highlights cement oct2014

OCTOBER 2014

Thinking beyond

EPC Semen Indonesia gains newest

OK™ mill World’s firstPostgraduate Cement Plant Engineering Degree

2 HIGHLIGHTS CEMENT – October 2014

LETTER FROM THE PRESIDENT

Strong partnerships for a stronger futureDespite the cement market still being in a cyclical downturn, we are on track at FLSmidth having the highest level of unannounced orders for three years. We are seeing growth in opportunities in countries including the Democratic Republic of Congo, Angola, Nepal and Indonesia, which you can read about in this edition of Highlights. Recently, we announced several important large orders, including the supply of a complete equipment package for a 3,000 tpd greenfield plant in the Democratic Republic of the Congo under the flagship of Lucky Cement Limited and the Rawji Group (page 4). Another is the major modernisation project of Holcim’s Ada plant in the US (page 5).

Product development and innovation are a hallmark of FLSmidth’s contribution to the cement industry. Our most recent major release is the new version of the OK Mill, which has been commissioned at Semen Indonesia’s Tuban cement plant in Java, Indonesia. This newest version of the OK Mill is a prime example of how FLSmidth applies performance data and practical knowhow gained from operations around the world. Close collaboration with cement plants is an important element of FLSmidth research. Our research partnership with Titan Cement (page 24) in conducting tests on its OK Mill reflects our commitment to delivering solutions that help meet our customers’ business challenges.

Contributing to local society is also central to the value we offer, in particular training of local workforces. Our joint initiative with the Helwan University in Egypt is an example of the long-term efforts being made in overcoming the critical shortage of skills in operating cement plants. Read about the FLSmidth sponsorship of Helwan University’s new post-graduate cement plant engineering degree on page 8.

360° certainty solution: Design, Build and Operate For cement plant owners and investors in today’s demanding business environment, we are continuing to see a greater need for strong partnerships to add capacity and expand into new markets – from design and engineering to operation and maintenance. FLSmidth continues to strengthen its offerings in all these areas. Read more about FLSmidth’s Design, Build and Operate solution on page 26.

Welcome to Highlights Cement.

Per Mejnert Kristensen President, Cement Division

SCAN TO VIEW PER MEJNERT KRISTENSEN

INTRODUCE THIS EDITION OF eHIGHLIGHTS

3HIGHLIGHTS CEMENT – October 2014

CONTENTS

Editor-in-chiefNadia Haagen Pedersen Managing editorCharlotte Lærke Backmann Content editorKit Franklin MommeAssociate editorsBrenda Kaplan, Bharathkumaar Soundararajan Editorial boardMark Brugan, Palle Erik Grydgaard, Sten Stoltze, Martin Strouhal, Hari TRLayout: Cross-Border Communications

© 2014 FLSmidth. All rights reserved. Reproduction permitted quoting ‘Highlights’ as source.

All product names used herein are trademarks of their respective owners.

Editorial office: FLSmidthVigerslev Allé 77DK-2500 Valby, Copenhagen, Denmark Tel: +45 36 18 10 00Fax: +45 35 45 44 27Email: [email protected]/ehighlights

cement.flsmidth.com gives you more details and additional articles

SCAN HERE FOR PDF VERSION OF THE HIGHLIGHTS MAGAZINE

USE THESE QR CODES AS A QUICK WAY TO GET MORE INFORMATION VIA YOUR SMARTPHONE OR TABLET. DOWNLOAD THE SCANNER AT GETSCANLIFE.COM

FRONT COVER: ILLUSTRATION OF FLSMIDTH’S NEWEST OK™ MILL, RECENTLY COMMISSIONED AT SEMEN INDONESIA’S TUBAN CEMENT PLANT (SEE PAGE 6)

Letter from the President 2

NEW ORDERS New cement plant for the Democratic

Republic of Congo 4

FLSmidth to modernise

Holcim US Ada plant 5

INNOVATIONNew graphite seal optimises kiln

performance 12

The new ECS/ControlCenter™

V8 process control system 18

FLSmidth research delivers

silo-safe cement 24

Innovative fabric filter design 28

FLSmidth® STRIKE-BAR® crusher 34

FEATURESWorld’s first Postgraduate Cement

Plant Engineering Degree 8

Right first time 14

Thinking beyond EPC 26

SITE REPORTSClinkerisation project underway

in Nepal 22

Gas-insulated switchyard in India 32

Great teamwork and reliable

technology minimise plant disruption 36

PRODUCTS & SOLUTIONSSemen Indonesia gains newest

OK™ mill 6

Delivering to customer needs 21

News in brief 38

Upcoming events 40

8

22

24


NEW ORDERS

FLSmidth has been selected to supply a complete package of equipment and engi-neering for a greenfield cement plant in the Democratic Republic of the Congo. The plant will be located in the province of Bas-Congo, approximately 250 km west of the capital Kinshasa. Worth EUR 68 million, the contract includes all the engineering, equipment and support for the construction of the 3,000 tpd plant.

The equipment to be supplied includes FLSmidth crushers, pyroprocessing equip-ment and vertical mills for raw meal, coal and cement grinding – all well-proven machinery that is characterised by high productivity, flexibility and energy efficiency.

DR Congo’s largest cement producerThe partners behind the project are Yunus Brothers Group (YBG) of Pakistan under the flagship of Lucky Cement Limited and

Rawji Group of the Democratic Republic of the Congo. Together, they have formed a joint venture, and the new entity, Nyumba Ya Akiba sarl, will become one of the country’s largest cement producers.

Lucky Cement is Pakistan’s largest producer (7.75 million tpy) and a leading exporter of high quality cement. Founded in 1993, the company has developed to be the Pakistani cement industry’s trendsetter in terms of business excellence, innovation and envi-ronmental performance. It is part of YBG, which is among Pakistan’s leading business houses with an unparalleled reputation for professional management and strong business ethics.

The Rawji Group includes companies involved in commerce, industry and finance. Its history goes back to 1910 when Mr Meraldi Rawji, an Indian businessman, started trading activities in the Congo. Today, the fourth generation of the Rawji family is in charge of the group’s interests that range from import and distribution of products and equipment and manufacture of soaps, edible oils and cosmetics to property and banking services. With its extensive activities, the group has in-depth knowledge of the country’s social fabric and its economy.

Growth market“In addition to its enormous mineral re-sources, the Democratic Republic of the

DR Congo’s newest greenfield cement plant in more than 40 years

New cement plant for the Democratic Republic of the Congo

CONTACT HUBERT [email protected]

Read more about new orders on www.flsmidth.com/announcements

FROM L-R: MR. AHMED MASHKOOR, MR. CARSTEN ZACHER GRAUGAARD, MR. MUHAMMAD ALI TABBA, MR. JOHANNES ENGELSBY HANSEN, MR. HUBERT SUINAT


Congo is characterised by growing stability and a rapidly increasing population. There is therefore an urgent need for cement for the development of infrastructure and housing. For the past 40 years, no new cement plants have been constructed in the Republic, therefore it is a very interest-ing market for FLSmidth,” says Per Mejnert Kristensen, President of FLSmidth’s Cement Division.

The projectNyumba Ya Akiba and the project’s finan-ciers highlight FLSmidth’s proven ability to supply environmentally optimised and energy-efficient equipment. They demanded a solid technology provider with a proven ability to deliver reliable products, particu-larly because of the challenging conditions under which the plant will be installed and operated.

The site of the new plant, Kinsua village in Songololo territory of the Bas-Congo province was selected because of the good quality raw materials in its vicinity. The new plant will provide much-needed cement for housing construction and road building in a rapidly growing region. DR Congo is Africa’s second-largest country and there is a significant gap between its current pro-duction capacity and demand for cement. As the political climate is beginning to stabilise, investments in the economy are likely to take place. The new plant will also be well placed for exports to neighbouring countries.

FLSmidth is proud to have been chosen by two highly professional and experienced business partners to supply a state-of-the-art cement plant in a region with vast potential for growth.

FLSmidth selected as supplier for Holcim (US) Ada Oklahoma Plant modernisation project

FLSmidth has been selected to supply the major equipment pieces needed as Holcim looks to modernise its Ada Oklahoma plant. The modernisation of the pyro pro-cess is expected to deliver lower emissions of nearly all air pollutants while anticipating an increase in the plant’s capacity.

The contract includes a dryer crusher, a single-stage preheater with an ILC-calciner, a dedusting cyclone, a ROTAX-2® kiln, a kiln bypass system, a Duoflex® kiln burner and Cross-Bar® cooler.

With the installation of two new FLSmidth dust collectors, the project will significantly improve the plant’s ability to reduce the particulate emissions.

This contract further demonstrates FLSmidth’s ability to help US cement producers prepare for the upcoming NESHAP regulations.

CONTACT SCOTT [email protected]


FLSmidth’s newest version of the OK mill has been commissioned at Semen Indonesia’s Tuban cement plant in east Java as part of its plans to use advanced, high-quality technology that delivers the lowest possible energy consumption and the minimum possible environmental impact.

FLSmidth’s new OK mill, featuring an updated mechanical package and structural design, will provide the required boost to Tuban’s grinding capacity, helping to make the plant more effective and energy-efficient.

Based on market dataThis latest version has been developed using the performance data from other FLSmidth OK mills as well as the practical know-how and experience gained from working with them. Important parameters included reducing maintenance requirements and maintaining competitive pricing.

The update included reviewing and evaluating the complete me-chanical package and structural design of the mill.

Of the many updates applied to the mill, the most significant included optimising the grinding pressure needed for grinding ordinary and high-Blaine cement. The grinding profile of the roller and table enable a narrow wedge-shaped grinding area, without compromising the peak pressure, which is the highest of any mill in the market. The table profile ensures uniform bed thickness, which eliminates the need for additional rollers or rolling scrapers to remove material accumulated inside the dam ring.

The new OK mill includes the latest version of the ROKSH separa-tor, which is an updated version of the standard OKS separator. Requiring extremely low power, the ROKSH is a low-wear, highly efficient separator and is one of the most durable ‘top seals’ in the market.

Semen Indonesia gains newest

Amidst a buoyant cement industry in Indonesia, South East Asia’s largest cement supplier, Semen Indonesia, is continuing to raise the bar on cement production capacity and efficiency.

PRODUCTS & SOLUTIONS

FLSmidth’s OK millFLSmidth’s OK mill is a vertical roller mill designed for cement and slag grinding. It combines drying, grinding and separation processes into just one unit and can provide savings of approxi-mately 40 percent in power consumption compared with tradi-tional ball mills. This latest version has been commissioned at cement plants in Brazil, Indonesia and India, joining the more than hundred FLSmidth OK mills in operation around the world.

OK™ mill

CONTACT KLAUS BØGESKOV [email protected]


Optimal airflowFluid dynamics played a vital role in the development of the new OK mill. The airflow through the nozzle ring and inside the mill was carefully analysed to ensure the right amount of material was lifted into the separator. To minimise wear, it was also important to know the air velocity required in the mill to optimise the load on the guide vanes and rotor.

Increasing demands for cementIndonesia’s economic growth in recent years, resulting in continuing investments in infrastructure development, has had a significant influence on the country’s cement production demands. As Indo-nesia’s leading cement supplier, PT Semen Indonesia has played a major role in servicing the cement demands. The company’s Tuban plant is located in East Java and has a total output of 33,600 tpd. Tuban’s four lines have all been supplied by FLSmidth. Tuban required extra grinding capacity at two of its lines. Even though the plant operates with many ball mills, it needed more effective and energy- efficient mills. This was a key reason for the choice of an OK mill.

The OK mill was put into service in 2013 as an Ordinary Portland Cement (OPC) finish grinder. The mill was fitted to grind clinker from the older but updated production lines Tuban 1 & 2. However, Tuban also needed to use it for Portland Pozzolana Cement (PPC) finish grinding for cement containing trass, a volcanic tuff that is harder than the normal Pozzolane and has a higher level of moist content. The upgrade project started in 2010, and the new OK mill 42-4 with a capacity of 250-300 tph, began operations in October 2013.

Beating performance requirementsKlaus Bøgeskov, Project Manager at FLSmidth, explains how some of the installation and commissioning challenges were tackled: “We often face challenges in space limitations when installing new equipment. It was no different at Tuban Cement as the OK mill had to be squeezed between two existing mills. We solved it by modifying the mill’s design to fit the plant’s layout.”

Klaus Bøgeskov explains that the OK 42-4 mill was guaranteed to 250 tph OPC according to ASTM C-150 Type 1 (Standard Specification for Portland Cement). “But when the PGT certificate was signed, the mill was running 253tph at a Blaine value of 3559cm2/g,” he says, adding, “The total power consumption goals for the main motor, separator and fan motor were 26.8 kWh/t, and we achieved a figure of 24kWh/t.”

FLUID DYNAMICS WAS APPLIED TO ACHIEVE THE AIRFLOW CONDITIONS NECESSARY TO OPTIMISE PERFORMANCE AND REDUCE WEAR

“WE OFTEN FACE CHALLENGES IN SPACE

LIMITATIONS WHEN INSTALLING NEW

EQUIPMENT. IT WAS NO DIFFERENT AT TUBAN

CEMENT PLANT AS THE OK MILL HAD TO BE SQUEEZED BETWEEN

TWO EXISTING MILLS.”Klaus Bøgeskov,

Project Manager at FLSmidth


FEATURES

FLSmidth and Helwan University in Egypt launch new education programme, paving the way for a cement plant career

World’s first Postgraduate Cement Plant Engineering Degree

CONTACT CRISTINA [email protected]


Operating and maintaining cement plants requires a high level of competence, and a critical shortage of skills in some local regions has made it difficult to operate plants at maximum efficiency.

One of those regions was Egypt, where FLSmidth has had difficulty employing qualified engineers with the right experience and skillset. This is a key reason behind FLSmidth’s drive for a postgraduate cement engineering diploma degree programme in Egypt. Launched in February 2014, the degree has been put together in partnership with Helwan University.

Cristina Holmark, General Manager of Global FLSmidth Institute, has led FLSmidth’s development of the degree. She explains, “The idea was to create a graduate level degree that could bridge the educational and qualification gap for engineers and prepare them adequately for a potential career in the cement industry. We also saw it as a good opportunity to play a very positive role in the local community as well as nurture loyalty among FLSmidth Group employees.”

The degree is a combination of academic theory and practical experience, which is designed to equip cement plant engineers with the knowledge and hands-on experience required for cement plant operation and maintenance. It makes effective use of different learning styles to stimulate and motivate students.

Cristina Holmark elaborates, “Students are exposed to lectures with professors from Helwan University, group work and plant visits. The plants involved are Ramliya and Wadi el Nile where students will be exposed to our high safety standards and on-the-job challenges.”

Successful knowledge transferThe diploma degree is part of an extensive education programme that started in late 2009 with the search for an academic partner.

Cristina Holmark says, “We looked into and spoke with several universities in Egypt and the choice fell on Helwan University rela-tively quickly. Apart from being located close to cement plants, Helwan University showed the most interest and demonstrated high commitment. The university is a large public university with around 100,000 students and 21 faculties, so we are very pleased to be partnering with Helwan.”

Less than a year after an agreement was reached, the first phase of the programme was launched by the FLSmidth Helwan Cement Institute. This involved a pilot project of two semesters that was an essential part of developing a workable, sustainable educational programme resulting in the diploma degree.

“We wanted to create this degree according to established academic processes,” explains Cristina. “This involved extensive train-the-trainer programmes, including formal training sessions in Denmark and Egypt as well as peer-to-peer training.

During the pilot project, FLSmidth Group engineers did the student lectures, while the university’s professors observed and learned. We feel this process has equipped the professors well, so they would be able to teach the course material independently following the pilot project.”

And the pilot project was quite a success. Of its 33 graduates, 11 have been employed at three different plants operated and maintained by FLSmidth and others have found employment in related industries.

A world-first for the cement industryMeanwhile, during the pilot project, extensive preparation was taking place for the full implementation of the cement diploma degree. This involved obtaining approval from Egypt’s Higher Counsel of Ministry of Education, a process that took one year. With the ministry’s blessing, the degree was sanctioned allowing 16 students to begin their new educational venture in February 2014. >>

The Helwan Postgraduate Cement Engineering Diploma Degree This is a diploma degree course offered by Egypt’s Helwan University and created in partnership with FLSmidth.

The degree is taught by the University’s staff and provides three semesters of academic teach and a practical project supplemented by short cement-specific courses.

Sixteen students from different Egyptian cement companies are enrolled in the programme for 2014 and 2015.


Cristina Holmark emphasises that the programme is now owned by Helwan University, following the success of the pilot project and handover process: “FLSmidth’s role in the future is to help with marketing and promotion as well as training the professors. We will provide any necessary support, but it is the university’s programme now.”

“We are very happy that the goal we set out to achieve in 2009 has come to fruition. Helwan is now the first university in the world to offer a degree like this, so we are proud to be behind it,” she adds.

Professor Yasser Sakr, Helwan University President, sees many benefits for the university, claiming, “This degree provides an attractive value proposition for the university. Our partnership with FLSmidth has enabled us to prepare an innovative curriculum and a commercially viable offering to the private sector, and it has meant we have developed state-of-the-art facilities for our students.”

STUDENTS AFTER A DAY OF CLASS ROOM LECTURES OUTSIDE OF THE TRAINING CENTRE

WORLD’S FIRST POSTGRADUATE CEMENT PLANT ENGINEERING DEGREE

“WE’RE NOT JUST OPERATING A PLANT, WE

ARE SUPPORTING THE COMMUNITY AND

WORKING ACTIVELY WITHIN IT. TRANSFERRING

KNOWLEDGE IS A FUNDAMENTAL PART

OF THIS.” Cristina Holmark,

General Manager of Global FLSmidth Institute


Professor Sakr is also convinced that it provides significant benefits to students: “The degree will provide the students with marketable skills and almost certainly a stepping stone to employment. The international environment offered through the collaboration with FLSmidth is very valuable, in particular.”

Bonding with the local community The cooperation between Helwan University and FLSmidth is a public-private partnerships in Egypt. It is expected to benefit the industry, the tertiary education system, local society in general, and FLSmidth’s profile in Egypt. Indeed, Denmark’s Ministry of Foreign Affairs has identified this as a role-model example of CSR, and the Danish governmental aid organisation, DANIDA, has supported the project under its ‘Innovative Partnership Develop-ment’ (IPD) Programme.

Cristina Holmark is convinced the programme has strengthened FLSmidth Group’s ties to the local community by playing an active

role in raising the education and skill levels of cement plant engi-neers: “We want the partnership to make a long-term difference for the community. It is a sign of our commitment to the country and the plants that we operate and maintain for our customers.”

Initiating and developing local programmes such as these is the FLSmidth Institute’s core business. Other similar projects currently underway internationally include an energy efficiency training programme in Vietnam and a vocational programme for unem-ployed youths in India.

“For FLSmidth as a whole, it’s important to realise that we’re not just operating a plant, we are supporting the community and working actively within it. Transferring knowledge is a fundamental part of this,” asserts Cristina Holmark. “I believe we have 33 grad-uates and 16 current students on the FLSmidth Helwan Cement Institute programme who can attest to that.”

PROMOTIONAL LAUNCH OF THE POSTGRADUATE CEMENT ENGINEERING DIPLOMA DEGREE, OFFERED BY HELWAN UNIVERSITY, CAIRO, EGYPT IN COOPERATION WITH FLSMIDTH, COPENHAGEN, DENMARK

POSTGRADUATE STUDENTS ON FIRST

SEMESTER


Newgraphite seal optimises kiln performance

Designed for fast installation on any kiln, FLSmidth’s new kiln graphite seal reduces ID fan power consumption

Energy efficiency and low maintenance is essential to optimal kiln performance. The new FLSmidth kiln graphite seal reduces the need for maintenance and optimises the operation pressure stability by preventing false air entering the system.

FLSmidth provides a highly effective kiln seal that utilises carbon graphite. The seal, which fits any kiln, uses a staggered arrangement of overlapping graphite blocks [1] held in place by a wire rope system to ensure an efficient seal against the outer air casing [3]. The arrangement allows the graphite blocks to move independently with the radial movement of the kiln without the graphite blocks getting stuck or damaged. The locking plates [4] on the rear flange [2] is a key design feature that prevents false air from entering the kiln system.

The inlet seal air casing is designed to handle back spillage, directing it to the hopper for collecting in the bin.

Trial assembly of the modular frames and thorough inspection of geometrical tolerances of the flanges in the workshop ensures the highest product quality standards.

INNOVATION

CONTACT MORTEN [email protected]

CONTACT NAVEEN [email protected]


Designed for predictable, low maintenanceA visual inspection can reveal whether maintenance is required. When it is necessary, the wire rope system and modular frame enables quick replacement of the graphite blocks, while spe-cially shaped distance spacers [5] prevent the need to dismount the flanges.

The wire rope system is comprised of counterweights and independent rope systems covering each row of graphite blocks. The ropes grip the graphite blocks tightly in place while also allowing for movement caused by kiln runout, ovality and expansion. This design allows for radial movement of up to +/-50mm and axial movement of approximately 300-400 mm.

The need for spare parts is limited, as the graphite blocks and wire ropes are interchangeable between the inlet and outlet seals. Furthermore, the graphite blocks’ self-lubricating prop-erties significantly reduce the wear of the sealing components. Typically, the expected wear on the graphite blocks is 5-8 mm per year, resulting in a long lifetime.

The wire rope is designed to run for a full production campaign, but as an added preventative measure, the seal’s locking system

will hold the graphite blocks in place in the unlikely event of wire failure.

Fast, cost-effective installation on all kilns The new graphite seal can be fitted on any type and size of kiln – not just FLSmidth kilns. The graphite seal modular concept is designed to fit to the existing casing and cooling mantle without the need for modifications.

Installation of the graphite seal typically takes seven to ten days. A large amount of pre-assembly can take place before installation. This is made possible by the seal’s modular design.

FLSmidth’s inlet and outlet graphite seal has been retrofitted on a non-FLSmidth kiln at NCC Egypt.

Inlet and outlet sealsTwo types of kiln graphite seals are available. The kiln inlet seal is designed to provide the interface between the kiln and pre-heater and the kiln outlet seal interfaces the kiln and the cooler.

Both seals are designed to help maintain optimal kiln operating conditions and to minimise the loss of expensive energy.

“VISUAL INSPECTION OF THE SEALING DURING OPERATION IS EASY. WE HAVE EASY ACCESS TO GRAPHITE SEAL BLOCKS AND WE CAN CHANGE

THESE WITHOUT COOLING DOWN THE KILN COMPLETELY IF NECESSARY. THAT IS A HUGE

ADVANTAGE. FURTHERMORE, ANY BACK SPILLAGE FROM THE INLET IS EFFECTIVELY HANDLED AND LEAD TO THE GROUND.”

Technical Project Manager, NCC Egypt

EACH MODULE IS DESIGNED TO BE PRE-ASSEMBLED BEFORE INSTALLATION

SCAN TO VIEW PRODUCT SITE ON FLSMIDTH.COM

CONTACT MORTEN [email protected]

CONTACT NAVEEN [email protected]


Right first time

FEATURES


Paul Dreyer looks back at the commissioning of the new Angolan cement production plant Fabrica de Cimento Do Kwanza-Sul S.A. (FCKS) with satisfaction. It was a difficult project with many obstacles, but despite the difficulties, we managed to commission the cement plant in the best possible way,” says the FCKS technical administrator. “From the crushers to the raw mill to the kiln and packaging plant, we managed to commission, start up and conduct successful performance tests the first try every time. Nothing failed; all key equipment behaved as it should. I have not experienced this before and it was beyond our expectations.”

The commissioning was all the more im-pressive considering the plant’s unique challenges. FCKS is located in a remote area near the town of Sumbe in the Kwanza Sul province, about 300 km south of Angola’s capital, Luanda. Even though Angola has vast mineral resources and a fast-growing economy, its cement industry is underdevel- oped and the country possesses very limited specialist cement expertise. As one of Angola’s newest and most modern cement plants, FCKS represents a significant step in the development of the country’s growing cement industry. “That is why it was import-ant to work with a reputable, experienced partner. This is how we saw FLSmidth,” says Paul Dreyer.

To complete the plant FCKS entered into an EPC contract with ETA Star International from Dubai. FLSmidth supplied all the design and all mechanical, electrical and automa-tion equipment for the cement plant.

Knowledge transfer forsustainable operationsFCKS has chosen to continue its close relationship with FLSmidth Group through an operation and maintenance (O&M) con-tract over the next five years. The contract sees NLSupervision – part of the FLSmidth Group employing all the necessary plant operators and maintenance personnel. It also includes sourcing and inventory control of spare parts and lubricants. The plant is run by the local recruitment and training divison with local personnel under the supervision of key NLSupervision staff – backed by the knowledge center of FLSmidth Group.

Paul Dreyer explains the reasons for outsourc-ing O&M: “Since the level of expertise and resources in the cement industry in Angola is still very limited, and because FCKS is relatively new to the cement industry, it makes sense to be assisted by people who are highly experienced in cement plant operations. >>

CONTACT SIMON [email protected]

Production underway at FCKS cement plant in Angola


It brings us a lot of benefits for FLSmidth Group to operate and maintain the plant, not just because we have FLSmidth equip-ment, but also because they can easily source spare parts and provide the right technical support.”

All equipment knowledge and many of the supervisors involved with the plant’s construc-tion and commissioning have now moved into the O&M team. Simon Lindberg, Project Manager says, “This will bring valuable experience and knowledge to the O&M team, which ensures the plant can continue full production during the transition period from commissioning to handover to O&M.”

But Paul Dreyer observes that even the most experienced O&M teams can run into chal-lenges, particularly in a developing nation such as Angola. “There are hiccups with any

new plant and it has taken time for the operations and maintenance team to find its feet, but the issues are being ironed out and we can see improvements daily. One key issue was the need for a huge expatriate workforce in the beginning. As a foreign company in Angola, it takes time and is not easy to recruit the right workforce and then build and manage a cohesive team.”

He adds: “My experience with FLSmidth is that they do not walk away from or try to hide a problem. In the event that an equip-ment problem arises, they take responsibility for rectifying it. This is a strong quality and is obviously part of the FLSmidth culture.”

In addition to operating the plant, the transfer of knowledge in efficient and cost-effective production methods to the local workforce is an equally important part of the O&M

agreement and a central reason for FCKS continuing to working with FLSmidth. In collaboration with the Angolan educational authorities, NLSupervision is setting up a training centre where courses will be offered in mechanical, electrical, process and safety skills.

Paul Dreyer says, “FLSmidth’s training division is very strong and we want to benefit from that as much as possible so we can become sufficiently skilled in cement plant operations. The ability to train our nationals is just as important as the pro-duction goals.”

The training centre will be operated by NLS Supervision, Angola, and helps to qualify local workers not only for the cement plant at Sumbe, but also more generally for the industrial environment of any state-of-the-art,

RIGHT FIRST TIME


cooperation, and the expertise and experi-ence of many solution-oriented people, working together as a team. We felt like we were one big family that had been through a lot together”, says Simon Lindberg.

Paul Dreyer believes the contribution from the FLSmidth team was a key factor: “The coorporation with FLSmidth and ETA played a huge role in the success of the commissioning and start-up of the plant, during which everything went to schedule.”

A foothold for future growthFCKS aims to achieve 1.1 million tpa clin-ker in the first year and then lift this to 1.3 million tpa during the second year, maintaining this production level over the plant’s lifetime. Paul Dreyer concludes, “Of course, we are looking to expand business in the long term and we have plans for a second line, but for now our main focus is to get the plant to full capacity and, with the help of FLSmidth, truly make our mark in the Angolan cement market.”

modern plant. This involvement in the local community is a significant contribu-tion to the development of the Angolan nation and is an example of both FCKS’ and FLSmidth Group’s commitment to Corporate Social Responsibility.

Close teamworkWhen the agreement for the 4,200 tpa plant was signed in 2008, FLSmidth’s project scope was the engineering, and the design and supply of all mechanical, electrical and automation equipment. All the machinery, from crushers to kiln and mill to packers, including automated control systems, were designed and supplied by FLSmidth to ETA Star International LLC of Dubai, who was responsible for the plant’s construction.

“The reputation and quality of FLSmidth’s equipment was a key factor in FCKS’ deci-

sion,” explains Paul Dreyer, emphasising the specialist skills FLSmidth brought to the project. Simon Lindberg, Project Manager discusses the challenges of working in a remote location: “The site is located about 30km away from the nearest large town, Sumbe, in an area with no existing facili-ties. There were many different parties involved and everyone lived in a compound just beside the plant. It was essential that the different teams could function well together and to help make this happen, recreational facilities, an organised office and a camp area was established.”

It was a complex project lasting from 2009 to 2013. Completing the plant successfully required a lot of hard work, dedication and good communication by all parties. “We managed to overcome the challenges through numerous design meetings, close

“IT BRINGS US A LOT OF BENEFITS FOR FLSMIDTH GROUP TO OPERATE AND MAINTAIN THE

PLANT, NOT JUST BECAUSE WE HAVE FLSMIDTH EQUIPMENT,

BUT ALSO BECAUSE THEY CAN EASILY SOURCE SPARE PARTS

AND PROVIDE THE RIGHT TECHNICAL SUPPORT.”

Paul Dreyer,Technical Administrator, FCKS


INNOVATION

The new ECS/ControlCenter V8 process control system

Trend-setter for modern usersIn line with current trends, the latest release of the ECS/Control-Center software is developed with focus on usability and making things easy to do. This marks a departure from many years of tradi-tional engineering of the system through technical tools.

The intention is to make everyday tasks easier to do – not only for operators, but also for the system maintenance engineers – by simplifying the most common tasks so that deep technical knowl-edge is not required. This will allow the users to focus on solving their tasks, rather than figuring out how to work the system.

FLSmidth recently released the brand new ECS/ControlCenter™ V8 process control system for the cement and minerals industries. It is now even better than before – more intuitive and simpler to use thanks to a new, modern and user-friendly design.


The perfect fitThe ECS/ControlCenter solution is tailor-made for the cement and minerals industries. It offers the best combination of high-quality standards combined with the necessary flexibility to adapt to ever-changing conditions on the plant.

Based on FLSmidth’s more than 25 years of experience in automat-ing large production plants, all our control system solutions come with “knowledge built-in”. Learning from previous projects, gather-ing experience and listening to feedback has enabled FLSmidth to make a control system that fits perfectly to customers’ needs.

As always, the ECS/ControlCenter software delivers the reliability, scalability and user-friendliness production plants need to be oper-ated effectively.

Beauty is in the detailsThe previous version of the ECS/ControlCenter software was already a very strong solution. So what makes the new version even better?

By carefully inspecting every part of the system, FLSmidth has identified missing features and identified opportunities for incre-mental improvements.

Through a unique combination of programming skills, experience in developing control system software, engineering and commis-sioning expertise and a very close relationship with customers, FLSmidth has been able to develop a new modern version of the control system launched more than 25 years ago.

The platformThrough five years of development – including two years of site testing to ensure high quality utilising the latest technologies and new effective programming paradigms, this is a product prepared for the future.

The system is built for better integration between different products on large installations, while at the same time avoiding annoying constraints and version dependencies. Combined with a strong server-client foundation, the new solutions will be perfect for implementation in a virtual environment such as VMware.

Product detailsFor operators, the system will seem much more intuitive and com-plete, with all functionality contained in one common “portal”, rather than a selection of “tools”. The new system is much more user-focused and provides a simplified operator environment with easy login and a personalised user environment. >>

CONTACT JAN [email protected]

FLSMIDTH’S ECS/CONTROLCENTER V8 SOFTWARE HAS JUST BEEN RELEASED


For example, each operator can choose a specific role such as “mill operator”, which will present only information relevant to the mill areas. This will improve focus on what really matters, without the confusion and potential information overload from areas handled by the other operators.

The system will also be available in a simplified version for touch control, for example for machine control out on the plant floor. This provides a uniform look and feel across the systems. Linking these decentralised control systems with an overall process control system requires minimum engineering and will provide easy access to all parts of the system directly from the central control room.

THE NEW ECS/CONTROLCENTER V8 PROCESS CONTROL SYSTEM

“THE ECS/CONTROLCENTER SOFTWARE OFFERS A MODERN, USER-FRIENDLY ENVIRONMENT FOR OPERATORS.”

The ECS/ControlCenter solution still comes with built-in high-performance communication drivers for Siemens, Rockwell and Schneider process controllers (PLCs) as well as OPC to allow for flexible hardware selection, while retaining the same user interface.

PLC programming is still required, but utilising the ECS/ACESYS function block library will encapsulate most of the complexity, leaving mostly interlocking to the programmer. It also provides DCS-like functionality and advanced faceplates with direct access to detailed diagnostics.

What’s next?The development of FLSmidth’s products never stops. The next release of the ECS/ControlCenter software and the supporting ECS/ACESYS library is planned for spring 2015 and will include improved focus on functional safety and full alarm management based on the ISA 18.2 standard. FLSmidth is continuously working on making its products even better – for the benefit of customers.


Deliveringto customer needsMy Home Industries (MHIL) is a joint venture between My Home Group and CRH plc, an Irish building materials conglomerate with 3,500 locations spread across 33 countries.

From three manufacturing units located in Melacheruvu in the Nalgonda district of Andhra Pradesh, MHIL produces 3.3 million tons of cement per annum. Another unit, Sree Jayajothi Cement – SJCL, in the Kurnool district of Andhra Pradesh produces 3.2 million tons per annum. To meet increasing demand for cement in domestic and inter-national markets, MHIL has also set up a cement grinding unit at Mulkapalli in Visakhapatnam district of Andhra Pradesh with a capacity of 2.0 million tons of cement per annum.

FLSmidth won an order for the modernisa-tion of MHIL’s Line II pyroprocessing unit, which consists of a six-stage ILC PH tower and a CIS-CFG cooler. This plant was sup-plied, constructed and commissioned by FLSmidth in 2002. After analysing MHIL’s requirements, FLSmidth provided a cost and time-efficient solution to meet MHIL’s upgrade objectives. Major objectives of this upgrade were increased clinker production

and technology upgrades to reduce power and fuel consumption. FLSmidth’s intention is to provide effective, engineered systems to meet customer requirements by using the best quality products.

MHIL already had an SF Cross-Bar™ cooler 2 X 4 in its Line I. MHIL had been very satisfied with the SF Cross-Bar cooler’s performance over the last five years and wanted to use the ‘best’ in cooling tech-nology at its Line II upgrade. FLSmidth engineered a system by modifying the cyclones 1, 2 and 4 with new preheater fans, new Cross-Bar 10X37 cooler and a new modular frame heavy-duty roller breaker (HRB). The system also included the new RABH & RABH fan, modifications to the bag house and kiln main drive.

The project was completed in three phases. Phase I included a new Cross-Bar cooler with new HRB. Phase II includes a new RABH and RABH fan, and Phase III includes

cyclone, calciner and kiln drive modification along with a new preheater fan.

The Phase I modification has been in oper-ation since January 2014 and the customer is satisfied with all the major benefits that the upgrade has delivered:• Clinker production at 2550 TPD• 10-12 Kcal/Kgcl savings in fuel

consumption• Cooler maintenance shutdowns de-

creased drastically since the upgrade• No major spare parts changed during

this period• No HRB maintenance shutdown in last

eight months• Mechanical HRB motor power drawn is

less compared to the conventional crusher.

Phase II is expected to be completed by December 2014 and Phase III before the middle of 2015. MHIL is satisfied with the Phase I modification and placed two more orders with FLSmidth in 2013 for the Jaya-jothi unit (new Cross-Bar cooler with HRB and PH modification) and two orders in 2014 for Line I (coal mill and PH modifica-tion).

PRODUCTS & SOLUTIONS

CONTACT ANILKUMAR [email protected]

The conditions before and after modification Guaranteed values Achieved Before after Phase III after Phase IParameters modification modification modification Clinker production, MTPD 2472 2750 2550 Savings in specific fuel consumption Δ, Kcal/Kgcl Nil 20 10-12 Clinker temperature at kiln discharge, degrees 134 + Ambient 65 + Ambient 64 + Ambient


In a move that reflects this demand, the Saurabh Group has awarded the Sarbottam Cement Plant’s clinkerisation project in Nepal to FLSmidth. This is the first full-scope supply of equipment to be undertaken by FLSmidth in Nepal. The 1200 tpd cement plant will be located about 50 km from Lumbini, the birthplace of Buddha.

FLSmidth scope of supply The project supply includes everything from the crusher and mills to pyroprocessing, electrical systems and automation. FLSmidth’s scope of supply:• Limestone crusher (Impact – 480 KW) • Limestone stacker (luffing) & bridge

reclaimer, material handling equipment• Raw mill grinding ATOX 30 & 32.5 RAR

air separator• Raw mill & coal mill bag house &

cooler ESP

• FRF silo (16 X 28m)• Preheater: 5-stage single string ILC• Rotary kiln (3.15 X 47m)• Clinker cooler: FLSmidth Cross-Bar®

Cooler 6 X 29 with clinker breaker• Coal mill TIRAX® ball mill (TM30 X 4.5

+ 2.30) with air separator RTKM 17.5• Electrical, automation & instrumentation

items (from 33 KW incomer to control system complete design and supply)

Progress at siteMechanical installations are in progress and the major installations, including limestone crusher, kiln, cooler, preheater and raw mill are nearing completion. This is closely followed by installation of the electrical and automation equipment.

“Being the largest producer of cement in Nepal, we awarded our new project

SITE REPORT

With the increasing need for dams, bridges, housing projects and other infrastructure generating more construction projects, the demand for cement in Nepal is growing year on year. Cement manufacturers are looking to build new plants in order to expand cement production capacity.

Clinkerisationproject underway in Nepal

Project timelineSigning of the contract 7 June 2012Effective date of contract 15 October 2012Completion of engineering 30 December 2013Supply of major equipment 6 May 2014Expected commissioning December 2014


‘Sarbottam Cement Pvt. Ltd.’ to FLSmidth. As our dream cement plant is being built now, we could see that FLSmidth’s team is fulfilling their commitment of lowest thermal and electrical energy consumption, and also honouring the trust that we placed in them through their meticulous planning, effort and cooperation,” says Mr. Bishnu Prasad Neupane, Managing Director of Sarbottam Cement.

Trial runs of equipment are expected to be performed in October 2014.

“This project was planned in such a way that there were no hurdles at site for want of drawing or materials, which relieved us of stress and saved our time in follow-up activities with the supplier,” adds Mr. Bimal Kumar Sawarthia, Finance Director of Sarbottam Cement.

Several ‘firsts’ in NepalIn addition to the fact that Sarbottam Cement is the first project for which equip-ment is supplied by FLSmidth in Nepal, Sarbottam Cement plant provides the first ATOX® mill (VRM) at a cement plant in Nepal. In addition, it is the first ECS, IMCC and intelligent network system to be in-stalled in Nepal as well. Sarbottam Cement Plant has also ordered a 70 tph OK 25-0 vertical roller mill for cement grinding, and packing plants from FLSmidth. The plant’s objective will be to produce 1,500 tons of OPC & PPC cement per day.

CONTACT MANOJ [email protected]

Saurabh GroupThe Saurabh Group was established in 1964 by well-known business man Mr. Lila Ram Neupane initially as a trading agency and a fleet of bus services. After coming to Nepal from Myanmar, the group diversified its activities when the founder’s son, Mr. Bishnu Prasad Neupane, joined the group in 1986. The group is now mainly involved in the production of cement, steel, tea, spun yarn, PP Woven fabrics, calcium carbonates and other products.

KILN DURING ERECTION


Lumps and blockages in cement silos have long been an issue at some cement plants. In the 1970s, FLSmidth conducted research on ball mills and cement storage that revealed the cause to be an unfortunate combination of insufficient gypsum dehydration in the mill, high silo storage temperature and lengthy storage time. When stored at high temperatures, the gypsum continues to dehydrate. The water released from the gypsum prehydrates the cement in the silo, and lumps begin to form.

In more recent developments, some plants have begun to report issues in silos storing cement produced in vertical mills. Similar to the past, these issues are the result of a combination of factors such as lower degree of gypsum dehydration or high rates of water injection such that the moisture content of the cement stored in silos is increased.

Real-world research Close collaboration with cement plants is an important element of FLSmidth research. It ensures that the complexities of industrial operations are considered from the outset and that the research can be applied in practice. Titan Cement is a valuable collaboration partner in this project. The FLSmidth Research and Process depart-ments were therefore pleased to be invited to carry out tests at Titan Zlatna Panega in Bulgaria. The plant produces OPC cement with 4% limestone and max. 3.5% gypsum using an OK™ Mill 30-4.

FLSmidth research delivers silo-safe cement

A current project examines how to avoid lumps and blockages in silos with vertical mill cement.

INNOVATION

CONTACT JESPER HAVN [email protected]


The field tests were a critical part of a study that also included labo- ratory tests and special analyses. The results showed that the cement storage stability can be controlled by adjusting the OK Mill temperature and water injection (if water is used). Optimum mill operation depends on specific plant conditions and constraints, including clinker temperature, availability of hot gas, climatic conditions, quality of the feed materials (clinker composition, amount of additive materials such as gypsum, limestone, slag and their water content), legislative requirements, and storage time in the cement silo.

The OK Mill field tests were performed over several weeks. Com-plete quality analyses were performed on cement product samples taken with the mill in operation with different process conditions. The mill outlet temperature was varied from 75 to 120 degrees Celsius and water injection was varied from zero to approximately 2.3 percent (mass) of the total production in the mill.

Mill temperature testsWithin the temperature range of the tests, the effects on gypsum dehydration and prehydration were clear.

Low mill outlet temperature• Cement produced at low mill temperatures (app. 75-80 degrees

Celsius) had a relatively low level of gypsum dehydration com-pared to typical mill cement. However, as the cement tempera-ture is low, the gypsum in the silo does not dehydrate. Thus making the cement silo-safe. This supports the conventional rule-of-thumb that cement temperatures below 70 degrees Celsius are silo-safe for longer periods of time (weeks).

• At low mill temperature excessive water injection should be avoided. • Vertical Roller Mill (VRM) cement produced with low mill outlet

temperature should not be stored in a silo together with high temperature cement (>70 degree Celsius).

High mill outlet temperature• Cement produced at high outlet temperatures (>110 degrees

Celsius) had significantly dehydrated gypsum. As a result, high temperatures in the silo do not cause problems.

• High mill temperature can produce cement with gypsum dehy-dration similar to ball mill cement, but water injection must be low to medium.

The graph illustrating the water content from gypsum in cement shows the impact of different VRM operating conditions evaluated in the study on gypsum dehydration.

Water injection testsThe impact of water injection is explained below.

In general water injected on the mill table acts as a grinding aid to increase production and lower power consumption. Water also helps reduce mill vibrations, especially with dusty clinker. Ideally, in this case it is better to study and improve the factors impacting clinker granulometry rather than use increased water injection rates.

• If water injection rates are maintained within recommended safe ranges, silo-safe cement with good quality can be produced.

• High water injection can cause prehydration, especially at low mill temperatures, resulting in lower cement strength and an increase in the total water fed to the cement silo

• Excessively high water injection rates may be problematic even at high temperatures and should be avoided.

• OK mill operation with no or minimal water injection is best for producing silo-safe cement

ConclusionOverall, the study confirms that it is possible for an OK Mill to produce cement of similar quality to a ball mill and to match the gypsum dehydration and behaviour in the cement silo. This can be achieved by ensuring that the proper operating parameters are used. The plant tests also show that it is possible to produce si-lo-safe cement over a range of operating parameters that can be varied according to specific site conditions.

Ongoing researchThe results of this study demonstrate the versatility of the OK mill. Further research is also being conducted to study the effects of temperature and water injection on power consumption, cement quality and storage stability. Activities include accelerated storage testing of cements at the FLSmidth laboratories as well as addi-tional field studies to investigate especially sensitive cements with high contents of aluminate, gypsum and alkalis, as well as blend-ed cements with very wet additives. If your plant is interested in participating in additional studies, please contact us.

Effect of temperature and water injection on gypsum dehydration

HIGH WATER INJECTIONMEDIUM WATER INJECTIONLOW WATER INJECTION

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Mill outlet temperature (°C)

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WATER CONTENT FROM GYPSUM IN CEMENT AS FUNCTION OF MILL OUTLET TEMPERATURE AND WATER INJECTION


Thinking beyond

For cement plant owners and investors in today’s demanding business environment, strong partners are a necessity to provide the elements and conditions for efficiently designing and building cement plants - adding capacity and expanding to new markets. Entering into an EPC contract is one way to minimise risk and streamline the process by providing a single source for the delivery of the plant.

But an EPC contract alone may not be enough to ensure that the plant’s long-term business goals are met. Owners and investors also need assurances that the ongoing operations and mainte-nance (O&M) of the plant will support the market potential: What happens after production is underway? How will it be staffed and run? How will the plant’s performance goals be monitorised and optimised?

Design, build and then operate The return on investments in a cement plant are achieved through maximising future cement sales. It is therefore vital that investors know how the cement plant will operate over the full extent of its lifetime and have certainty that it can deliver to its full potential. Planning for the long-term operating potential at the same time as preparing the EPC contract will reduce the investment risk, shorten payback time and maximise the return on investment.

The key is to bring an O&M strategy into the EPC planning from the outset. This will deliver assurances from the very beginning that the plant will run smoothly and deliver the expected return over the full lifetime of the plant.

A strategic approach to O&M requires extensive operational expertise and planning, but contributes significantly to a plant’s bottom line. An effective O&M strategy includes several elements, such as:

How a full-service partner can help safeguard investments in cement plants.

EPCFEATURES

FLSmidth’s Design, Build, Operate Solution FLSmidth provides a unique 360° certainty solution for the cement plant lifecycle, covering everything from initial raw material investigation and Engineering, Procurement and Construction (EPC) through to ongoing operation and main-tenance services.

Our combined EPC and O&M solution is a unique offering managed by some of the most experienced engineers in the business alongside locally recruited staff who are trained and integrated into our expert teams.

With 130 years of specialist know-how, FLSmidth can guarantee a fully sustainable and efficient model that will grow the plant – and profits – long after operations begin.


• Implementing and ensuring health, safety and environmental practices in accordance with international standards

• Having clear performance goals associated with the perfor-mance of the plant staff

• Ensuring sufficient technical expertise is available to run and maintain the plant

• Ensuring strong organisational and technical training capabilities• Securing that the supply chain and organisation is in place to

deliver original spare parts • Implementing IT systems for optimising plant management

and maintenance

One-source partnerForming a full plant lifecycle strategy may seem a complex task before construction begins. That is why it is important to work with a partner who can assist you to plan for the future and navigate every step of the process. A single-source supplier should have the capabilities to provide full life-cycle support, from initial raw material investigation through construction and commissioning to ongoing day-to-day performance. They need to know how to put together a complex industrial project, manage suppliers and contractors, build new organ-isation and ensure the operational organisation runs efficiently.

Risk sharing, in particular, should be carefully planned. Typically, the plant owner is responsible for fundamental supply issues, such as power, water, fuel and raw materials as well as capital investments in machinery and property. The full-service provider helps define specifi-cations and make recommendations where and when necessary.

The key is for the owner to be able to transfer the risk and com-plexities of the operations to a single partner who is responsible for engineering, procurement, construction, and operating and maintaining the facility according to best-in-class standards. This leaves the plant owner to focus on building the business and the marketing and selling of the cement.

Opening doors to financing Financing for a cement plant is challenging, and a complete design, build and operations strategy can make a significant difference to the financing terms. Early on, banks require risk assessments and certainty that production goals and cash flow targets will be met. However, this can only be predicted with reasonable accuracy if the daily operations have been planned in detail from the outset. Thorough strategic plan-ning demonstrates to financial institutions how long-term revenues will be generated and tailor-made solutions guide the investor through the entire process covering all financial institutions requirements to facilitate the credit needed with the right repayment strategy in place. In addition, having the right partner gives the financial institution the best guarantee that the plant will be a successful investment.

Sustainable, profitable operationsWith an end-to-end solution covering design, build and operations, cement plant owners can put their business goals into action, guar-anteeing the most efficient and sustainable model to develop the business and achieve the bottom-line results demanded over the lifetime of the investment. By guaranteeing the plant is operated and maintained according to the highest standards, the plant deliv-ers a lower total cost of ownership and ensures that the asset main-tains the highest possible value throughout the plant lifetime.

FLSmidthDesign, build & operate

CONTACT SAMIR [email protected]

CONTACT ANDERS [email protected]

PLANNING FOR THE LONG-TERM OPERATING POTENTIAL AT THE SAME TIME AS PREPARING THE

EPC CONTRACT WILL REDUCE THE INVESTMENT RISK, SHORTEN PAYBACK TIME AND MAXIMISE THE RETURN ON INVESTMENT.


Innovative fabric filter design reduces costs and cuts emissions

FLSmidth introduces two new DuoClean™ filtersFLSmidth has recently introduced two new, revolutionary DuoClean™ filter types – the DuoClean™ DC2 and the DuoClean™ DC8. Continuing FLSmidth’s objective of providing cost-efficient and effective filter solutions, the new DuoClean filters meet the strictest emission requirements, while reducing upfront costs. They feature an innovative octagonal shape and a compact, modular design.

Lars Gamborg, FLSmidth’s Global Product Manager for Fabric Filters, explains that FLSmidth set out to design a fabric filter that performed exceptionally, but at a lower cost of investment. “Based on this vision, we developed a compact filter that is simple to manufacture, transport and assemble, while also delivering low opera-tional costs, high performance and low emission. With the new, compact DuoClean filters, which are based on modules, we focused on manufacturability and con-structability, and this enabled us to create filters that minimise environmental footprint to an even greater degree.”

Further development of proven technologyAlready installed at more than 50 plants worldwide, the DuoClean filter has a proven design and technology concept. In creating the two new filters, FLSmidth has further developed the most important DuoClean features, including the cleaning system, gas distribution capabilities and the long-bag technology. A close look at supply chain and customer requirements revealed the need to reduce engineering, manufacturing and installation costs. To meet these needs, the new filters feature a standardised, modular design.

Advanced gas and dust distribution screenDuoClean’s technology is characterised by a dual-flow gas approach. Gas flows from the bottom and side of the bags ensuring low, uniform velocity over the entire bag filtration area. This allows the use of longer bags, which reduces the filter footprint.

CONTACT LARS GAMBORG [email protected]

INNOVATION


To ensure gas is distributed evenly to the hoppers and on the bags, individually designed gas distribution screens are used for each filter application.

Lighter filters reduce investment costsThe DuoClean DC2 and DC8’s modular design features eight identical panels as-sembled in an octagon. The filter uses simple reinforcement profiles and requires fewer components. Its near-round shape has a self-reinforcing, strengthening effect, which, together with the optimised casing and hoppers, means it is significantly lighter than comparable fabric filters. This leads to lower

capital expenditures (CAPEX) requirements, as lighter filters are easier and more cost-effective to fabricate, transport and assemble.

Easy transportation and installationThe octagonal shape also plays an important role in simplifying transportation and instal-lation. The filter’s steel components, trans-ported in standardised containers, are designed so the casing, the eight side-panels and the hole-plate elements are a perfect fit to the container. The container is packed efficiently utilising the entire space, so fewer containers are required. This helps to mini-mise transportation costs. >>

THESE 8 STEPS ILLUSTRATE A DUOCLEAN DC2 FILTER TAKING SHAPE. CONSTRUCTION AND INSTALLATION CAN BE AS QUICK AS JUST FOUR WEEKS. THE COMPONENTS ARRIVE ON-SITE IN CONTAINERS. YOU ONLY NEED A CRANE FOR THE FINAL MOVING OF THE PRE-INSTALLED COMPONENTS TO THE FINAL FILTER LOCATION; OTHERWISE ALL CONSTRUCTION IS DONE AT GROUND LEVEL.

8. WEATHER ENCLOSURE

1. PENDULAR SUPPORT AND SUPPORT BEAMS 4. GAS DISTRIBUTION SCREENS3. INTERNAL BRACING2. BOTTOM HOPPERS

5. CASING AND DUCT 6. TUBE SHEETS7. CLEANING SYSTEM

AND ACCESS LIDS


“AS A TECHNOLOGY LEADER, FLSMIDTH IS COMMITTED TO

DELIVERING EXCELLENT SOLUTIONS FOR REDUCING

EMISSION LEVELS NOW AND IN THE FUTURE. IT IS

DEFINITELY OUR OBJECTIVE TO PROVIDE OUR CUSTOMERS

WITH A FUTURE-SAFE INVESTMENT.”

Lars GamborgGlobal Product Manager, Fabric filters

TOP ACCESS

WALK-IN PLENUM

WEATHER ENCLOSURE

The filter components are then typically assembled at a dedicated area close to the plant, and construction is completed on-site. This process reduces the demand for scaffolding and crane capacity and means construction takes place quickly, safely and cost-effectively. The use of standardised, prefabricated parts reduces the risk of errors and optimises quality assurance.

Cleaning system increases bag lifetimeFLSmidth’s DuoClean filters ensure out-standing performance at a low operational cost. Thanks to the unique gas distribution and pre-separation of dust, the pulse jet cleaning system operates with a minimal number of cleaning cycles, resulting in low compressed air consumption, less wear of the bags and an increased bag lifetime.The low pressure cleaning system (cleaning pressure ≤ 2.0 bar), developed with exten-sive R&D, is also available to ensure efficient cleaning and reduced stress of the long bags. This means that the traditional high-pressure compressor (6-7 bar) can be replaced with a root blower, saving investment and operational costs.

Smaller filters for smaller applicationsFLSmidth’s DuoClean DC8 filter has been designed to meet the needs of smaller


SCAN HERE TO LEARN ABOUT MORE SUCCESSFUL CASES

BMIC, EgyptAt the BMIC cement plant in Egypt, all emission targets have been met suc-cessfully with the DuoClean DC8 filter. With a bag length of six metres, the filter operates at a gas flow of 72,000 Am3/h and temperature of 140 °C.

Lafarge Cement, Rezina, Moldova A nine-metre bag provides an emission guarantee of 10 mg/Nm3 on the kiln/raw mill at Lafarge, Rezina plant in Moldova. The filter operates at a gas flow of 630.000 Am3/h and tempera-ture range of 100-250 °C.

Performance test results show an actual emission at

1.24 mg/Nm3

Askale Cement, Gumushane, TurkeyThe Askale Gusmushane plant in Turkey selected the DuoClean DC2 filter for the plant’s cement mill due to the filter’s compact design and ability to handle large gas flows. With an emission guar-antee of 10 mg/Nm3, the filter has a 10-metre bag and operates at a gas flow of 850,000 Am3/h and tempera-ture of 95 °C.

CEMEX, APO, PhilippinesAt CEMEX APO in the Philippines, the DuoClean DC2 filter is installed on the plant’s cement mill. The eight-metre bag provides an emission guarantee of 15 mg/Nm3 at a gas flow of 780,000 Am3/h and temperature of 100 °C.

cement mill applications. Also featuring an octagonal-shaped casing, The DuoClean DC8 is a compact, one-compartment filter for use at a gas flow range of 45,000 to 150,000 Am3/h. With a small footprint and typical bag length of six to eight metres, it is up to 40 percent lighter than conventional filters.

Significant R&D investmentsThe new filter types are the result of sub-stantial R&D efforts by FLSmidth, in particular using computational fluid dynamics (CFD) to achieve optimal control of gas distribution and the ideal dualflow split. The CFD results demonstrated a well-distributed gas flow with a significant amount of dust being preseparated to the hopper. This delivers uniform gas speed to the bags, reduces compressed air usage and increases the lifetime of the bags, all factors that help reduce operating costs.

Lars Gamborg elaborates on FLSmidth’s R&D efforts: “We have invested extensively in R&D to ensure that a well-proven tech-nology is transformed into innovative filter solutions responding to the needs of to-day’s plants and industry trends. The test-ing was carried out at our R&D Centre Dania, which is now the biggest in the industry. Besides testing many prototypes, the full-scale pilot filter allowed us to test the 10m long bags in different operating conditions.”

“As a technology leader, FLSmidth is com-mitted to delivering excellent solutions for reducing emission levels now and in the future. It is definitely our objective to pro-vide our customers with a future-safe investment,” concludes Lars Gamborg.


India’s Reliance Cement chose a complete electrical and automa-tion package from FLSmidth for its 10,000 tonnes–per-day plant at Maihar, Madhya Pradesh. Signed on an EPC basis, the contract entailed complete engineering, procurement and commissioning of the first GIS system to be installed at an Indian cement plant.

From the time of the equipment’s arrival at the site, it took only 17 days to install, test, assemble and charge up the switchgear. Manag-ing risk was a key factor during the delivery and commissioning of the GIS system in terms of equipment selection, engineering, project execution and installation.

Indian cement industry’s first gas-insulated switchyard

When there is a need for high reliability and flexibility, low lifecycle costs and maximum environmental sustainability, gas-insulated switchgear (GIS) is the best choice over conventional air-insulated switchgear (AIS).

SITE REPORT

LONG VIEW OF GIS


Competitive sourcingFLSmidth applied its in-depth understanding of the cement-making process to select the equipment and components that would ensure optimum performance. Extensive global knowledge of the established electrical and automation OEM suppliers enabled the cost-effective sourcing of equipment.

Dynamic engineeringThe performance of any equipment supplied in a project depends on how well it is engineered to match site requirements. FLSmidth successfully met the challenges of bridging national, cultural and linguistic gaps between supplier and end-user, whilst fulfilling the customer’s expectations in terms of safety, acceptance, performance and service.

The engineering started with concept drawing followed by 3D modelling to mitigate any civil work issues. Complete testing of the equipment took place at the suppliers’ workshops to prevent unnecessary surprises at the site and save time in the execution phase, where only resonance frequency testing was necessary.

Seamless executionA well-structured organisation with dedicated managers for engi-neering, sourcing and logistics helped ensure efficient project execution. The process involved obtaining all the necessary approvals from customer consultants and electricity boards, securing the supply of special or ‘first-time’ equipment, and ensuring timely ordering, inspection and delivery. All logistics were well-planned and deliveries were tracked to ensure compliance with the agreed timelines.

InstallationThe FLSmidth site engineers, the customer’s engineers and the OEM engineers worked seamlessly together in identifying, installing and commissioning the various equipment parts. Civil engineering levels were verified against the approved drawings. After being installed, the equipment was tested as recommended by the OEM supplier.

About gas-insulated switchgearThe gas-insulated switchgear (GIS) in a substation is contained in an earthed metal (aluminium) enclosure, which is filled with high-insulation pressurised sulphur hexafluoride (SF6) gas as the insulating and arc-extinguishing medium. The switchgear equip-ment includes a circuit breaker, disconnecting switch, voltage transformer, current transformer, and surge/lightning arrester as

well as bushings and cable holders. GIS is compact, environmen-tally adaptable, safe and easy to operate and handle. It is reliable, flexible and requires minimal maintenance. GIS rated voltages range from 72.5 kV to 800 kV and rated short-circuit breaking current ranges up to 63 kA.

Indian cement industry’s second GIS solutionThe best reward any company can expect for exceeding a customer’s expectations is to receive another order from the same customer. Reliance Cement awarded FLSmidth a second electrical and automation EPC contract for the grinding unit in Kundanganj, Uttar Pradesh, India. Following the same successful engineering, procurement and commissioning model developed for the Maihar Plant, the GIS for this new site is already in use.

GIS – CLOSE-UP VIEW

JOINTLY CONTRIBUTED BY SUJITH VARGHESE GEORGE & SUDEEP SAR

CONTACT SUDEEP [email protected]


FLSmidth® STRIKE-BAR® crusher

The new crusher family memberThe FLSmidth STRIKE-BAR crusher is the newest member of the FLSmidth crusher family and a perfect match to the EV™ crusher. The STRIKE-BAR is a horizontal impact crusher for raw material crushing and, at first glance, it looks sturdy and heavy duty – and a bit similar to the EV.

The two machines certainly share some familiar features, but the skin deceives and a peek under the hood reveals the differences.

Crushing raw materials for cement presents a number of challenges, and it is important to select the right crusher for the job. Lime- stone comes in many forms and can exhibit different physical properties that causes varying degrees of wear of the machinery. Other factors to consider include the required reduction ratio and the size requirements of the end product. This is where a broad panel of crushers makes sense. At FLSmidth’s in-house test facilities, the correct material properties can be determined and the appropriate crusher selected.

The EV hammer crusher has been the preferred choice for raw material crushing at cement plants for many years. A billion tonnes of limestone has been crushed by this grand old machine. And now it is joined by a little brother.

INNOVATION

FLSMIDTH EV HAMMER IMPACT CRUSHER


IN MACHINERY OPERATING AT SUCH HIGH SPEEDS AND IMPACT FORCES, FLEXIBILITY

IN THE SYSTEM IS A MUST AND IT IS OF COURSE AN

INTEGRATED PART OF BOTH THE STRIKE-BAR CRUSHER

AND THE EV.

CONTACT HENRIK SØ[email protected]

The working principleThe main area of difference between the STRIKE-BAR crusher and the EV is the impact zone.

On traditional hammer crushers, the main impact occurs between a pivoting hammer, rock and a fixed breaker plate. The final crushing occurs between hammer and grate. The STRIKE-BAR crusher utilises the similar high-speed impact, but the main impact occurs between a fixed bar, rock and ‘flexible’ breaker plates.

In machinery operating at such high speeds and impact forces, flexibility in the system is a must and it is of course an integrated part of both the STRIKE-BAR crusher and the EV.

The EV utilises the fixed grate for fine crushing or grinding, making it suitable for high reduction ratios and small output (such as for a ball mill feed). The STRIKE-BAR crusher utilises several flexible breaker plates for crushing making it the right choice for medium course output (for example on vertical roller mills), easy wear adjustment and more flexible output size.

FLSMIDTH STRIKE-BAR CRUSHER

MaintenanceThe main crusher at a cement plant is the first machine in the process. This crusher processes heavy quarry boulders weighing up to five tonnes each and reduces them to mill-feed size. This kind of operation de-mands an extremely durable crusher. But no machine can perform endlessly under such circumstances; hence the crusher must be flexible from the perspective of wear com-pensation, maintenance and replacement of wear parts. It is important that crushers have several inspection hatches for easy regular

inspection and to enable free access above the rotor and breaker plates when major overhauls are needed. This is just one of the features that makes maintenance simpler and more cost-effective. Others include bolted-on wear segments, adjustable breaker plates, minimal use of different spare parts and chrome/manganese wear parts.

All of these challenges have been solved in the design of the STRIKE-BAR crusher, which is based on many years’ operational experience gained from the EV crusher.


When plant equipment fails, replacement technology is not the only answer. Teamwork plays a vital role in ensuring operations get quickly back to normal.

Something was amiss at the Tahama Cement Plant in Saudi Arabia. The gearbox installed on one of its mills had not been meeting performance requirements, and when the gearbox failed, a quick solution was needed to get the mill back into operation.

Meanwhile on another of Tahama’s mills, an FLSmidth MAAG® gearbox had consistently been performing to expectations. So when the decision had to be made for a replacement gearbox, the choice fell on FLSmidth MAAG.

The Tahama Cement Plant is owned by Southern Province Cement Company (SPCC), one of Saudi Arabia’s leading cement producers. SPCC operates three cement plants with a total cement production

Great teamworkand reliable technology minimise plant disruption

SITE REPORT

CONTACT PETER BROCKMANN [email protected]

UNCOVERED BREAK OF AUXILIARY DRIVE TO SHOW DESIGN - PRIOR TO INSTALLATION OF BREAK GUARD


capacity of over 8.4 million tpy. The Tahama plant produces more than 3.63 million tons of clinker a year. As of March 2015 the production will be even further increased to 5.45 million tons a year.

Peter Brockmann, Field Service Engineer at FLSmidth MAAG, arrived at the Tahama plant soon after the gearbox failure. The old gearbox had already been removed and Peter and his colleagues could quickly get to work. The project consisted overall of two parts. First, the foundation needed to be prepared. Then the gear-box could be installed, aligned and tested.

Peter Brockmann explains the challenge of preparing the foundation: “The foundation of the previous gearbox was quite complex and not compatible with the FLSmidth MAAG CPU. So the first part of the project involved completely overhauling and renewing the foundation.”

SPCC was aware of this challenge, and it was one of the main reasons FLSmidth MAAG had been chosen. Yet SPCC wanted assurances that the new gearbox would meet its performance requirements, as any potential malfunctions and resulting downtime would be costly. This is where FLSmidth MAAG’s professionalism and expert knowledge of the particular demands of a cement mill came to the fore. The installation engineers brought a professional attitude and they knew it was important to work as a team with the site’s staff, especially as time was of the essence.

Peter Brockmann says, “Our client wanted to know that we could make everything work despite the challenges of the project. It was important that the foundation was prepared properly so that the gearbox would have optimal conditions. We were confident we could deliver to SPCC’s expectations as we brought many years’ practical experience to the challenge and had completed many

similar projects before. The key, especially when you have to work at speed, is teamwork, which involves communicating and everyone taking responsibility for specific tasks.”

Preparing the foundationThe replacement of the foundation started with positioning and roughly aligning the gear unit to the mill. This included the precise control of the mill input flange and mounting the coupling connect-ing the mill to the gearbox.

With the gearbox fixed and grounded, the oil system and piping could be installed. This was followed by testing the oil system before the equipment was flushed. Then, as the last steps before the final spin test and hot commissioning of the mill, the protection interlocks were tested and the motor and gear unit were aligned.

Today, the mill is once again fully operational thanks to the FLSmidth MAAG CPU and the quick response and professionalism of the SPCC and FLSmidth MAAG teams.

Great teamworkand reliable technology minimise plant disruption

“THE FOUNDATION OF THE PREVIOUS GEARBOX WAS QUITE COMPLEX AND

NOT COMPATIBLE WITH THE FLSMIDTH MAAG CPU. SO THE FIRST PART OF THE

PROJECT INVOLVED COMPLETELY OVERHAULING AND RENEWING THE

FOUNDATION.”Peter Brockmann,

Field Service Engineer at FLSmidth MAAG


FLSmidth launches Service Agreement Concept for on-site plant inspections, remote support, assistance and training

Improvements in technology are increasing the lifecycles of cement plant equipment. But even the most reliable, advanced equipment requires maintenance to optimise its perfor-mance. With a ‘preventive maintenance’ approach, cement plant owners can combat the uncertainty of maintenance and avoid unplanned stoppages. FLSmidth has launched a flexible service concept based on the principles of preventive maintenance that aims to ensure maximum availability of the plant while reducing the cost of maintenance.

Jacob Jørgensen, Head of FLSmidth’s Service Department in Denmark, says, “Cement plant owners are looking for high availability in their operations. Stoppages are unavoid-able to a certain point, but their effect on production time can be minimised if they are planned. This is why we have developed

a flexible service agreement concept that gives plant managers everything they need to effectively plan their maintenance.”

Regular inspections for peace of mindCentral to the service concept are regular onsite inspections, which aim to monitor the equipment and reveal potential issues before they arise. After each inspection, a comprehensive report is produced, which provides valuable insight into the plant’s day-to-day operations. These reports are particularly useful in the event of an unex-pected failure between inspections. In such cases, the service agreement will facilitate that FLSmidth can provide instant technical support in between inspections solving issues based on the intimate knowledge of the plant.

“FLSmidth has published a comprehensive service catalogue, and everything contained within the catalogue can be included within the service agreement,” explains Jacob


NEWS IN BRIEF

Plant Service AgreementsOptimising cement plant operations

CONTACT JENS PETER [email protected]

CONTACT JACOB JØ[email protected]

“THE FLSMIDTH SERVICE AGREEMENT CONCEPT IS A GOOD

MATCH TO OUR OWN RELIABILITY-CENTRED

MAINTENANCE STRATEGY AND IT CREATES INCREASED CONTINUITY IN THE SERVICES DELIVERED AND

LOWERS THE COST OF THE MAINTENANCE.”

Mr. Amir Feroze, General Manager, Maple Leaf Cement’s

Jørgensen. “It applies to everything from crushers, stackers and all types of mills through to gear units, kilns and coolers. It also covers a plant’s automation systems. The agreement can mean extended war-rantees to the equipment.”

Jacob Jørgensen emphasises the importance of training as part of the service agreement: “In addition to providing on-site assistance, we offer training in the use of cement plant equipment. This is valuable for plant managers to ensure their personnel have the right skills to operate the equipment.”

Reduce the cost of maintenanceMaple Leaf Cement in Pakistan is one plant that recognises the opportunity to reduce the cost of maintenance through a long-term approach to service. Mr. Amir Feroze, Maple Leaf Cement’s General Manager says, “The FLSmidth Service Agreement Concept is a good match to our own reliability-centred maintenance strategy and it creates increased continuity in the services delivered and lowers the cost of the maintenance.”

FLSmidth’s service agreement covers every-thing from a one-time equipment inspection to full flow sheet service agreements, including continuous inspections and tech-nical support. It provides several benefits. As it is based on a fixed-price agreement, costs are predictable for the duration of the agreement. At the same time, mainte-nance budgets are reduced by eliminating non-value-adding costs resulting in more favorable pricing of the individual inspec-tion. “We estimate that plants can save between 10 and 20 percent on mainte-nance by pre-scheduling inspections,” says Jacob Jørgensen, adding, “There is also less need for inventory as the inspections lead to better spare part planning.”

39HIGHLIGHTS CEMENT – October 2014 39HIGHLIGHTS CEMENT – October 2014

ABC™ INLET DURING CONSTRUCTION

The existing air beam grate cooler was suffering from high maintenance costs and poor cooler efficiency. Several options were reviewedfor the upgrade of the cooler. After detailed review and analysisHolcim chose a selective solution, upgrading the following key com-ponents of the cooler, while minimising capital costs for the upgrade:• New ABC™ (air blast controlled) fixed inlet with two new

undergrate fans• Compartmentalisation of the existing cooler, adding new

compartments, floor plates, and inter-compartment seals• New tube conveyor to transport the spillage material, replacing

the existing open-style drag chain• New pocket type grate plates for the entire cooler

Holcim and FLSmidth worked together closely on the upgrade,incorporating Holcim design parameters into the final equipmentarrangement. Additionally, while both parties realised that all newfans for the cooler would further improve results, only the fans forthe inlet were replaced, and the rest of the existing fans wererearranged and re-used.

The equipment for the project was delivered in late 2011, buta strong Colombian market postponed the plant’s planned shut-down for cooler upgrade and installation until October of 2012when the cooler upgrade was installed during a scheduled main-tenance stoppage. The shutdown, from flame-off to flame-on,lasted 20 days.

FLSmidth has visited the plant twice since the installation, and thecooler continues to perform well, with high reliability, limitedmaintenance and good fuel consumption.

CONTACT MARK [email protected]

cooler upgrade

In May 2011, Holcim and FLSmidthpartnered to upgrade the existing clinker cooler at Holcim’s Nobsa plant in Colombia.

Performance testing Guarantee description Guarantee Obtained Capacity 3,300 tpd 3,449 tpd Fuel consumption savings -20 kcal/kg -50 kcal/kgClinker temperature 165˚C 164 ˚C


The online edition – eHighlights Cement - is enriched with videos, animations, images and links to related material. The eHighlights online platform is constantly updated with new content.

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As a global player, FLSmidth regularly attends events and confer-ences all over the world. At these events, we present the full range of our products and services and we offer the opportunity for a no-obligation discussion about your cement plant requirements.

Here are some of the events where you can meet us in the com-ing year. Be sure to stop by and see us!

Upcoming events

DATE EVENT LOCATION

October 29-30, 2014 FLSmidth seminar Tehran, Iran

November 11-13, 2014 AUCBM Marrakech, Morocco

November 12-13, 2014 CBI New Delhi, India

April 21-25, 2015 AFCM Hanoi, Vietnam

April 26-30, 2015 IEEE-IAS/PCA Toronto, Canada

Stay updated on eHighlights where you will find information about previous and upcoming events, conference presentations and papers.

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APRIL 2013

A source for good

service Cement

evolution of SCMAutomation technologies enabling

ICE

OCTOBER 2013Reliability-focused

performanceHow will the industry move ahead in cooperation with the

equipment suppliers?

APRIL 2014

Avoid expensiveunforeseen shutdowns

Loan bundlingsaves money

O&M Cementreaches new heights

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