holeta. It was outbid by a
Chinese firm in that instance but retained its interest
in the rapidly-growing Ethiopian market.23
In June 2012, Birla again stated its intention to
expand overseas, recently forming a wholly-owned
Ethiopian subsidiary, Birla Corp Cement Manufactur-
ing plc, to establish a plant. “We plan to go (to Ethiopia)
for exploration of limestone and to set up a cement
plant,” said a Birla Corp official. “We would also ex-
plore opportunities to set up power plants there.”23
Elsewhere, CH Clinker was established in June
2009 and anticipated commissioning of a 0.9Mt/yr
ETHIOPIA
plant by the end of 2012, with others reporting that the
company had a plan for a 3.2Mt/yr plant. This project
has apparently not been pursued since this announce-
ment or may be running significantly behind schedule.
The Ethio-cement project was also launched in
2009 with the aim of constructing a 1.2Mt/yr plant to
fill the expected cement deficit in the country. This also
appears to have made little progress since.
Future prospects
Ethiopia, while still poor, is experiencing rapid real-
terms economic growth at a time when much of the
global economy is struggling with issues relating to
ongoing recessions and debt crises. Indeed, in June
2012 the IMF raised its economic growth forecast for
Ethiopia for 2012-2013 from 5.5% to 7.0%.24 With
inflation in the region on the decline, the heady GDP
growth figures of the past decade are unlikely to be
matched in the future, but growth is expected to re-
main strong.
Another economic ace that Ethiopia has up its sleeve
is one of the largest populations in Africa, currently
around 91m.1 This is forecast by the UN to increase
drastically to 120m in 2020 and to 278m in 2050.25
With a workforce of this size and strong growth, the
country has the potential to become a major regional
economy in east Africa.
In cement terms, the government is certainly not
holding back. It has stated that it wants Ethiopia, a net
importer of cement in 2011 and now with an import
ban, to increase its production by a factor of 10 in just
three or four years, an increase to 27Mt/yr.26
The current expansions and projects go some of
the way to this target, but the case for multinational
companies entering the market at this time is very
clear. Although barriers to investment and a historical
bias towards domestic companies exist, the recent PPC
acquisition should make the country inviting for more
foreign firms.
The potential is certainly large. Assuming that the
country hits the UN population forecast in 2020 with
cement consumption of 300kg/capita/yr, domestic
demand will hit ~36Mt/yr. The same assumptions in
2050 reveal the potential for ~80Mt/yr of cement con-
sumption in Ethiopia!
With figures like these and considering the constant
jitters in the European cement markets and overcapac-
ity in some Asian hubs, the country is attractive to
multinational cement companies. PPC, Birla and the
Chinese firms are among the first movers into the
Ethiopian cement market but they will not be the last.
References
1. CIA World Factbook website, ‘Ethiopia,’ https://www.cia.gov/library/
publications/the-world-factbook/geos/et.html.
2. World Bank Indicators website, ‘GDP per capita (current US$),’
http://data.worldbank.org/indicator/NY.GDP.PCAP.CD
3. ‘Global Cement Directory 2013,’ PRo Publications Intl. Ltd., Epsom
UK, November 2012; and work towards publication of ‘Global Cement
Directory 2014,’ PRo Publications Intl. Ltd., Epsom, UK.
4 - 26. See online article, http://www.globalcement.com/articles.
globalcementMAGAZINE January 2013 51
 Contents Subscribe Ad Index
IRAQ
Peter Edwards, Global Cement Magazine

Iraqi cement focus

A turbulent political history
has stunted the growth of Iraq,
a country with vast natural oil
reserves. Now that the US-led
occupation has given way to
self-governance, the country
has turned up the wick on
its (re)-development. Recent
speculation surrounding the
possible doubling of its known
oil reserves has put Iraq in a
strong position to become an
economic and political leader
in the Middle East. The cement
industry will have an important

role to play in this development
and is seeing major investment
in production capacity.
Above: The Sinjar cement
plant dates from the late
1980s. It underwent an exten-
sive re-fit in 2011 courtesy of
Austroplan Austrian
Engineering GmbH.1
Below: Sporadic
GDP/capita (red)2 and ce-
ment production data (blue)3
for Iraq since 1982.
4000
4000 Claimed 2002 production 6.83Mt
3500
3500
3000
3000
F
ormerly part of the Ottoman
Empire, Iraq came under control of
the British in the early part of the 20th
Century. In 1932 it became a Kingdom
and in 1958 it declared itself as a ‘Republic,’ although
in reality a series of six military dictators ruled.
The most infamous of these leaders was Saddam
Hussein, who came to power in 1979. He led Iraq into
a territorial conflict with neighbouring Iran that lasted
from 1980 to 1988 and invaded Kuwait in 1990, trig-
gering the Gulf War of 1991.
Throughout the rest of the 1990s Hussein’s regime
taunted the established western powers after US-led
sanctions against the oil-rich nation. In 2003, amid Much of Iraq’s inherent wealth is tied up in its oil,
growing fears over Hussein’s access to and willingness which provides 90% of all government income.4 This
to use weapons of mass destruction (WMD), allied will provide a very strong source of revenue for the
forces invaded the country, toppling the Hussein re- country’s (re)-development in future years. Speculative
gime in April of that year. No WMD were found. results from 2011 have led the government to claim
that it has the largest reserves in the world, although
Economy with ‘just’ its existing 171bn barrels, it sits 12th in the
The 10 years since the removal of Hussein have been list of oil producers and third in the list of oil reserves.1
characterised by economic improvement amid contin- Despite this, unemployment and corruption re-
ued violence and lawlessness. Foreign firms, especially main major barriers to fair and wide distribution of
in the oil sector, are Iraq’s increasing wealth. It remains hard to set up new
7000
7.0 investing heavily in Iraq enterprises due to government regulations and 25% of
despite the risks. the population remains in poverty.2
6000
6.0 Since 2003, Iraq’s
economy has steadily Cement industry - History
5000
5.0 improved due to the re- From the start of cement production in Iraq at Badoosh
Cement production (Mt)

2500
2500
GDP/capita (2011 US$)

moval of UN sanctions in 1955 until 2003 all cement factories in the country
4000
4.0
2000
that had been in place were owned and operated by the government.3 After
2000
3000
3.0 since 1990. This has al- Badoosh started production, further plants were
1500
1500 lowed its GDP/capita to added over the next three decades by a government
2000
2.0 return to pre-sanction keen to develop Iraq’s standing as a major regional
1000
1000
levels and highlights player across a number of development indicators.
500
500 1000
1.0 two decades of lost Iraqi This drive to develop the economy brought 15 ce-
economic development ment plants into production in Iraq but, although the
00 0.0
0
as a result of the Hussein country’s headline capacity was fairly high, it suffered
1994
1990

1998

2002

2010

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
1982
1984
1986
1988

1992

1996

2000

2006
2008
2004

regime’s hostile relation- from severe overcapacity. The country was briefly a ce-
Year ship with the west. ment exporter in the mid 1980s.5

52 globalcementMAGAZINE January 2013

 IRAQ
Company Plant Location Established Lines Process Line 1 Line 2 Line 3 Line 4 Theoretical capacity
Iraqi General Qaim Qaim 1989 1 Dry 3200 - - - 3200t/day 1.0Mt/yr
Cement Co Fallujah Fallujah 1978 3 Dry 300 350 350 - 1000t/day 0.5Mt/yr
Kubaisa Kubaisa 1983 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
Kirkuk Kirkuk 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
Northern Badoosh - Old Mosul 1955 2 Wet 300 300 - - 600t/day 0.2Mt/yr
Cement State Co. Badoosh - New Mosul 1978 2 Dry 1250 1250 - - 2500t/day 0.8Mt/yr
Badoosh - Ext Mosul 1983 1 Dry 3200 - - - 3200t/day 1.0Mt/yr
Hammam Al Ali - I Mosul 1963 2 Wet 350 350 - - 700t/day 0.23Mt/yr
Hammam Al Ali - II Mosul 1 Wet 1200 - - - 1200t/day 0.38Mt/yr
Private Group Sinjar Sinjar 1985 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
Southern Najaf Najaf 1975 1 Wet 700 - - - 700t/day 0.23Mt/yr
Cement State Co. Al Kufa Kufa 1977-78 4 Wet 1500 1500 1500 1500 6000t/day 1.9Mt/yr
Muthana Muthana 1984 2 Dry 2500 3000 - - 5500t/day 1.76Mt/yr
Babil Hindia Barrage 1957 2 Wet 250 300 - - 550t/day 0.18Mt/yr
Samawa Samawa 1957/1973/1986 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
Lafarge Bazian Sulaimaniah Sulaimaniah 2 Dry 3600 3600 - - 7200t/day 2.3Mt/yr
(Leased from Gov.) Bazian Sulaimaniah 1 Dry 7000 - - - 7000t/day 2.2Mt/yr
Kerbala Kerbala 1984 2 Dry 3200 3200 - - 6400t/day 2.0Mt/yr
MASS Global MASS Iraq Sulaimaniah 3 Dry 5500 5500 5500 16,500t/day 5.3Mt/yr

Throughout its time as a cement producer, Iraq has more than just cement at that time. In 2003 the level, Above: List of integrated
cement plants that have
benefited from its natural limestone and gypsum as as measured by the USGS returned to ~2Mt/yr.3 produced cement in
well as its oil. In addition to having a lot of limestone, Iraq, drawn from a number
it is also of unusually high quality, Cement industry - Since 2003 of sources. Not all plants are
in that it has a high percentage of Following the US-led invasion in active at present.
GDP (2011 est.)4 US$138.8bn
calcium carbonate (CaCO3). This 2003, UN sanctions were lifted and
2
means that more cement is pro- GDP/capita (2011 est.) US$3501 cement capacity began to rise. Pro- Left: Summary statistics for
duced per tonne of limestone, which Population (July 2012)4 31.1m duction, as reported by the USGS, Iraq and its cement industry.
theoretically enables a more efficient Official oil reserves4 171bn barrels has risen by a factor of more than
process. Iraq’s limestone is also very three since 2003 to around 6.5Mt/yr Below: Map of Iraq with key
Area4 438,317km2
close to the surface, allowing low- in 2011 from a theoretical capacity settlements and
cost mining. Integrated plants6 19 of around 32.5Mt/yr.3 neighbouring countries.
Since 2003 the Iraqi cement sec- Integrated capacity6 32.5Mt/yr Turkey
tor has been split into two categories. Average plant capacity6 1.70Mt/yr
On one side are the former state-run
• Mosul
Iran

plants and on the other side are new

private operators. Lafarge acquired two plants post- Sinjar •
2003 and took over the running of a third in 2008. 150km

Other private operators include the Al-Rawi group,

Kirkuk • • Sulaimaniah
which operates three plants and MASS Global, which
a
commissioned its first kiln at Sulaimaniah in 2010 and Syri • Qaim
Iran

a second in 2011. Also under private ownership is the

Sinjar Cement Plant, owned by a consortium of family Kubaisa •
members. • Rutba Fallujah • • BAGHDAD
Jordan

Cement industry - Reported production Kerbala • •Hindia Barrage

The United States Geological Survey’s (USGS) records Najaf • Kufa
of Iraqi cement production in the 1990s confirm that
production was fairly low for a country of its size at Saud Samawa •
i Ara Nasiriyya•
around 2Mt/yr from 1993 to 2001.3 However, like bia • Basra
other outside parties the USGS’ access to information
about Iraq’s internal affairs was largely restricted. Muthana •
In 2002 the country reported a large increase in its
Kuw

cement production to nearly 7Mt. However, it is now

known that Hussein’s regime was lying about a lot
ait

globalcementMAGAZINE January 2013 53

IRAQ
Below: The Lafarge Bazian
Cement plant in Kurdistan,
Iraq. Source: Mohamed Sedek,
Lafarge Bazian Cement. Entrant
into Global Cement Photogra-
phy Competition 2013.
54 globalcementMAGAZINE January 2013
Throughout 2011 and 2012 a number of new pro-
jects were announced that have seen the real potential
capacity of Iraq’s industry increase. Also detailed are
rumours regarding potential future market entrants:
Dangote Cement: Speaking in October 2012, the
President and Chairman of Nigeria’s Dangote Group,
Aliko Dangote, raised the possibility of taking Dangote
Cement to Iraq as part of its mission to reach 100Mt/yr
of cement capacity.7
Fallujah Cement Factory: The Fallujah Cement Fac-
tory was previously operated by the Iraqi government
between 1978 and 1986, when it ceased operations.8
In the new political climate in February 2012,
it was agreed by an Iraqi company and the govern-
ment that the company invest in the plant over a 20
year period to 2032 and bring the plant’s capacity to
1.5-2.0Mt/yr from its original 0.6Mt/yr capacity.
Global Cement speculates that the new plant is unlikely
to be commissioned before the close of 2014.
GRD: Sinoma (Suzhou) Construction Co has placed
an order for an MPS 5000 B vertical roller mill for raw
material grinding from Germany’s Gebr. Pfeiffer.9 The
grinding plant will be set up in GRD Cement Plant
Company’s 5000t/day cement plant located near the
town of Sulaimaniah in northern Iraq.
Kerbala Cement: Lafarge plans to triple cement pro-
duction over the next two to three years at its plant in
Kerbala. It expects to realise the potential of its Kerbala
plant and produce 1.8Mt/yr in 2013 or 2014.10
In January 2013 it was announced that the Inter-
national Finance Coporation (IFC), a member of the
World Bank Group, would provide a US$70m loan to
help renovate the plant.11 “This financing will help ad-
dress the cement shortage that Iraq is facing and help
the country meet supply gaps in its infrastructure,”
said Guy Ellena, IFC Director for Manufacturing,
Agribusiness and Services in Eastern and South-
ern Europe, Central Asia, the Middle East and
North Africa. Kerbala Cement is a joint venture
between Lafarge and
MerchantBridge, a Lon-
don-based private equity
group. The financing is
being supplemented by
a US$20m loan from
Proparco, a develop-
ment financial institution
funded by the French
Development Agency
and private shareholders.
Lucky Cement: In April 2012 Pakistan’s Lucky
Cement Company decided to set up a greenfield ce-
ment grinding plant with a 0.87Mt/yr production
capacity in Iraq under a joint venture scheme.12
MASS Cement: MASS Cement contracted China’s
Sinoma to build a three line cement plant in Bazian
district near Sulaimaniah in 2007, with the first two
2Mt/yr kilns coming online at the end of 2009 and
August 2011. The third line, another 2Mt/yr-capacity
design, will commence production in March 2013.13
The company intends to increase its Iraqi produc-
tion to 10Mt/yr by constructing another two 2Mt/yr
lines, although it is unclear where or when these plants
will be constructed.
Nokan Group: In September 2012 Sinoma of
China signed a contract for the construction of a
5300t/day (1.6Mt/yr) factory for Nokan Group in the
north of Iraq.14
Samawa Cement: In June 2011 the Iraqi government
awarded a US$110m contract to Turkey’s Partner
Teknik to re-boost the struggling Samawa Cement
plant in south Iraq.15 The plant, which has a design ca-
pacity of 2Mt/yr has produced less than a fifth of that
amount in recent years following years of neglect.
The project aims to increase the plant’s cement
production to 1.8Mt/yr, 90% of its original capacity, by
mid 2014. A Turkish and Iraqi consortium will own
73% of the plant as part of a joint venture lasting a total
of 15 years, with the remaining 27% owned by the Iraqi
Ministry of Industry and Minerals.
Sinjar Cement: The Sinjar Cement plant endured a
difficult birth between 1981 and 1990. Upon comple-
tion it was only in operation for 18 months before
production was halted by the first Gulf War.1
The plant limped through the 1990s producing at a
low level and was a victim of sabotage in the 2003 US-
led invasion. The plant was radically altered in 2011
via an Iraqi-Turkish investment group, which hired
Austroplan Austrian Engineering GmbH and Turkey’s
Perkam as contractors.
The project’s progress means that the plant
produced 2000-2500t/day (~0.7Mt/yr) by the start
of 2012 with the aim of returning to 1.8Mt/yr in the
second quarter of 2013 when further work is finished.
Umm Qasr: In October 2011 the Basra Investment
Commission licensed a project to construct a new
3000t/day cement factory in Umm Qasr, near Basra.16
Cement industry - Future development
At the start of 2012, Global Cement
estimated the total combined ca-
pacity of the plants that were able to
operate in Iraq at around 10-11Mt/
yr, giving an adapted approximate
capacity utilisation rate in the re-
gion of ~45%.1

In 2013, the pace of redevelopment in Iraq’s cement
industry continues, with a possible further 11.3Mt/yr
of cement capacity to be realised in 2013 or early 2014.
This, combined with the estimated current capacity
currently in operation, could give rise to a production
capacity of 21-22Mt/yr by the end of 2014. However,
even this will not be enough to feed the expected
35Mt/yr of demand from Iraqi development that is
expected in 2015.10
If these much higher production levels are realised,
private cement companies will certainly have followed
the ‘advice’ given in our January 20121 report to max-
imise their production in Iraq by any means possible.
The country plans to build 2.5 million homes by 2015
- high cement demand indeed.
However, with constant project updates and a
dearth of solid information regarding completion
timescales, it remains difficult to get a handle on the
actual production rate in Iraq. As suggested by the use
of the term ‘theoretical capacity’ above, there remains
a gulf between the capacity ‘written on the side’ of
many Iraqi cement plants and the amount of cement
that they can actually produce, the result of decades of
poor maintenance.
What is clear is that cement consumption is increas-
ing, with one source estimating an increase in cement
demand growth from just 6% in 2008 to over 20% in
2011, when cement consumption was estimated to
have hit 20Mt.10 Demand is centred on Baghdad, Basra
and the northern Kurdish regions around Mosul.
Cement industry - Concerns
While the economic and construction factors are in
place for a surge in cement use in Iraq, not all signs
point to unbridled growth in the Iraqi cement indus-
try. The vast discrepancy between Iraqi production
costs and selling prices seen previously, which helped
to drive the current construction and renovation
trend, may be losing significance in 2013.
In July 2011 Iraqi cement cost US$58/t to pro-
duce but was being sold at US$90-120/t.1 This
difference is potentially under threat from two direc-
tions. Firstly, as cement supplies increase, prices will
likely decrease, making sales less lucrative. Secondly,
there is the risk, at least in the south of Iraq, that
foreign imports are undercutting Iraqi producers
on price. The USGS reports that Iraq was one of the
largest importers of cement in 2010, around two thirds
of its requirements.3 In December 2012 it was reported
that Iranian 42.5N cement was reportedly reaching the
Iraqi market in 50kg bags for as little as US$45-55/t.
Undercutting by foreign firms was a concern high-
lighted by Southern State Cement Co. in September
2012. It threatened to stop production amid a US$50m
stockpile of cement that it was unable to sell, blaming
importers of cement.17 It called on those in charge of
public projects to seek out Iraqi-made cement.
With this in mind, Iraqi cement producers must
take steps to ensure that they do not lose the benefits of
their new investments to cement dumping, a situation
that is currently underway in Nigeria.18 With Lafarge
IRAQ
estimating 10% year-on-year cement demand growth
in Iraq in 2012,19 Iraqi producers need to act so that
importers do not take an irrecoverable lead in Iraq.
Conclusion
The Iraqi cement industry is now well into a period
of expansion and renovation by a mixture of local,
foreign, public and private investors. They have been
attracted to the country and the cement industry by
the need to update the Iraqi cement infrastructure to
sell cement locally and develop the country.
As Iraq’s new cement production technology comes
online, its strong economic growth and unique set of
natural advantages offer the potential for it to gain an
advantage in terms of cement production compared to
its immediate neighbours.
With sufficient upgrades and a more stable future,
Iraq should be able to meet domestic demand and ex-
port surplus production either by road, rail or by sea,
as it did in the 1980s.
However, for all its natural and strategic advantages,
a major disadvantage of Iraq’s location are the nearby
countries with large cement excesses. In the immedi-
ate area, Iran and the United Arab Emirates will have
no qualms in supplying ‘cheap’ cement to Iraq, given
their current overcapacities. Also within shouting
distance of the lucrative Iraqi market are exporters in
Pakistan and India as well as those from further afield
like Vietnam.
Other potential stumbling blocks in the future
include a potential deterioration in political stability,
irregular fuel supplies and a risk of public perception
that Iraqi-made cement may be of a lower standard
than that which is imported from abroad.
References
1. ‘Global Cement Magazine - January 2012’, PRo Publications
International Ltd., January 2012.
2. World Bank Indicators website, ‘GDP per capita (current US$),’
http://data.worldbank.org/indicator/NY.GDP.PCAP.CD.
3. United States Geological Survey, Various reports, http://minerals.
usgs.gov/minerals/pubs/country/africa.html#iz. Below: Baghdad, the capital of
4 - 19. See online article, http://www.globalcement.com/articles. Iraq, stretching into the desert.
globalcementMAGAZINE January 2013 55
 Contents Subscribe Ad Index
AUCBM 2012 REVIEWED
Robert McCaffrey, Editor, Global Cement Magazine

17th Arab International Cement Conference and

Exhibition - AUCBM Dubai 2012 - Reviewed
The 17th Arab International Cement Conference and Exhibition, organised by the Arab Union for Cement and Building
Materials (AUCBM), has been successfully held at the Dubai World Trade Centre in Dubai, UAE. Over 650 delegates
attended the event, which also featured nearly 140 exhibition booths in what was one of the largest - and certainly best
organised - cement exhibitions ever held in the Middle East. The next AUCBM meeting will take place in Marrakesh.

1: Anis Haider of ITECA, right,

being visited by Ali Riahi of
Scantech.
2: David Hughes, left and
Klaus-Martin Rupp manning
the Andrew Webron stand.
3: Cemengal’s display Moisés
Nuñez Rodriguez, centre, and
Fernando Dueñas Pozo, right,
in discussion with a visitor.
T he conference and exhibition took place at the
large and modern Dubai World Trade Centre,
which was well-serviced by good transport links and
on-site hotels. The event took place over two and a half
days, such was the large number of presentations that
had been offered to the organisers. The exhibition, fea-
turing nearly 140 exhibition stands, was of very high
quality, with very smart exhibition stands and carpet-
ing, and regularly-served fresh coffee. The exhibition
was busy for the first two days of the event.
Aimo Haack of ThyssenKrupp Polysius spoke
about cement grinding with the Polycom high pres-
sure grinding roll system, allowing a reduction in
specific electricity costs. Aimo suggested that the
Polycom system has only 46% of the energy consump-
tion of a ball mill (a vertical roller mill has an energy
consumption of around 53% of a ball mill). The Poly-
com grinding system is best teamed-up with the Sepol
high-efficiency separator.

1 2 3

4: Sebahattin Akbas, left,
welcoming visitors from
Egypt to the Möllers stand.
5: Eduardo Tena Recalde,
right and Alejandro Corcuera
Rodriguez of Aceros y Sumin-
istros pose for the camera.
6: Haver & Boecker’s Claus
Ohlmeyer, far left, in discus-
sion with visitors
and colleague Alan
Arbotante, right.
Given that there were 47 papers, of only 20 minutes
each, spread over the course of the two and a half days
of the conference, Global Cement Magazine here re-
ports on just a few of the highlights of the conference.
The first speaker, Tareq Samaha from RAK Com-
pany for White Cement, told the audience that there
was a huge oversupply in the UAE, with around 30Mt/
yr of cement production capacity, but with demand
only amounting to 10Mt in 2012. “Despite the contin-
ued oversupply, UAE real estate has been recovering
from the crisis, thanks largely to increased tourism,
as well as an Arab-Spring induced demand for stable
safe-havens in the Arab world.”
Dispelling VRM myths
Thomas Fahrland of Loesche next sought to dispel
some of the myths surrounding the quality of cement
produced by vertical roller mills. It was said, when
VRMs were first introduced into the cement industry
in the early 1990s, that the cement they produced
would have a higher water demand, a retarded set time
and a lower compressive strength due to a steeper par-
ticle size distribution, different particle shapes and due
to gypsum dehydration.
Thomas showed that there is more fine (over-
ground) material in cement produced in a ball mill
system, due to the high number of impacts and the mill

4 5 6

56 globalcementMAGAZINE January 2013


7 8
inefficiency. He pointed out that there are a number
of different adjustment options in a VRM that allow
you to tailor your particle size distribution (and water
demand) to customer demands. However, using par-
ticle image analysis, the sphericity of cement particles
is similar for ball mill and VRM-produced cements,
apart from for particles above 50 microns, but which
have no influence on strength development.
In a ball mill, gypsum is dried and converted into
reactive hemihydrate, necessary as a setting regula-
tor. The lower mill temperature and shorter residence
time of cement in a VRM will result in a difference in
gypsum performance, but again there are a number
of measures that can be taken to optimise the result-
ant cement, for example, using a little more gypsum,
adding a small amount of hemihydrate, increasing the
mill exit temperature or reducing the moisture content
of the mill air supply. Thomas effectively dispelled the
VRM myths in his excellent paper.
John Dicom of FLSmidth stepped up to the mi-
crophone to speak about automation technologies to
enable an intelligent collaborative environment (ICE).
Remote locations, lack of skilled personnel, rising
energy costs and intense competition are among the
most pressing concerns for the global cement industry,
according to John Dicom.
ICE allows remote access to plant information,
including performance monitoring, asset manage-
ment, process control and optimisation and predictive
maintenance. The ICE centre in Denmark collects in
plant information and can benchmark plants against
each other in real time, as well as feeding back to the
plants advanced information about the performance of
the cement plant and its equipment. 140 plants already
use the system.
Cement Sustainability Initiative
Philippe Fonta of the WBCSD stated that the Cement
Sustainability Initiative now represents one third of the
world’s cement production, (two thirds of the global
10
AUCBM 2012 REVIEWED
cement capacity outside of China),
but that there are no member
companies in the Middle East (or
Australia). Companies that sign up
9
to the CSI are required to comply
with the organisation’s charter within
three years of signing up.
The first priority is to eliminate fatalities from the 7: A busy coffee break provided
industry. In fact, 56% of industry fatalities involve ideal networking opportunities.
moving vehicles, 10% are falls from height and 8%
involve being hit by moving machinery.
The second priority for the CSI, to reduce CO2
emissions, will be brought about by improving energy 8: A very busy MVW Lechten-
efficiency, the use of alternative fuels, clinker substi- berg exhibition stand!
tution and through the use of Carbon Capture and
Sequestration (CCS).
Wilfred Zieri of A TEC, who stated as his hobby
9: Intensiv-Filter’s new owner,
‘alternative fuels,’ spoke about his company’s ReduDust Himenviro exhibited, left to
solution for excess volatiles such as sulphur, chlorine right Vidhan Sharma, Rajeev
and potassium. A TEC and Holcim have jointly de- Sood and Markus Schröder.
veloped a process to wash the dust to create a brine,
which can then be precipitated, oxidised and neutral-
ised (and - expensively - crystallised) to create pure
enough potassium chloride salts that could be sold as a
10: KIMA was well represented
base product (at Euro300/t) for fertilisers. A pilot plant
at this year’s AUCBM.
has been completed, as well as designs for a full scale
plant which would cost around Euro10m.
Energy matters
Uwe Maas for ThyssenKrupp Polysius pointed out that
11: Andreas Renetzeder, right
the use of an intermediate crusher in a clinker cooler
and Ruggero Baldo of Scheuch
can raise the temperature of the exhaust air by 30-40°C, smile for the camera.
while simultaneously lowering the clinker tempera-
ture. Uwe also mentioned the Prepol Step Combustor,
for the use of alternative fuels: feed screws push fuels
onto an ignition table where they are ‘lit’: the materials
then cascade down an inclined grate, with a residence 12: Shakespeare Foundry was
time of around 15 minutes, using pneumatic transport. out in force this year from both
the UK and Egypt.
The first installation will be in spring 2013 and we look
forward to the first results.
11 12
globalcementMAGAZINE January 2013 57
AUCBM 2012 REVIEWED

13: AUMUND’s team left to

right, Peter Müller, Emil Catalina
and Christian Spättmann.

14: Conveyor belt specialists

SIG: left to right, Luca De
Stefano, Franceso Violante and
Guido Scolari.

13 14

15: Loesche, A TEC and Greco

had an impressive presence
at the show: Christian Helmreich
from Greco, left and Dietmar
Kirchebner of A TEC are
seen here manning the
extensive display.

16: A lively stand for casting

specialist Fonderia Gelli.

15 16

17: Teutrine, acquired by

FLSmidth in September 2012.
Left to right: Gabriele Teutrine,
Rudolf Henneboele and Frank
Henning reported a high level
of enquiries.

18: ThyssenKrupp Polysius and

ThyssenKrupp Fördertechnik
had an impressive exhibition
stand as usual!
17 18

19: Fives FCB in discussions with

customers at its stand.

20: Wieland Lufttechnik’s stand;

Wolfgang Wieland, left and
Gerd Borrmann are seen here
manning their stand.

19 20

21: Frey Cement Consultancy;

left to right Berthold Frey, Kurt
Barbian, Manal Ragab, Edgar
Hovorka.

22: Caroline Woywadt of

grinding specialists Gebr.Pfeiffer
welcomes another well-known
grinding specialist! 21 22

58 globalcementMAGAZINE January 2013

 SPECIALISTS IN
CAST PARTS
FOR THE CEMENT
INDUSTRY
Aceros y Suministros, S.A.
was founded in 1951. We
manufacture and supply all types
of cast, machined and forged
spare parts for an extensive
range of machinery used in the
production and processing of
cement.
Our collaboration with leading
cement engineers and the largest
cement plants worldwide for
over 40 years has provided us
with the know-how, experience
and training our company needs
to meet the most demanding
requirements for spare parts
within the cement industry.
9-10 MAY 2013
gl bal
cemtrader
CONFERENCE • EXHIBITION • BUSINESS •NETWORKING
A meeting for suppliers,
shippers and users
of supplementary
cementitious materials,
coal and petcoke and
of cement and clinker
for the cement and lime
industry.
Focus on supply and
demand trends in the
markets, shipping and
freight cost trends
and contracting and
pricing trends. Including
networking and business
opportunities.
Aceros-CemTrader.indd 1
SPÉCIALISTES DANS
LA FONDERIE
DE PIÈCES POUR
L’INDUSTRIE DU CIMENT
Aceros y Suministros S.A. a été
fondée en 1951. Nous fabriquons et
fournissons tout type de pièces de
rechange, mécanisées et fondues,
ainsi que des pièces forgées, pour
diverses gammes de machines de
production et de traitement du ciment.
Notre collaboration avec les
principaux fournisseurs d’équipements
et de services pour l’industrie de
ciment et des minéraux, et les plus
importantes installations de ciment au
monde pendant plus de 40 ans, nous
a apporté un savoir-faire, une maturité
et une préparation nous permettant
de satisfaire les plus hautes exigences
quant aux pièces de rechange de
l’industrie du ciment.
Pol. Ind. Padura, 1 - E-48830 SODUPE (VIZCAYA) Spain
Tel. +34 94 669 38 40 (ext. 4) - Fax +34 94 669 38 47
P.O. Box. 237 - E-48080 BILBAO/Spain
E-mail: corcuera@acerosysuministros.com
recambios@acerosysuministros.com
http: www.acerosysuministros.com
London, UK
www.Cemtrader.com
Markets, Shipping, Prices
SCMs, Coal
Petcoke, Clinker,
& Cement
Who should attend?
Suppliers , traders, shippers
and users of fly ash, slag-based
products, silica fume, mill-scale,
natural pozzolans, FGD/DSG
and other gypsum,
other supplementary
cementitious materials
Suppliers , traders, shippers
and users of cement, clinker,
coal and petcoke in the cement
& lime industry
16/01/2013 09:07
AUCBM 2012 REVIEWED
23: Aniruddha Joglekar, left
and Ali Riahi proudly man the
Scantech stand.

24: Filter media guru Kayser

Filtertech welcomes visitors as
they line up for the camera.

25: Robert McCaffrey, editor of

Global Cement, readies himself
for his very popular presenta- 23 24
tion on the second day.

26: HEKO Ketten, the chain

expert, welcomes visitors. Dirk
Schmidt of HEKO can be seen in
the centre.

27: Global Cement’s stand was

popular with delegates. Here
visitors from Lafarge pose for
the camera.

28: Di Matteo, conveying and

secondary fuel technology 25 26 27 28
specialists. Seen here are Dr.
Luigi Di Matteo, left and
Svetoslav Chopov.

29: Karl Haugen, left and a

vistor to the Haugen
System AB stand. The company
is a specialist in vacuum systems
for industrial
spillage management.

30: The Gambarotta Gschwendt

team; left to right, Davide
Gambarotta, Luca Mastrorocco 29 30
and Umberto Gambarotta.

31: Intercem Engineering;

Visitors are welcomed by Olaf
Michelswirth. The company
has been very active in Africa in
recent times.

32: FLSmidth had a large,

impressive display to accom-
modate its various divisions of-
fering a multitude of disciplines
for the cement industry.
31 32

33: Global Cement’s stand; left,

Paul Brown, second from left
Sören Rothfahl. Visitors Tareq
Samaha of RAK White Cement
second from right and right,
Mahdi A-Al-Ghamdi
of Yamama Cement.

34: The Beumer Group in

discussions with a visitor.
Mohamed Saffour, left and
Wolfgang Schulte, centre.
33 34

60 globalcementMAGAZINE January 2013


Dirk Lechtenberg of MVW
Lechtenberg stated that regu-
latory issues and fuel price
distortions currently complicate
the use of alternative fuels (AF)
in the MENA region. Dirk men-
tioned that the majority of AF
used in the MENA region at the
moment is derived from munici-
pal solid waste. He suggested that
half a billion dollars of fuel costs
could be saved each year if the ce-
ment plants in the MENA region
switched over to 60% AF use.
That is a lot of profit that is cur-
rently going to the coal producers
but which could be retained by
the cement manufacturers. Partly
because of this fact, the 8th
Global CemFuels Conference on
alternative fuels in the cement
and lime industry will take place
in Istanbul on 12-13 March 2013.
Çağlan Beçan of the Turkish
Cement Manufacturers Asso-
ciation spoke about the industry
and its future prospects. Turkish
inflation is around 6%, while
the economy is now growing
at around 2-3%. Construction
sector growth has slowed dra-
matically, from 17% in 2010, to
only 1% in 2012. In 2012, Turkey
had 68 cement plants, with 48 inte-
grated plants and 20 grinding plants.
Turkish cement production was 68Mt,
with 56Mt sold in Turkey. In 2011,
12Mt of cement and 2.4Mt of clinker
were exported, to Iraq, Syria, Libya,
Algeria and Egypt and to 90 other
countries around the world. Cement
production is expected to amount to
96Mt in 2020, with a potential export
tonnage of 18Mt. Cağlan mentioned
that the economic turmoil in Athens
and the rest of the EuroZone is having
a knock-on effect on cement demand
from Turkish cement manufacturers.
AF consumption amounts to only 2% in Turkey at
the moment but is expected to increase rapidly, while
the clinker factor is expected to drop with increasing
use of supplementary cementitious materials. There
are no areas of Turkey that do not have seismic haz-
ards, but some areas have higher levels of hazard than
others. Around eight million sub-standard housing
units are expected to be demolished and reconstructed
over the next 20 years in order to reduce seismic haz-
ards, with resultant huge increases in cement demand.
Muayad Matar of the Najran Cement Company,
Saudi Arabia, ended the second day of the conference
with a presentation on his company’s 27.1MW waste
AUCBM 2012 REVIEWED
heat recovery (WHR) system,
supplied by Sinoma Energy Con-
servation Ltd with Holtec India
as the engineering and supervi- 35: Christian Pfeiffer’s stand
sion consultant and NESMA as was always very busy!
the local contractor, with a total
cost of around US$45m.
Around 22% of the heat pro-
duced by the pyroprocessing
system can be used by the WHR
system and this will produce 34%
of the electrical energy required
by the plant. The project came
about due to a shortage of heavy
fuel oil (HFO) for the cement
35
industry in Saudi Arabia and to
avoid stoppages due to grid inter-
ruptions. Incidentally, the second
Global CemPower Conference
on waste heat recovery in the ce-
ment industry will take place in 36: Mertec AG once again had a
London in June 2013 (see www. very stylish custom-made stand.
CemPower.com). Left, Peter Arnold (CEO) in
discussions with a delegate.
Conclusions
The 17th Arab International
Cement Conference and Exhibi-
tion was very well-organised and
boasted the smartest-looking
36
cement exhibition ever staged
36
37: Dirk Lechtenberg of second-
ary fuel guru MVW Lechtenberg
giving his presentation.
38: The gala dinner took place
in the desert: On arrival 4wd
vehicles delivered guests after
some spirited (!) driving to the
evening’s venue, which offered
an excellent barbecued feast
and dance entertainment.
37
37
in the Middle East. The mod-
38
erators kept the programme to
time and there were many nug-
gets of valuable information in
the conference presentations.
We look forward to meet-
ing conference attendees at the
next AUCBM conference, on
environmental impact abate-
ment technology, in Marrakesh,
Morocco in December 2013.
globalcementMAGAZINE January 2013 61

TRADING
Yves De Moor, Director & CEO, Group DML Ltd.
Email: info@dmltrading.eu
Tel: +32 9 336 7083
A trader’s view
Overcapacity: How long will Africa remain a solution as an offset destination?
F or countries with excess cement capacity Africa is
a destination market for export sales. With African
consumption rising from 82.7Mt in 2000 to 179Mt
in 2010 and continuing to rise by 10%/yr, one might
expect that Africa could solve all of their problems,
with consumption possibly going through 250Mt
in 2014. However, this is not the case, even though
there is a forecast surge in African consumption from
153.8kg/capita in 2008 to 250kg/capita by 2014-2015. No
other continent grows at a rate of 62% in just six years.
This is a very interesting situation if you are a ce-
ment producer considering building a cement plant in
Africa because by the time you finish construction your
capacity could already fall short by 30%! Consequently
architects and engineers must design a cement plant to
adapt and to upgrade for fast expansion from one to two
kilns and beware that the investments in logistics should
follow that rhythm, not common in other markets.
Africa is literally squeezed between two continents
trying to get rid of cement. On one side there is Europe,
which has had a devastating drop in demand. I heard that
a third of construction companies in the Netherlands
will go out of business in 2013 and the Spanish cement
market, once good for 54Mt/yr is now more than 50%
below its peak. Greece has dropped to a third of previous
consumption and other countries in the Mediterranean
report excess capacity except Algeria. On the other side
many Asian countries have too many cement plants.
Conclusion? Europe and Turkey have more excess
capacity than the West-African markets can absorb and
in the east of Africa, excess capacity in countries like
Pakistan, Iran and Vietnam exceed the cement deficit
between Djibouti and Mozambique.
Whereas in 2011 all African countries except South-
Africa were net importers, this is no longer the case.
North-African countries like Egypt and Tunisia are
satisfying domestic demand, but the big surprise comes
from Nigeria. For the first time Aligote Dangote’s back-
yard is dealing with an excess capacity of up to 1Mt/yr.
Will countries like Chad, Niger, Mali and Burkina-Faso
reduce imports from Europe and Asia through the Gulf
of Guinea and instead get Nigerian cement from the
northern provinces with lower haulage costs?
Not only are more and more coastal African coun-
tries becoming self-sufficient, but landlocked countries
are building cement plants. Within two years cement
could come from the heart of Africa towards the coast.
While this may not lead to massive exports, it would
eventually make overseas imports and then transport by
62 globalcementMAGAZINE January 2013
Contents Subscribe Ad Index
road pointless. It is obvious that this trend is bad news
for cement traders. It is also bad for all of the countries
that already suffer from excess capacity.
In 2010 Africa had a total cement capacity of
177Mt/yr and it produced 158Mt. The pace at
which Dangote is building new cement plants in
Nigeria, Senegal, Zambia, Republic of Congo, Tanza-
nia and Ethiopia, the rate that HeidelbergCement is
moving in Togo and the growing Indian cement plant
investments in Africa make me believe that, despite the
high growth rate, rapid construction and upgrades to
older plants will reduce the current African deficit of
40Mt/yr by over half.
We all know that domestic prices in Africa are high,
sometimes very high. It’s in contrast with what cement
exporters and traders are able to get. They do not take
any advantage of those high retail prices in Africa and
CIF or CRF wholesale export prices will not go up in
the future unless sea freight soars again. This is unlikely
in 2013 at least. With idling vessels around the world
at places like the Bosphorus in Turkey, I don’t expect
freight rates to go up that much and make importing ce-
ment to Africa more expensive. Cement import prices
will remain very low because the deficit will decrease
and the offered cement capacities coming from Europe,
Turkey and Asia will only increase. What if Algeria,
Egypt and Nigeria become net exporters and just make it
worse? Where can that cement now imported into Alge-
ria (mainly from Spain and Portugal) go to in the future?
In fact the global overcapacity needs several destina-
tion markets with growing deficits to offset its excess
capacity. This will not happen. Despite higher demand
in Africa we will see shrinking deficits there due to rapid
capacity addition. I forecast the global cement over-
capacity to get worse in 2013.
As for clinker, it is not exported to traders in
Africa. Clinker volumes shipped to Africa to date
have mostly been internal group sales. Apart from one
Pakistani group, Seatrade, which has its own terminal in
Maputo, Mozambique, I don’t know of any free importer
in Africa that has its own grinding facilities, although
Cemengal from Spain has announced that the first East
African ‘Plug & Grind’ unit is due to be commissioned
during 2013.
Finally, more and more African countries will be-
come self-sufficient, you will see them raise import
duties to discourage importation of foreign cement to
distort their domestic markets. We already see that trend
today in Nigeria.
 Contents Subscribe Ad Index
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ending 21 December 2012 declined by 0.55% from Regular contributors receive a free
the previous week, marking the fifth weekly drop
in a row. A China Securities Journal report quoted subscription to Global Cement Magazine!
Digital Cement as saying that the operating rate of ce-
ment mills across the country has been declining while
the cement stocks continued going up on the back of
sluggish demand.
The cement price in north China remained stable but de-
mand is falling. Indeed, most of the cement factories in Hebei
province actually slowed production down in December 2012.
In eastern China region, the cement price remained stable in early
December 2012, but some companies were not optimistic about future
prices. Downstream demand is also weakening in that region. Prices in central
and southern China continued to fall, with prices in Guangdong and Guangxi drop-
ping by US$3.20 - 4.80/t during the week to 7 December 2012.

Egypt: CEPMAS, the official Egyptian statistics agency, reported a 2.3% month-on-
month increase in the price of OPC in November 2012, when a 50kg bag cost US$4.26.

Zambia: Rapid growth in the construction sector and the temporary disturbance in production at
Zambezi Portland Cement Factory in Ndola, coupled with high demand from road-building and
the export market, have contributed to the sudden increase in the prices of cement on the
local market.
The National Council for Construction (NCC) has said cement on the local market
which previously fetched US$9.89/bag (50kg) is now hovering at US$13.31-15.50/bag
on the black market. The situation has reportedly brought panic to the construction
industry.
Levy Zulu, chairperson of the National Council for Construction (NCC), said
that he was enthusiastic about numerous capacity additions in Zambia, but
warned against Zambian producers exporting large volumes to neighbouring
countries at the expense of Zambian consumers.

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 January 2013 63

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 Contents Subscribe Ad Index
Dr Robert McCaffrey Editor, Global Cement Magazine (rob@propubs.com)
The Last Word
Thirsty? You will not be alone...
T he news in this month’s Global Cement Magazine
that Cemex is to institute a global water manage-
ment strategy for its cement plants (and presumably all
of its other industrial assets as well, since cement pro-
duction is not necessarily a thirsty industry, but concrete
production certainly is a major user of water) is a fantas-
tic, far-sighted development.
In common with the other multi-nationals, most
notably the signatories to the WBCSD’s Cement Sustain-
ability Initiative, Cemex has foreseen that sustainability
is crucial for its continued existence. With the news that
the company will ‘regularise’ its water management,
with a view to reducing its specific water consumption,
Cemex has brought to the forefront of its environmental
agenda the issue of a thirsty world.
Although drought has been a problem around the
world since before biblical times, we are heading into
an age where - whatever happens with climate change
- water will become more scarce, more sought-after and
more valuable. The planet’s burgeoning population will
ensure that there will be less water available per person
in much of the world. Under-investment in water infra-
structure (which, ironically, would be cement-intensive),
over-pumping of slowly-regenerating underground aq-
uifers, increases in water-intensity in our lifestyles (and
diets) and increasing pollution of water sources will all
lead to a reduction in the availability of water. An in-
crease of the planet’s population from 7 billion now to
around 9 billion in 2050 will further reduce the water
available to each of us on average.
For example, the experts1 suggest that a country or
region experiences ‘water stress’ when annual water
available per person drops below 1700m3. Below this
level, and down to 1000m3, periodic water shortages can
be expected, and below 1000m3/person/year, the area is
said to be facing ‘water scarcity.’ The UN Food and Agri-
culture Organisation estimates that by 2025, two-thirds
of the planet’s population will be living under water stress
(where not enough water is available for sanitation and
waste disposal, for example) and 1.9bn people will be
living in countries or regions with water scarcity. Even
now, nearly 900m people have inadequate access to safe
drinking water. Six million children each year die from
diseases caught from insanitary water. That’s equivalent
to one London Olympic stadium full, every five days. No
wonder Cemex is bringing water to the front of its global
sustainability agenda. Well done.
THE LAST WORD
Too much of a good thing?
Reading this issue’s news, our always-interesting column-
ist Yves De Moor and Peter Edwards’ excellent article on
the cement industry in Ethiopia is enough to make me
dispair. As usual, my dispair is over the ridiculousness of
human nature and our own collective stupidity (don’t be
offended - I’m sure that you are one of the clever ones).
As usual, in various parts of the world, we are hurtling
towards a self-made industrial car-crash and there is
seemingly nothing that we can do to prevent it happen-
ing. Why-oh-why do we perpetually drive our factories,
companies, national and global cement industry towards
over-capacity? Is it greed? Hubris? Ignorance? All three?
I sometimes imagine a conference table in the head
office of some cement company - it could be a big com-
pany, it could be a small company - and surrounding
it the company’s directors. The managing director has
been updating them with market trends. They have
made a small profit in the last year and demand is ris-
ing, but their competitors have started building a new
cement plant which will take market share from them,
while at the same time flooding the market with product
and reducing the price (and profitability). What do they
do? Swallow their pride and take a reduced market share
while probably maintaining their profits? Or borrow
the money to build a new plant to compete with their
countrymen and compatriots? You only have to look
around the world to see which way the majority of those
decisions have gone over the years: Build, build, build. In
the end, with region-wide overcapacity, everyone loses.
Except, that is, for the plant builders and perhaps the
shippers. With ‘Chinese prices,’ the barriers to entry into
many cement markets are now lower than they have ever
been. Oversupply also offers shippers (and perhaps those
countries with a structural shortage of cement, like the
US) a good business opportunity.
Although centrally-planned cement industries do
not always work out for the best (for example the inex-
plicably oversupplied and indebted Vietnamese cement
industry), a sensible central policy on allowing min-
ing and cement plant construction permits would go
a long way to ensuring reasonable prices to consumers
and reasonable profits to cement producers. If required,
region-wide coordination might be necessary, but this is
not beyond the wit of mankind. Perhaps, for once, we
can change human nature. Or is that too much to ask?
1 http://en.wikipedia.org/wiki/Water_scarcity
globalcementMAGAZINE January 2012 65
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