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Thinking
beyond
EPC
Semen Indonesia
gains newest
OK mill
Worlds first
Postgraduate Cement
Plant Engineering Degree
Strong partnerships
for a stronger future
Despite 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
Holcims Ada plant in the US (page 5).
Product development and innovation are a hallmark of FLSmidths
contribution to the cement industry. Our most recent major release
is the new version of the OK Mill, which has been commissioned
at Semen Indonesias 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 Universitys new post-graduate cement plant engineering
degree on page 8.
360 certainty solution: Design, Build and Operate
For cement plant owners and investors in todays 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 FLSmidths Design, Build and Operate solution
on page 26.
Welcome to Highlights Cement.
Per Mejnert Kristensen
President, Cement Division
cement.flsmidth.com
gives you more details and
additional articles
Editor-in-chief
Nadia Haagen Pedersen
Managing editor
Charlotte Lrke Backmann
Content editor
Kit Franklin Momme
Associate editors
Brenda Kaplan,
Bharathkumaar Soundararajan
Editorial board
Mark Brugan, Palle Erik Grydgaard,
Sten Stoltze, Martin Strouhal, Hari TR
Layout: 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:
FLSmidth
Vigerslev All 77
DK-2500 Valby, Copenhagen, Denmark
Tel: +45 36 18 10 00
Fax: +45 35 45 44 27
Email: highlights@flsmidth.com
www.flsmidth.com/ehighlights
CONTENTS
FEATURES
Worlds first Postgraduate Cement
NEW ORDERS
14
26
SITE REPORTS
Republic of Congo
FLSmidth to modernise
Holcim US Ada plant
INNOVATION
in Nepal
22
32
performance
12
18
24
28
OK mill
34
21
News in brief
38
Upcoming events
40
24
22
NEW ORDERS
CONTACT HUBERT SUINAT
HSU@FLSMIDTH.COM
FLSmidth selected as
supplier for Holcim (US)
Ada Oklahoma Plant
modernisation
project
Semen Indonesia
gains newest
OK mill
FLSmidths OK mill
FLSmidths 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 approximately 40 percent in power consumption compared with traditional 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.
Optimal airflow
Fluid 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 cement
Indonesias economic growth in recent years, resulting in continuing
investments in infrastructure development, has had a significant
influence on the countrys cement production demands. As Indonesias leading cement supplier, PT Semen Indonesia has played a
major role in servicing the cement demands. The companys Tuban
plant is located in East Java and has a total output of 33,600 tpd.
Tubans 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 energyefficient 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 requirements
Klaus Bgeskov, 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 mills design to fit the plants layout.
Klaus Bgeskov 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.
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 Bgeskov,
Project Manager at FLSmidth
FEATURES
CONTACT CRISTINA HOLMARK
CRHO@FLSMIDTH.COM
Worlds
first
Postgraduate Cement Plant
Engineering Degree
During the pilot project, FLSmidth Group engineers did the student
lectures, while the universitys 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 industry
Meanwhile, during the pilot project, extensive preparation was taking
place for the full implementation of the cement diploma degree.
This involved obtaining approval from Egypts Higher Counsel of
Ministry of Education, a process that took one year. With the
ministrys blessing, the degree was sanctioned allowing 16 students
to begin their new educational venture in February 2014. >>
10
WORLDS FIRST
POSTGRADUATE CEMENT PLANT
ENGINEERING DEGREE
STUDENTS AFTER A
DAY OF CLASS ROOM
LECTURES OUTSIDE OF
THE TRAINING CENTRE
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.
Cristina Holmark,
General Manager of Global FLSmidth Institute
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
role in raising the education and skill levels of cement plant engineers: 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 Institutes core business. Other similar projects currently
underway internationally include an energy efficiency training
programme in Vietnam and a vocational programme for unemployed youths in India.
For FLSmidth as a whole, its important to realise that were 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 graduates and 16 current students on the FLSmidth Helwan Cement
Institute programme who can attest to that.
11
12
INNOVATION
CONTACT MORTEN HANSEN
MOH@FLSMIDTH.COM
CONTACT NAVEEN SEELAM
NKS-IN@FLSMIDTH.COM
New
graphite seal
optimises kiln
performance
Designed for fast installation
on any kiln, FLSmidths new
kiln graphite seal reduces ID
fan power consumption
EACH MODULE IS
DESIGNED TO BE
PRE-ASSEMBLED BEFORE
INSTALLATION
SCAN TO VIEW
PRODUCT SITE ON
FLSMIDTH.COM
13
14
Right
FEATURES
first time
Production underway
at FCKS cement plant
in Angola
The commissioning was all the more impressive considering the plants unique
challenges. FCKS is located in a remote area
near the town of Sumbe in the Kwanza Sul
province, about 300 km south of Angolas
capital, Luanda. Even though Angola has
vast mineral resources and a fast-growing
economy, its cement industry is underdeveloped and the country possesses very limited
specialist cement expertise. As one of
Angolas newest and most modern cement
plants, FCKS represents a significant step in
the development of the countrys growing
cement industry. That is why it was important 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 automation equipment for the cement plant.
15
16
RIGHT
FIRST TIME
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
17
18
INNOVATION
The new
FLSMIDTHS ECS/
CONTROLCENTER V8
SOFTWARE HAS JUST
BEEN RELEASED
19
20
THE NEW
ECS/CONTROLCENTER V8
PROCESS CONTROL SYSTEM
The ECS/ControlCenter solution still comes with built-in highperformance 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.
Whats next?
The development of FLSmidths 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.
Delivering
to customer needs
Achieved
after Phase I
modification
2550
10-12
64 + Ambient
21
22
SITE REPORT
Clinkerisation
project underway in Nepal
Project timeline
Signing of the contract
Effective date of contract
Completion of engineering
Supply of major equipment
Expected commissioning
7 June 2012
15 October 2012
30 December 2013
6 May 2014
December 2014
Saurabh Group
The 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 founders 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
23
24
INNOVATION
CONTACT JESPER HAVN ERIKSEN
JEHE@FLSMIDTH.COM
FLSmidth
research
delivers silo-safe
cement
The OK Mill field tests were performed over several weeks. Complete 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 tests
Within 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 compared to typical mill cement. However, as the cement temperature 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 dehydration 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 tests
The 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.
The field tests were a critical part of a study that also included laboratory 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.
0.6
0.5
0.4
0.3
0.2
0.1
0
60
70
80
90
100
110
120
130
25
26
FEATURES
Thinking beyond
EPC
How a full-service partner can
help safeguard investments in
cement plants.
FLSmidth
Design, build
& operate
27
28
INNOVATION
FLSmidth introduces two
new DuoClean filters
FLSmidth has recently introduced two new,
revolutionary DuoClean filter types the
DuoClean DC2 and the DuoClean
DC8. Continuing FLSmidths 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, FLSmidths 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 operational costs, high performance and low
emission. With the new, compact DuoClean
filters, which are based on modules, we
focused on manufacturability and constructability, and this enabled us to create
filters that minimise environmental footprint
to an even greater degree.
Innovative
Further development of
proven technology
Already 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 screen
DuoCleans 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.
1. PENDULAR SUPPORT
AND SUPPORT BEAMS
2. BOTTOM HOPPERS
3. INTERNAL BRACING
6. TUBE SHEETS
7. C
LEANING SYSTEM
AND ACCESS LIDS
8. WEATHER ENCLOSURE
29
30
TOP
ACCESS
WALK-IN
PLENUM
WEATHER
ENCLOSURE
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 Gamborg
Global Product Manager, Fabric filters
SCAN HERE TO
LEARN ABOUT MORE
SUCCESSFUL CASES
BMIC,
Egypt
At the BMIC cement plant in Egypt, all
emission targets have been met successfully 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.
Askale Cement,
Gumushane, Turkey
The Askale Gusmushane plant in Turkey
selected the DuoClean DC2 filter for
the plants cement mill due to the filters
compact design and ability to handle
large gas flows. With an emission guarantee of 10 mg/Nm3, the filter has a
10-metre bag and operates at a gas
flow of 850,000 Am3/h and temperature of 95 C.
CEMEX, APO,
Philippines
At CEMEX APO in the Philippines, the
DuoClean DC2 filter is installed on the
plants 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.
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 temperature range of 100-250 C.
Performance test results show
an actual emission at
1.24
mg/Nm3
31
32
SITE REPORT
Indian cement
LONG VIEW
OF GIS
industrys first
gas-insulated switchyard
Indias Reliance Cement chose a complete electrical and automation package from FLSmidth for its 10,000 tonnesper-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 equipments arrival at the site, it took only 17
days to install, test, assemble and charge up the switchgear. Managing risk was a key factor during the delivery and commissioning of
the GIS system in terms of equipment selection, engineering,
project execution and installation.
JOINTLY CONTRIBUTED BY
SUJITH VARGHESE GEORGE &
SUDEEP SAR
GIS CLOSE-UP
VIEW
Competitive sourcing
FLSmidth 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 engineering
The 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
customers 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 execution
A well-structured organisation with dedicated managers for engineering, 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.
Installation
The FLSmidth site engineers, the customers 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 switchgear
The 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 equipment includes a circuit breaker, disconnecting switch, voltage
transformer, current transformer, and surge/lightning arrester as
well as bushings and cable holders. GIS is compact, environmentally 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 industrys second GIS solution
The best reward any company can expect for exceeding a
customers 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.
33
34
INNOVATION
FLSmidth
STRIKE-BAR crusher
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.
FLSMIDTH EV HAMMER
IMPACT CRUSHER
FLSMIDTH STRIKE-BAR
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.
Maintenance
The 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 demands an extremely durable crusher. But no
machine can perform endlessly under such
circumstances; hence the crusher must be
flexible from the perspective of wear compensation, maintenance and replacement of
wear parts. It is important that crushers have
several inspection hatches for easy regular
35
36
SITE REPORT
CONTACT PETER BROCKMANN
PEB-CH@FLSMIDTH.COM
UNCOVERED BREAK OF
AUXILIARY DRIVE TO
SHOW DESIGN - PRIOR
TO INSTALLATION OF
BREAK GUARD
Great teamwork
and reliable technology
minimise plant disruption
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.
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.
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.
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.
37
38
NEWS IN BRIEF
Plant Service
Agreements
Successful
cooler upgrade
The existing air beam grate cooler was suffering from high maintenance costs and poor cooler efficiency. Several options were reviewed
for the upgrade of the cooler. After detailed review and analysis
Holcim chose a selective solution, upgrading the following key components 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 equipment
arrangement. Additionally, while both parties realised that all new
fans for the cooler would further improve results, only the fans for
the inlet were replaced, and the rest of the existing fans were
rearranged and re-used.
The equipment for the project was delivered in late 2011, but
a strong Colombian market postponed the plants planned shutdown for cooler upgrade and installation until October of 2012
when the cooler upgrade was installed during a scheduled maintenance stoppage. The shutdown, from flame-off to flame-on,
lasted 20 days.
FLSmidth has visited the plant twice since the installation, and the
cooler continues to perform well, with high reliability, limited
maintenance and good fuel consumption.
Performance testing
Guarantee description
Capacity
Fuel consumption savings
Clinker temperature
Guarantee
3,300 tpd
-20 kcal/kg
165C
Obtained
3,449 tpd
-50 kcal/kg
164 C
39
40
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paths
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FLSmidth
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Reliability-focused
OCTOBER 2013
performance
APRIL 2013
service
equipment
suppliers?
Cement
evolution of SCM
APRIL 2014
Avoid expensive
unforeseen shutdowns
Loan bundling
saves money
O&M Cement
reaches new heights
Automation
technologies enabling
ICE
Meet with us
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.
Highlights Cement also comes in an interactive tablet-friendly
version available for iPad. Download the app free in iTunes.
As a global player, FLSmidth regularly attends events and conferences 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 coming year. Be sure to stop by and see us!
Upcoming events
DATE
EVENT
LOCATION
Marrakech, Morocco
AFCM
Hanoi, Vietnam
IEEE-IAS/PCA
Toronto, Canada
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