March 2017

Global Cement news Burners Efficiency Grinding Lime Brazil
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Contents Subscribe Ad Index
MARCH 2017 MAGAZINE
AHEAD OF THE GAME

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with a vertical cement mill. Operational since January 2017!
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Process Signals D-PMS
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Torque D-TMS
Predictive
Failure Detection
DALOG Condition Monitoring System
Vibration D-CMS
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GLOBAL CEMENT MAGAZINE
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Editorial Director
Dr Robert McCaffrey
rob@propubs.com
(+44) (0) 1372 840951
Editor
Welcome to the March 2017 issue of Global Cement Magazine, the worlds most widely-
Peter Edwards
read cement magazine, which contains the usual up-to-date industry news, technical peter.edwards@propubs.com
articles and features. (+44) (0) 1372 840967
This issue contains the second part of Xavier dHuberts report on burners for the cement
sector, with contributions from all of the major players from Page 10 onwards. We also Web Editor
David Perilli
look at the lime sector (Page 24), roller press maintenance (Page 20) and plant efficiency david.perilli@propubs.com
(Page 29). There is also a review of the 11th Global CemFuels Conference & Exhibition, (+44) (0) 1372 840952
which took place successfully in Barcelona, Spain in February 2017. Read our review of
the event from Page 34 onwards.
Commercial Director
Our country focus in this issue switches to Brazil, the scene of a major downturn in Paul Brown
paul.brown@propubs.com
cement demand in recent years. Over-reliance on oil and mineral exports, coupled Mobile: (+44) (0) 7767 475998
with political instability at home and the wider global economic malaise have led to a
staggering decline in production in the country, from 72.1Mt in 2014 to 57.2Mt in 2016.
This is still a very significant market in global terms, albeit one that has had to adjust to Business Development Executive
Sren Rothfahl
a harsh new reality. And it could get worse for Brazil in 2017, with the President of the soeren.rothfahl@propubs.com
national cement association stating recently that the situation facing the sector was the Mobile: (+44) (0) 7850 669169
worst in the industrys history. Read the whole report from Page 50 onwards.
In the global cement news this month we see a variation in fortunes for the big cement Company manager
producers around the world. Cemex has reported a slight improvement in performance Sally Hope
sally.hope@propubs.com
for 2016, with a 6% improvement in underlying profits, albeit with regional variations.
US-based Eagle Materials also reported improvements in its finances for the nine months
to December 2016. Over in Europe, it appears that the fortunes of Italian producers Subscriptions
may finally be picking up. Both Buzzi Unicem and Cementir reported moderate Amanda Crow
amanda.crow@propubs.com
improvements in their 2016 results and HeidelbergCement reported in its results that
it had benefitted from the new assets that it picked up when it acquired Italcementi.
Meanwhile in Spain, Cementos Portland Valderrivas highlights the continuing malaise Office administration
in that country, with a swing to a massive loss in 2016. We await to see how the results Jane Coley
jane.coley@propubs.com
of LafargeHolcim and others fit in.
The views expressed in feature articles are those of the named
We hope you enjoy this issue of Global Cement Magazine - the author or authors. For full details on article submission, please
worlds most widely-read cement magazine! see: www.GlobalCement.com
Peter Edwards
Editor ISSN: 1753-6812
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GLOBAL CEMENT CONTENTS
Global Cement articles

10 Latest burner profiles
10 Combustion consultant Xavier dHubert looks at the latest
designs of the major cement kiln burner manufacturers, with
contributions from KHD, FCT, FLSmidth, Unitherm, Polysius
(tkIS), Dynamis, Fives-Pillard, A TEC and Rockteq.
20 An introduction to roller press maintenance

20 Serdar Esendemir outlines ways to limit abrasion and effective-
ly maintain

roller presses, based on experience with Mardin
imentos four roller presses used for cement production.

24 Lime contract round-up
We present a range of recently-completed and ongoing
24
projects from around the global lime sector.

29 Improving efficiency at an Egyptian cement plant
Cement efficiency specialist Osama Aly Ahmed describes a
case-study in which an Egyptian cement plant was able to
monitor and improve its overall energy efficiency using a
number of measures.
29
34 11th Global CemFuels 2017 - Reviewed
Robert McCaffrey reviews the 11th Global CemFuels Conference
& Exhibition, which took place successfully in February 2017 in
Barcelona, Spain.
38 Product and Contract News

Plant project for thyssenkrupp Industrial Solutions in Algeria;
Belgian order for Gebr. Pfeiffer; Loesche lands Bangladesh deal.
European cement
40 European cement news
34 Changes to EU ETS approved; HeidelbergCement results

boosted by Italcementi; CPV records massive loss.
Cement in the Americas

47 American cement news

38 Cemex offer for Trinidad Cement accepted; Argos launches
Honduran plant; Cemex sees improvement.
6 Global Cement Magazine March 2017 www.GlobalCement.com

GLOBAL CEMENT CONTENTS
50 Brazil: Still finding the bottom of the curve...

Once the epitome of the rapidly-rising BRIC group, Brazils
economy and cement sector have taken a massive knock since
40
2008.Here we look at the countrys cement producers, recent
production and consumption trends, recent news events and
sector outlook.
Asian cement
57 Asian cement news
47
Vietnamese exports fall; Production slows in India;
Taiwan Cement chairman dies after fall.
Middle East and African cement

60 Middle East and African cement news
CBMI hands over plants in Algeria and Nigeria; Lafarge faces
probe by French government over alleged ISIS dealings in
Syria; Wind farm for Mombassa Cement.
Regulars and comment 50

63 Global Cement prices
Cement prices from around the world: Subscribers to Global
Cement Magazine receive additional information.
64 Subscription form for Global Cement Magazine

Use this form to subscribe to Global Cement Magazine,
60
or subscribe online at www.GlobalCement.com.
65 The Last Word
63
This issue: How many bird species are there at your cement
plant? Join the Global Cement Bird Watch!
66 Advertiser Index & Forthcoming issue features

A list of advertisers and editorial preview for next two issues.
65
GLOBAL CEMENT: DIARY
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8 Global Cement Magazine March 2017
NO PROBL EM.
Copyright by NASA
Maerz lime kilns are extremely efcient in every environment. They also
operate unmanned. Is it a bit lonely where you are? No problem: maerz.com
160106_RZ_Maerz_INS_Mond_A4.indd 1 06.01.16 10:59

GLOBAL CEMENT: BURNERS
Xavier DHubert, Combustion Consultant
Latest burner profiles
In this article each cement burner OEM was given the opportunity to present the main
features of its burners as well as provide insight into design concepts and their evolution.
The emphasis is on the latest offering of each OEM, even though several still sell burners
from previous generations. As not all OEMs responded, the excersise has been completed
using information found in the available literature. For more information on the evolution of
burner design trends, see the February 2017 issue of Global Cement Magazine.
T his article will present information from burner

OEMs regarding the following burners:
suction effect on the surrounding secondary air and
hence mixes the air and fuel efficiently.
The single-nozzle design was then applied on
KHD Pyrojet; coal-fired burners. Prior to 1979, coal burners mainly
FCT Turbujet; used swirl air for flame stabilisation and axial air
Unitherm MAS; through an annular gap for additional shaping at the
Polysius (tkIS) Polflame; outer circumference. This outer axial air gap created
Dynamis D-Flame; a layer of cold air around the fuel cone, which delayed
FLSmidth Jetflex; the mixture of fuel and swirl air.
Fives-Pillard Novaflam; The introduction of a nozzle ring for axial air, or
A TEC-Greco Flexiflame; jet air, greatly improved the combustion: The jet air
Burners from Rockteq International. entrains the secondary air with high-velocity jets and
mixes it in a more efficient manner, with the fuel cone
Each entry comprises text from the OEM unless in the centre. This is the KHD Pyrojet burner.
stated otherwise, followed by the authors comments. However, environmental focus in the 1980s re-
They are in no particular order. Companies that offer vealed that, due to the high flame temperature and
kiln burners for lime or mineral applications are not the availability of oxygen and nitrogen at the base of
represented. Nor are cement companies that design the flame, the burner gave rise to high levels of NOx.
their own burners, for example Lafarge (prior to the To moderate these emissions, the amount of jet air
LafargeHolcim merger) and Buzzi Unicem, as those was reduced and the pressure increased.
burners are rooted in some of the OEMs designs. In 2000 the nozzle tip was simplified, leading to
the current, all-welded design, with a more compact
KHD Pyrojet tip. At the same time, KHD introduced the cooling
KHD has supplied kiln burners for more than 100 tube to the Pyrojet burner. The cooling tube carries
Below: Traditional KHD design years. The modern burner systems from KHD started the refractory of the burner and protects the support
with standard cooling tube. with the high-pressure gas burner without primary tube that bears the static load of the burner. It enables
air in 1979. This burner featured a relatively small a fast exchange of the refractory in case of failures,
Below right: New design number of independent nozzles, from which the gas while the emergency cooling air protects the burner
with cooling tube. emerges at a supersonic velocity. This creates a strong support tube from further damage. The required cool-
ing air demand is 1.5% of the total
combustion air.
While 10-15 years ago, burners
often featured many central chan-
nels and pipes for various alternative
fuels, both operational results and
CFD studies showed that burners
should not be unnecessarily large.
With intelligent mixes of fuels or
slide assemblies that can be ex-
changed during operation to adapt to
different fuel scenarios, the diameter
of the burner can be reduced to a rea-
sonable minimum.
The advantages of easier burner
adjustment and generally better com-
10 Global CementMagazine March 2017 www.GlobalCement.com

in order to improve the trajectory of particles into

the kiln. This avoids unburned particles falling to the
clinker bed and associated problems with localised
reducing conditions and brown clinker. The amount
and pressure of the air, as well as the angle, is custom-
designed depending on the specific characteristics of Left: An FCT Turbujet
burner in the workshop.
the alternative fuel, including its particle size, shape,
lower heating value, composition and other relevant
parameters, as well as the specifics of the kiln.
Typical values for used for the Turbujet cement
kiln burner are: Primary air pressure: 250700mbar;
Primary air rate: 610%; Axial burner momentum:
614N/MW; Coal velocity: 26-32m/s; Solid alterna-
bustion should be balanced against the trade-off of tive fuel velocity: 35-45m/s.
higher NOx emissions, an increased electrical energy Where NOx needs to be kept at a minimum, higher
demand for primary air fan/blower and, of course, primary air pressure (up to 700mbar) is used to mini-
the reduced cooler efficiency, as the cold primary air mise the quantity of primary air while keeping flame
reduces the use of secondary air. Todays ever-chang- recirculation. FCT burners typically provide early
ing fuel scenarios require a flexible burner design ignition of fuel (close to the burner tip) which has
concept. KHD offers an adjustable swirl system for a been shown to reduce peak flame temperature and
better distribution of solid alternative fuels, which are produce less NOx. Other measures can include seg-
injected through the central pipe. mentally variable primary air, leading to variations in
fuel/air proportions within the flame, or water sprays
Xavier dHubert (XdH): The KHD Pyrojet is one that reduce peak flame temperature.
of the best known burners in the cement industry. FCT has addressed the main wear and mainte-
KHD had attempted to follow the trend of adjust nance problems on the burner with a coal channel
able primary air jets with the Pyrostream burner that has protection from either ceramic tiles or a hard
but this design has not been developed futher as the wearing steel, such as Duraplate or similar. Alterna-
mechanical adjustment is costly and requires more tive fuel pipes are made from specially-hardened steel
maintenance. A burner that could incorporate all the to protect against wear.
novelties and features of all competitors would not
result in a good overall solution. XdH: Clients appear to be more and more reluc-
tant to pay for specific studies (CFD and modeling).
FCT Turbujet Therefore burners have to have features that allow the
FCT is an Australian combustion specialist. Its operator flexibility in fuels mix, load, NOx control,
approach to cement kiln burners focuses greatly flame shape and intensity.
on scale modelling and CFD simulation. The
Turbujet is a high momentum kiln burner that Unitherm MAS
provides a very firm and steady flame that can be Unitherm has been a burner company for 60 years
designed to fit every kiln situation. and, at the start, offered early versions of the then
Primary air slots provide effective jets that result standard three-channel burners. In the 1990s the
in better mixing of the secondary air into the flame. company invented the Mono Air System (MAS)
The swirl air channel is located on the inside of the burner. At the time it was the only burner that offered
petcoke/coal channel in order to provide better dis- a combined axial and radial primary air channel that
persion of the fuel cloud. This configuration provides
an intense mixing of the pulverised coal, resulting in
an ignition point close to the burner that makes it
possible to burn low volatility fuels.
The flame shape is controlled by a single valve that
balances the total amount of primary air between the
axial and swirl air channels. The amount of primary
air is controlled by a variable frequency drive.
Left: A modern Unitherm
Most FCT burners have their configuration spe- MAS burner.
cifically optimised for the individual kiln using CFD
modelling. Parameters used include: Amount and
pressure of primary air; Positioning of the burner
into the kiln; Best thermal profile; Fuel injection ve-
locities, and other parameters. For solid alternative
fuels, FCT has developed the Lofting Air system

In the 1990s fuels that were dif-

ficult to ignite, such as anthracite and
petcoke, began to be used. Polysius
Right: A Polflame and separate therefore began to find a new burner
injection pipe in a German technology, leading to the develop-
cement plant.
ment of the Polflame VN burner.
The concept of adjustable ejection
angle with moving nozzles allows for
the setting of the flame characteris-
tics depending on the burnout of the
coal or solid alternative fuel.
Alternative fuels substitution and
stricter emission limits are the driv-
ers for the ongoing development of
the burner, which is designed to fulfil
ends in adjustable (angle-wise) flexible jets. This was such requirements as high clinker
a fairly revolutionary concept that demonstrates how quality, smooth kiln operation, (e.g. kiln inlet tem-
sound design and marketable ideas can go together. perature control), and a high flexibility with regard
One of the arguments for the MAS design is that to the fuel mix.
a single adjustable air stream is more efficient and ef- However, the burner is not the only means of
fective than mixing two different streams. It is more feeding the sintering zone with fuel. In several cases
efficient as there is no energy loss in the mixing of separate fuel injection pipes are used. The reason is
the two air streams and is more effective as the large that alternative fuels can only be injected when the
angle variation of the primary air exit jets strongly temperature level in the system is high enough and
shape the flame. The shape can be easily reproduced the complete burnout is assured. That is why the kiln,
using a simple crank with a scale of 0-10 that is after ignition, is usually started with a traditional
mounted at the cold end of the burner. Because of fuel, such as lignite. For the start-up the burner
this efficiency, lower primary air pressure (and exit nearly reaches 100% of its capacity. After reaching
velocity) can be used, avoiding the need for high the necessary temperature level the standard fuel is
pressure blowers. Also a single primary air channel reduced depending on the alternative fuel substitu-
reduces the diameter of the burner, an important tion rate, which means that the burner must have a
point for good combustion. very high degree of flexibility.
While initially kiln engineers worried about mov- Constant high alternative fuel use may lead to
ing parts inside a burner, the flexible hoses and the extremely large burners as the air velocity is limited
rings used to vary the angles of injection have proven at the burner tip and more than one extra alternative
to be remarkably sturdy and smooth to operate. The fuel channel is needed. This is the reason that tkIS
mechanism rarely has to be repaired. recommends having a certain amount, for example
The MAS burner offers several optional features up to 50%, of the solid alternative fuels injected
such as a disconnectable outer-pipe tip; a pneumo- through the burner and installing separate injection
deflector for lifting solid alternative fuel particles pipes for the remainder. This means that burners
up into the flame, and a focus on the ejection angle can stay at a reasonable diameter. Injected above the
of the coal stream (convergent or divergent) to help main burner, the poorer grade solid alternative fuel
control NOx emissions. gets more time to dry out, will have a greater chance
of dispersing and better burning and will not drop on
XdH: The notion of effective momentum was first the clinker bed.
brought to the market by Unitherm. Even with a large The challenge at present and in the near future
adjusting capability, some operations end-up with an remains limits to gaseous emissions. Furthermore
extreme setting. suppliers are requested to design the burner without
knowing the fuel that might be used after a new plant
Polysius (tkIS) Polflame was completed. Despite this, the sintering zone length
The industrial culture of the more than 150 year old and temperature must still be controlled carefully.
Polysius AG now continues under the new name
thyssenkrupp Industrial Solutions (tkIS) OU Cement XdH: With its coal channel located inside or out-
Technologies. side the primary air (or both) true flexibility can be
Over the years Polflame burners were devel- achieved. As a full cement engineering provider tkIS
oped to cope with new requirements, first for direct takes a larger view and goes in the direction opposite
firing of the kiln using mill exhaust gas containing to mainstream thinking. Clients may have to be con-
coal dust, then indirect firing systems and today, the vinced - for many years they have heard the message
wide variety of alternative fuels. that all fuels must go through the burner!

Images are for descriptive purpose only and may be subject to change.
FIVES_PILLARD_PUBLI_NOVAFLAM_EN_A4_220217_VECT.indd 1 22/02/2017 07:15

FLSmidth Jetflex
The Jetflex burner is a good illustration of the

development of a new burner to satisfy the changes
imposed by the market.
In a similar way that Pillard developed its
Rotaflam burner back in the late 1980s to match
Right: Dynamis
the requirements of low-NOx burners, or the way
D-Flame burner. that Greco developed the Flexiflame in the early
2000s to handle the high momentum fad of the dec-
ade, the Jetflex, the successor to the well-known
Duoflex, is geared to the ever increasing alterna-
tive fuel substitution rate, especially the use of solid
alternative fuel in the main burner.
Several new ideas were incorporated into the
design of this burner and many more were assessed
during development. The intensive use of CFD and
modeling is a characteristic of the development of
new burners in the 21st Century.
Dynamis The new ideas include: Rectangular flat shaped
Dynamis was founded in 2003 by Eng. Guilherme primary air nozzles that are either fixed or that can
who studied and worked with professor Clemente be adjusted in orientation in order to shape the flame;
Greco from Brazil. At that time it offering consulting A common and adjustable (in and out the main body
services but is now an engineering and project com- of the burner) centre pipe for solid fuels, which gives
pany as well as a supplier of customised equipment. the fuel the possibility to expand prior to coming into
The Multichannel D-Flame burner is designed contact with the combustion air (for a higher reten-
with both axial and radial primary air channels, tion time).
which are fixed. It has 18 orifices for the injection of Central air (with or without swirl air) has an
external and tangential primary air. Some operational important role for cooling and flue gas internal re-
improvements include: 1) Finer C3S crystals; 2) The circulation. The prime benefit is that the burner has
ability to use high sulphur fuels without fouling; 3) a smaller diameter, leading to closer proximity of
Stable kiln operation, and; 4) Increased refractory the primary air and solid alterantive fuels and better
lifespan. mixing and burning.
For Dynamis, maximising secondary air en- Another novel approach for high solid alternative
trainment is a very important concept, followed by fuel substitution is to mix it with the solid fossil fuel,
minimising primary air injection. With respect to (which represents a small fraction of the heat input),
momentum, Dynamis uses the concept of kinetic though a common pipe located in the centre of the
energy, with a bigger emphasis on the speed than burner.
mass flow to design burner tips. When designing a As is the trend in the market, the Jetflex comes
burner, calculations of such values as flame impulse, with various option, such as the primary air jets
turbulence index and swirl number are important to being fixed or orientable, and the possible inclusion
match the design with the fuels, secondary air tem- (or not) of a swirl air channel.
perature, kiln diameter and other parameters.
These complement the geometrical design
characteristics of the burner tip, including the
respective locations of air and fuels injection,
number and size of air jets and so forth.
Dynamis has published several articles
about its studies in the optimum number of
primary air axial jets. The findings indicate
Right: An FLSmidth that fewer jets, down to a certain minimum
Jetflex burner at the CRH value, are more effective than a large number
Rohonk plant in Slovakia.
of jets.
XdH: Dynamis demonstrates how a newer

company with fewer references can design a
good burner of a simpler design but yet one
that is still very effective. It has focused on
key burner tip geometry to optimise a well-
known design.

Fives Pillard Novaflam
XdH: This represents quite an innovative design.
Still a new burner, the main features such as flat noz- Fives Pillard has, for a long time, been the only inde-
zles and the deceleration and expansion chamber for pendent cement kiln burner supplier, having led the
solid alternative fuels will have to be further demon- way with the conventional three-channel burners
strated. It is interesting to see the many differences and then the well-known Rotaflam burner. This
there are between the previous Duoflex and the was the first to depart for the traditional axial air-
Jetflex, which demonstrates the capacity of suppli- solid fossil fuel-swirl air channel arrangement and
ers to challenge themselves to offer the right burner the beginning of the evolution of burners to lead or
for the prevailing market requirements. follow market needs.
For about eight years Pillard has been of-
fering the Novaflam, which incorporates
many ideas in one burner. Several variants
have since either been added or tested on the
drawing board.
CFD results clearly demonstrated
that it would be possible to design the
Novaflam burner as a mono air channel with
two separate, controllable primary air outlets
at the burner tip. The axial and swirl air help
to achieve a sharp, low diameter flame, that is Left: Fives Pillard
Novaflam burner.
well controlled by the high air velocity in the
axial air at the periphery of the flame. It has a
good capability to repeat flame shapes. Cross-
sections are fixed to avoid the negative impacts
of kiln temperature variation on tip shape that
are caused by thermal expansion.
The key feature is a single primary air inlet
and double primary air outlet (axial and radial)
Contact:

with the swirl injection at a

progressive angle. Using a
crank at the back end of the
burner, the radial tip can be
moved back and forth to
adjust the flame width while
Right: A Greco Flexiflame
the primary air pressure is
being installed. adjusted to vary the burner
impulse using a valve.
XdH: The Novaflam has

the largest market share. As
with the FLSmidth Jetflex,
the Novaflam shows the
ability of burner suppliers
to re-invent themselves and
adjust previous features in
order to stay close to the
competition and the needs
of cement plants. On the other hand Pillard empha- XdH: Here we again see a burner supplier that is
sises larger amount of axial air but stays with having capable of more than one offering, with concepts that
many and small air injection slots. would have been rejected years ago, in order to best
match a given cement plants requirements. The im-
A TEC-Greco Flexiflame pact that adjusting one air channel has on the other
The Greco burner company became well known in two, when using a single primary air fan, may be
the 1990s thanks to its founder Prof. Clement Greco viewed as difficult by some operators.
who travelled around the world promoting his burner
concepts such as the all concentric design. However Rockteq International
at the time the company was offering engineering The Rockteq burner is a classical multi-primary air
only, having its clients manufacture the burners channel burner with coal sandwiched between axial
from Grecos supplied drawings. The company later primary air and radial primary air.
became a full OEM. The features of the burners are: Concentric supply
The main principles of the Flexiflame burner of all fuels and primary air. The primary air (axial air,
are the fact that it has no moving parts and three swirl air and central air) is supplied by three separate
main primary air channels, axial, radial/swirl, and concentric ring channels and is measured and effec-
dispersion, with the fossil solid fuel channel being tively regulated by adjustable flaps. The triple supply
located between the axial and swirl channels and the of the air allows an optimum set up of the flame
dispersion channel. shape. By means of the good mixture of air/oxygen
The benefits are to offer a robust and flexible and fuels a short turbulent flame will be achieved.
burner, with the relative amount of primary air be- The high exit velocity of the primary air at the
tween the swirl and the dispersion channels offering burner tip (Venturi effect) guarantees a good in-
adjustment between lower NOx (more swirl) and terference of the secondary air, approximately 85%
higher solid alternative fuel (more dispersion). of the whole combustion air, and a high external
The Flexiflame is capable of a larger turn-down. recirculation, which improves the flame shape and
Sometimes plants anticipate an increase in produc- reduces the heat load in the kiln outlet area. Thus the
tion output but dont want to have an oversized fire-resistant wear of the kiln lining is also reduced.
burner initially. The burner has the
ability to plug (and later unplug)
some of the air slots to allow for the
optimum amount of primary air flow Axial air Coal, meat/bone meal
in relation to the stoichiometric + complementary air
Tangential air
requirement over a large burner + natural gas
Liquid fuel +
Right: A burner from Rockteq. output capacity. Compressed air
A recent variation is the Flexi- Central air
flame Ecopro burner which injects Solid fuel
solid alternative fuels into the flame
root through a ring channel. This re- Swirl air Ignition burner
quires careful preparation (grinding)
of the solid alternative fuels.

Turbu-Jet AF
Delivering performance
Features Benefits
High momentum design Optimised heat flux profile
Simple operation Stable flame
Highly flexible flame shape Stable coating
Long life burner tip High alternative fuel substitution
Easy maintenance Low NOx
Award winning AF lofting air system Low primary air
Our designs, evolving over decades of industrial experience and the application of
FCTs proprietary modelling techniques, give you complete flexibility for your operation.
We target real bottom line results for you.
Call FCT Combustion now to discuss how

we can deliver benefits to your plant.
www.fctcombustion.com
sales_ALL@fctinternational.com
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Europe +49 3222 1096283 | MENA +90 850 766 2409
Good combustion of the coal is achieved by mix- Should multi-channel burners be equipped with
ing oxygen into the flame core, due to the position one fan/blower per channel for easier control of the
of the coal pipe located between axial and swirl air. respective primary air flows?
Therefore coal as supporting fuel for the solid sec-
ondary fuels guarantees a hot and short flame. As well, there may be some considerations that
Central air and swirl air generate an optimum are not currently taken on board as mainstream
internal recirculation, with a correspondingly high burner features by the major manufacturers. These
residence time for the combustion of solid second- could include such features such as O2 injection to
ary fuels. Furthermore, by internal recirculation of boost alternative fuel burning or H2O injection to
the combustion gases the spontaneous formation of control NOx. These are installed on several burners
NOx decreases. but are usually upgrades conducted with compro-
mise, instead of being inherent options at the design
XdH: The Rockteq burner design has its roots in stage;
the Greco design, down to keeping the square axial Operational aggravations with burners will always
air jets that were Grecos signature in the late 1990s, exist, including the premature failure of the outer
with the idea of having everything concentrically ar- concrete protection, the (lack of) effectiveness of air
ranged around the axis of the burner. For instance, canons to remove the so call rhino horn, the need to
even the liquid fuel lances are split into four to keep change burner tips during commissioning to find the
to the letter of that principle. proper swirl angle, or excessive wear of the spacers
A regional player with good manufacturing qual- inside the coal channel.
ity, it offers a strong focus on the central air, with jets One can also see that EPC companies have now
instead of a perforated plate, which is a feature of designed burners that stand comparison with the
burners where axial primary air injection is achieved ones from the burner specialists
by small jets / open channels, in order to achieve in-
ternal recirculation around the root of the flame. This More conclusions
offers greater flame adjustment capability for the very Despite the research conducted towards these two
experienced operator. articles and my 30-plus years of experience in the ce-
ment sector, I am unsatisfied with a conclusion that is
Conclusions limited to simply a list of important technical factors.
There are several key parameters that must be kept in I have found that a lot of cement companies, either
mind when selecting a new rotary kiln burner, as well at the plant or HQ level, have their list of preferred
as some questions to ask. These include: suppliers, either published or implicit. Such lists dont
evolve much with time, if at all, and are often the re-
Size, shape (round, square, rectangular, twin), num- sult of past choices usually based on the OEMs past
ber and locations of the primary air jets (either just market share.
axial or a combination of axial and swirl) as to their I hope that my research, in which I have presented
effectiveness, especially for multi-fuel burners; a large variety of designs, will assist all of those in-
volved in buying and operating new kiln burners in
The effectiveness of the various built-in features of the cement sector. Plants should decide first which
the burners designed to ensure good dispersion of category of burners fit their own philosophy of
the solid alternative fuels (mostly fluff type) when operation and needs. They should then approach
exiting the burner in order to ensure complete com- all suppliers that they think can deliver the desired
bustion while in suspension. result. Otherwise a complete and fair comparison
between the different designs will be very difficult.
Effectiveness of the so-called central / cooling / re-
circulation air channel;

ENERGY INTENSIVE
INDUSTRIES /
INNOVATIVE TECHNOLOGIES
Fuels, Combustion, & Air Pollution Control
Analytical & Advisory Services: Market

research, studies and intelligence gathering
Business development: Technical articles

and webinar organization
when it comes to ...
secondary fuel
energy efficiency
bypass optimization
calciner efficiency
combustion improvement
flue gas cleaning
...
dont just
Xavier dHubert Senior Consultant
toss the dice!
Tel: +33 6 44 23 66 57 or +1 502 819 0614
Email: xavier.dhubert@earthlink.net Ask the world leading process and
simulation experts for the
cement industry
+ 49 241 4134492-50 www.aixergee.de

GLOBAL CEMENT: GRINDING
Serdar Esendemir, Mardin imento
An introduction to roller press maintenance

The welding of rollers, the costs of roller tyres, bearings and housings, unexpected downtime
and other costs of maintenance are all important in cement plants that use roller presses.
Here, Serdar Esendemir outlines ways to limit abrasion and effectively maintain roller presses,
based on experience with Mardin imentos four roller presses used for cement production.
Rollers Adaptability of installation feature
Required crushing capacity, grain size, abrasiveness, It is not adequate simply to protect the rollers by
temperature of material are important design criteria welding via the appropriate methods at convenient
for determining various parameters of the rollers times. Rollers are designed with some installation
used in roller presses, including rotation speeds, di- values according to criteria given by the plant at the
ameters, widths and working pressures. From these, design stage. Installation values must be registered
loads and energy values are calculated. and saved. These include the size and structural fea-
During periods of high sales intensity, some ce- tures of the feed material, gap between rollers (for
ment plants can operate at full or even higher than both loaded and unloaded operation) and commis-
100% capacity and roller maintenance can take a sioning, operation, safety and grinding pressures.
back seat. In such cases, abrasion reaches the buffer Sometimes, in order to reach higher capacity, the
layer by removing the hard layer. Faster abrasion and gap interval is reduced and/or operating pressure is
breakage then occurs in the rollers. Moreover, cracks increased. Under such circumstances, undesirable re-
can occur in the roller shaft. The roller then becomes sults can occur due to sudden shocks and unbalanced
unusable and may have to be scrapped. loads, if the installation values are not first applied.
However, by careful coordination of the produc- This subject should be examined as a trio of: 1: Pro-
tion and maintenance departments, synergies in duction rate, 2: Energy Costs; 3: Wear expenses.
maintenance and inspection works can (and must) Plants can change the design values of the roller
be captured. A method should be developed for this press to increase production in some cases. However,
purpose. First, the roller must be checked at each rel- they must take into consideration potential problems
evant period and, if necessary, welding repairs must that might occur in the rollers, including the high
be carried out. cost of potentially catastrophic failures. It is always a
Appropriate welding must take place before abra- risky decision and machines should be operated ac-
sions reach the buffer layer. Not reaching the buffer cording to the design values.
layer means that abrasive materials are always in con-
tact with hard surfaces, leading to controlled wear
and protection of the rollers.
Motor Gravity
Feeder
Aux. Drive
Frame
Right - Figure 1: Roller

press schematic.
Gear Reducer Cooling Water
Distributor
Oil cooler
Hydraulic
cylinder Bearing
Inspection
Door Accumulator


20-25mm 20-25mm Left - Figure 2: The

maximum mechanical stress
occurs within 20-25mm
Mechanical stress Mechanical stress of the roller surface.
max max
Fixed roller
Sliding roller
Template should not be used together. If there is even a few

The template is derived according to the diameter millimetres difference in the diameter of the rollers,
and width of roller and it should be kept. Welding is the larger roller will abrade the smaller roller.
controlled by the template. Generally, these templates
are provided by the machine manufacturers. It is nec- Control
essary to protect the templates. Rollers should be checked every day if serious wear
problems or high maintenance costs are expected.
Operation of metal detectors Abrasion should be repaired before it reaches the
and separators buffer layer by providing penetration with the appro-
There should be a metal separator and metal detector priate welding method.
on the belt conveyor that feeds the roller press. This
equipment should be operated at the original sensitiv- Welding companies
ity. Otherwise, pieces of metal that are included in the A very important subject is welding companies and
feed material can reach the rollers. The metal could welders. Factory employees, who are responsible for
leave an indent in the roller surface or even break it. this field, should give a higher level of importance to
this issue.
Final layer welding profile Worn rollers that have been sent for repair
There are several kinds of welding profile for the final should be controlled before welding, during surface
layer, including rhombic, sergeant, hexadur, straight cleaning, during lathing, at the end of lathing and
Below - Figures 3-7:
line profile with circumferential linear pattern at 20- during welding. 3: Straight line pattern
25cm intervals, plus many more. with circumferential lines
Different kinds of profile may give different re- Welding method every 20-25cm.
4: Rhombic profile.
sults. The distance between profiles must be kept Just as a surgical operation should not be done with-
5: Sergeant profile.
short and equal. Straight line profile is most com- out anaesthesia for the patient, a successful welding 6: Hexadur profile.
monly used because of its quick and easy weldability operation should not be done without annealing. 7: Zig-zag (weave) profile.
3 4 5
6

after abrasion. After abrasion of the profile surface, Therefore, pre-tempering, the temperature of
appropriate technical profile welding will extend the the tempering during welding and tension-
life of the rollers. relieving annealing are all very critical. Prior
to the welding the specified surface tempera-
Mutual rollers
Rollers that are bought from different companies
ture must be reached homogeneously across
the surface of the roller.
7

Mardin imentos roller presses
Mardin imento has four cement roller presses. Three (numbers 1-3) have diameters of 1000mm and
widths of 930mm. Cement mill number 4 has rollers with diameters of 1400m and widths of 800mm.
Welding procedures on site

2. An ultrasonic crack test is performed after lath-
1. One of the most important points to consider is ing is complete. If the result is satisfactory, welding is
that the underside of the zone to be welded must not allowed. If there are still cracks, lathing should con-
be empty. The zone to be welded must be checked, tinue until reaching a surface without cracks. During
cleaned, tempered and welded correctly. In a mill the crack test, weighing and welding approvals, fac-
system that has just stopped, it is often the case that tory technical personnel are required.
the temperature required for welding is already met
due to the residual heat from operation. Rollers can 3. After obtaining suitability for welding, pre-
be used many times without any fault by using this annealing is performed by heating to 200-250C.
method of maintenance. The rate of temperature increase should not exceed
30C/hr, although this may vary depending on the
2. The local conditions surrounding the broken diameter of the roller.
part should be thoroughly checked. If there is a gap
around this, it should be broken. Otherwise, breaks 4. After annealing, buffer welding is completed.
may occur on the roller surface during subsequent
operation after welding. 5. After buffer welding, tension-relieving annealing
takes place. The temperature of the roller is increased
3. Welding chassis must be connected near the area to 550-600C at a rate of not more than 30C/hr.
that requires welding. The tension-relieving annealing process should con-
tinue at this temperature for a minimum of 10hr. The
4. If there is a revision stop and a lot of abrasion on temperature is then reduced to 200-250C. Again,
the buffer side of the roller, surface of the rollers the temperature difference of the roller will not
should be abraded and welded by heating. If it is exceed 30C/hr.
done without heating and penetration is not ensured,
it is possible that parts may break. The carbon elec- 6. Hardfacing welding and profile filling are
trode method is commonly used for abrasion but it then completed.
has some risks. Local grinding can also be used. It is
a new method and is less risky. 7. Final measurement controls should then take
place. Polyester slings must be used during transpor-
5. Penetration of the roller shaft is the most tation to protect the roller bearing surface parts.
sensitive issue.
Summary
Welding procedures in the workshop The procedures described above may vary in different
1. The worn surface of the roller is lathed. This pro- application areas and sectors. However, it is always
cess continues until the cracked surface finishes. In best to gain experience in person. Each factory must
some cases, cutting tools are broken so the rollers are set up its own control criteria as above for rollers and
annealed until 100C before lathing and it is stripped must monitor welding, electrodes, contractors, abra-
with carbon or special electrodes. As mentioned sions and many other parameters.
above the grinding and lathing method is recom-
mended, instead of carbon electrodes.
Right - Figure 8: A
cracked roller due to
incorrect annealing.
Far right - Figure 9: The result

of penetration is breakdown of
the hard surface weld and wear
on the buffer layer.


Cimprogetti Srl - A. Grellier - 02.2017
Flex Reversy Lime kiln
A proven
operational
excellence
Simple design and high productivity combined

with minimal CAPEX investment;
Improved flexibility combined with minimal
maintenance;
Totally integrated automation and process control
driven to an environmental friendly design.
limestone size assial symmetrical

from design
20 to 150 mm
Bespoke design to ensure
To optimize the quarry yield uniform limestone loading into
reducing quarry operation for the shafts together with even
achieving higher lime quality. fuel distribution.
modularized
assembly simpler kiln
shell design
Bespoke design for work-shop
preassembled structural, Outstanding R&D investments
mechanical and electrical focused to achieve an user
modules aimed to minimised friendly design with reduced
site-erection activities with CAPEX and improvement of
significant benefits in terms of kiln performances.
time and cost.
W
W
W.
CI
MPR
O
GE
T
TI
.
COM
Cimprogetti Srl - Via Pasubio, 5 - 24044 Dalmine (Italy)
ph.+39 035 4550 111 - fax +39 035 4550 335 - email: inform@cimprogetti.com
GLOBAL CEMENT: LIME
Global Cement staff
Lime project round-up
Here, Global Cement Magazine rounds up some of the latest projects from around the global
lime sector...
Cimprogetti
Malaysia: RCI Lime Sdn Bhd has awarded to Algeria: In May 2016 an important contract was
Cimprogetti a contract for the upgrade of the soft- signed by Cimprogetti Srl together with Bedeschi
ware and hardware of the Control System (HMI) SpA for the supply, on an engineering and pro-
concerning its kilns No. 4 and No. 5 and hydration curement (EP) basis, of a complete plant for the
plant No. 1. production of lime for the steel industry. The supply
RCI Lime, a prominent Cimprogetti customer features the engineering and equipment for two Flex
since 2001, has developed, at its Ipoh site, a complete Reversy 9 type lime kilns with a capacity in excess
lime production plant featuring four Twin shaft verti- of 400t/day each. They will be natural gas fired and
cal kilns of its Twin-D and Flex Reversy designs for will be supplied complete with upstream and down-
a total nominal production of 1500t/day quicklime, stream handling systems.
as well as two hydration and classification units. The The client, Algerian Qatar Steel (AQS), is a par-
largest use of lime is in steel manufacturing, as a ticipation between Sider Co. & National Investment
flux to remove impurities such as silica, phosphorus Fund (Algeria) and Qatar Steel International (Qatar).
and sulphur. Bedeschi SpA, a well-known Italian company that
specialises in the construction and design of large
plants for the brick industry, cement sector and port
logistics, will provide the facilities and equipment for
the materials handling system.
India: Chemical & Mineral Industries Pvt. Ltd.

(CMI), of Jodhpur, Rajasthan, India, has sucessfully
operated a 300t/day Twin-D lime kiln from Cim-
Right: Two of RCI Limes four
Cimprogetti lime kilns. progetti since 2014. In 2016 the company was put
into the Limca Book of Records 2016 for installing
Indias first petcoke fired Twin-D lime kiln.
The Cimprogetti twin shaft regenerative (TSR)
kiln is a two-shaft vertical kin which uses the
Iran: Cimprogetti has been awarded a contract by

Middle East Mines Renovation & Development
Company (MEMRADCO), a subsidiary of Middle
East Mines and Minerals Holding Company (MID-
HCO), which specialises in iron ore, copper and coal.
Through a consortium partnership, GMI Projects
Right: A Cimprogetti Flex Hamburg GmbH will act as project coordinator for
Reversy 9 lime kiln of the type
to be supplied by the company all technical aspects of the engineering, procurement
to clients in Algeria, Iran and and construction (EPC) project.
the US. The engineering delivery, already underway, is
the first step in the supply of three Flex Reversy 9
type natural gas fired lime kilns, each with a nominal
quicklime and dolomite capacity of 400t/day. They
will be installed at Butia, Kerman Region. The supply
also includes material handling systems and a bag-
ging plant.

GLOBAL CEMENT: LIME
regenerative process for lime calcinations with

high fuel-efficiency and very low emissions. The Above: CMI launched Indias
first petcoke-fired Twin-D lime
quicklime produced is of high reactivity, high Cimprogetti celebrates half a Century kiln in 2014.
brightness, high purity and consistent quality.
In 2017 the Italian lime kiln manufacturer
India: In October 2016 Cimprogetti conducted Cimprogetti Srl celebrates half a century of activity.
a fuel conversion project at Jindal Steel & Powers As part of its celebrations it has relaunched its logo
Angul site. Two existing RD-12 model lime kilns, and a presents a new tagline the green edge of lime
of 500t/day capacity each, were converted to burn technologies.
mixed gas, a mixture of coke oven gas and blast The company explains that Green reflects
furnace gas. Cimprogettis attention to the environment and its
The project confirms the commitment growing sensitivity to the environmental perfor-
of Cimprogetti in assisting the clients which mance of its plants. It is engaged in research and
operate in the steel field to utilise low value development to find alternative fuels, technical and
fuels, particularly the tail gas recovered from engineering solutions arrangements and flexible syn-
the steel process, thus allowing significant ergies with the goals of reducing the consumption
cost savings. of virgin resources and environmental emissions,
energy consumption and sustainable development.
Confidential clients Edge refers to the fact that Cimprogetti says it is
A confidential client has recently ordered a on the cutting edge with respect to the high quality
Cim-Microsep separator for one of its European and performance of its plants. Technologies refers
facilities. A separate client in North America has to the fact that Cimprogetti is, the aggregate of the
awarded Cimprogetti a contract for the supply latest lime technologies.
of a Flex Reversy 4 lime kiln with a capacity in In its 50th year the company has further identi-
excess of 200t/day. fied three routes to success.
Elsewhere, a producer of high calcium and
dolomitic lime, limestone and derived prod- 1. Consolidating its heritage in terms of its social
ucts has awarded Cimprogetti a contract for and human capital, its intellectual and technological
the design and supply of a CIM-HYDRAX-4G know-how and through new investments;
MAX model hydrator for one of its European
facilities. This new order confirms the renewed 2. Increasing knowledge and technologies, in the
confidence of this prominent customer towards light of the new horizons that Industry 4.0 is track-
Cimprogetti technology. Over the past six years, ing, and;
Cimprogetti has been entrusted with the provi-
sion of equipment and plants featuring the fuel 3. Converting this aim into technical solutions
conversion of three PFR kilns, a 20t/hr CIM- and in a change of mindset to increase the integra-
HYDRAX-4G model hydrator, a high-efficiency tion of supply chain processes for the benefit of
CIM-MICROSEP 200 HS separator, a high- the customer.
efficiency CIM-MICROSEP 300 HS separator
and a tubular grinding mill.

GLOBAL CEMENT: LIME
Right: The SIC HPK lime kiln

installed for Carrieres et Chaux
du Mali in Mali.
Far right: Micronising mill

installed by SIC for Zao
Izvestnyac in Russia.
Societ Impianti Calce (SIC)

2000 years since the Roman achitect
and encyclopedist Vitruvius first laid
down the implementation criteria for
lime production, Societ Impianti Calce
(SIC) continues the trend of Italian tech-
nology in lime plant manufacturing.
Here it outlines some recently com-
pleted projects, outlining its problem
solving approach and bespoke solutions
tailored to different clients.
Right: The Santa Rosa Lime Completed projects

CBK kiln has recently undergone
a wholesale renovation by SIC. Mali: SIC recently completed the test-
ing and commissioning of a single
shaft HPK lime kiln for Carrieres
et Chaux du Mali. Located in Sema
Falcadi, near Bamako, the kiln uses
heavy fuel oil to produce 100t/day of
quicklime, primarily for the gold mines
in the area.
Russia: In November 2016 SIC

completed the commissioning and
running test of a micronisation plant
in Karachay, Russia for Zao Iz-
vestnyac. The plant receives limestone
of diameter <10mm and produces
100% micronised calcium carbonate at <160m. Trinidad & Tobago: A plant installed by SIC in
The heart of the system consists of an S100 2010 for the company Santa Rosa Lime Trinidad &
micronising mill. Tobago, comprising a 50t/day CBK kiln with a meth-
While this may sound small, the particle size is ane combustion system and a 5t/hr hydrating plant,
not particularly low for this type of mill, which is was stopped for a year for due to corporate reasons.
capable of reducing limestone to 10m. However, SIC has now completed a complete revamp and
the most challenging part of the clients request was update in collaboration with US-based KNS. It was
its need to have absolutely zero residual over 160m. recommissioned in December 2016 and has since
This means that, in fact, the system is set to produce re-entered production.
particules of 98m.
After the commissioning phase of the mill and the Projects in advanced testing
contractual running tests, it was possible to test the Vietnam: In 2014 a contract was signed between SIC
S100 mill and produce different particle sizes. This and Huong Hai Group in Ha Long City for the largest
demonstrated the ease of setting up the S100. lime plant ever to be built in Vietnam at that time. It
comprised two DSS Double shaft square kilns, each

111 YEARS
OF LOESCHE HISTORY
55% MARKET SHARE IN
THE CEMENT INDUSTRY
For more info see:

www.loesche.com
LOE_AD_Q1_2017_A4.indd 1 12.01.17 10:58

GLOBAL CEMENT: LIME
Ukraine: In January 2017,

SIC completed the delivery of
equipment for the realisation
Right and below: The Huong of a 5t/hr hydration system
Hai Group lime plant is Vietnam for the steelmaker Metinvest
has undergone commissioning. Ukraina in Mariupol.
The plant, built by the Ital-
ian company Termokimik,
will produce hydrated lime
used for the neutralisation of
gaseous emissions. The plant
engineering required special
precautions because the tem-
perature of the project ranges
from -26C to +38C. Assem-
bly has already begun on site.
of a capacity of 300t/day of quicklime that were to be
fed with limestone of 50-100mm. A petcoke combus- Tunisia: All of the equipment related to a hydration
tion system and two hydration lines of 10t/hr were plant project have recently been delivered to Societe
also supplied. Chaux el Hamma, which is currently assembling its
The first kiln and the two hydration lines have plant in Gabes, Tunisia.
already been tested after reaching the contractual The plant was designed to allow the production
parameters. The second kiln has already undergone not only of the standard hydrated lime but also
commissioning and is waiting for the green light of hydrated lime with a particle sizes of 15m for
from the customer prior to entering production. special uses.
Projects under construction New projects

Russia: A 400t/day DSS kiln with a double round India: In March 2016 SIC was awarded a tender for
shaft and a limestone feed size of 30-60mm is at the the construction of a DSS (Double Round Shaft) kiln
end of the assembly phase for Tetranox, located in with production of 450t/day of quicklime for the
Rostov on Don, Russia. SIC engineers will soon begin Steel Authority of India. The new kiln will be part of
the commissioning and the running of the plant is a steel factory in Bokaro.
expected by the first semester of 2017 The provision, comprising the kiln, grinding
and screening, sees SIC committed, in consortium
Tanzania: In January 2017 SIC provided a new HPS 5 with SIC India organisation, to the turnkey con-
model air separator to an ARM Cement plan, located struction of the entire project, starting from the
in Tanga, Tanzania. This is the third time that SIC has creation of concrete works to the full commissioning
been selected to provide equipment by the Kenya- of the plant.
based cement manufacturer. The kiln will be fed with limestone of 25-50mm
in diameter and will be
able to use different fuels,
either separately or indi-
vidually.
As part of the project,
some pre-existing build-
ings have already been
demolished ahead of
construction. Excavation
and construction of the
concrete works of the new
plant has also begun.

GLOBAL CEMENT: EFFICIENCY
Osama Aly Ahmed, Efficiency Specialist
Improving efficiency at an Egyptian cement plant
Here cement efficiency specialist Osama Aly Ahmed describes a case-study in which an
Egyptian cement plant was able to monitor and improve its overall energy efficiency using
a number of measures.
T o assess the potential to save energy, one needs

to produce an energy budget to get a feel for the
existing situation. Key factors in producing such a
1. Recording main electricity bills and sub-meter
data;
2. Analysing past, present and future energy use;
budget include: 3. Identifying and quantifying significant energy
users (SEU);
A. Management commitment: The managing direc- 4. Identifying drivers affecting SEU levels;
tor must approve of such an energy policy. There must 5. Developing baselines and performance indicators
be clear communication between management and for each SEU;
the team that is using data to monitor and improve 6. Review operational control for all SEUs
performance. Communication is also key within the 7. Technical energy audits
team. Findings and reports should be published in 8. Identify opportunities for improved performance,
common areas of the plant and the head office should review and decide on action plans.
be informed of progress.
Useful questions include: How much energy was
B. Planning: Commitments to energy policy must used in the 12 months ending last month? How much
be translated into objectives, targets and action plans. did it cost? How much was used in the year earlier pe-
riod? How much will be used in the next 12 months?
C. Roles and responsibility: Roles must be identified How does this compare to the target? Why are there
for all persons that have a direct influence on signifi- deviations? Is the plant using too much energy? If so,
cant energy use. They must be documented. how much should it be using?
D. Scope: A scope must be outlined. What is and is Egyptian case-study details

not included? This may include looking only at elec- Using each of the eight points above in turn, we shall
trical consumption, thermal energy or a combination now look at an Egyptian case-study. One of the most
of the two. modern cement plants in Egypt produces around
5500t/day clinker. It uses heavy fuel oil as its thermal
E. Boundaries: Where does the plant begin and energy source, has one vertical raw mill and one ver-
end? This must be clearly defined. Will the admin- tical cement mill. It uses bucket elevators to take raw
istration buildings also be included or just the main meal to the preheater and all of the silos.
plant equipment? Will the quarry be included or not? It was decided that the plant would focus on elec-
tricity use and the use of heavy fuel oil and that the
F. Legal: The project must comply with legal require- boundaries would include the production line (raw
ments. This is often on a monthly basis according to mill, preheater, kiln, cement mill, plus utilities) and
applicable local legal and other requirements related all the buildings within and including the plant fence.
to energy use and efficiency. The quarry was not included.
Outline steps 1. Table 1 shows the plants energy consumption for

The main aims of the energy analysis and budget 2013 to 2016 inclusive. Energy management began in
include identifying and documenting all of the sig- June 2016.
nificant energy uses within the defined boundaries,
obtaining a baseline of energy performance, identi- 2. Figures 1 & 2 show data relating to energy use in
fying indicators to use in measuring progress against 2015, the baseline year. It can be seen that consump-
the baseline, setting energy objectives and targets tion is resulting in rising costs that do not hit the
and, finally, establishing an energy action plan. The required budget for both electrical use and heavy fuel
energy management system must be evaluated at oil use.
least once a year and are improvements made based
on the results of the evaluation. In more detail this 3. The SEUs are shown in Figure 3. The scope in
will include: saving energy is related to a three axis target of

Year Production (Mt) Electrical Specific power Thermal Specific thermal Specific heat
consumption (kWh) consumption (kWh/t) consumption (kWh) consumption (kWh/t) consumption (kCal/kg)
2013 1.52 131,376,400 86.251 1,530,907,499 1005
2014 1.20 126,719,700 105.56 1,198,732,500 998.5
2015 1.70 142,389,400 83.644 1,708,479,463 1003.6 815
2016 1.87 155,784,699 83.327 1,676,069,123 896.5 799
Above - Table 1:
Summary of energy use increasing running time, decreasing stoppage 160 60
time and keeping maintenance to scheduled
Electrical consumption (million kWh)

at Egyptian cement plant, 140
2013 - 2016.
50
periods only. 120
40
Right - Figure 1: Annual costs 100
4. Looking at just the vertical cement mill (See
Million Euro
and usage of electrical energy 80 30
at the Egyptian cement plant. Table 2), it is possible to calculate the energy
Each months data point is the intensity index (EII) by comparing the base- 60
20
sum of the 12 months to that line data with new monthly data. This should 40
month of 2016. For example 10
be less than 1, indicating improvement on the 20
data for March 2016 shows
sums for April 2015 to March baseline. Table 2 and Figure 4 show that this 0 0
May
Jan
Feb
Mar
Apr
Jun
Aug
Sep
Nov
Dec
Oct
Jul
2016 inclusive. has already been achieved. The difference be-
Cost tween the actual and expected consumption
Usage (kWh) values should be negative and the cumulative
summation of the difference should be on an
infinite downward trend. The trend of specific 1800 400
Right - Figure 2: Annual costs 1600 350
and usage of thermal energy energy consumption can be seen in Figure 5.
1400 300
at the Egyptian cement plant. It is important to not lose sight of customer
1200
Heavy oil used (t)
Each months data point is the satisfaction throughout an efficiency drive. The 250
Million Euro
sum of the 12 months to that
1000
average properties for cement produced dur- 800 200
month of 2016. For example
ing each month of 2016 is shown in Table 3. It 600 150
data for March 2016 shows
sums for April 2015 to March shows that the average surface area according 400 100
2016 inclusive. to Blaine was 3424cm2/g. There is significant 200 500
Cost potential to increase the amount of energy 0 0
May
Jan
Feb
Mar
Apr
Jun
Aug
Sep
Nov
Dec
Oct
Jul
Usage (t) saved by reducing the separator rotor speed,
while remaining within the customers require-
ments. Continued monitoring of the coarse
portion that is recycled from the separator is
recommended so that the separator speed can Non-SEU activities = 3,935,300kWh, 3.0%
be kept as low as possible without allowing the (Packing = 1,937,400kWh)
(Crusher = 1,667,100kWh)
coarse fraction through the separator.
(Administration = 330,800kWh)
5 & 6. Each of the SEUs has operating param-

Kiln (SEU)
eters that affect their energy use. As for the
33,651,400kWh
cement mill rotor separator speed (above), 25.4%
Right - Figure 3:
each needs to be identified, quantified, re-
Energy used by SEUs and non
SEU activities at the Egyptian corded and communicated, monitored and
cement plant in 2015. controlled through identified measuring
points. This will achieve accurate monitoring
and identification of opportunities.
7. The recommendations of audits should be Raw mill (SEU)

included in the opportunities list, see below. Cement mill (SEU) 49,816,400kWh
45,061,500kWh 37.6%
34.0%
8. The opportunities list is a list of all known
opportunities to improve energy performance,
including those that may be rejected. It must
be assigned to a designated staff member, sustainable development based on business sense by
along with a target completion date, enabling examining the potential for retrofit solutions, renew-
an action plan for each upcoming period. The ables and alternative energy sources. A selection of
opportunities list unlocks new horizons for projects has been identified and is shown in Table 4.

Month Production Electrical energy Expected Energy intensity Difference Cumulative Specific energy 2015 mean specific
(t) consumption (kWh) demand (kWh) index (EII) (kWh) summation consumption energy consump-
Year
(kWh) (kWh/t) tion (kWh/t)

January 90,361 4,328,100 47.89788
February 55,245 2,382,100 43.11883
March 93,956 2,932,600 31.21248
April 107,838 3,383,700 31.37762
May 107,712 3,359,400 31.18873
June 111,728 3,504,400 31.3656 34.64464
2015
July 91,027 3,056,800 33.58125

August 135,040 4,369,800 32.3593
September 130,471 4,470,900 34.26739
October 124,274 4,092,000 32.92724
November 142,131 4,694,200 33.02739
December 174,665 5,835,900 33.41196
January 141,032 5,024,300 4,625,957 1.0861 398,343 398,343 35.62525 34.64464
February 144,812 5,355,600 4,730,868 1.1321 624,732 1,023,075 36.98312 34.64464
March 195,483 6,370,300 6,137,188 1.038 233,112 1,256,187 32.58753 34.64464
April 149,884 5,053,700 4,871,626 1.0374 182,074 1,438,261 33.71749 34.64464
May 145,243 5,372,400 4,742,830 1.1327 629,570 2,067,831 36.98905 34.64464
June 94,910 3,614,100 3,345,884 1.0802 268,216 2,336,047 38.07923 34.64464
2016
July 109,702 4,053,000 3,756,429 1.079 296,571 2,632,618 36.94546 34.64464

August 162,763 5,746,200 5,229,081 1.0989 517,119 3,149,737 35.30409 34.64464
September 104,353 3,314,300 3,607,966 0.9186 -293,666 2,856,072 31.76047 34.64464
October 194,794 5,750,700 6,118,072 0.94 -367,372 2,488,700 29.52196 34.64464
November 152,019 4,779,100 6,467,718 0.8869 -731,718 1,756,982 45.491 34.64464
December 207,392 5,736,000 4,930,890 0.9692 -151,790 1,605,192 27.65777 34.64464
1.6 Above - Table 2: Key data and

efficiency data for the Egyptian
1.4 cement plants cement mill in
2015 and 2016.
1.2
1.0
EII
Left - Figure 4: Energy-

0.8 intensity index (EII)
throughout 2016.
0.6
0.4
Dec
Oct
Sep
Nov
Feb
Apr
Jun
Aug
Jan
Mar
May
Jul
40
35
30
25 Left - Figure 5: Monthly
20 specific energy consumption in
15 2016, showing 2015 average.
10 2015 mean
5 2016
0
Dec
Oct
Sep
Nov
Feb
Apr
Jun
Aug
Jan
Mar
May
Jul

Month Strength Setting time Surface area

In the future the plant intends to report
(N/mm2) (cm2/g)
on a major decision to switch from heavy
fuel oil to coal as its primary fuel, due to 2 Day 28 Day Initial (min) Final (hr:min)
the high cost of heavy fuel oil. This will January 18.39 53.15 229 4:36 3725
have mixed effects on the entire pyropro- February 20.01 50.19 199 4:33 3747
cessing system, which the plant intends
Right - Table 3: Average March 20.25 52.54 216 4:32 3690
properties of cement made by to report upon in these pages.
April 20.22 51.00 230 4:38 3545
the Egyptian cement plant by
month in 2016. Training May 21.10 52.47 247 5:30 3351
Throughout the implementation of June 18.54 51.74 245 5:28 3285
energy management practices, it is July 17.65 52.59 237 5:26 3290
important that all staff are aware of the
August 18.26 52.31 221 5:20 3291
programme and its main targets. To help,
it is advisable to keep both soft and hard September 19.40 53.68 230 4:53 3299
copies of all energy manuals, bills, poli- October 19.90 53.11 228 4:56 3274
cies and audits. Management reviews, November 20.51 53.27 220 4:35 3290
meetings, maintenance records, process
December 19.30 N/A 228 4:51 3298
and maintenance procedures should be
used to design and conduct reviews of all
projects, from the very small to the very large.
Conclusion
R
educe energy intensity on a continual basis;
The implementation of energy management systems

in cement plants is both easy and cost effective, given
strong commitment from management and the avail-
E ncourage continued identification of
opportunities to improve energy performance;
ability of adequate technical resources. In the case of

the Egyptian cement plant, zero or low cost measures
have proven to be a strong tool in convincing all
D evelop a framework to set and follow up energy
objectives and targets;
company staff of the potential benefits that can be

achieved if a commitment to continuous improve-
ment becomes an integrated part of the companys
U se energy efficiency concepts in the design of
retrofitted or replacement equipment;
culture and day-to-day behaviour.

In general, management should provide all neces-
sary resources and required information to enable the
C ompliance with applicable legal and other
requirements to which it subscribes;
company to achieve its energy objectives and targets.

The system should help the plant management to
commit to:
E nsure and support the purchase of energy-
efficient products and services.
All of these should be regularly reviewed and up-

dated as necessary.
Right - Table 5:
Opportunities identified by the Project SEU Saving Capital Operating Payback Project Risk Priority
Egyptian cement plant, along
affected cost cost duration factor
with costs, payback time and
priority level.
5 = High priority / risk
Bypass reduction Kiln EGP10m 0 0 Immediate 3 months 2 3
1 = Low priority / risk.
Compressed air leakage All EGP1m 0 0 Immediate 3 months 1 5
1 Egyptian Pound (EGP) = Operation optimisation Kiln EGP1m 0 0 Immediate 3 months 2 3
US$0.056 or Euro0.053
Quality optimisation Kiln & EGP1m 0 0 Immediate 3 months 3 3
as at 9 February 2017.
Cement Mill
Heat recovery Kiln EGP15m EGY75m Not estimated 60 months 9 months 5 1

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and Control Systems
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20
For further information please visit www.kimaE.de
GLOBAL CEMENT: CONFERENCE REVIEW
Robert McCaffrey, Editorial Director
11th Global CemFuels 2017 - Reviewed
The 11th Global CemFuels Conference 2017 in Barcelona welcomed 185 delegates from 37
countries, and included 30 exhibitors, 20 presentations on alternative fuels in the cement
industry, two field trips to local cement plants and an impressive CemFuels Awards dinner.
The 12th CemFuels Conference will take place in Berlin, Germany on 20-21 February 2018.
T he conference started with a pres-

entation from Michele Graffigna
from HeidelbergCement, who gave
from Lafarge and Holcim, the Ireland-
based CRH is now the worlds leading
cement producer in terms of AF use,
some details on the Italcementi acqui- with a company-wide thermal sub-
sition and the use of alternative fuels stitution rate (TSR) of 39%, followed
1: Joe Harder of OneStone
(AF) in the combined group. Due to by Cemex on 26% and HeidelbergCe-
Consulting outlined major trends
in alternative fuels in the global the acquisition, HeidelbergCement ment on 21%. Generally producers
cement industry. created a new Mediterranean region in developing countries use a higher
with 19 plants. Spanish landfill costs proportion of biofuels - which Joe
are still low, but around 50% of waste Harder suggested should be secondary
is handled by MRF plants all the byproducts, rather than being spe-
same. Countries like Morocco show cially produced since these crops will
great potential, with a large cement compete for land and resources with
sector and relatively low AF usage food crops. The coal price is not tied to
age. However, the first shipment of
1 the oil price, stated Joe, and since the
refuse-derived fuel (RDF) from Italy summer of 2016 the price of thermal
was stopped at the port and import of coal has started to increase again after
waste-derived fuels was banned. This five years of steady declines, leading
has led to a greater effort to create to an increase in interest in the use of
2: Sebastian Rosin of Atritor Ltd, RDF from local waste. On the other AF. Joe pointed out that Geocycle, es-
the conferences most mature hand, the fuel crisis in Egypt in 2013 tablished in the 1970s by Holcim, now
delegate, was awarded the
drove the whole sector towards the operates in more than 40 countries
Global CemFuels Personality of
The Year Award. use of alternative fuels. The Kattameya and has over 2000 employees. This is
waste treatment facility was the first a model that other cement companies
to be based at a cement plant in Egypt could usefully copy and try to improve
and other projects have driven AF upon. Dr Harder suggested that a
use in HeidelbergCement plants in number of cement companies have set
the country. challenging targets for AF use, some
The second presentation was given of which are challenging enough that
by Joe Harder of OneStone Consult- 2 they are unlikely to be met. Coal and
ing, who spoke on global trends in petcoke prices, availability of AF and
AF. He pointed out that a huge range cement capacity growth, and the avail-
of AF usage rates exists through the ability of pre-treatment facilities will be
industry, from plants burning no AF major criteria for the future develop-
3: Combustion consultant Xavier to plants that can and do use 100% AF ment of the use of AF.
dHubert presented the evolu- substitution. Joe stated that in Europe Andy Hill next gave a presenta-
tion of burners for the cement
sector, with a focus on the use of
the thermal substitution rate is around tion with a very short title, EU AF,
alternative fuels. Read the second 39%, whereas in North America it is but which Andy described as a huge
part of Xaviers major review of only 5%. In the Netherlands the rate topic. An increase in immigration
burners from Page 10 onwards in is around 85%, down to 23% in Spain into Germany has led to an increase in
this issue.
and only 7% in Greece. Chinas rate production of waste and an oversupply
is currently 2%, but is said to be ris- of SRF, while Russian bans on cement
ing fast. The use of AF in Germany imports and Indian demonetisation
has plateaued at around 60%, partly have also led to pressure on SRF prices.
due to economics, partly due to sup- Other uncertainties are Brexit, the rise
ply and partly due to technical issues. 3 of Donald Trump, and Chinas sustaina-
Due to its purchase of selected assets bility push. Chinas Green Fence policy

4: All smiles on the Thorwesten
Vent / robecco / Yara Industrial
stand. Left to right: Christian
Fink (robecco), Ralf Schestak
(Thorwesten Vent) and Carsten
Pries (Yara Industrial).
5: The stand of US-based

4 5 6 tyre derived fuel equipment
manufacturer
EcoGreen Equipment.
6: A busy scene at the Keith

Walking Floor stand, a
producer of unloading and
related equipment.
7: Staff from Molinari Recycling

answer questions about the
7 8 9 companys shredding equipment.
8: Christophe Garcia (left)

is increasing quality control on imported waste and generally a highly processed engineered fuel. Andy and Eric Plantie (right) on the
may eventually lead to the end of waste imports. said that the market for SRF worldwide is around Precimeca stand.
There is a global oversupply of waste at the moment, 60Mt. SRF is increasingly being pelletised, mean-
so a Chinese ban would strongly impact on prices ing that it can then be more easily co-processed and 9: UNTHA shredding
and profitability elsewhere in the industry. On the incinerated with coal. Freight rates are starting to technologys Daniel Wresnik
other hand, Europe currently loses around 600Mt of rise again from historic lows, with price increases explains an aspect of the
companys technology to an
waste each year to landfill that could be used as fuels also being seen in container rates. Andy sug- interested visitor.
and for other uses. Around 30% of municipal waste gested that oil prices are now unlikely to rise above
still ends up in landfill, although US$75/barrel due to the impact
there is a 2030 target of only 10%, of American drillers. 10: A busy scene at
the impressive Grupo SPR stand,
EU-wide. An extension of Ex- Vagner Maringolo of a Spanish manufacturer of
tended producer responsibility Cembureau next spoke about waste processing and fuel
legislation should lead to more opportunities for increased waste preparation equipment.
inherently recyclable products, take-up for the European ce- The company won the prize for
best exhibition stand.
and a reduction in supply for ment industry. Vagner points out
RDF. At the same time, competi- that the EU is moving towards a
tion from the waste-to-energy
10 ban on landfilling for municipal 11: Schenck Process
Leos Volesky (right) answers
(WtE) sector is likely to increase. waste, which will give a strong
a visitors question.
CO2 prices are likely to increase, boost to the supply of alterna-
possibly to Euro40/t, by 2030, although the Euro- tive fuels. A Cembureau/Ecofys study on the market
pean cement industry may cease to be competitive potential of AF brought up a number of interesting 12: Jason Titmus of
at a rate of around Euro20/t. Plastics production will conclusions. Around 10Mt of waste was co-processed Thermoteknix Ltd, a producer
of infra-red imaging equipment
continue to grow worldwide, while paper recycling is in cement kilns in the EU28 in 2015, representing for the sector, poses on the
at a high level already. The bulk of recycled paper is around 2% of total combustible waste each year, but company stand.
shipped to China, but again, higher quality barriers representing 10% of all of the energy recovery from
may decrease the amount admitted to China in the waste in the EU.
13: The BHS Europe, Nihot and
future. RDF has a CV value up to 15MJ/kg, while SRF Jaime Ruiz de Haro, president of Cemex Spain NRT stand had an
has a calorific value (CV) of above 15MJ/kg and is and president of Oficemen, the Spanish Cement Pro- interactive display.
11 12 13

ducers Association, next spoke including RDF, agricultural waste,

about the development of AF in dried sewage sludge and tyre-
14: ATS Group / Walter Materials Spain. Average cement consump- derived fuel (TDF). Agricultural
Handlings Basri Ogut (left)
answers questions from tion in Spain in the last 50 years waste is the largest waste stream
delegates from Al Rajhi Cement. was 25Mt/yr. However, consump- of more than 30 - 35Mt each year,
tion spiked to more than 50Mt but production is geographically
in 2007, and has plummeted to 14 widely spread and the material has
just over 10Mt in 2016, a demand relatively low CV. Each year Egypt
level last seen in the 1960s, pre- generates more than 21Mt of mu-
cipitating a huge crisis in the nicipal waste, forecast to reach
cement and construction indus- 35Mt by 2025. At the moment
try. Spain is the largest exporter only around 0.5Mt is used each
15: Animated discussions on
the Presona stand.
of cement and clinker in Europe. year, but the best case scenario
In Spain, 29 of the 33 Spanish would be to use around 5Mt/yr.
cement plants are authorised to Around 1Mt of sewage sludge is
use AF, and 77 types of waste 15 produced each year, but a major
have been authorised for use in challenge is to reduce its mois-
Spain. The tonnage of AF used ture content to economic levels.
in Spain has plateaued at 0.7- The amount of tyres produced
0.8Mt/yr for the last five years, at each year is estimated at around
a TSR of around 24%. RDF is the 300,000t, but only 10% of this
16: Enotecs Yerey Garca Surez
(left) and Juan Carlos Quintero mostly widely used AF, at over amount is used by the cement in-
Fernndez. 250,000t/year, followed by tyres dustry. On the AF demand side,
(100,000t), biomass and animal the Egyptian cement industry
meal. De Haro pointed out that 16 has a TSR of only around 7% but
high disposal fees strongly drive the majority of cement plants in
the use of AF in the cement Egypt have active plans to start
industry, and he suggested that to use or to use more AF in the
stronger implementation and next five to ten years. One of the
enforcement of regulations and main problems is that a gigajoule
17: The SPEX Europe stand. The fees will be the main driver of of energy from AF is not appreci-
company makes specialist increased AF use in the coun- ably less expensive than energy
laboratory equipment. try. In Spain a realistic target from coal or petcoke. The qual-
has been set to use 30% TSR ity and security of the supply is
by 2020, 45% by 2030, and 70% also an issue, and Mrs Sakr stated
by 2050.
17 that regulatory support will be
Mrs Dalia Sakr of the Inter- required to improve the qual-
national Finance Corporation ity of waste-derived fuels. As in
spoke about the use of AF in other countries, the enforcement
18: A smiling Weima team. From
left to right: Patrick Henzler, Egypt, starting with the energy and increase in tipping fees will
Kay Schulte, Erik Hagen and crisis of 2013 when gas supplies strongly drive the availability of
visitor Andres Salazar of were diverted from the cement AF in Egypt.
Eco Green Equipment. In the events next session, on
industry to the power industry.
This caused a fall in production alternative fuels production ad-
of 50% and this caused the in- vances, Daniel Wresnik of Untha
19: Lindner Recyclingtechs dustry to move strongly towards
18 spoke about new trends in SRF
Gerd Tischner (left) and Marco
Egger (right) proudly display the
not only increased use of coal production. Daniel suggested
companys Award for most but also increased use of AF. Mrs Sakr introduced that a strong trend in the industry is towards single-
innovative technology for a major study of potential sources of AF in Egypt, step shredding. He introduced several completed
alternative fuels use.
20: Discussions aplenty on the

stand of Finnish waste bale
opening and wrapping systems
manufacturer Cross Wrap Oy.
21: Westeria Frdertechniks

Felix Poth (right) in discussion
with delegates. 19 20 21

projects including Geocycle producer N+P next spoke on the

22: Entsorgas Camilla Bonetti
projects in Vietnam, the US subject of SubCoal SRF pellets. (left) and Piotr Laube (right) on
and Mexico. Requests from the N+P has a reference plant at the company stand.
industry led to the company to Delfzijl in the Netherlands for
develop the XR mobil-e mobile SubCoal production, and pellets
23: Borja Alonso (left) and
shredder. Both the mobile and have been shown to be hydro- Tim Hamer of alternative fuel
stationary shredders use slow-
22 phobic, while being capable processing and handling
running single shaft shredding of being co-ground with coal. equipment producer Vecoplan
for rough, medium and fine SubCoal has a CV of 23.8MJ/ smile for the camera.
shredding of waste. kg, and can be transported in
Next, Eric Planti of containers, with no de-baling 24: Alternative fuel feeding and
Precimeca introduced the tyre- required at the end user, unlike dosing experts from Di Matteo
shredding capabilities of his some other types of AF. Loesche Frderanlagen. Right to left:
Luigi Di Matteo, Clelia Di Matteo,
company, which include both vertical roller mills and Atritor Svetoslav Chopov and
stationary and mobile tyre shred- grinding systems have both been Roberto Dombrower
ders. The company has striven used to grind SubCoal pellets. (Colombian representative).
towards clean-cut and homo- 23 N+P is busy setting up SubCoal
geneous size of chips as well as production facilities closer to 25: Jakob Overgaard (centre)
a consistent output through a number of cement industry and Per Cederberg (right) of
the lifetime of the knives and users around Europe, includ- ReTec Milj answer a question
no exposed beading wires that ing a new Euro14m 120,000t/ from a visitor to their stand.
could lead to the clogging of yr production plant at Teesport,
the dosing system. Tyre supply near Middlesborough in the UK. 26: Discussions on the Metso
is not prone to seasonality of SubCoal pellets from the plant Denmark stand.
supply and offers 25-30MJ/kg will have moisture content of
(6-7000kcal/kg), allowing nearly less than 8%, with CV of more 27: Thomas Jennewein of
1:1 substitution by weight with than 20GJ/t, with the majority of FLSmidth Pfister explains the
coal or petcoke. TDF has a bulk
24 the output of the plant... companys feeding and dosing
density of around 0.5t/m3, is al- systems to interested visitors.
most incompressible and can be
stored outside with no ill-effects.
TDF has a chlorine content of
<0.1%, and sulphur content 28: Rubn Snchez
Veiga of Cementos
of less than 1.5%, making it a Cosmos (centre) visits
relatively easy-to-use alternative burner manufacturer
fuel. Eric mentioned a case study FCT Combustion.
of a LafargeHolcim cement plant
with a TSR of 60% using 70,000t
25
of AF, of which 3000t is whole
tyres and 15,000t was imported
tyre chips of inferior quality. The
plant specified that, instead of
using imported chips, a new tyre
shredder would have to produce
10t/hr of clean cut product, at a 28
particle size of lower than 50mm.
The plant settled on a fully-auto-
matic stationary tyre shredder 26
with two high-torque low-speed Scan the QR code below or enter the bit.ly
shearing rotors, capable of ac- code into your brower to read more about the
cepting tyres up to a maximum CemFuels Conference & Exhibition, see the con-
diameter of 1200mm. The ro- ference photo gallery and access the video....
tors will automatically reverse
rotation direction to prevent
any potential jam. The system See more
http://bit.ly/
includes a tyre chip classifier to
2lDXSkr
ensure that all output is of below
50mm chip size.
27
Neville Roberts of fuel-

GLOBAL CEMENT NEWS: PRODUCTS & CONTRACTS
Contents
Algeria: Plant project for thyssenkrupp Belgium: Order for Gebr. Pfeiffer
Industrial Solutions
Subscribe
t hyssenkrupps Industrial Solutions has been awarded a contract by

Socit des Ciments de Sigus, part of Groupe Industriel des Ciments
G ebr Pfeiffer has received an order from
Cemminerals to supply a grinding plant
for slag and cement. The plant in Flanders will
Ad Index
dAlgrie (GICA), to build a cement plant at Sigus, in the Wilaya of Oum El use a MVR 5300 C-6 type mill. The order was
Bouaghi, near Constantine. The plant will have a clinker production ca- taken in December 2016 and the mill is sched-
pacity of 6000t/day. Operation is planned to start in early 2019. No exact uled for commissioning in early 2018.
value for the order was disclosed but it was placed above US$100m. The Pfeiffer MVR 5300 C-6 slag and ce-
GICA has launched several projects to increase its cement produc- ment mill will be used to grind five different
tion capacity from 12Mt/yr to 20Mt/yr by 2019. ThyssenKrupp previously cement qualities as well as pure slag to three
received an order from GICA in 2013 to build a 6000t/day cement plant. different fineness degrees. The mill is guaran-
teed to achieve capacities of 132t/hr for pure
slag, ground to 5000cm Blaine, and of up to
Bangladesh: Orders for Loesche 200t/hr for CEM II, ground to a fineness of
3500 Blaine. The mill main drive is designed
L oesche has received an order to supply a 56.3+3 CS type vertical roller

mill for the Aman Groups Haria 2 cement plant at Narayangonj, near
Dhaka, the Bangladeshi capital. The contractor for this order is the China
for an installed power of 4600kW, and the SLS
4750 BC high-efficiency classifier, mounted
on top of the MVR mill, enables high material
National Heavy Machinery Corporation (CHMC). It follows a previous fineness degrees of up to 5000 Blaine.
order by the Aman Group for a Loesche LM 56.3+3 CS mill that was sup- In addition to the MVR mill the contract
plied in 2014 for the Haria 1 line. The new mill was supplied in late 2016. includes handling equipment, two in-feed
The roller mill for the Haria 2 line has a production capacity of 240t/ devices to enable moist slag and dry clinker
hr for Portland and composite cement clinker with a fineness of 3200 to be fed to the mill separately, the plant filter,
Blaine or 175t/hr of ground-granulated blast-furnace slag (GGBFS) with the plant fan, the magnetic drum separator
a fineness of 4500 Blaine. It has a drive power of 5300kW. In addition to and all ductwork including chutes, expansion
the mill, the scope of supply also specifies additional technical equip- joints and the stack. The scope of supply also
ment for the grinding plant including a rotary feed, a two-way chute, a includes a hot gas generator for the heating
metal detector and a permanent magnet drum separator. of the mill, as well as all electrical drives, start-
ers, frequency converters and the electrical
switchgear.
UK/Spain: Thermoteknix launches Multi-View system at Global CemFuels Conference
T hermoteknix announced the launch of its

ThermaScope HD kiln and cooler camera Multi-View
system at the Global CemFuels Conference 2017, which
took place on 2-3 February 2017 in Barcelona, Spain.
The new measurement, recording and analysis system
for Thermoteknix HD kiln and cooler cameras pro-
vides real time screen displays with picture-in-picture
layouts to coordinate and continuously record video
data and events. A user Interface has been introduced
to maximise the image presentation and to carry out
temperature recording, I/O, alarms and analysis in the
background. Full OPC compliance gives integration to
plant automation and control without the need for cus-
tom programming.
An updating time line provides access to past his-
tory allowing the user to scroll the kiln and/or cooler Multi-View provides the engineer with the ability to
video backwards or forwards in time to review, recall trend prospectively or retrospectively any point or area
or compare fuel changes and events in the pyro pro- in the image by placing tools on the live (or historic)
cess. ThermaScope Multiview software allows the image to show the effects caused by changes in opera-
operator to navigate graphically through past events, tional parameters, fuel, combustion, kiln speed, or other
viewing the kiln process as on-going and illustrated in factors affecting production and clinker quality.
the timeline.

Sustainable Strength through Innovation
ONLY
HERE!
PLAN TO JOIN US IN:
Calgary, Alberta May 21-25, 2017
www.cementconference.org
IEEE 2017 March 2017.indd 1 21/02/2017 16:16

NEWS
Germany: HeidelbergCement results

- a strong solution for the environment boosted by Italcementi assets
BALE OPENER H eidelbergCements sale revenue, volumes and prof-

its were all boosted by its acquisition of Italcementi
in 2016. Preliminary figures for the group show that its
revenue rose by 13% year-on-year to Euro15.2bn in
2016 from Euro13.5bn in 2015. Its cement sales volumes
rose by 28% to 104Mt from 81.1Mt and its operating
income rose by 7% to Euro2bn from Euro1.85bn. The
group said that 2016 had been its best year since the
financial crisis in 2008. However, on a pro-forma basis,
taking into account the contributions of Italcementi in
2015 and 2016, the groups sales revenue fell slightly
and cement sales volumes and operating income rose
far less steeply.
The year 2016 was an important milestone for
The ReTec Bale Opener can open Key Points: HeidelbergCement, said Bernd Scheifele, chairman
bales of various types of material. Automatic reversing at high
of the managing board. With the acquisition of
Both wired bales and plastic loads, for example, with
Italcementi, we made a big leap in growth and achieved
wrapped bales can be opened. impurities.
the best operating income since the financial crisis. The
Able to open virtually any type integration of Italcementi is well under way and offers
Materials: of bales without adjustment
RDF/SRF bales significant earnings potential resulting from the imple-
or change in settings or
mentation of identified synergies.
Straw bales programming.
By region, HeidelbergCements Western and South-
PET/Plastic bales Capacity up to 80 t/h depending ern Europe division reported rising sales volumes of
Recovered paper/cardboard on size and density of the bales.
cement but falling revenue and operating income. Im-
bales Few wear parts ensures proving markets in Germany and the UK were offset by
economical operation. weak demand in Italy, France and Spain and the falling
value of the British Pound versus the Euro. By contrast
ReTec Milj ApS ReTec develops, constructs and manufactures special
machines for the waste and recycling industry. We offer revenue, cement volumes and operating income were
Tel.: +45 7456 8106
www.retec.dk practical solutions to our customers needs, helping all up in the Northern and Eastern Europe-Central Asia
them increase profitability in their business.
area with a particular emphasis in Norway. Notably,
demand growth was also reported in Russia driven by
markets in Moscow and St Petersburg. In North Amer-
ica financial figures rose in 2016 but revenue fell in the
last quarter of the year. Strong sales were recorded in
UK/Ireland: Quinn to build border terminal the north and south of the US but a drop in sale vol-
Q uinn Cement is planning to build a Euro2.9m port facility at

Warrenpoint Harbour in County Down in Northern Ireland,
UK. The 7500t terminal will be operated over a 10-year period in
umes was noted in the Canadian Prairie provinces due
to falling oil production. In the groups Asia area sales
volumes rose but revenue and operating income fell in
conjunction with the Warrenpoint Harbour Authority, according 2016 due to a significant fall in prices in Indonesia and
to the Irish Independent. Final commissioning for the project Thailand. Finally, in the Africa-Eastern Mediterranean
was approved in late January 2017. The investment is intended Basin region the market picture was mixed with small
to complement the companys update to its terminal in Roches- increases in sales volumes, a drop in sales revenue and
ter, Kent in England and to help the company cope with the UKs a slight increase in operating income due to increased
decision to leave the European Union. market competition in Sub-Saharan countries.
Denmark: FLSmidths results improve

order intake and revenue declined for the company as
F LSmidths revenue for its cement division has risen

by 10% yearon-year to Euro576m in 2016 from
Euro526m in 2015. Its order intake rose by 63% to
a whole in 2016.
After a weak first half activity picked up, finishing
the year on a strong note. Rising commodity prices
Euro615m from Euro377m. The equipment manufac- positively impacted sentiment in the mining industry in
turer said that orders had picked up in the second half 2016, although it has yet to translate into higher capi-
of 2016. Although it added that the market for new ce- tal investments. The cement industry is showing early
ment capacity remains largely unchanged with supply signs of recovery, said group chief executive officer
outweighing demand on a global level. Overall, both Thomas Schulz.

CEMENT NEWS: EUROPE
EU: Changes to ETS approved
T he European Parliament has voted to approve a

proposal by the European Commission to reduce
carbon credits by 2.2%/yr from 2021 in its Emissions
Trading Scheme (ETS). This is an increase from the 1.74%
reduction specified in existing legislation. It will also
double the capacity of the 2019 market stability reserve
(MSR) to absorb the excess of credits or allowances on
the market.
Members of the European Parliament (MEP) want to
review the so-called linear reduction factor with the
intention of raising it to 2.4% by 2024 at the earliest.
In addition MEPs want to double the MSRs capacity to
mop up the excess of credits on the market. When trig-
gered, it would absorb up to 24% of the excess of credits
in each auctioning year, for the first four years. They have
agreed that 800 million allowances should be removed
from the MSR as of 1 January 2021. Two funds will also Casting a
confident glance
be set up and financed by auctioning ETS allowances.
A modernisation fund will help to upgrade energy
systems in lower-income member states and an innova-
at the future!
tion fund will provide financial support for renewable
energy, carbon capture and storage and low-carbon
innovation projects.
The draft measures were approved by 379 votes to
263, with 57 abstentions. MEPs will now enter into ne-
gotiations with the Maltese Presidency of the European
Council in order to reach an agreement on the final
shape of the legislation, which will then come back
to Parliament.
Meanwhile, the environmental campaign group
Sandbag has complained that the new proposal fails to
hold to the European Unions (EU) emissions reduction
targets by 2030 that were signed as part of the Paris
Agreement in 2016.
Unless the Council intervenes to substantially
strengthen the system, the EU ETS will now become
simply an accounting mechanism, leaving meaningful HARDTOP Bimetal Castings provide
climate action to happen elsewhere. The fact that the
carbon price is unchanged as a result of the vote, still
high wear resistance
at a paltry Euro5/t, speaks volumes. Without being rea- increased durability
ligned with real emissions levels in 2020, the EU ETS may reduced overall costs
well end up existing for 25 years by 2030 without giving
any substantial impetus to decarbonisation, said Rachel
high efficiency
Solomon Williams, Managing Director at Sandbag. reduced expense for maintenance
minimised downtime
raised production
Russia: Siberian demand could fall 10% added profit
S ibirsky Cement expects that demand for cement in Sibe-
ria will fall by 8 10% to 4.7 - 4.8Mt in 2017. The cement
producer said that its output decreased by 22% to 2.15Mt
from its Kemerovo Region-based Topkinsky Cement, by 3% Reichelstrasse 23
to 0.75Mt from its Krasnoyarsky Cement plant and by 10% D-39124 Magdeburg
to 0.27Mt from its Timlyuisky cement plant, according to the Germany
Prime Tass news agency. Overall its cement production fell
by 17% year-on-year to 3.17Mt in 2016. It has blamed falling
phone: +49 (0) 391 532969-0
production on an overall decline in Russias cement market.
fax: +49 (0) 391 532969-21
e-mail: sales@hardtop-gmbh.com
Global Cement Magazine March 2017 41 web: www.hardtop-gmbh.com
18-19 MAY 2017 DSSELDORF
NEWS: EUROPE
gl bal CONFERENCE
12th
Italy: Cementir sales rise marginally
slag
EXHIBITION
AWARDS 2017
The 12th Global Slag Conference will bring together
C ementir Holdings sales revenue has risen by 6% year-
on-year to Euro1.03bn in 2016 from Euro0.97bn in
2015. Its earnings before interest, taxation, depreciation
and amortisation (EBITDA) increased by 2% to Euro198m
from Euro194m and its sales volumes of cement rose
by 7.9% to 10.1Mt from 9.4Mt. The gains arose from the
slag producers and slag users from around the world companys purchase of Compagnie des Ciments Belges
for business, technical exchange and networking. during 2016. On a like-for-like basis revenue fell slightly,
EBITDA fell more deeply and sales volumes of cement
If your business is slag, make it your business to attend rose modestly in the period.
Strong performance in the Scandinavian countries
the 12th Global Slag Conference in Dsseldorf!
and Malaysia have substantially offset lower earnings
in Turkey, Egypt and Italy. Also, group results have been
negatively affected by the depreciation of the Turkish
Lira and, since the Brexit vote, the British Pound, together
with the fall in the value of the Egyptian Pound and
geopolitical events in Turkey and Egypt, said Francesco
Caltagirone Jr, chairman and chief executive officer of
Cementir Holding.
Spain: CPV records massive loss
C ementos Portland Valderrivas (CPV) has made

a loss of Euro225m in 2016. It increased from
a loss of Euro62m in 2015. It reported that its sales
fell by 7.6% year-on-year to Euro536m in 2016 from
Euro580m in 2015. It attributed this to the sale of its
US subsidiary, Giant Cement, falling sales in Tunisia, a
decrease in the value of the Tunisian Dinar and rising
Global slag markets fuel prices.
The cement producers sales volumes of cement
New applications fell slightly to 7.2Mt in 2016. However, once sales
Networking and business from Giant Cement are removed then, its sales vol-
umes rose by 1.6% due to a 49% increase in exports
Worlds largest slag-related exhibition! from Spain. This compensated for declining markets
in Spain and Tunisia.
International Slag Association sponsors CPV said that overall cement consumption in
Spain fell by 3.1% to 11.1Mt in 2016, although this
was partially offset by exports rising by 5.6% to
9.8Mt. Reduced domestic demand and rising ex-
ports have led to clinker production rising slightly
in 2016 to 17Mt. It added that cement consumption
increases were slowing down in the US, although
the regions its subsidiary Giant Cement operates
in reported above average increases of almost 11%
to November 2016 in the South East, Mid Atlantic
and New England regions. In Tunisia it reported that
the market fell by 3.9% to 7.2Mt and that exports to
Event partner Organiser Algeria and Libya had fallen.
gl bal
cement
TM
MAGAZINE
42 Global Cement Magazine March 2017
CEMENT NEWS: EUROPE
Making decisions regarding the realisation of a new

coal grinding system, as part of a complete new
clinker line, or as an independent job?
You will demand the best from your supplier. But
ensuring that your system will end up un-compromised
in terms of fire and explosion protection, with a small
footprint and a low cost structure and easy to maintain,
is not that easy!
Have your project supported by an independent
specialist, right from the beginning.
Coal Mill Safety Pte Ltd

www.coalmillsafety.com
info@coalmillsafety.com
Lithuania: Akmenes pivots away from Russia
M andatory cement certification in Russia has forced Akmens

Cementas and other cement producers based in the east
of the European Union (EU) to send their exports elsewhere. The
Lithuanian cement producer has compensated for this by moving
its sales in other markets, according to the Verslo Zinios newspa-
per. Akmenes Cementas sales fell by 8% year-on-year to Euro51m
in 2016 from Euro55.4m in 2015.
Your project,
Around 60% of its sales revenue came from local sales in Lithu-
ania, 20% from sales in other Baltic countries and Belarus and 20% our solution
from Scandinavian countries. Previously, exports to the Russian
enclave of Kaliningrad accounted for 30% of the companys rev- We deliver customised solutions for operators
enue. The company expects to generate sales of Euro54m in 2017 and investors of cement plants throughout
based on existing contracts.
the world. Intercem is the competent and
experienced partner for planning, detail
engineering, project handling of greenfield
projects and the conversion/modernisation
Germany: Claudius Peters reports contin- of production systems. Our 3-level system
ued low capital investment in key sectors makes it possible for us to offer both used
and modernised products, to compile new
L angley Holdings, the UK-based owner of Claudius Peters,
has reported that its subsidiarys revenue fell by 14%
year-on-year to Euro106m in 2016 from Euro124m in 2015.
solutions made
from used
Claudius Peters orders on hand rose by 13% to Euro50.3m and new
from Euro57.7m. The plant engineering manufacturer noted components
that the industries it serves, including cement and gypsum,
or to create
remain at a low point in their business cycle and that capital
investment is low. completely
The divisions order intake did improve in the final quar- new systems.
ter and with commodity prices coming off the bottom there
are signs that the climate is improving, although it is too early
to call a recovery. In all, the results were satisfactory in a still And all that: FastFairFlexible
much subdued sector, said Langley Holdings chairman An-
thony J Langley. He added that poor markets in Brazil and
Russia affected the divisions results. However, Claudius Pe-
ters China performed quite well due to export projects with
Intercem Engineering GmbH
Chinese contractors, and divisions in France, the US, the UK,
Intercem Installation GmbH
Spain and Italy did well.
Carl-Zeiss-Strae 10 | 59302 Oelde
Germany | Tel.: +49 2522 92058-0
E-Mail: info@intercem.de | www.intercem.de
Global Cement Magazine March 2017 43
GLOBAL CEMENT NEWS: EUROPE
Italy: Buzzi Unicem reports moderate improvement
A recovery in sales volumes in Central and Eastern

Europe helped Buzzi Unicem to maintain stable sales
in 2016. Its net sales rose slightly to Euro2.67bn in 2016
started to improve in the second half of the year, hitting
an overall decline of 1% as a decline in construction in-
dustry investment started to soften. Also of note, sales
from Euro2.66bn in 2015. Cement and clinker sales vol- of oil well cement started to recover towards the end of
umes remained flat at 25.6Mt. It also reduced its net debt the year.
to Euro942m from Euro1.03bn. The cement producer re- Cement sales volumes in the US started to decline
ported slowing sales growth in the US, a decline in Russia early in the year, eventually falling by 1.7%, with a no-
and a continued marked fall in sales in Italy. table weakness in demand in Texas, particularly in the
By region, the cement producer said that cement and Houston area. Again, oil well cement products declined
clinker sales volumes fell by 6.2% year-on-year due to a over the year as a whole but showed signs of recovery
reduction in exports. Volumes rose in Germany by 3.4% in the final months of the period. Finally, Buzzi Unicems
despite low prices. Poland reported an 11.9% boost in associate company in Mexico Corporacin Moctezuma
volumes, driven by the second half of the year, despite saw its cement sales volumes rise slightly compared to
lower prices compared to 2015. In Russia sales volumes 2015, supported by rising prices.
Eu
UK: Fairport project at Ketton Germany: Menzel is 90
F airport Engineering has reported work on its

replacement of two electrostatic (ESP) filters at
Hansons Ketton cement plant in Rutland. Follow-
M enzel Elektromotoren is celebrating its 90th anniversary in
2017. Kurt Menzel originally founded the manufacturer of
industrial electric motors on 7 September 1927. Despite turbulent
ing discussion in early 2016 Fairport was contracted events in its early years, including the economic depression in
to replace ESP filters at the plants mills 9 and 10. the 1930s, bomb damage during World War Two, its subsequent
Both mills were shut down for planned three-week dismantling by the Soviets and the Berlin Blockade, the company
periods each to remove the old filters and install the continued operating in Berlin. Kurt Menzels grandson, Mathis
new ones. Menzel, runs the company today.
First Class European Quality Motors...

to keep your projects in motion.
Electrical medium and low voltage motors

between 500 and 35,000 kW
Asynchronous motors with squirrel

cage and slip ring rotor
Replica motors and custom designed

solutions
Solutions for kilns, cement and raw mills,

crushers, fans,...
With 125 years of experience in development, design and production of electrical machines, ELIN Motoren GmbH is one of the most traditional
industrial enterprises in Austria. As an innovative and sustainable company ELIN Motoren GmbH has built one of Europes most modern motor- and
generator manufacturing sites in 2008. The companys strengths lie in the production of small and medium quantities, as well as custom products,
designed precisely according to customers specifications.
WE KEEP THE WORLD IN MOTION.
www.elinmotoren.at
NEWS: EUROPE
UK: Greenbank supplies feeder system to

Padeswood
We provide for your safety
G reenbank has supplied a GWF feeder system to Hanson
Cements Padeswood plant in Flintshire. The system is
designed to feed raw materials into the processing plant at a
predetermined rate.
The constant and
reliable feed rate of the
GWF feeder is achieved
by having a shear gate to
set a constant material
bed depth for the given
particle size combined
with an inverter drive to
control the feeder belt
speed, said Rod Molyneux,
Product Sales Engineer
at Greenbank. Visit us
at Stan
Greenbank Group has d R 69-6
previously supplied the
plant with wear-resistant
pipework and a pipe
system for a new shred-
ded refuse fuel line into Above: The Hanson Padeswood cement plant.
the kiln.
Explosion protection
Finland: RL-Trans orders mobile bulk for industries typically using coal, lignite,
truck loader from Dino pet coke and secondary fuels
L ogistics company RL-Trans has ordered a Dino DS400

mobile bulk truck loader. The loader has loading bel-
lows and a capacity of 90m/hr. The Dino can be used to
Thorwesten Vent are your experts in explosion
venting and pressure shock resistant design and
fill 53t into extra-large bulk trucks, such as those used construction. Thorwesten Vent offers explosion
in Finland, within two hours. Following the completion protection-related consultancy for the planning of
of a bulk terminal RL-Trans wanted to be able to deliver new as well as the correction of existing grinding
packed bulk goods. It then made the order via screw facilities for solid fuels.
conveyor manufacturer Van Beek based in the Nether-
lands. We provide for your safety!
Andreas Lindedahl, Market Manager at RL Trans, said,
We are increasingly being asked whether we can de- Highly efficient self-reclosing explosion vents
liver bulk goods packed for example in big bags. This led
us to look for a way of quickly loading big bags into our Customized safety solutions comprising
bulk trucks. engineering and hardware supply
The maximum weight for trucks is higher in Finland
than in other EU countries. A truck may in fact weigh 76t Professional consulting and assistance
in the country. We can therefore get 53t into a silo truck,
says Lindedahl.
THORWESTEN VENT GmbH

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

67 JUNE 2017 ANTWERP, BELGIUM
gl bal
1st Cement and Clinker
Transport and Logistics
cemtrans
Major exhibition
www.cem-trans.com
CONFERENCE & EXHIBITION
Following requests from the cement industry and a global survey of potential Whats at CemTrans?
attendees, Global Cement is pleased to announce the inaugural Global CemTrans
Conference and Exhibition on cement and clinker transport and logistics - From Meet the delegates sessions
Silo to Site, which will take place in Antwerp, Belgium, on 6 - 7 June 2017.
Subjects: Global cement
The conference will cover all aspects of transport and logistics, from the
and clinker supply and
cement plant silo to the final job site, in bags, big bags and bulk; in trucks, on
barges, in ships, via rail including intermodal transport. The event will focus on demand trends; Packaging
moving cement and clinker from A to B while optimising profitability.
advances; Logistics optimi-
If you are involved in cement and clinker transport and logistics, then you
should certainly attend Global CemTrans Conference and Exhibition in Antwerp! sation; Transport options
Business opportunities
and a warm welcome!
ring
Featu
1st CemTrans Exhibition
yle
an-st
Please contact Paul Brown with all
B e l g i
! exhibition enquiries:
a l evening paul.brown@propubs.com,
soci Tel +44 1372 840950
or Mob: +44 776 7475 998
Who should attend?

Senior management
Cement plant personnel
Transport managers
Packing plant managers
Equipment producers
Cement and clinker traders
Cement and clinker shippers
Bulk terminal managers
Software providers
Fleet managers
Cement buyers
Cement sellers
Service providers
Consultants
Analysts
... in fact, anyone with an

interest in cement and
clinker transport and
logistics!
Organised by:
gl bal
cement
TM
MAGAZINE
CemTrans 2017 fullpage.indd 1 21/02/2017 16:12

THE AMERICAS :GLOBAL CEMENT NEWS
US: Cemex sees improvement in 2016

in energy, agriculture and manufacturing. It also noted
C emex saw its profit grow in 2016, as it reported that

its operating earnings before interest, taxation,
depreciation and amortisation (EBITDA) rose by 6% year-
growth in infrastructure spending in the last quarter of
2016 following the US presidential election.
In South and Central America and the Caribbean net
on-year to US$2.75bn from US$2.59bn in 2015. On a sales fell by 9% to US$1.73bn from US$1.89bn. Cemex
like-for-like basis adjusted for investments, divestments noted a flat market for cement sales volumes in Co-
and currency fluctuations it rose by 15%. Its net sales fell lombia in 2016 and high competition in a soft demand
by 3% to US$13.4bn from US$13.8bn, although on a like- market. In Europe net sales fell by 5% to US$3.3bn from
for-like basis they rose by 4%. Sales volumes of cement US$3.43bn. Here, cement sales volumes fell in Spain and
remained stable at 66.7Mt. The company hailed a 10-year Poland through the year. However, sales volumes rose
high in net income for 2016 and said that sales had in- by 7% in the UK due in part to higher sales of blended
creased on a like-for-like basis in the fourth quarter due cement that resulted from fly ash scarcity. Sales vol-
to higher prices and higher volumes in Mexico, the UK umes in Germany remained flat in 2016 but the market
and Germany. picked up in the second half of the year supported by
By region Cemex saw its net sales rise in both real- the residential sector. Finally, the groups Asia, Middle
terms and on a like-for-like basis to US$2.86bn from East and Africa division reported that its net sales fell by
US$2.84bn. It said that cement volume growth dur- 7% to US$1.54bn for US$1.65bn with a significant dip of
ing the quarter and full year 2016 was mainly driven 14% in sales volumes of cement in the fourth quarter of
by the industrial and commercial, formal housing and the year although volume remained flat in the year as
self-construction sectors. In the US net sales remained a whole. The Philippines suffered from poor weather
static at US$3.67bn but they rose on a like-for-like basis. towards the end of the year although Cemex noted that
The company said that construction spending for the cement demand weakened in the second half of the year
cement-intensive segments in the industrial and com- in conjunction with the transition to a new government.
mercial sector grew by 1% in 2016, reflecting growth In Egypt, government infrastructure spending drove ce-
in the lodging and office segments, offsetting a decline ment demand.
GLOBAL CEMENT NEWS: THE AMERICAS
Honduras: Argos plant launched

Trinidad & Tobago: Cemex TCC offer accepted
C emexs indirect sub-

sidiary Sierra Trading
C ementos Argos has inaugurated its
0.3Mt/yr cement grinding plant at San Lor-
enzo. It spent US$25m on the upgrade project
has successfully made its and it has created 100 new direct and indirect
offer and take-over bid jobs. The plant, formerly known as Cesur Grind-
for Trinidad Cement. The ing Station, was purchased from Lafarge in 2013.
subsidiary received the The refurbished plant will add to the cement
Foreign Investment License from the Trinidad & Tobago Min- producers assets in the country, which include
istry of Finance to confirm that all terms and conditions of an an integrated cement plant in Comayagua and a
amended offer made in January 2017 had been accepted. terminal in San Pedro Sula.
Cemex increased its offer to buy a controlling stake in Trini-
dad Cement in mid-January 2017 with a value of up to around
US$100m. However, the directors of Trinidad Cement recom- Mexico: Cemex to sell GCC stake
mended twice that its shareholders reject the offer. Although
Cemex has passed the threshold required to take control of
Trinidad Cement its share offer remained open in Jamaica for
C emex has said that it will start selling its
23% minority stake in Grupo Cementos
de Chihuahua (GCC). The cement producer
local shareholders until 7 February 2017 due to local legislation. previously announced its intent to sell its
stake but it sought permissions from the regu-
lators first. It intends to sell its shares via a
public offering authorised by the Comisin
Mexico: Cementos Moctezuma completes second Nacional Bancaria y de Valores and conducted
line at Apazapan plant through the Mexican Stock Exchange. It will also
run a private placement to eligible investors out-
C ementos Moctezuma has completed its second production line

at its Apazapan plant near Veracruz. The unit now has a cement
production capacity of 2.75Mt/yr following an investment of over
side of Mexico.
Venezuela: Corporacion Socialista

US$150m. Miguel ngel Yunes Linares, Constitutional Governor of
del Cemento output to rise
Veracruz, Efran Gonzlez Flores, Municipal Constitutional President
of the Municipality of Apazapan, Fabrizio Doneg, General Manager
of Moctezuma Corporation and others attended a ceremony to mark
the operational start-up of the new line in late January 2017. Follow-
T he Corporacion Socialista del Cemento
expects to produce 6Mt of cement in 2017
to meet national demand. Marco Tulio Diaz,
ing the expansion, the cement producer has a production capacity of president of the construction federation Feder-
8Mt/yr in the country. acin Bolivariana de la Construccin, said that
distribution channels are to be reinforced, ac-
cording to the El Universal newspaper. He added
Canada: Colacem faces opposition the country expects to export 0.3Mt of cement
T he Champlain Township council in Ontario has voted against plan-

ning changes to allow Colacem to build a cement plant in nearby
LOrignal. However, the United Counties of Prescott and Russell have
in 2017. In 2016 about 55% of cement produc-
tion was despatched
to the popular housing
voted in favour of the project, according to the Review newspaper. program Gran Misin
The cement producer requires approval from both bodies in order to Vivienda Venezuela
proceed with the project. It wants to build a 3000t/day cement plant and 45% was reserved
at the site next to a limestone quarry that it already operates. for the private sector.
Venezuela: Vencemos needs US$47m for fleet US: Headwaters shareholders

approve Boral takeover
T he Venezolana de Cementos (Vencemos) Guayana grinding plant
in Bolivar state needs US$47m to repair its transport fleet. Union
head Johnny Linares said that only four vehicles out of 65 are work- T he shareholders of Headwaters have ap-
proved the acquisition of the company by
ing correctly in comments made to the Ultimas Noticias newspaper. Australias Boral. Over 98% of the votes cast were
The fleet is used to move clinker from the cement producers Perti- in favour of the deal. Boral will now continue to
galete cement plant to the grinding plant. Capacity utilisation at the seek regulatory approval for the purchase and it
plant fell to 28% at 97,000t in 2016 from 346,000t in 2012. Linares plans to complete the deal by mid-2017. Headwa-
added that the national cement industry only received an invest- ters Construction Materials division is one of the
ment of US$7m in 2016 but that he believes it requires US$25m/yr. largest marketers of fly ash in the US.

THE AMERICAS :NEWS
US: Eagle sees improvement
E agle Materials revenue has risen by 5% year-

on-year to US$933m in the first nine months
of its financial year to 31 March 2017 from
US$891m in the same period of the previous year.
The Blaine - Master
Its net earnings rose by 43% to US$162m from The only producer of six
US$113m. Sales from its cement division rose by different Blaine apparatus
7% to US$359m from US$335m. However, sales
volumes fell slightly to 3.89Mt. Sales volumes of
cement from its joint-venture in Texas grew faster Including demo film:
than wholly-owned plants, despite cement prices
falling as production shifted from oil well cement How to use the Blaine apparatus
to construction-grade cement over the past year.
Argentina: Sales fall by over 10%

Blaine, manual
S ales of cement in Argentina fell by 10.7% year-on-
year in 2016, according to data from the National
Statistics and Censuses Institute. Domestic construc-
and Blaine,
semiautomatic
tion declined by 12.7%.
Brazil: SNIC downbeat about 2017
T he National Union of Cement Industry (SNIC) has

said that 2017 may be the worst year on record for
the local cement industry after domestic sales fell by
11.7% year-on-year to 57.2Mt in 2016. SNIC President
Paulo Camillo Penna added that following capacity Blaine,
utilisation rates of 70% in 2015 and 57% in 2016 that PC operated,
he expects the rate to fall below 50% in 2017. SNIC fully automatic
forecasts that sales of cement will contract by 5 7%
in 2017. Read more about the Brazilian cement sector
on Page 50 of this issue of Global Cement Magazine.
US: SSI Shredding Systems announces

new Director of Engineering
S SI Shredding Systems has appointed Paul Bre-

ithaupt as its Director of Engineering. He will be
overseeing the day-to-day engineering operations as
Blaine Dyckerho,
semiautomatic,
well as working to optimise SSIs internal processes
and products.
Breithaupt (see below) has been working with an
engineering consulting firm in Portland, Oregon for
the past seven years. There he primarily worked on
capital projects for major food manufacturers such
as Nabisco. He holds a degree in Manufacturing En-
gineering from California Polytechnic State University.
Blaine Dyckerho,
PC operated,
fully automatic,
1 or 2 cells
TESTING Bluhm & Feuerherdt GmbH

Motzener Strae 26b 12277 Berlin / Germany
Phone: +49 30 710 96 45-0
www.testing.de info@testing.de
COUNTRY REPORT: BRAZIL
Peter Edwards, Global Cement Magazine
Brazil: Still finding the bottom of the curve...
Once the epitome of the rapidly-rising BRIC group (Brazil, Russia, India and China), Brazils
economy and cement sector have taken a massive knock since 2008. This has been due to
the global economic downturn exacerbated by the countrys reliance on mineral exports
and accompanying political upheaval. Here we look at the countrys cement producers,
recent production and consumption trends, recent news events and sector outlook.
B razil spans 8.5 million km2 of land across 26

states. It is the largest country in South America,
occupying around two thirds of the land mass. It is
110.4 million-strong workforce was employed pri-
marily by the service sector (71%), while agriculture
and industry employed the remaining 15.7% and
also the fifth-largest country in the world. With a 13.3% respectively. Unemployment rose from 9% in
population of 215 million in 2017, it is also the sixth 2015 to an estimated 12.3% in 2016, indicating dete-
most populous country in the world. rioration in the national economy.
Economy Cement industry - Introduction

Brazil is one of the BRIC group of economies, classi- The Brazilian cement industry dates back to the late
cally defined, along with Russia, India and China, as 19th Century, when the earliest cement plants were
a large and rapidly-growing developing economy. It built. Industrial-scale production began in 1926 with
experienced a milder recession than many economies the launch of the Companhia Brasileira de Cimento
as a result of the 2008 global economic downturn, Portland cement plant. It only took until 1933 for
driven by strong domestic growth and exports of raw domestic production to overtake imports.
materials. However, as the downturn became pro- In the 1950s and 1960s Brazils economy grew
longed the countrys reliance on raw material exports rapidly on the back of significant government in-
came unstuck due to a dearth in demand. vestments, including the construction of its new
Brazilian GDP fell from US$2.62tn in 2011 to capital Brasilia in the countrys interior. This led to
US$2.46tn in 2012, according to the World Bank, sta- a significant rise in cement demand, with produc-
bilising around that level in 2013 and 2014. However tion increasing from just 1.4Mt in 1950 to 5.6Mt
GDP nose-dived by a further 28% to US$1.78tn in in 1965 (See Figure 1). Consumption rose from
2015. The CIA World Factbook estimates that GDP 12.9kg/capita in 1935 to 67.7kg/capita in 1962. Dur-
fell by a further 3.3% in 2016. The countrys GDP/ ing this time, Brazil became self-sufficient in terms of
capita is estimated at US$16,200. cement production.
The Brazilian economy remains largely reliant The growth of the cement sector accelerated in
upon commodity exports, including coffee, automo- the 1970s, with the establishment of 22 new plants.
biles, steel, cement and crops. In 2015, it exported Production more than tripled from 9.0Mt in 1970 to
US$190.1bn of goods and imported US$172.4bn. Its 27.1Mt in 1980. However, demand stagnated in the
Right: The statue of Christ

the Redeemer overlooking
Rio de Janeiro, Brazils most
populous city.

70
70
60
60
50
50
Cement production (Mt)
Left - Figure 1: Brazilian

40
40
cement production (Mt)
between 1950 and 2015.
30
30 Source: SNIC.
20
20
10
10
0
0
1
1950 2
1955 3
1960 4
1965 5
1970 6
1975 7
1980 8
1985 9
1990 10
1995 11
2000 12
2005 13
2010 14
2015
8080
7070
6060
5050
Cement sales (Mt)
Left - Figure 2: Brazilian

4040
cement sales (Mt) between
2001 and 2016.
3030 Source: SNIC.
2020
1010
00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Below - Figure 3: Regional

1980s following the oil crisis of the late 1970s. At this in the populated and cement-intensive South East Brazilian cement sales (Mt)
time capacity utilisation languished at just 45%. By of Brazil, the location of major cities such as Rio de between 2014 and 2016.
1990 production had fallen back to 25.8Mt. Janeiro and So Paulo. The largest percentage drop, Source: SNIC.
In the 1990s and 2000s cement demand picked up 29.9%, was seen in the Central West region. 2014
once more, with sales rising by 54% to 39.9Mt in 2000 2015
2016
and by a further 20Mt by 2010, reaching 59.1Mt in
that year. Higher levels of civil construction, incen-
tives to build real estate, general increases in salaries, 40
40
credit expansion and reductions in interest encour- -21.4%

35
aged economic growth and cement in the late 2000s.

30
30
Brazilian cement production peaked in 2014 at

Cement sales (Mt)
25
Cement sales (Mt)
72.1Mt, before falling back to 65.3Mt in 2015. Ce-

ment sales fell from 70.9Mt in 2014 to 57.2Mt in 20
20
-17.7%
2016, on the back of the countrys poor economy (See 15
-29.9% -13.0%
Figure 2). This represents a decrease of 19.3% in just 10
10
-6.2%
two years. 5
A regional breakdown of sales between 2014 and 00

Norte Nordeste Centro-Oeste Sudeste Sul
North North East Central West South East South
2016 is shown in Figure 3. While all regions have seen 2014
Region
2015 2016
declines, the largest volume drop (7.1Mt) has been

Figure 4: Integrated and 0Mt 1-5Mt 5-10Mt 10-15Mt <15Mt
grinding cement plants in
Brazil. States are colour-coded Roraima
by integrated cement production
Amap
capacity.
Source: Global Cement
Directory 2017. 71
39
33 36 64,73 11
Amazonas Par Maranho
Cear 4635 Rio Grande
66 do Norte
37 38 20,51 Paraiba
Piaui 34 80
8-9 Pernambuco
Acre 2263 21
17
Rondnia 48 Alagoas
INTEGRATED Tocantins 31
54 Mato Grosso Bahia 74
41 57 Sergipe
1. Cimento Nacional, Sete Lagoas, 1.0Mt/yr 32
58
2. InterCement, Apia, 2.0Mt/yr 68 Gois
40
3. InterCement, Bodoquena,0.8Mt/yr 45
19
4. InterCement, Ijaci, 2.5Mt/yr 69,70 Minas Gerais
5. InterCement, Jacarei, 0.3Mt/yr 77
1 52 6 27 7
6. InterCement, Pedro Leopoldo, 2.6Mt/yr 28 44 59 Espirito Santo
Mato Grosso 3 56 76 25 24 50
7. InterCement, Santana do Paraiso, 0.5Mt/yr 72
do Sul So Paulo 4 14 42 30
8. InterCement Brasil, Suape, 0.3Mt/yr 26,67,79
75,78 43 47 5 29 12 Rio de Janeiro
9. Cimentos La Union, Suape, 0.5Mt/yr
2 16 55 49
10. CIA de Cimento Itambe, Balsa Nova, 0.6Mt/yr Paran 18 62 15,23
10 61
11. Cimento Apodi, Dionisio Torres, 0.6Mt/yr
13
12. Cimento Rio Branco, Rio de Janeiro, 0.2Mt/yr Santa
13. Supremo Cementos (50% SECIL), Testo Central, 0.3Mt/yr 65 Catarina
14. Cimento Tupi, Pedra do Sino, 1.5Mt/yr 60
Rio Grande
15. Cimento Tupi, Volta, 1.0Mt/yr (Closed) do Sul
16. InterCement, Cajati, 1.3Mt/yr
17. InterCement,Campo Formoso, 1.2Mt/yr 59.Votorantim, Pedro Leopoldo, 2.6Mt/yr
18. InterCement, Cerrado Grande, 1.2Mt/yr 38. Itapui Barbalhense Industria de Cimentos, 60. Votorantim, Pinheiro Machado, 0.6Mt/yr
(Cimento Nassau), Barbalha, 1.0Mt/yr 61. Votorantim, Salto de Pirapora, 4.8Mt/yr
19. InterCement Brasil, Cezarina, 1.2Mt/yr
39. Itautinga Agro-Industrial (Cimento Nassau), 62. Votorantim, Rio Branco do Sul, 4.3Mt/yr
20. InterCement, Joao Pessoa, 1.0Mt/yr
Alexio, 0.8Mt/yr
21. InterCement, Sao Miguel do Campos, 0.9Mt/yr 63. Votorantim, Sobradinho, 2.2Mt/yr
40. LafargeHolcim, Cocalzinho, 0.4Mt/yr
22. Ciplan, Sobradinho, 2.5Mt/yr 64. Votorantim, Sobral (I), 1.2Mt/yr
41. LafargeHolcim, Candeias, 1.0Mt/yr
23. CSN Cimentos, Volta Redonda, 2.4Mt/yr 65. Votorantim,Treze de Maio, 1.5Mt/yr
42. LafargeHolcim, Cantagalo, 1.0Mt/yr
24. Empresa de Cimentos, Vespasiano, 1.3Mt/yr 66. Votorantim, Xambio, 0.9Mt/yr
43. LafargeHolcim, Itapeva, 0.3Mt/yr
25. LafargeHolcim, Barroso, 1.2Mt/yr 67. Votorantim, Cantagalo, 1.1Mt/yr
44. CRH, Matozinhos, 1.0Mt/yr
26. CRH, Cantagalo, 0.6Mt/yr 68. Votorantim, Aguau, 1.2Mt/yr
45. LafargeHolcim, Montes Claros, 1.0Mt/yr
27. LafargeHolcim, Pedro Leopoldo, 1.9Mt/yr 69. Votorantim, Edealina, 2.0Mt/yr
46. Mizu Cimentos Especiais (51% Votorantim),
28. CRH, Arcos, 0.7Mt/yr 70. LafargeHolcim, Edealina, 2.0Mt/yr
Barauna, 1.1Mt/yr (Planned)
29. LafargeHolcim, Rio, 0.8Mt/yr 71. Votorantim, Primavera, 1.2Mt/yr
47. Mizu Cimentos Especiais (51% Votorantim),
30. Itabira Agro-Industrial (Cimento Nassau), Mogi das Cruzes, 0.5Mt/yr 72. Votorantim, Ribero Grande, 1.5Mt/yr (Mothballed)
Cachoeiro, 0.9Mt/yr 48. Mizu Cimentos Especiais (51% Votorantim), 73. Votorantim, Sobral (II), 1.0Mt/yr (Due 2017)
31. Itaguassu Agro-Industrial (Cimento Nassau), Pacatuba, 0.4Mt/yr 74. Cimento Apodi, Santo Amaro das Brotas,
Nossa Senhora do Socorro, 0.7Mt/yr 49. Mizu Cimentos Especiais (51% Votorantim), 1.6Mt/yr (Announced in 2014)
32. Itaguarana Agro-Industrial Rio de Janeiro, 0.9Mt/yr 75. Cemento Tupi, Adrianopolis, 1.5Mt/yr
(Cimento Nassau), Ituacu, 1.0Mt/yr 50. Mizu Cimentos Especiais (51% Votorantim), (Announced in 2015)
33. Itaituba Industria de Cimentos do Para (Cimento Nassau), Vitoria, 0.9Mt/yr 76. CSN Cimentos, Arcos, 0.6Mt/yr (Announced in 2016)
IItaituba, 0.4Mt/yr 51. Ricardo Brennand, Pitimbu, 1.5Mt/yr 77. CSN Cimentos, Romaria, (Announced in 2015)
34. Itapessoca Agro-Industrial (Cimento Nassau), 52. Ricardo Brennand, Sete Lagoas, 1.0Mt/yr 78. Supremo Cementos (50% SECIL),
Goiana, 0.8Mt/yr Adrianopolis, 1.7Mt/yr
53. LafargeHolcim, Caapor, 1.7Mt/yr
35. Itapetinga Agro-Industrial, (Cimento Nassau), 79. Votorantim, Volta Redonda, 0.4Mt/yr
54. Votorantim, Corumb, 0.2Mt/yr
Mossoro, 0.3Mt/yr
55. Votorantim, Santa Helena, 3.2Mt/yr 80. Votorantim Cimentos, Caapor, 2.0Mt/yr (Due in 2017)
36. Itapicuru Agro-Industrial, (Cimento Nassau),
Codo, 0.2Mt/yr 56. Votorantim, Ita de Minas, 2.3Mt/yr
37. Itapissuma (Cimento Nassau), Fronteiras, 0.9Mt/yr 57. Votorantim, Laranjeiras, 2.9Mt/yr
58. Votorantim, Nobres, 0.9Mt/yr

Cement industry - Plants ducers are responsible for just 17 integrated facilities
In 2017 there are 71 active integrated cement plants between them, with just 17.4Mt/yr of capacity (20%
in Brazil that share a total of 85.7Mt/yr of cement of national capacity). Figure 5 provides a breakdown Below - Figure 5: Breakdown
capacity, according to the Global Cement Directory of the market by producer type. of Brazilian integrated
cement capacity in 2017.
2017. There are an additional nine proposed and Source: Global Cement
mothballed plants, plus 20 active cement grinding Cement industry - Producer profiles Directory 2017.
plants and one closed grinding plant. Their distribu- Votorantim: The largest producer by installed
tion is not even, with production and consumption integrated cement capacity in Brazil is
focused strongly in the most populous states of So Votorantim, which has 22 active
Paulo, Minas Gerais, Rio de Janeiro and Bahia, close plants and 35.0Mt/yr of ca-
to the coast (See Figures 4 and 6). pacity. This gives it around Others
41% of the national 15.1Mt/yr
Cement industry - Summary of producers integrated market.
There are a total of 16 integrated cement produc- Votorantim was
ers in the Brazilian market. Out of these, only two founded in Brazil in
(LafargeHolcim and CRH) are not Brazilian-owned 1918 when it began C Nassau Votorantim
entities. Indeed, multinationals Cemex and Hei- producing textiles. 7.0Mt/yr 35.0Mt/yr
delbergCement are notable by their absence from Cement was first Multinationals
t/yr
the market. produced by the CRH 2.3M 13.6Mt/yr
The market, home to 19 producers in the 1990s, group in 1936. Today
has become increasingly concentrated in recent its interests also span
years. 54 of the 71 integrated facilities currently in aluminium, pulp and LafargeHolcim
operation are run by just four producers. Together, paper and banking. It also 11.3Mt/yr
Votorantim, InterCement, LafargeHolcim and Ci- operates cement plants in InterCement
mento Nassau share 68.3Mt/yr of capacity, around Turkey, Bolivia, Canada and 15Mt/yr
80% of the integrated total. The remaining 12 pro- the USA.
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GRINDING 8. LafargeHolcim, Carapina 16. Votorantim, Itaja
9. InterCement, Santana Do Paraso 17. Votorantim, Sao Luis
1. CIMAR, Sao Luis
10. Votorantim, Caucaia 18. Votorantim, Sepetiba 2 1,17
2. Votorantim, Barcarena North
11. InterCement, Cubato 19. Arabian Cement & 10
3. Cimento Tupi, Mogi das Cruzes Cementos Relampago (On hold)
12. Votorantim, Esteio (Closed) 21
4. InterCement, Nova Santa Rita 20. Provale, Cachoeiro de 15 North East
13. Votorantim, Imbituba
5. InterCement, Brumado Itapemirim
14. Votorantim, Cubato
6. CRH, Santa Luzia 21. Votorantim Cimentos, Poty
15. Votorantim,Porto Velho Central West 5
7. LafargeHolcim, So Paulo
S East
98
0Mt 1-5Mt 5-10Mt 10-15Mt <15Mt
7 6 19 20
South 3
16 11,14
Above - Figure 6: Cement 13
grinding plants in Brazil in 2017.
Votorantims cement sales fell by 6% year- 12
4
Regions are colour-coded by on-year to 35Mt in 2015 from 37Mt in 2014. It
cement sales in 2016, as blamed the downturn in Brazil in particular.
shown in Figure 3. Although it has not yet released full results for
Source: Global Cement
Directory 2017 and SNIC.
2016, the first nine months saw its total profit fall The US$258m plant has a production capacity of
by 15.8% year-on-year to US$262m compared to the 1.2Mt/yr. It will serve the North and North East re-
first nine months of 2015. The gross profit attributable gions of Brazil.
to cement over the same period was US$146m. This This plant in Primavera is part of Votorantim
figure was up marginally year-on-year compared to Cimentos major investment plan, explained Walter
the first nine months of 2015, when the group made Dissinger, CEO of Votorantim Cimentos. Despite
US$142m. the challenging situation in Brazil, we are moving
In June 2016 Votorantim Cimentos inaugurated forward with our long-term vision and our confi-
a new cement plant at Primavera in Par state. dence in the development of the country.
World
Recent news highlights

Competition concerns project due to the poor Brazilian economy. The cement pro-
ducer originally planned a joint venture in 2014 with Cementos
In October 2016 Brazils antitrust watchdog Cade decided to end Relampago Company, an affiliate of Cementos La Union, to
its investigation into 18 companies from the cement and allied build a 0.23Mt/yr plant for US$28.7m.
sectors over alleged anti-competition practices. The allegations
were that some of the companies had reached an agreement to Major refractory merger
refuse to provide three types of cement to competitors outside of Brazils Magnesita was one of two major international refractory
an economic group, which would lead to increased prices of the companies that announced they would be merging in October
products, according to the Valor Economico newspaper. 2016. Together with Austrias RHI, the company will form RHI
Cade had earlier determined that punishments were to be Magnesita, bringing together complementary businesses, both
applied to Holcim Brasil (part of LafargeHolcim), Cimento Tupi in terms of products and geographical footprint. The deal is ex-
and Votorantim Cimentos. However, case leader Paulo Burnier pected to conclude in the second quarter of 2017.
decided that there was insufficient evidence to apply sanctions to
the majority of companies concerned. He also noted that some Titan buys stake in Cimento Apodi
of the companies had already been set punishments by Cade for In August 2016 Greeces Titan Cement agreed to acquire an
involvement in other cartel practices. equity stake in Companhia Industrial de Cimento Apodi, a
Brazilian cement producer that operates in Cear in Northeast
Bad market freezes Arabian Cement Brazil. Through a joint venture agreement, Cimento Apodi is now
In December 2016 Arabian Cement reported that it had frozen jointly owned and controlled on a 50/50 basis by the Dias Branco
its plans to build a cement grinding plant in the north-west of Group and a TITAN-Sarkis subsidiary, in which Titan is the
Brazil. It said that there was no investment efficiency for the majority shareholder.
Gambarotta Gschwendt. T
bulk solid mechanical h
TIREX- Receiver from trucks and feeder for several bulk materials Ap
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dCement_43,2x15cm_2016.indd 1
InterCement Brasil: The second-largest cement pro- Despite the challenging market, LafargeHol-
ducer in Brazil is InterCement Brasil, part of Cimpor cim launched a new cement line at its plant in
Inversiones, which is in turn owned by InterCement Barroso in May 2016. At the time the group said that
Participaes. It has 12 integrated cement plants in the construction of the new line was part of its strat-
operation that share a capacity of 15.0Mt/yr. This egy to reduce the cost per tonne of its cement, while
gives it 17.5% of national integrated capacity. improving quality and efficiency, in order to operate
InterCement traces its history back to the estab- profitably in a low investment environment. It claims
lishment of the Portland Eldorado plant in 1968. that the line is the most efficient in Brazil.
Then known as Camargo Corra, the company made Equipment includes the worlds largest vertical ce-
its first cement in 1974. For 20 years it did not expand ment mill from Gebr. Pfeiffer and an FCB Horomill
greatly, adding a second production line in 1991 and for raw materials. The plants total capacity will rise
a second plant in 1993. However, in 1997 it acquired to 3.6Mt/yr and the new line will allow the total cost
plants in Minas Gerais, followed by the construction per tonne of cement to fall by around 25% between
of four new plants, starting in 2001. It added further 2014 and 2017. At the time Eric Olsen, the CEO of
Brazilian plants in 2006 and 2008. LafargeHolcim, said, The opening of Barroso is key
InterCement sold 28.1Mt of cement across all op- to our strategy in Brazil and will allow us to further
erations in 2015, a 6.1% decline compared to 2014, improve our cost structure while we continue to sup-
during which it sold 30.0Mt. In financial terms sales ply our customers with our high-quality solutions.
revenues from cement came to Euro2.5bn, down
from Euro2.6bn in 2014. It made a net loss for the Cimento Nassau: Cimento Nassau traces its history
year of Euro20.2m, compared to a Euro41.0m profit back to 1951, when it was founded by Joo Santos,
in 2014. an entrepreneur who had previously been involved
The companys annual report for 2015 states that in various other cement enterprises. Today it oper-
political and economic uncertainty led to a con- ates 10 integrated cement plants in Brazil that share a
traction in demand combined with an increase in capacity of 7Mt/yr, enough to give it an 8.2% market
capacity in the Brazilian market. It sold 10.5Mt of ce- share by capacity. It operates through a number of
ment in Brazil in 2015, a 16.3% decrease from 12.6Mt subsidiaries, shown in Figure 4.
of cement sold in 2014. It also factored in devaluation
of the Real against the US Dollar. Other producers: The remaining integrated produc-
Although the company has not yet reported full ers and cement grinding plants can be seen in Figures
results for 2016, it has released information relating 4 & 6. The vast majority are Brazilian-owned. One
to the first nine months of the year in Brazil. Between major exception is Irelands CRH, which took over
January and September 2016 the decline in cement three integrated plants with a total capacity of 2.3Mt/
sales continued, collapsing by 19.2% to 6.5Mt, com- yr in 2015, following the LafargeHolcim merger.
pared to the first nine months of 2015. The value of
sales was even more alarming, falling by 41% year- Economic and cement industry forecast
on-year to Euro397m. In its January 2017 update the International Mon-
etary Fund forecasts that the Brazilian economy will
LafargeHolcim: The third-largest cement manu- grow by just 0.2% in 2017, following an estimated
facturer by installed integrated capacity in Brazil is contraction of 3.5% in 2016. GDP growth is expected
the worlds largest multinational cement company, to increase to 1.5% in 2018, suggesting that the con-
LafargeHolcim. The 2015 merger between the former struction sector may see moderate improvement in
Lafarge and Holcim gave rise to 11.3Mt/yr of inte- the medium term.
grated cement capacity for the group in Brazil. This However, the National Union of Cement Industry
gives it around 13% of the local market. LafargeHol- (SNIC) has already said that 2017 may be the worst
cim was forced to sell a number of integrated assets year on record for the domestic cement industry,
as a condition of the merger. These were sold to with its new President Paulo Camillo Penna describ-
Irelands CRH. ing the current situation as the worst in the industrys
In 2015 LafargeHolcim reported that Brazil had history. He added that following capacity utilisation
dragged down otherwise solid performances in rates of 70% in 2015 and 57% in 2016 that he expects
South America. For the continent as a whole, the the rate to fall below 50% in 2017. SNIC forecasts
multinational sold 27.9Mt of cement during the year, that sales of cement will contract by a further 5-7%
a 1.2% fall year-on-year compared to 2014. In Brazil in 2017 compared to 2016. This would represent sales
they fell by 5.6% year-on-year. of 53.2-54.3Mt.
Like the other producers, LafargeHolcim has not In light of this, it appears that the Brazilian market
yet released full results for 2016. In the first nine could be set for further consolidation in the short to
months, however, it reported that Brazil had re- medium term. Producers that have just brought new
mained a tough market and was the target of tough capacity online may soon be ruing their decisions if
cost-cutting measures. conditions do not improve.

GLOBAL CEMENT NEWS: ASIA
Thailand: SCG building revenues rise New Zealand: HR Cement

launches Eco-Cem brand
S iam Cement Groups Building Materials divisions sales revenue fell by 4%
year-on-year to US$4.9bn in 2016. Its profit fell by 17% to US$241m. It
blamed the falling sales and profit on increased competition, falling earn- H R Cement has launched Eco-Cem,
a brand of pozzolanic cement. The
ings before interest, taxation, depreciation and amortisation (EBITDA) and cement producer says it will source its
increased depreciation expenses. Overall, across the groups chemical and pozzolan from the Central Plateau on the
packaging division, sales revenue fell but profits rose in 2016 driven by the North Island, according to the Scoop news
chemical business. website. The cement producer operates a
Roongrote Rangsiyopash, the president and chief executive officer of cement grinding plant at Mt Maunganui
Siam Cement Group, said that the company is focusing on expansion strate- near Tauranga. It also produces an Or-
gies within the Association of Southeast Asian Nations (ASEAN) region. Its dinary Portland Cement branded as HR
1.8Mt/yr cement plant in Myanmar started commercial production in early Cement General Purpose Cement.
2017 and a cement plant in Laos is undergoing commissioning.
Tajikistan: Production up
Kazakhstan: Kokshe Cement to launch later in 2017
C ommissioning of the Kokshe Cement plant in the Akmola region is

expected to be completed later in 2017. Construction and installation
T ajikistan increased its cement pro-
duction to 2Mt in 2016, an increase
of 0.5Mt from 2015, according to the
work at the site has been completed, according to the Kazakh government. Minister of Industry and New Technolo-
The plant will have a cement production capacity of 2Mt/yr and has cost gies. This is due to new cement plants
US$187m to build. opening in Vahdat, Bobojonghafourov
and Yovon, according to the Asia-Plus
news agency. The country now intends
Pakistan: Lucky on the rise to export its excess to neighbouring
countries. In 2016, Tajikistan exported
L ucky Cements sales rose by 13% year-on-year to US$514m for the

six months to 31 December 2016 from US$454m in the same period
of 2015. Its profit after tax rose by 14% to US$83m from US$73m. It at-
cement to Afghanistan, Kyrgyzstan and
Uzbekistan. Small volumes of cement
were also exported to Russia.
tributed the increase in revenue on rising sales volumes and its cost of
sales fell due to lower fuel costs. Pakistan: New plant for
Its cement sales volumes rose by 5.4% Khyber-Pakhtunkhwa
to 3.5Mt from 3.3Mt, although exports fell
by 16.3% to 0.75Mt from 0.9Mt. Overall the
cement producer reported that its market
share in Pakistan grew to 18.8%.
U K-based Asian Precious Minerals has
announced plans to build a US$400m
cement plant in Pakistans Khyber-
Pakhtunkhwa province. Asian Precious
Minerals CEO Nadim Khan, Executive
Director Peter Frost, Country Manager
India: ACC sales fall in challenging 2016 Irshad Ali Khokhar and Jason Mumtaz of
the British High Commission met with
A CCs net sales fell by 4% year-on-year to US$1.63bn in 2016 from

US$1.70bn in 2015. Sales volumes of cement fell by 2.7% to 23.0Mt
from 23.6Mt and operating earnings before interest, taxation, depreciation
provincial Chief Minister Pervez Khattak to
discuss the plans in early February 2017.
The project hopes to take advantage of
and amortisation (EBITDA) fell by 7.5% to US$211m from US$229m. How- infrastructure demand being driven by
ever, profit after tax rose by 2.7% to US$90m from US$87.5m. The company the China-Pakistan Economic Corridor.
described the market conditions in 2016 as challenging. It added that the
economic slowdown following the implementation of the governments Taiwan: Taiwan Cement
demonetisation policy was easing. chairman dies after fall
The highlight of the year was strong cost saving measures, especially
on fuel flexibility and raw materials. Focusing on our high quality, high
performance product portfolio played an important role in the overall
performance for the year. We are encouraged by the governments plans to
L eslie Koo, the chairman of Taiwan
Cement, died from injuries sustained
from a fall on 23 January 2017. He had
invest in infrastructure, said Neeraj Akhoury, Managing Director and chief suffered head injuries after falling down
executive officer of ACC. a flight of stairs at a hotel in Taipei while
The cement producers 1.35Mt/yr grinding plant at Sindri, Jharkhand attending a wedding. He was 62 and had
was commissioned at the end October 2016, joining a 2.79Mt/yr integrated led Taiwan Cement since 2003.
plant at Jamul, Chhattisgarh that was commissioned earlier in 2016. The Nelson Chang, Koos brother-in-law,
new plants are expected to strengthen ACCs market presence in the east of has been appointed as the acting chair-
the country. man of Taiwan Cement.

Vietnam: Exports fall in 2016

The Philippines imported 3.8Mt of cement and clinker
D ata from the General Department of Vietnam

Customs has shown that exports of cement fell by
7.1% year-on-year to 14.7Mt in 2016 and by 16% year-
worth US$185m from Vietnam in 2016 and Bangladesh
imported 4.7Mt worth US$141m, accounting for 33%
and 25.1% respectively of the countrys total clinker and
on-year to US$561m in value terms. Bangladesh and the cement exports in 2016. Increased competition in export
Philippines remained the major importers of cement and markets has been blamed on rival products from Thai-
clinker from Vietnam in 2016. land and China.
Australia: Housing concerns Cambodia: Project update from SCG
A delaide Brighton has raised concerns

about a South Australia state plan to
build housing and tourism facilities near to
T hailands Siam Cement Group (SCG) has announced that it is prepar-
ing to open its third cement plant in Battambang Province, Cambodia
in 2018. Chan Sophal, the governor of Battambang, said that SCG started
its Birkenhead cement plant in Adelaide. At building the plant in 2016. SCG is a majority shareholder in the local pro-
a public meeting held by the Development ducer Kampot Cement. Once operational the plant will have a production
Assessment Commission, a local planning capacity of 1.8Mt/yr.
body, the cement producer expressed its
concerns that building more housing would
create more complaints about the plants ac- Japan: Sales fall for Ube Industries
tivities, according to the Portside Messenger
newspaper. Adelaide Brighton added that
the government should consider building
U be Industries net sales have fallen by 5.8% year-on-year to US$1.49bn
for the first nine months of 2016 from US$1.59bn in the same period
in 2015. Its operating income fell by 21% to US$109m from US$139m.
buffers to reduce noise and dust pollution The cement producer blamed the declines on weak demand for cement,
from the site. The local government wants low prices and rising prices of coal in the third quarter, despite a strong
to build a tourism development near export market.
Cruickshanks Beach and the cement plant.
Sri Lanka: Dalmia Cement Bharat backs new brand

India: Jammu and Kashmir
criticised over halted project I ndias Dalmia Cement Bharat has partnered with Sri Lankan import firm
Oliver Impex to launch the Vijaya Cement brand. The SLS 107 certified
product has a strength class of 42.5N. AHM Fowzie, the State Minister
T he Comptroller and Auditor General of

India (CAG) has criticised the manage-
ment of Jammu and Kashmir Cements for
of National Integration and Reconciliation, was the chief guest at the
launch event.
allowing a contractor to abandon a contract

to upgrade a cement plant without incur- Iran: Cement production slows as ministry makes big
ring a financial penalty. The subsequent cement order
reduction in production between 2010
and 2014 led the plant to lose an estimated
US$5.6m, according to a report seen by the
Early Times newspaper.
D ata from the Ministry of Industries, Mining and Trade of Iran reports
that the countrys cement production fell by 1.4% year-on-year to
42.7Mt in the first nine months of the Iranian calendar year that started
Engineering contractor Promac Engi- on 31 March 2016. Cement production has fluctuated in recent years due
neering Industries was originally awarded to weak domestic demand, according to the Trend News Agency. Other
a US$10.5m contract to upgrade the plant issues the cement industry has experienced have included a recession in
in 2005. Work started in June 2006 but the the local construction industry, low supplies of natural gas, low interna-
contractor left the site in 2010. The original tional oil prices and declining exports.
terms of the agreement required Promac to In related news, the Ministry of Roads and Urban Development Iran has
complete the upgrade within 26 months agreed to purchase 2Mt of cement from local producers. Irans Bank Mas-
and pay a financial penalty if the plants kan, also known as the Housing Bank, will finance the road building plan
production capacity fell, if any increase in and the cement producers will receive the money in cash, according to
power or fuel consumption occurred or if Abdolreza Sheikhan, secretary of Irans Cement Industry Employers Asso-
the contract was delayed. Additionally, a ciation. In comments to the Tasnim news agency, Sheikhan added that he
packing plant that was built as part of the hoped the money would ease stagnation in the Iranian cement industry.
contract remained unused until 2015. Sheikhan also commented on plans to export cement to Syria and talks to
remove a ban of imports of Iranian cement in Iraq.

India: India Cements sales

revenue rises India: Legal officer arrested for causing loss at
Malabar Cements
I ndia Cements sales revenue has risen
by 19% year-on-year to US$187m in
the quarter that ended on 31 Decem- T he Vigilance and Anti-Corruption Bureau, a corruption body in the
state of Kerala, has arrested Prakash Joseph, a legal officer at Mala-
ber 2016 from US$156m in the same bar Cements, in relation to a loss of US$0.4m. The state-owned cement
period of 2015. Clinker and cement producer signed a contract with a company owned by businessman VM
sales volumes rose by 22% to 2.36Mt Radhakrishnan to sell cement, according to the Hindu newspaper. Staff
from 1.94Mt. The cement producer at Radhakrishnans company withdrew a deposit for the deal without
said that it found the result gratifying the knowledge of Malabar Cements. Prakash Joseph then allegedly
in view of the uncertainty created by misinformed his employers about the location of the court handling
the governments demonetisation a legal challenge to the withdrawal. Radhakrishnan has previously
policy from November 2016, although been investigated by police in connection with corruption charges at
the company had not experienced any Malabar Cements.
negative impact itself. It also reported
that a steep price increase for petcoke
and imported coal had been noted Uzbekistan: Ahangarancement makes more
during the period.
Overall, India Cements income
rose by 8% to US$558m for the nine
months of 31 December 2016 from
A hangarancement JSC has increased its cement production by 5.2% year-
on-year to 1.86Mt in 2016 from 1.78Mt in 2015. Clinker production grew
by 4.9% to 1.34Mt from 1.28Mt, according to the Trend News Agency. In total,
US$518m in the same period in 2015. the Eurocement-owned cement producers sales of cement rose by 4.8% to
Its profit rose by 78% to US$20.9m 1.86Mt. Cement and clinker production rose by 4.1% and 3.4% respectively
from US$11.7m. in 2015.
Pakistan: Maple Leaf South Korea: Hanil Cement and LK Investment Partners
Cement sales grow by 11% chosen as preferred bidders for Hyundai Cement
M aple Leaf Cements sales revenue

increased by 11% year-on-year to
US$114m in the first half of its financial
H anil Cement and LK Investment Partners have been chosen as the pre-
ferred bidders for the acquisition of Hyundai Cement. They won out
against rival bidders as their offer was higher than expected at US$567m, ac-
year, the six months to 31 December cording to the Maeil Business Newspaper. They were bidding to buy an 85%
2016. Its profit rose by 12% to US$25m, stake in Hyundai Cement. If the purchase completes then Hanil Cement could
according to the Dawn newspaper. increase its market share to 30% from 20% at present.
Growth was attributed to cement
sales in the local market, despite a sig-
nificant drop in exports to Afghanistan
Kazakhstan: Rudny plant coming after seven years
and an increase in the price of coal.
Bangladesh: Loesche T he Rudny cement plant in the Kostanai region is due to be commis-
sioned in 2017. The US$46m unit has a cement production capacity of
0.5Mt/yr, according to a local government official reported upon by Interfax.
receives two hot gas orders Construction of the plant has been put on hold repeatedly since 2010 due to
L oesche Shanghai has signed a con-

tract with China National Heavy
Machinery Corporation to supply two
a lack of finance.
India: Indian power company seeks partners to build

sets of 35MW thermal power hot gas
generator systems to the Bangladesh cement plants
market. It will also provide installation
and technical services. No information
on the price of the contract or the end
N TPC is looking for cement producers to help it build cement plants to take
advantage of its fly ash and electricity. The power generation company is
asking cement producers to submit expressions of interest for partnerships to
user has been disclosed. Loesches build 1Mt/yr cement plants near its power stations, according to the Times of
Shanghai subsidiary has previously India. Partners will have to source their fly ash from NTPC but will be respon-
supplied a 32MW automated con- sible for marketing their own products. NTPC has previously tried to enter the
trol hot gas generator system to the cement market since 2008, both with partners, including the Cement Corpo-
Yadong Cement plant. ration of India, and on its own. It produces 65Mt/yr of fly ash.

GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Contents
Syria: Lafarge faces probe by French government over ISIS allegations
Subscribe
Ad Index
T he French government has confirmed that
it is investigating LafargeHolcim over
alleged illegal activities by the former
Sherpa filed a complaint in Paris against Lafarge for
allegedly financing terror-
ism in November 2016. The
company Lafarge in Syria following complaint accused it of main-
European Union (EU) sanctions that taining commercial relations
were imposed in 2012. The Paris with the Islamic State group in
prosecutors office said that a probe Syria in 2013 and 2014 so it could
was opened in October 2016 after continue operating a cement plant in
the French Ministry of Economy and the country.
Finance filed a complaint against the At the time, Lafarge denied financ-
cement producer. LafargeHolcim, the ing so-called terrorist groups. The company
company formed from a merger be- said it had launched a thorough and independent
tween Lafarge and Holcim in 2015, said investigation into the allegations to determine whether
that it was, in the process of establishing its internal code of conduct had been properly followed
the facts concerning our activities in Syria. and if procedures needed to be adapted. It said it would
A group led by the non-government organisation implement any remediation measures required.
UAE: RAK environmental body South Africa: Trade union complains about
investigates cement plant emissions Chinese workers at PPC project
T he Environment Protection and Development

Authority (EPDA) of Ras Al Khaimah is investi-
gating unexpected emissions from a cement plant
T he Congress of South African Trade Unions, a federation of un-
ions, has publicly complained about government permission
granted to Chinas CBMI Construction to bring workers into the
in Khor Khuweir. Residents had reported high lev- country. CBMI Construction was awarded a tender for a US$90m
els of dust from the site, according to the Khaleej upgrade project at PPCs Slurry plant in 2015 and the union says
Times. An initial inspection by the EPDA has blamed it was allowed to import 242 Chinese workers to work on it. It is
the emissions on a blocked filter. It has also ordered alleged that these workers have been working in the country since
the company that runs the plant to conduct an in- October 2015 and will continue to do so until 2018. The federation
ternal investigation and submit a detailed report on has asked the Department of Labour to look into the issue.
the incidents.
Previously the Ministry of Climate Change and
Environment had ordered the one-month closure
Saudi Arabia: Yamama suspends five lines
of a cement plant in the same area for breaking
emissions rules. The EPDA has since installed sur-
veillance cameras at 20 quarries and six cement
Y amama Cement has temporarily shut down five of its produc-
tion lines. The lines have a joint clinker production capacity of
5600t/day. The decision was made due to poor market conditions,
units in the emirate. low demand for cement and high inventory.
Kenya: Wind power Jordan: AUCBM opens regional office

for Mombasa
M ombasa Cement is prepar-

ing to build a 36MW wind
T he Arab Union for Cement and Building Materials (AUCBM)
has opened a regional office in Amman. The office will be
managed by Khaled Tarawneh, the
farm by its plant in Vipingo. Power from General Manager of Arab Company
the unit will be used for the companys for White Cement Industry and an
cement plant and sold to Kenya Power, AUCBM board member. The office
according to the Daily Nation newspaper. is intended to support mem-
The project will consist of 12 3MW turbines ber companies of the AUCBM
and it is estimated to cost US$2.5m. The ce- towards training workers at ce-
ment plant is also planning upgrades at a ment plants and supporting the
cost of US$72m. AUCBM with its events.

AUCMB March 2017.indd 1 21/02/2017 16:21
GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Kenya: EAPCC AGM delayed

Africa: CBMI handovers
C BMI Construction (Sinoma) has issued pa-

perwork passing over completed projects to
Lafarge Africa, a part of LafargeHolcim, for projects
T he annual general meeting of the East African
Portland Cement company had to be delayed fol-
lowing the non-attendance of the companys auditors.
in Algeria and Nigeria. The meeting required the presence of the office of the
A provisional taking-over certificate (PTC) was Auditor-General or its appointee Deloitte East Africa to
signed by representatives of Unicem, a joint ven- proceed. The management was unaware that procedures
ture partly operated by Lafarge Africa in Nigeria, had changed, according to one of the companys direc-
at Sinomas Beijing headquarters on 18 January tors. The meeting was rescheduled for 3 February 2017.
2017. Tomas Lorent, Lafarge Africa Project Man- EAPCC has a poor corporate governance record
ager and Liu Xinwang, CBMI Project Manager following the accusation of its chief executive of
signed the paperwork on behalf of their compa- sexual harassment and reports of theft of stock in late
nies. The certificate was signed eight weeks ahead November 2016, among other incidents.
of the contract. The new production line at the
Calabar cement plant in Cross River State started
operation in the summer of 2016. It includes one Egypt: Misr Beni Suef delays coal mill
of the worlds largest vertical roller mills, supplied
by Loesche.
Meanwhile, a different PTC was signed on the
M isr Beni Suef Cement has delayed the installation of
a coal mill at its Beni Suef plant to the third quar-
ter of 2017. Farouk Mostafa, managing director of the
same day by Didier Michel, Lafarge Algerias Pro- company, said that the delay has been caused by a short-
ject Manager and Gu Jinjun, CBMI Project Manager age of US Dollars needed to pay to import the mill and
at Lafarge Algerias headquarters in Algiers. The its spare parts and general currency variations with the
2.7Mt/yr CILAS Biskra cement plant, a joint opera- Egyptian Pound that has raised prices, according to Daily
tion between Lafarge Algeria and Souakri Group, News Egypt. The mill was originally planned for Decem-
was commissioned in the summer of 2016. ber 2016.
Africa: Bollor outlines CBMI work Saudi Arabia: Najrans net profit halved
B ollor Logistics has detailed its work on two ce-

ment plant projects in Nigeria and South Africa
working with Chinas CBMI Construction. Teams
N ajran Cements net profit fell by 51.2% year-on-year
to US$33m in 2016 from US$68.1m in 2015. Its rev-
enue fell by 35% to US$1.89bn from US$2.9bn. It blamed
from the logistics and transport firm in China and the fall in earnings on lower sales volumes due to low ce-
Africa have managed both projects. ment demand. It said this was caused by a slowdown of
Supplying equipment to the United Cement construction activities, an increase in energy prices and
Company of Nigeria (Unicem) plant near Calabar finance expenses.
involved transporting 500 twenty-foot equivalent
units (TEU) and 150,000t of project cargo with the
shipment of 12 break bulk vessels to the Calabar
Port. This was completed by more than 5000
round trips from the port to the construction site
by truck. This project also included transporting
cement mills, out of gauge items of cargo that
weigh 125t each. Two multi-axle hydraulic trailers
were used to transport these 14 pieces of cargo
in one shipment. A preliminary road survey and
subsequent adjustments to the road infrastructure
quality were required for successful delivery.
Bollor is also completing work for CBMI in Jordan: Rashadiya to generate 25% of
South Africa. Work on a 3000t/day PPC plant in Li- power from the sun
chtenburg started in August 2015 and is expected
to be completed in the autumn of 2017. The com-
pany secured the break bulk sea transportation
and inland transport of the construction material
L afargeHolcims Rashadiya cement plant is set to gen-
erate up to a quarter of its power from a solar plant
that will start operations in July 2017. Dubais Adenium
and cement plant equipment cargo. To date, 200 Energy Capital signed a deal for the cement producer to
TEUs have been moved to the site and 45,000t of develop the photovoltaic (PV) facility. Previously the PV
freight cargo have been transported from Jing- unit was reported to have a capacity of 15MW but this
tang and Tianjin port in China to the plant site in has not been confirmed. In October 2016 Adenium En-
South Africa. ergy Capital said it had commissioned four PV parks in
Jordan with a total capacity of 50MW in total.

GLOBAL CEMENT: PRICES
Here Global Cement Magazine presents its monthly review of global

cement prices, in US$ for easy comparison. Much more price informa-
tion (including the latest information on prices and market trends Do you have your finger on the cement
throughout the global cement industry from our price correspondents) price pulse where you are?
is only available to subscribers of Global Cement Magazine. If so, Global Cement Magazine needs you!
To get additional prices, you should subscribe - See page 64. In
this issue subscribers receive more information from Senegal, Nigeria, Send cement prices to
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subscription to Global Cement Magazine!
Brunei: Cement prices in Brunei are set to fall after and depress prices,
the Energy and Industry Department at the Prime according to Religare
Ministers Office (EIDPMO) abolished the cement analysts Navin Sahadeo,
import quota policy on 1 January 2017. A new Siddharth Vora and Aman
policy is expected to open up the market for all Chaplot. New entrant Emami
types of cement, boosting construction activities in Cement will focus on Chhattis-
the country at a time when the Sultanate is striving garh and West Bengal, JSW Cement
to diversify its economy away from oil and gas. The Ltd has aggressive expansion plans for
cement market was previously regulated under an west and south regions and Vadraj Cement Ltd, a
import quota system, in which the quantity of im- regional cement maker, will enter the western mar-
ported cement was controlled and limited. kets of Gujarat and Maharashtra in the next fiscal
The EIDPMO move will provide more opportu- year. All three could increase competition for larger
nities in the construction and other sectors, create pan-India companies.
more spin-offs for our local micro, small and me- This disruption could induce pricing volatility,
dium enterprises (MSMEs) and benefit the people especially in the western and eastern markets in
as a whole. An open market will result in compe- the next two years, say the authors. With virtu-
tition, which, in turn, will reduce prices of cement ally no change expected in pan-India utilisation
and the cost of construction. This will also ensure levels in the 2018 fiscal year (FY18) and only mod-
that there will be sufficient cement supply. The est improvement in FY19, we see little scope for
cheaper price will also promote export opportuni- margin-accretive cement price hikes. We believe
ties for local producers, the department said in a the hikes, at best, will be to pass along cost pres-
press statement. sures, said the Religare analysts.
Expansion of regional cement companies to
Trinidad & Tobago: Trinidad Cement lowered other states will lead to increased volatility. There
its cement prices from US$8.13/bag (50kg) to have been several instances in the past where ce-
US$7.10/bag on 9-11 February 2017, dubbing the ment companies have aggressively expanded in
move as a Carnival Sale. The move appears to be new regions and disrupted the pricing in the mar-
in response to prolonged competition from im- ket, said an anonymous brokerage analyst quoted
porting company Rock Hard Cement, which, by by the researchers. A month after Vadraj Cement
importing cement from as far away as Turkey, can announced its plans to set up a plant in Gujarat,
offer cement at lower prices than the market is ac- cement prices in that market fell from about
customed to. Local media speculates that a cement US$3.74/bag (50kg) to US$3.00/bag.
price war could be on the cards in the com-
ing months, with both Rock Hard and
Trinidad Cement looking to maintain
their share of a subdued market.
Cement sales in 2016 were as low Prices are for cement in metric tonnes, unless stated otherwise. Where a source has given a range,
as those of 2002 and December the published price is the minimum value.
2016 sales were 35% lower FOB {+ the named port of origin} = Free On Board: The delivery of goods on board the vessel at the
than those of December 2014. named port of origin (loading), at sellers expense. Buyer is responsible for the main carriage/freight,
cargo insurance and other costs and risks.
India: The entry of new ce- CIF {+ the named port of destination} = Cost, Insurance and Freight: The cargo insurance and delivery
ment manufacturers and of goods to the named port of destination (discharge) at the sellers expense. Buyer is responsible for
expansion of regional cement the import customs clearance and other costs and risks.
companies into larger markets ASWP = Any safe world port.
are likely to increase competition
Conversions to US$ from local currencies are as at the time of original publication.

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MARCH 2017 MAGAZINE

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GLOBAL CEMENT: THE LAST WORD
How many bird species are there at your cement plant? Join the Global Cement Bird Watch!
Robert McCaffrey Editorial Director, Global Cement Magazine (rob@propubs.com)
I was recently visiting the Sant Vincen dels Horts ce-

ment plant of Cementos Molins S.A., on the field trip
of the Global CemFuels Conference in nearby Barcelona,
diminutive wren (as the bird book describes it, tiny,
dumpy and irascible), I count it as a good day.
Ive had some real oddities in my garden, includ-
when I noticed a small dark bird perching on a stump, ing a moorhen (I am 1km away from the nearest open
just between the preheater tower and the main petcoke water), a pheasant (Im 1.5km away from the nearest
storage building. The bird bobbed up and down a few farmland) and a juvenile peregrine falcon (which was
times and then flew into the nearest tree. It reminded me the fastest-moving bird Ive ever seen). This winter
of a wagtail, only it was much darker. I didnt get a great Ive had a single fieldfare that has been visiting the
look at it. Then, at the end of the tour, we congregated garden for a month, progressively eating the apples I
at the striking concrete-built headquarters building, and have been saving for the birds, and I was amazed to
I noticed a tiny bird singing for all it was worth in the see a flock of six redwings hopping about at the end
coniferous tree just outside the entrance. It was hard of January. Fieldfares and redwings are visitors from
enough to even spot it, let alone identify it and it soon Scandinavia - when it gets too cold for them up there,
flew off. However, seeing these two birds in such an in- they come to damp but mild England for some respite
dustrial location made me think. before going home for the spring and summer.
I have taken to bird-watching in the last ten years or I know that there are other birds out there, nearby,
so. My previous house had a tiny garden and no view of but unless they actually land in my garden, I cant count
the garden from the house. Over ten years, I might have them. Black-headed gulls, Canada geese and swans fly
seen a handful of birds - mostly the apparently gregarious over, but unless they land, they are not on my list. A pair
but actually very aggressive robin (as shown at right, in of lapwings (which emit noises like an old 80s-era space
a picture taken by Global Cements commercial director invader machine) nest on nearby farmland, but alas,
Paul Brown). However, when I moved to a house with a theyve never visited my garden. I cant count them on
view of the garden, my birdwatching took off. I started to my list. Ive had a few species that I have not been able to
notice all sorts of birds, many of which I had never seen absolutely identify, and these remain off my list as well.
before. I bought a bird identification guide and started to Anyway, at that Spanish cement plant, I thought to
write down all the different birds that I saw. I have now myself, I wonder how many different bird species there
seen 35 different species in my own back garden. are at this cement plant? And then I wondered, which
Along with the everyday birds - like dunnocks, rob- cement plant in the world has the most different bird
ins, jays, blackbirds, wood pigeons, blue tits, great tits species?
and carrion crows - I also see some slightly more unusual So, heres a challenge: Starting on 1 April 2017, please
birds. These would include the great-spotted wood- start to count how many different species of birds you
pecker, the sleek nuthatch (the only bird in the UK that find in your cement plant (including the quarry and in
can climb down a tree), the lovely gentle collared dove, any land owned by the cement plant that adjoins the
the raucous and cheeky starlings, the pirates of the bird plant). You have one year in which to count (to 31 March
world - the magpies, the occasional shy song thrush, a 2018), meaning that you will see a full years worth of
few chaffinches and sometimes a glimpse of a goldfinch. migrant birds coming and going. I think that most plants
However, these are not the rarest birds in my garden. will see more than 30 different species. Some might get
After nine years of looking, I am still finding new species past 50. I wonder if any might even get to 100? There will
that visit. Only this year a coal tit perched at the very top be a mention and a pat on the back next year for the win-
of a tree at the end of the garden and only a powerful pair ners - and acknowledgement for all plants taking part.
of binoculars allowed me to identify this single bird. On Feel free to encourage the birds to come to you by giving
the other hand, sitting by my window working one day, them a home, providing new habitats and feeding them!
a goldcrest - Europes smallest bird, weighing around 6g Please email me at rob@propubs.com to let me know if
but still capable of flying across the North Sea - started you are taking part - I can send you a spreadsheet to help
to look for seeds in my plant pots. I moved my head to you count your species.
get a better look and he or she flew off - but this is a Finally, we need a good name for this grand global
bird that is nearly impossible to mis-identify. Once seen, endeavour and here it is: The Global Cement Bird Watch.
never forgotten. When, once or twice a year, I spot the Good luck and happy birding!

GLOBAL CEMENT: ADVERTISER INDEX
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20 97-2
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ars 7
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TM
MARCH 2017 MAGAZINE
AHEAD OF THE GAME TM

MAGAZINE
The worlds most widely-read cement magazine
Advertisers: March 2017

aixergee GmbH 19 Mersmann@aixergee.de www.aixergee.de
22nd Arab-International Cement Conference, Sharm El Sheikh 61 aicce22@aucbm.org www.aucbm.org
Cimprogetti Srl 23 inform@cimprogetti.com www.cimprogetti.com
Coal Mill Safety Pte Ltd 43 info@coalmillsafety.com www.coalmillsafety.com
DALOG Diagnosesysteme GmbH IFC, 3 info@dalog.net www.dalog.net
Doppelmayr Transport Technology GmbH OBC dtt@doppelmayr.com www.doppelmayr-mts.com
ELIN Motoren GmbH 44 contact@elinmotoren.at www.elinmotoren.at
FCT International 17 sales_ALL@fctinternational.com www.fctcombustion.com
Fives Group 13 pillard-sales@fivesgroup.com www.fivesgroup.com
Gambarotta Gschwendt Srl 54, 55 gambarotta@gambarotta.it www.gambarotta.it
Gebr. Pfeiffer SE FC kv-p@gebr-pfeiffer.com www.gebr-pfeiffer.com
Global CemTrans Conference 2017, Antwerp, Belgium 46 rob@propubs.com www.Cem-Trans.com
Global Slag Conference 2017, Dsseldorf, Germany 42 rob@propubs.com www.GlobalSlag.com
Hardtop Gieereitechnologie GmbH 41 info@hardtop-gmbh.de www.hardtop-gmbh.de
HEKO Ketten GmbH IBC info@heko.com www.heko.com
IEEE-IAS/PCA Cement Conference 2017 39 bill@world-class-events.com www.cementconference.org
Intercem Engineering GmbH 43 info@intercem.de www.intercem.de
Keith Mfg. Co. 47 sales@keithwalkingfloor.com www.keithwalkingfloor.com
Kettenwulf 4 service@kettenwulf.com www.kettenwulf.com
Kima Echtzeitsysteme GmbH 33 contact@kimaE.de www.kimaE.de
Loesche GmbH 27 Karin.Boeker-Mahr@loesche.de www.loesche.com
Maerz Ofenbau AG 9 caren.mueller@maerz.com www.maerz.com
NEXA Industries 19 info@nexa-industries.com
ReTec Milj 40 pce@retec.dk www.retec.dk
robecco GmbH 8 robert.becker@robecco.de www.robecco.de
ROCKTEQ International GmbH 15 hartwig.keller@rockteq.de www.rockteq.com
Testing Bluhm & Feuerherdt GmbH 49 info@testing.de www.testing.de
Thorwesten Vent GmbH 45 thorwesten.vent@thorwesten.com www.thorwesten.com
Total Lubricants 53 william.duchatelle@total.com www.lubricants.total.com
Next issue: April 2017 Following issue: May 2017

Advertising deadline: 20 March 2017 Advertising deadline: 28 April 2017
Country reports: East & West Africa, Middle East, Iran Country reports: Canada, USA
Plant report: Hanson (HeidelbergCement) Ketton Works, UK
Plant report: LafargeHolcim Exshaw, Canada
Brexit, Environmental protection, Process control, Loading,
Optimisation, Packaging, Palletising Fans, Grinding, Kilns, Bulk handling, Refractories,
Alternative fuels, Slag
Event preview: IEEE-IAS/PCA Cement Conference
Distribution: Interpack, Hanover Fair, Distribution: IEEE-IAS/PCA Cement Conference, Calgary,
1st Global CemProcess Conference, London, UK Canada; Global Slag Conference, Dsseldorf; Schttgut
To advertise: Paul Brown - paul.brown@propubs.com +44 (0) 776 74 75 998

Sren Rothfahl - soeren.rothfahl@propubs.com +44 (0) 7850 669169
Editorial contributions: editorial@propubs.com +44 (0) 1372 743 837

Anzeige_BW_09_00:Anzeigenentwurf 06.03.2009 18:32 Uhr Seite 1
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Global Cement news Burners Efficiency Grinding Lime Brazil

Contents Subscribe Ad Index

MARCH 2017 MAGAZINE

AHEAD OF THE GAME

DALOG March 2017.indd 1 21/02/2017 15:00

DALOG March 2017.indd 2 21/02/2017 15:00

EasyFairs SOLIDS SCHTTGUT

Experts for the bulk material

For over 90 years, KettenWulf, as an expanding global company, has stood

Reclaimer Chains for Chains for Sprockets for the

KettenWulf Betriebs GmbH T + 49.(0)2973.801-0 service@kettenwulf.com

This issues front cover... MARCH 2017 MAGAZINE

a ready2grind operational since January 2017.

For more information: www.gebr-pfeiffer.com

www.GlobalCement.com Global Cement Magazine March 2017 5

Global Cement articles

20 An introduction to roller press maintenance

38 Product and Contract News

34 Changes to EU ETS approved; HeidelbergCement results

Cement in the Americas

47 American cement news

6 Global Cement Magazine March 2017 www.GlobalCement.com

50 Brazil: Still finding the bottom of the curve...

Middle East and African cement

Regulars and comment 50

64 Subscription form for Global Cement Magazine

65 The Last Word

66 Advertiser Index & Forthcoming issue features

1st Global CemProcess Conference

robecco secure center RSC  2th Global Slag Conference

robecco dust control RDC IEEE-IAS/PCA Cement Conference

12th Global Insulation Conference

25-26 September 2017, Krakw, Poland

26-28 September 2017, Nrnberg, Germany

14th TMB International Technical Seminar

17th Global Gypsum Conference

www.robecco.de 22nd Arab-International Cement Conference

160106_RZ_Maerz_INS_Mond_A4.indd 1 06.01.16 10:59

Latest burner profiles

T his article will present information from burner

10 Global CementMagazine March 2017 www.GlobalCement.com

in order to improve the trajectory of particles into

www.GlobalCement.com Global Cement Magazine March 2017 11

In the 1990s fuels that were dif-

12 Global CementMagazine March 2017 www.GlobalCement.com

FIVES_PILLARD_PUBLI_NOVAFLAM_EN_A4_220217_VECT.indd 1 22/02/2017 07:15

The Jetflex burner is a good illustration of the

XdH: Dynamis demonstrates how a newer

14 Global CementMagazine March 2017 www.GlobalCement.com

with the swirl injection at a

XdH: The Novaflam has

16 Global CementMagazine March 2017 www.GlobalCement.com

We target real bottom line results for you.

Call FCT Combustion now to discuss how

18 Global CementMagazine March 2017 www.GlobalCement.com

Analytical & Advisory Services: Market

Business development: Technical articles

when it comes to ...

+ 49 241 4134492-50 www.aixergee.de

An introduction to roller press maintenance

Rollers Adaptability of installation feature

Right - Figure 1: Roller

20 Global CementMagazine March 2017 www.GlobalCement.com

20-25mm 20-25mm Left - Figure 2: The

1st Global CemProcess Conference

robecco secure center RSC 2th Global Slag Conference

12th Global Insulation Conference

17th Global Gypsum Conference

Analytical & Advisory Services: Market

Business development: Technical articles