4. 4 HIGHLIGHTS CEMENT – APRIL 2015 5HIGHLIGHTS CEMENT – APRIL 2015
New greenfield plant for CEMEX
plant in Colombia
FLSmidth has been awarded a contract
from the Mexican cement producer
CEMEX for the supply of a 2,800 tpd
cement production line to be installed at
its new Cementera del Magdalena Medio
S.A.S. cement plant.
The plant is located approximately 135 km
from the capital of Antioquia, Medellin in
the department of Antioquia. The line will
use the latest production technologies and
achieve high environmental and quality
standards. The department of Antioquia is
a region in Colombia that is expected to
see an increase in cement demand
resulting from continued economic growth
as well as planned investments in
infrastructure.
In addition to engineering services, project
management, and commissioning, all
major processing machines are included.
The pyro processing line consists of an
FRM™
mill for raw grinding, an ATOX®
coal
mill, 5-stage ILC preheater with a Low NOx
calciner, a FLSmidth®
Cross-Bar®
cooler,
and a two-pier kiln. Pfister®
weighing and
dosing systems, MAAG®
gear reducers,
gas analysers as well as all Airtech process
filters are also included.
NEW ORDERS
New greenfield plant for
CEMEX,
Colombia
CONTACT FELIPE ARANGO
FELIPE.ARANGO@FLSMIDTH.COM
Read more about new
orders on www.flsmidth.com/
announcements for Misr Cement Company
NEW ORDERS
Two mills
Qena Cement
Misr Cement Company (MCC Qena)
was established in 1997, at which time
FLSmidth was contracted to construct
the cement plant. Production started
up in 2002 with an annual production
of 1.8 million tpy of clinker. MCC Qena
today employs around 420 people.
MCC Qena has signed two contracts with
FLSmidth for the supply of an ATOX®
vertical coal mill, an OK™
vertical cement
mill, Pfister®
weighing and dosing systems,
Maag®
gear reducers and Airtech filters.
The plant is located in the Valley Sondos,
approximately 45 km from Luxor in Egypt.
FLSmidth supplied the equipment for MCC
Qena’s original 1.4 million tpy cement
plant in 1999. But in 2014, the plant had
an actual production of 1.8 million tpy of
clinker, without any modifications of the
line.
Key to the decision to choose FLSmidth's
equipment was the ability to meet MCC
Qena's high demands for performance and
reliability.
Consequently, many plants have begun to
install coal mills in order to improve
production stability. This is a key reason for
MCC Qena choosing the ATOX 25 vertical
coal mill. The energy-efficient ATOX coal
mill grinds and dries all types of coal and
can be installed at a relatively low cost.
MCC Qena will also take delivery of an OK
42/4 vertical cement mill. FLSmidth’s OK
mill is one of the most reputable roller mills
for finish grinding of Portland cement, slag
and blended cements. In fact, it is the only
vertical roller mill specifically designed for
cement grinding and has been consistently
shown to use 15-20 percent (3-5 KWh/MT)
less power than other cement vertical roller
mills and 25-40 percent less power than
ball mills. The OK mill’s high energy
efficiency is expected to contribute
significantly to MCC Qena’s profitability
and competitiveness.
Anders Josefsen, General Manager, at
FLSmidth comments: “This contract with
MCC Qena reflects what we see as an
increasing demand for full-service solutions
based on standalone products. FLSmidth is
ideally positioned to meet this demand
thanks to our complete range of cement
plant equipment and services covering the
entire cement plant lifecycle – from the
initial plant project to maintenance and
upgrades.”
Alaa Abdel Hamed, Plant Manager, at
MCC Qena says: “We asked FLSmidth to
specify a set of production levels for the
equipment we required and as they were
able to do that, it confirmed for us their
reliability in delivering to our needs.
Besides, our existing line, which is based
on FLSmidth equipment, has performed
above expectations. Therefore, we trust
FLSmidth equipment and are convinced
the new equipment is the best choice for
our operations."
Stable production
Cement plants in Egypt face a unique
challenge in that the gas supply is quite
unstable. This can significantly affect
production, leading to clinker production
being at a standstill for weeks at a time.
CONTACT ANDERS JOSEFSEN,
ANJO@FLSMIDTH.COM
CONTACT SCOTT ZOLOTSKY
SCOTT.ZOLOTSKY@FLSMIDTH.COM
Read more about new
OK™
Vertical Roller Mill at
www.flsmidth.com/okmill
New line
for CEMEX's
Odessa plant
FLSmidth has been selected to supply a new
cement production line to be installed at
CEMEX’s Odessa cement plant located in
western Texas, USA. The new 2,540 tpd
production line will help CEMEX keep pace
with the rapidly growing cement demand
from the oil and gas industry in the West
Texas market.
The expansion will utilise state-of-the-art
production technology resulting in higher
fuel efficiency and improved productivity.
The equipment scope includes a 5-stage ILC
preheater with a Low NOx
calciner, 3-pier
kiln, FLSmidth®
Cross-Bar®
cooler, Duoflex®
burner, Pfister®
weighing and dosing
systems, gas analysers and three Fuller-
Kinyon®
pumps. Furthermore, an FLSmidth
control system will ensure the highest level
of operational efficiencies. The project will
be supplied on an EPC (Engineering,
Procurement, and Construction) basis.
FLSmidth is to deliver an ATOX vertical coal mill and an OK
vertical cement mill to Egypt’s Misr Cement Company (MCC
Qena), which will improve the plant's production stability and
ensure high energy efficiency.
5. 4 HIGHLIGHTS CEMENT – APRIL 2015 5HIGHLIGHTS CEMENT – APRIL 2015
New greenfield plant for CEMEX
plant in Colombia
FLSmidth has been awarded a contract
from the Mexican cement producer
CEMEX for the supply of a 2,800 tpd
cement production line to be installed at
its new Cementera del Magdalena Medio
S.A.S. cement plant.
The plant is located approximately 135 km
from the capital of Antioquia, Medellin in
the department of Antioquia. The line will
use the latest production technologies and
achieve high environmental and quality
standards. The department of Antioquia is
a region in Colombia that is expected to
see an increase in cement demand
resulting from continued economic growth
as well as planned investments in
infrastructure.
In addition to engineering services, project
management, and commissioning, all
major processing machines are included.
The pyro processing line consists of an
FRM™
mill for raw grinding, an ATOX®
coal
mill, 5-stage ILC preheater with a Low NOx
calciner, a FLSmidth®
Cross-Bar®
cooler,
and a two-pier kiln. Pfister®
weighing and
dosing systems, MAAG®
gear reducers,
gas analysers as well as all Airtech process
filters are also included.
NEW ORDERS
New greenfield plant for
CEMEX,
Colombia
CONTACT FELIPE ARANGO
FELIPE.ARANGO@FLSMIDTH.COM
Read more about new
orders on www.flsmidth.com/
announcements for Misr Cement Company
NEW ORDERS
Two mills
Qena Cement
Misr Cement Company (MCC Qena)
was established in 1997, at which time
FLSmidth was contracted to construct
the cement plant. Production started
up in 2002 with an annual production
of 1.8 million tpy of clinker. MCC Qena
today employs around 420 people.
MCC Qena has signed two contracts with
FLSmidth for the supply of an ATOX®
vertical coal mill, an OK™
vertical cement
mill, Pfister®
weighing and dosing systems,
Maag®
gear reducers and Airtech filters.
The plant is located in the Valley Sondos,
approximately 45 km from Luxor in Egypt.
FLSmidth supplied the equipment for MCC
Qena’s original 1.4 million tpy cement
plant in 1999. But in 2014, the plant had
an actual production of 1.8 million tpy of
clinker, without any modifications of the
line.
Key to the decision to choose FLSmidth's
equipment was the ability to meet MCC
Qena's high demands for performance and
reliability.
Consequently, many plants have begun to
install coal mills in order to improve
production stability. This is a key reason for
MCC Qena choosing the ATOX 25 vertical
coal mill. The energy-efficient ATOX coal
mill grinds and dries all types of coal and
can be installed at a relatively low cost.
MCC Qena will also take delivery of an OK
42/4 vertical cement mill. FLSmidth’s OK
mill is one of the most reputable roller mills
for finish grinding of Portland cement, slag
and blended cements. In fact, it is the only
vertical roller mill specifically designed for
cement grinding and has been consistently
shown to use 15-20 percent (3-5 KWh/MT)
less power than other cement vertical roller
mills and 25-40 percent less power than
ball mills. The OK mill’s high energy
efficiency is expected to contribute
significantly to MCC Qena’s profitability
and competitiveness.
Anders Josefsen, General Manager, at
FLSmidth comments: “This contract with
MCC Qena reflects what we see as an
increasing demand for full-service solutions
based on standalone products. FLSmidth is
ideally positioned to meet this demand
thanks to our complete range of cement
plant equipment and services covering the
entire cement plant lifecycle – from the
initial plant project to maintenance and
upgrades.”
Alaa Abdel Hamed, Plant Manager, at
MCC Qena says: “We asked FLSmidth to
specify a set of production levels for the
equipment we required and as they were
able to do that, it confirmed for us their
reliability in delivering to our needs.
Besides, our existing line, which is based
on FLSmidth equipment, has performed
above expectations. Therefore, we trust
FLSmidth equipment and are convinced
the new equipment is the best choice for
our operations."
Stable production
Cement plants in Egypt face a unique
challenge in that the gas supply is quite
unstable. This can significantly affect
production, leading to clinker production
being at a standstill for weeks at a time.
CONTACT ANDERS JOSEFSEN,
ANJO@FLSMIDTH.COM
CONTACT SCOTT ZOLOTSKY
SCOTT.ZOLOTSKY@FLSMIDTH.COM
Read more about new
OK™
Vertical Roller Mill at
www.flsmidth.com/okmill
New line
for CEMEX's
Odessa plant
FLSmidth has been selected to supply a new
cement production line to be installed at
CEMEX’s Odessa cement plant located in
western Texas, USA. The new 2,540 tpd
production line will help CEMEX keep pace
with the rapidly growing cement demand
from the oil and gas industry in the West
Texas market.
The expansion will utilise state-of-the-art
production technology resulting in higher
fuel efficiency and improved productivity.
The equipment scope includes a 5-stage ILC
preheater with a Low NOx
calciner, 3-pier
kiln, FLSmidth®
Cross-Bar®
cooler, Duoflex®
burner, Pfister®
weighing and dosing
systems, gas analysers and three Fuller-
Kinyon®
pumps. Furthermore, an FLSmidth
control system will ensure the highest level
of operational efficiencies. The project will
be supplied on an EPC (Engineering,
Procurement, and Construction) basis.
FLSmidth is to deliver an ATOX vertical coal mill and an OK
vertical cement mill to Egypt’s Misr Cement Company (MCC
Qena), which will improve the plant's production stability and
ensure high energy efficiency.
6. 6 HIGHLIGHTS CEMENT – APRIL 2015 7HIGHLIGHTS CEMENT – APRIL 2015
Compared with traditional hardfacing solutions, which require
frequent repairs resulting in downtime, the TRIBOMAX surface
requires limited or no repair. In the unlikely event that it becomes
damaged, it can be spot repaired in-situ and rollers and sleeves
can be refurbished as necessary.
Whereas some solutions are limited in rollersize due to complex
manufacturing requirements, our TRIBOMAX surfaces are suitable
for all aftermarket applications and can be applied to any rollersize
at a short lead time. Rollers having applied TRIBOMAX surfaces
can be supplied either as solid rollers or as shrink-fitted solutions
that reuse the main shaft, which is an ideal way to reduce the
overall cost.
INNOVATION
Keeping the
rollers turning
Innovative TRIBOMAX™
wear solution for
hydraulic roller presses boosts performance
and prolongs roller lifetime.
Unique properties
The TRIBOMAX surface is based on known welding technology,
but its formulation and constituent components have been
especially adapted by FLSmidth to yield outstanding
performance. FLSmidth selected the TRIBOMAX wear surface for
its rollers after several years of careful research and testing,
including the evaluation of 20 different technologies. Not only
has it shown outstanding wear properties, but also superior
toughness and unprecedented resilience towards hard particles
and tramp material.
Reduced total costs
The TRIBOMAX™
surface is expected to give FLSmidth’s roller press
rollers a minimum life of 25,000 hours extending up to 40,000
hours. (read more on pages 34-37) As TRIBOMAX is an advanced
welding technology utilising high-end material formulations, the
purchase cost is higher than traditional hardfacing solutions.
However, the TRIBOMAX solution is lower priced than most
similar high-end solutions.
The durability, flexibility and ease of maintenance of the
TRIBOMAX surface make it a highly cost-effective solution with a
low total cost of ownership. Due to the flexibility of the welding
technology and FLSmidth process knowledge, the surface
thickness can be tailored to accommodate specific needs to
achieve a specified lifetime.
CONTACT DAVID DAM OLSSON
DDO@FLSMIDTH.COM
Normal hardfacing rollers are susceptible to premature failure when
the hard surface is overloaded by tramp metal or oversized materi-
als. A key property of the TRIBOMAX surface is its extreme tough-
ness, which makes it more durable and significantly less susceptible
to damage compared with traditional hardfacing surfaces.
FLSmidth’s TRIBOMAX®
wear solution is a new roller press wear
surface designed specifically to withstand the demanding condi-
tions of grinding clinker, slag and raw mix. Its high resistance to
wear and surface overloading prolongs roller lifetime significantly,
making it a highly cost-effective solution for roller presses.
What is TRIBOMAX?
Tribology is the science and engineering of interacting surfaces
in relative motion. It includes the study and application of the
principles of friction and wear. The name TRIBOMAX is derived
from this science.
The TRIBOMAX wear solution is based on unique plasma
transfer arc welding deposit technology. This results in a pure
metallurgical composition with fewer impurities, such as cracks
and porosities, compared with conventional hardfacing.
The TRIBOMAX surface’s microstructure formulations give it a
special ability to achieve a high surface friction and an
autogenous wear layer.
TRIBOMAX surface highlights:
• Longer wear life than traditional hardfacing solutions – more
than 25,000 hours
• One wear solution for cement, slag and raw mix
• Higher resistance towards tramp material than existing
hardfacing solutions
• Low maintenance and cost-effective
• Reduced risk of failure
• Low total cost of ownership
“THE DURABILITY,
FLEXIBILITY AND EASE
OF MAINTENANCE OF
THE TRIBOMAX
SURFACE MAKE IT A
HIGHLY COST-EFFECTIVE
SOLUTION WITH A LOW
TOTAL COST OF
OWNERSHIP.”
7. 6 HIGHLIGHTS CEMENT – APRIL 2015 7HIGHLIGHTS CEMENT – APRIL 2015
Compared with traditional hardfacing solutions, which require
frequent repairs resulting in downtime, the TRIBOMAX surface
requires limited or no repair. In the unlikely event that it becomes
damaged, it can be spot repaired in-situ and rollers and sleeves
can be refurbished as necessary.
Whereas some solutions are limited in rollersize due to complex
manufacturing requirements, our TRIBOMAX surfaces are suitable
for all aftermarket applications and can be applied to any rollersize
at a short lead time. Rollers having applied TRIBOMAX surfaces
can be supplied either as solid rollers or as shrink-fitted solutions
that reuse the main shaft, which is an ideal way to reduce the
overall cost.
INNOVATION
Keeping the
rollers turning
Innovative TRIBOMAX™
wear solution for
hydraulic roller presses boosts performance
and prolongs roller lifetime.
Unique properties
The TRIBOMAX surface is based on known welding technology,
but its formulation and constituent components have been
especially adapted by FLSmidth to yield outstanding
performance. FLSmidth selected the TRIBOMAX wear surface for
its rollers after several years of careful research and testing,
including the evaluation of 20 different technologies. Not only
has it shown outstanding wear properties, but also superior
toughness and unprecedented resilience towards hard particles
and tramp material.
Reduced total costs
The TRIBOMAX™
surface is expected to give FLSmidth’s roller press
rollers a minimum life of 25,000 hours extending up to 40,000
hours. (read more on pages 34-37) As TRIBOMAX is an advanced
welding technology utilising high-end material formulations, the
purchase cost is higher than traditional hardfacing solutions.
However, the TRIBOMAX solution is lower priced than most
similar high-end solutions.
The durability, flexibility and ease of maintenance of the
TRIBOMAX surface make it a highly cost-effective solution with a
low total cost of ownership. Due to the flexibility of the welding
technology and FLSmidth process knowledge, the surface
thickness can be tailored to accommodate specific needs to
achieve a specified lifetime.
CONTACT DAVID DAM OLSSON
DDO@FLSMIDTH.COM
Normal hardfacing rollers are susceptible to premature failure when
the hard surface is overloaded by tramp metal or oversized materi-
als. A key property of the TRIBOMAX surface is its extreme tough-
ness, which makes it more durable and significantly less susceptible
to damage compared with traditional hardfacing surfaces.
FLSmidth’s TRIBOMAX®
wear solution is a new roller press wear
surface designed specifically to withstand the demanding condi-
tions of grinding clinker, slag and raw mix. Its high resistance to
wear and surface overloading prolongs roller lifetime significantly,
making it a highly cost-effective solution for roller presses.
What is TRIBOMAX?
Tribology is the science and engineering of interacting surfaces
in relative motion. It includes the study and application of the
principles of friction and wear. The name TRIBOMAX is derived
from this science.
The TRIBOMAX wear solution is based on unique plasma
transfer arc welding deposit technology. This results in a pure
metallurgical composition with fewer impurities, such as cracks
and porosities, compared with conventional hardfacing.
The TRIBOMAX surface’s microstructure formulations give it a
special ability to achieve a high surface friction and an
autogenous wear layer.
TRIBOMAX surface highlights:
• Longer wear life than traditional hardfacing solutions – more
than 25,000 hours
• One wear solution for cement, slag and raw mix
• Higher resistance towards tramp material than existing
hardfacing solutions
• Low maintenance and cost-effective
• Reduced risk of failure
• Low total cost of ownership
“THE DURABILITY,
FLEXIBILITY AND EASE
OF MAINTENANCE OF
THE TRIBOMAX
SURFACE MAKE IT A
HIGHLY COST-EFFECTIVE
SOLUTION WITH A LOW
TOTAL COST OF
OWNERSHIP.”
8. 9HIGHLIGHTS CEMENT – APRIL 20158 HIGHLIGHTS CEMENT – APRIL 2015
environment and society is central to
FLSmidth’s strategy, and we wanted to
understand the impact of our offering and
specifically how we create value.”
ACC Ramliya Cement Plant
Built by FLSmidth, the Ramliya plant
consists of two production lines, which
together have a production capacity of 4.2
million tpy.
Following its construction, Arabian Cement
Company chose to outsource ACC
Ramliya’s clinker production to FLSmidth
through a comprehensive operations and
maintenance (OM) contract. In addition
to managing the plant’s daily operations,
FLSmidth recruits and employs the plant’s
entire operational staff. This 360-degree
knowledge of the ACC Ramliya plant
meant FLSmidth was ideally placed to
conduct a study of the plant’s impact on its
surroundings and stakeholders.
Shared value benefits all
The study identifies and describes four
essential aspects of the plant’s total
impact. In addition to economic,
environmental and social impacts, it
defines the business value proposition
delivered to the plant’s owners.
Thomas Westergaard-Kabelmann, partner
at Qbis, was responsible for the impact
assessment in collaboration with Deloitte.
He explains the importance of
understanding the entire perspective of a
cement plant’s operations and not just the
economic value delivered to the owners:
“The customer is only one part of the
puzzle; it’s important to see the complete
picture. Cement plants have a large impact
on the local environment and society, and
if you do good in one aspect of the plant’s
impact, it is likely to have a positive impact
on all the other aspects.”
He continues: “Delivering profits and
socio-economic benefits results in shared
value, and if ACC Ramliya can optimise its
social and environmental impacts, not only
will the customer benefit, but it will have a
positive impact on economic activity in the
region.”
Per Mejnert Kristensen, Group Executive
Vice President at FLSmidth sees the
performance of the ACC Ramliya plant as
the result of a long-term focus on
responsible business. He says, “We believe
strongly there is a co-relation between the
big picture of corporate social responsibility
and the bottom line performance of our
customer, and we are pleased to see that
the impact assessment from ACC Ramliya
demonstrates this co-relation.”
Outstanding utilisation
Not surprisingly, the study revealed that for
ACC Ramliya to make a positive
contribution to its surroundings, it needs
to perform well commercially. And ACC
Ramliya’s commercial performance tells an
outstanding success story. In the period
2010 to 2013, during which Egypt’s
cement production capacity expanded by
40 percent, ACC outstripped its
competition, increasing market share from
2.9 to 7.8 percent. Notably, Egyptian
cement consumption in this period
increased by only two percent.
Several factors contribute to ACC
Ramliya's excellent performance.
Responsiblebusiness boosts
performance
FEATURES
CONTACT MORTEN JESS NIELSEN
MJN@FLSMIDTH.COM
We believe strongly there
is a co-relation between
the big picture of corporate
social responsibility and the
bottom line performance
of our customer
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
Egypt’s ACC Ramliya
cement plant doesn’t
just deliver a
utilisation rate 10
percent higher than
the industry average,
it beats industry
norms in energy
consumption and
emission reductions.
Cement plant operations have a significant
impact on the local environment and the
economy. But although this has long been
recognised, exactly what that impact is has
been the subject of much debate. With
cement production predicted to increase
by at least 50 percent towards 2050, the
challenge for the cement industry is how
to balance the world's requirements for
cement and the need to reduce CO2
,
waste and other gaseous emissions.
In a bid to gain a comprehensive
understanding of a cement plant’s impact,
FLSmidth commissioned a ground-breaking
impact assessment of the Arabian Cement
Company (ACC Ramliya) Cement Plant in
Egypt. The assessment was performed by
the consultancy firms Deloitte and Qbis,
who have considerable experience in
assessing a business’s impact on society.
Morten Jess Nielsen, CSR Advisor at
FLSmidth, explains why the assessment
was initiated: “Responsibility to the
8 HIGHLIGHTS CEMENT – APRIL 2015
9. 9HIGHLIGHTS CEMENT – APRIL 20158 HIGHLIGHTS CEMENT – APRIL 2015
environment and society is central to
FLSmidth’s strategy, and we wanted to
understand the impact of our offering and
specifically how we create value.”
ACC Ramliya Cement Plant
Built by FLSmidth, the Ramliya plant
consists of two production lines, which
together have a production capacity of 4.2
million tpy.
Following its construction, Arabian Cement
Company chose to outsource ACC
Ramliya’s clinker production to FLSmidth
through a comprehensive operations and
maintenance (OM) contract. In addition
to managing the plant’s daily operations,
FLSmidth recruits and employs the plant’s
entire operational staff. This 360-degree
knowledge of the ACC Ramliya plant
meant FLSmidth was ideally placed to
conduct a study of the plant’s impact on its
surroundings and stakeholders.
Shared value benefits all
The study identifies and describes four
essential aspects of the plant’s total
impact. In addition to economic,
environmental and social impacts, it
defines the business value proposition
delivered to the plant’s owners.
Thomas Westergaard-Kabelmann, partner
at Qbis, was responsible for the impact
assessment in collaboration with Deloitte.
He explains the importance of
understanding the entire perspective of a
cement plant’s operations and not just the
economic value delivered to the owners:
“The customer is only one part of the
puzzle; it’s important to see the complete
picture. Cement plants have a large impact
on the local environment and society, and
if you do good in one aspect of the plant’s
impact, it is likely to have a positive impact
on all the other aspects.”
He continues: “Delivering profits and
socio-economic benefits results in shared
value, and if ACC Ramliya can optimise its
social and environmental impacts, not only
will the customer benefit, but it will have a
positive impact on economic activity in the
region.”
Per Mejnert Kristensen, Group Executive
Vice President at FLSmidth sees the
performance of the ACC Ramliya plant as
the result of a long-term focus on
responsible business. He says, “We believe
strongly there is a co-relation between the
big picture of corporate social responsibility
and the bottom line performance of our
customer, and we are pleased to see that
the impact assessment from ACC Ramliya
demonstrates this co-relation.”
Outstanding utilisation
Not surprisingly, the study revealed that for
ACC Ramliya to make a positive
contribution to its surroundings, it needs
to perform well commercially. And ACC
Ramliya’s commercial performance tells an
outstanding success story. In the period
2010 to 2013, during which Egypt’s
cement production capacity expanded by
40 percent, ACC outstripped its
competition, increasing market share from
2.9 to 7.8 percent. Notably, Egyptian
cement consumption in this period
increased by only two percent.
Several factors contribute to ACC
Ramliya's excellent performance.
Responsiblebusiness boosts
performance
FEATURES
CONTACT MORTEN JESS NIELSEN
MJN@FLSMIDTH.COM
We believe strongly there
is a co-relation between
the big picture of corporate
social responsibility and the
bottom line performance
of our customer
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
Egypt’s ACC Ramliya
cement plant doesn’t
just deliver a
utilisation rate 10
percent higher than
the industry average,
it beats industry
norms in energy
consumption and
emission reductions.
Cement plant operations have a significant
impact on the local environment and the
economy. But although this has long been
recognised, exactly what that impact is has
been the subject of much debate. With
cement production predicted to increase
by at least 50 percent towards 2050, the
challenge for the cement industry is how
to balance the world's requirements for
cement and the need to reduce CO2
,
waste and other gaseous emissions.
In a bid to gain a comprehensive
understanding of a cement plant’s impact,
FLSmidth commissioned a ground-breaking
impact assessment of the Arabian Cement
Company (ACC Ramliya) Cement Plant in
Egypt. The assessment was performed by
the consultancy firms Deloitte and Qbis,
who have considerable experience in
assessing a business’s impact on society.
Morten Jess Nielsen, CSR Advisor at
FLSmidth, explains why the assessment
was initiated: “Responsibility to the
8 HIGHLIGHTS CEMENT – APRIL 2015
10. 10 HIGHLIGHTS CEMENT – APRIL 2015 11HIGHLIGHTS CEMENT – APRIL 2015
The plant operates at a significantly higher
utilisation rate than its industry peers.
Measured over 2012 and 2013, it operated
at 83 percent utilisation, significantly
higher than the industry standard of 73
percent (Auerbach Greyson, EFG
Hermes, 2014). Most of its cement is then
sold to areas of high demand, such as
Greater Cairo and the Nile Delta.
At ACC Ramliya, production manager
Mahmoud Abdel Ghany explains his
production philosophy: We work to keep
our customers satisfied and to sustain the
plant performance. High production is not
a challenge, but it is not that simple. We
can easily produce 7,000 tonnes of clinker
a day, but if the machines break down the
next day due to overproduction, we cannot
meet our customers' demand for cement.
He continues: The challenge is finding the
optimum point of production where
everything is in balance, and the machines
keep on running. At this point we have
sustained performance, the lowest energy
usage, lowest heat consumption, optimal
production and lowest cost.
It is the combination of high utilisation and
a highly effective sales strategy that has
boosted ACC Ramliya's market share and
profitability. And indeed, the success of
high utilisation rate can be attributed to
FLSmidth, who is responsible for the clinker
production enabling ACC Ramliya to
deliver high quality cement.
Egypt Country Manager at FLSmidth Salem
Sousou says, The cooperation between
FLSmidth and ACC Ramliya is essentially a
partnership, because what benefits one
part benefits the other. As operator of the
plant, FLSmidth is able to act on behalf of
our customer and we see that as having an
intimate relationship with our customer.
Environmental impact
Sine Bøgh Skaarup, Process Manager at
FLSmidth, identifies emissions as one of the
key areas that the cement production
industry needs to address.
RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE
FLSmidth's operations
at ACC Ramliya have
resulted in:
• A 10 percent higher utilisation rate
than the industry average
• Very low SO2
and CO2
emissions
• 14 percent lower energy usage than
than the Egyptian industry in general.
• A high proportion of local staff
• Only 1 percent of the local staff are
expats
• An employee turnover of only 1.5
percent
“THE CHALLENGE IS
FINDING THE OPTIMUM
POINT OF PRODUCTION
WHERE EVERYTHING IS IN
BALANCE, AND THE
MACHINES KEEP ON
RUNNING.“
Mahmoud Abdel Ghany
Production Manager, ACC Ramliya
“Carbon emissions from cement
production currently represent about five
percent of global emissions. With global
cement production still on the rise, we
have to maintain focus on reducing these
emissions, which we can do by closely
monitoring cement plant operations and
always trying to do better,” she says.
Measurements at ACC Ramliya from 2011
showed that NOx
emissions are not always
under the required limit, while SO2
and
CO2
emissions have been well under the
limit. And despite Ramliya in 2011
delivered six percent of Egypt’s total
cement production, it was only responsible
for two percent of total suspended
particles (TSP), which was unrivalled in the
industry.
Coal – the sustainable choice?
A particular challenge for not just the ACC
Ramliya plant, but also most cement
producers in Egypt is the gas supply, which
is too unreliable to support stable
operations resulting in low utilisation and
production rates.
So in 2013, FLSmidth and Ramliya’s
owners made the bold move of switching
from a gas supply to coal. This has in effect
increased Ramliya’s CO2
emissions by 10
percent. And even though more cement
plants are likely to make this switch,
leading to an estimated 15 percent
increase in CO2
emissions nationwide, the
use of coal provides greater socio-
economic benefits.
“The impact assessment estimates that a
30 percent switch from domestic cement
production to imports will cost nearly
19,000 jobs and a loss in gross value
added (GVA) of EGP 16.5 billion,” explains
Thomas Westergaard-Kabelmann,
continuing, “Importing clinker and cement
emits at least six times more CO2
than the
amount emitted by coal-based cement
production.”
11. 10 HIGHLIGHTS CEMENT – APRIL 2015 11HIGHLIGHTS CEMENT – APRIL 2015
The plant operates at a significantly higher
utilisation rate than its industry peers.
Measured over 2012 and 2013, it operated
at 83 percent utilisation, significantly
higher than the industry standard of 73
percent (Auerbach Greyson, EFG
Hermes, 2014). Most of its cement is then
sold to areas of high demand, such as
Greater Cairo and the Nile Delta.
At ACC Ramliya, production manager
Mahmoud Abdel Ghany explains his
production philosophy: We work to keep
our customers satisfied and to sustain the
plant performance. High production is not
a challenge, but it is not that simple. We
can easily produce 7,000 tonnes of clinker
a day, but if the machines break down the
next day due to overproduction, we cannot
meet our customers' demand for cement.
He continues: The challenge is finding the
optimum point of production where
everything is in balance, and the machines
keep on running. At this point we have
sustained performance, the lowest energy
usage, lowest heat consumption, optimal
production and lowest cost.
It is the combination of high utilisation and
a highly effective sales strategy that has
boosted ACC Ramliya's market share and
profitability. And indeed, the success of
high utilisation rate can be attributed to
FLSmidth, who is responsible for the clinker
production enabling ACC Ramliya to
deliver high quality cement.
Egypt Country Manager at FLSmidth Salem
Sousou says, The cooperation between
FLSmidth and ACC Ramliya is essentially a
partnership, because what benefits one
part benefits the other. As operator of the
plant, FLSmidth is able to act on behalf of
our customer and we see that as having an
intimate relationship with our customer.
Environmental impact
Sine Bøgh Skaarup, Process Manager at
FLSmidth, identifies emissions as one of the
key areas that the cement production
industry needs to address.
RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE
FLSmidth's operations
at ACC Ramliya have
resulted in:
• A 10 percent higher utilisation rate
than the industry average
• Very low SO2
and CO2
emissions
• 14 percent lower energy usage than
than the Egyptian industry in general.
• A high proportion of local staff
• Only 1 percent of the local staff are
expats
• An employee turnover of only 1.5
percent
“THE CHALLENGE IS
FINDING THE OPTIMUM
POINT OF PRODUCTION
WHERE EVERYTHING IS IN
BALANCE, AND THE
MACHINES KEEP ON
RUNNING.“
Mahmoud Abdel Ghany
Production Manager, ACC Ramliya
“Carbon emissions from cement
production currently represent about five
percent of global emissions. With global
cement production still on the rise, we
have to maintain focus on reducing these
emissions, which we can do by closely
monitoring cement plant operations and
always trying to do better,” she says.
Measurements at ACC Ramliya from 2011
showed that NOx
emissions are not always
under the required limit, while SO2
and
CO2
emissions have been well under the
limit. And despite Ramliya in 2011
delivered six percent of Egypt’s total
cement production, it was only responsible
for two percent of total suspended
particles (TSP), which was unrivalled in the
industry.
Coal – the sustainable choice?
A particular challenge for not just the ACC
Ramliya plant, but also most cement
producers in Egypt is the gas supply, which
is too unreliable to support stable
operations resulting in low utilisation and
production rates.
So in 2013, FLSmidth and Ramliya’s
owners made the bold move of switching
from a gas supply to coal. This has in effect
increased Ramliya’s CO2
emissions by 10
percent. And even though more cement
plants are likely to make this switch,
leading to an estimated 15 percent
increase in CO2
emissions nationwide, the
use of coal provides greater socio-
economic benefits.
“The impact assessment estimates that a
30 percent switch from domestic cement
production to imports will cost nearly
19,000 jobs and a loss in gross value
added (GVA) of EGP 16.5 billion,” explains
Thomas Westergaard-Kabelmann,
continuing, “Importing clinker and cement
emits at least six times more CO2
than the
amount emitted by coal-based cement
production.”
12. 12 HIGHLIGHTS CEMENT – APRIL 2015 13HIGHLIGHTS CEMENT – APRIL 2015
ACC Ramliya’s Production Manager,
Mahmoud Abdel Ghanry, explains how
people are central to maintaining stable
production: The key to finding the
optimum point of production is having the
right people operating equipment. That is
why we have development plans for all our
employees and why we put tremendous
effort into training them. They will
determine how it will run and that takes
the right knowledge and experience.”
Thomas Westergaard-Kabelmann points
out that contributing to the development
of local skills also has other impacts
beyond just cement plant operations.
“Improving a person's competencies gives
them more opportunities for employment
and career development. As their income
is increased, their standard of life
improves,” he says.
Perfect partnership
According to Per Mejnert Kristensen,
Group Executive Vice President at FLSmidth
the study has great significance for
FLSmidth, acknowledging FLSmidth’s
partnership with Arabian Cement
Company and long-term presence in
Egypt.
He says: “We are highly satisfied that this
study shows that ACC Ramliya is delivering
value to its owner as well as the society in
which it operates. This is, after all, why we
are in business. However, the study also
shows that we and our industry peers
must be vigilant in improving the way we
do things to reduce our environmental
footprint and remain economically viable.
We are equally driven by this quest.”
Better skilled workforce
A key driver of ACC Ramliya’s social impact
is its contribution to employment.
FLSmidth’s ability to operate the plant
efficiently depends on the presence of a
qualified labour force. But this was not
always a given as there is a shortage of
workers with the experience and skills
needed for the cement industry.
So in 2009, FLSmidth established a cement
training and recruitment centre in Egypt
aimed at enhancing plant workers’
professional and technical skills in all
aspects of operations and maintenance.
At least 85 percent of plant staff has
passed through the training centre since its
opening. This means that FLSmidth can
confidently employ local technicians and
engineers, rather than importing foreign
labour.
To help develop competencies at an even
broader level, FLSmidth has partnered
with the Helwan University in Egypt in
establishing the world’s first Postgraduate
Cement Plant Engineering Degree. It is
initiatives such as these that have been
instrumental in building the skills and
know-how that have become the
backbone of the plant’s high utilisation
rate.
Salem Sousou elaborates, “The
development plans we have developed for
all employees at the plant increase their
skill level and ultimately their employability
over time. We’ve seen this result in an
employee turnover rate of 1.5 percent,
which is very low. That means we’re
retaining our valuable competencies,
which boosts the plant’s performance
further.”
RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE
THE ILLUSTRATION SHOWS ACC
RAMLIYA'S IMPACT ON THE LOCAL
ENVIRONMENT AND SOCIETY AND
HOW THE DELIVERY OF PROFITS AND
SOCIO-ECONOMIC BENEFITS RESULT
IN SHARED VALUE.
CO2
EMISSIONS
• When using gas, Ramliya’s CO2
emissions are below industry
average
• Shift to coal has increased
Ramliya‘s CO2
emissions by
around 10%
ENERGY
• 14% lower Gj/t cement than
Egyptian industry
• Consistently lower over last
three years
SO2
, CO and TSP EMISSIONS
• Low SO2
, CO and TSP emissions
• In 2011, ACC Ramliya emitted
2% of total TSP, but accounted
for 6% of the total cement
production in Egypt.
NOx EMISSIONS
• 2011-2013 too high compared to
the legal limit (600mg/m)
• Health impact uncertain due to
desert location
MARKET SHARE
ACC’s market share has increased
from 2.9% to 7.9% due to
• High utilisation rate
• High demand/high price
segment
• Extended customer reach
REVENUE
• 10 percentage point higher
utilisation rate with an estimated
increase in revenue of EGP 493m
in 2012-2013.
EBITDA
• 10 percentage point higher
utilisation rate is estimated
to have increased EBITDA
by EGP 178m in 2012-2013
HEALTH and SAFETY
• Lost Time Injury Frequency (LTIFR)
2012-13 too high
• Lost Time Injury Frequency (LTIFR)
2014 improved
LOCAL JOBS
• 99% of employees are Egyptians
TRAINING
• Own training; FLS-Institute
• 85% of all employees trained
• 35-65% jump in knowledge
• Change in job behaviour after
training rated as satisfactory or
very satisfactory
EDUCATION
• Together with Helwan University,
FLSmidth established a post-
graduate diploma degree in
cement engineering
Job creation
Ramliya/FLSmidth Egypt
• Direct jobs: 272/937 jobs
• Indirect jobs: 695/2,335 jobs
• Induced jobs: 264/887 jobs
SUPPLY OF DOMESTIC
CEMENT
• Use of coal will secure domestic
cement production
• If 30% of domestic cement
production is replaced by import,
it is expected to result in the loss
of nearly 19,000 jobs and EGP
16.5bn in Gross Value Added
GROSS VALUE ADDED
from cement industry
• Direct: EGP 24bn
• Indirect: EGP 23bn
• Induced: EGP 8bn
• Total GVA: EGP 55bn
CUSTOMER
IMPACTS
SOCIAL
IMPACTS
ECONOMIC
IMPACTS
ENVIRONMENTAL
IMPACTS
Positive impact
Negative impact
WE ARE HIGHLY SATISFIED
THAT THIS STUDY SHOWS
THAT ACC RAMLIYA IS
DELIVERING VALUE TO ITS
OWNER AS WELL AS THE
SOCIETY IN WHICH IT
OPERATES. THIS IS, AFTER ALL,
WHY WE ARE IN BUSINESS.
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
About Arabian Cement Company
Arabian Cement Company (ACC) was established in 1997 by a group of Egyptian
entrepreneurs, who aspired to establish a leading Egyptian cement company.
The cement factory is located in the Suez Governorate. It produces five million
tonnes of first quality cement, approximately 10 percent of Egypt's production.
The company is a joint venture between Cememtos La Union, a Spanish investor
holding the majority of shares, and a group of Egyptian investors. The company
was listed on the Egyptian stock exchange in May 2014.
Impact assessment
Deloitte and Qbiz conducted a socio-
economic impact assessment of the
operations and maintenance of the ACC
Ramliya cement plant in Egypt. The overall
objective was to determine the total
impact of FLSmidth’s products and
services, including the impact on a cement
plant’s competitiveness and financial
performance, on the supply and value
chain, and on society as a whole.
13. 12 HIGHLIGHTS CEMENT – APRIL 2015 13HIGHLIGHTS CEMENT – APRIL 2015
ACC Ramliya’s Production Manager,
Mahmoud Abdel Ghanry, explains how
people are central to maintaining stable
production: The key to finding the
optimum point of production is having the
right people operating equipment. That is
why we have development plans for all our
employees and why we put tremendous
effort into training them. They will
determine how it will run and that takes
the right knowledge and experience.”
Thomas Westergaard-Kabelmann points
out that contributing to the development
of local skills also has other impacts
beyond just cement plant operations.
“Improving a person's competencies gives
them more opportunities for employment
and career development. As their income
is increased, their standard of life
improves,” he says.
Perfect partnership
According to Per Mejnert Kristensen,
Group Executive Vice President at FLSmidth
the study has great significance for
FLSmidth, acknowledging FLSmidth’s
partnership with Arabian Cement
Company and long-term presence in
Egypt.
He says: “We are highly satisfied that this
study shows that ACC Ramliya is delivering
value to its owner as well as the society in
which it operates. This is, after all, why we
are in business. However, the study also
shows that we and our industry peers
must be vigilant in improving the way we
do things to reduce our environmental
footprint and remain economically viable.
We are equally driven by this quest.”
Better skilled workforce
A key driver of ACC Ramliya’s social impact
is its contribution to employment.
FLSmidth’s ability to operate the plant
efficiently depends on the presence of a
qualified labour force. But this was not
always a given as there is a shortage of
workers with the experience and skills
needed for the cement industry.
So in 2009, FLSmidth established a cement
training and recruitment centre in Egypt
aimed at enhancing plant workers’
professional and technical skills in all
aspects of operations and maintenance.
At least 85 percent of plant staff has
passed through the training centre since its
opening. This means that FLSmidth can
confidently employ local technicians and
engineers, rather than importing foreign
labour.
To help develop competencies at an even
broader level, FLSmidth has partnered
with the Helwan University in Egypt in
establishing the world’s first Postgraduate
Cement Plant Engineering Degree. It is
initiatives such as these that have been
instrumental in building the skills and
know-how that have become the
backbone of the plant’s high utilisation
rate.
Salem Sousou elaborates, “The
development plans we have developed for
all employees at the plant increase their
skill level and ultimately their employability
over time. We’ve seen this result in an
employee turnover rate of 1.5 percent,
which is very low. That means we’re
retaining our valuable competencies,
which boosts the plant’s performance
further.”
RESPONSIBLE
BUSINESS BOOSTS
PERFORMANCE
THE ILLUSTRATION SHOWS ACC
RAMLIYA'S IMPACT ON THE LOCAL
ENVIRONMENT AND SOCIETY AND
HOW THE DELIVERY OF PROFITS AND
SOCIO-ECONOMIC BENEFITS RESULT
IN SHARED VALUE.
CO2
EMISSIONS
• When using gas, Ramliya’s CO2
emissions are below industry
average
• Shift to coal has increased
Ramliya‘s CO2
emissions by
around 10%
ENERGY
• 14% lower Gj/t cement than
Egyptian industry
• Consistently lower over last
three years
SO2
, CO and TSP EMISSIONS
• Low SO2
, CO and TSP emissions
• In 2011, ACC Ramliya emitted
2% of total TSP, but accounted
for 6% of the total cement
production in Egypt.
NOx EMISSIONS
• 2011-2013 too high compared to
the legal limit (600mg/m)
• Health impact uncertain due to
desert location
MARKET SHARE
ACC’s market share has increased
from 2.9% to 7.9% due to
• High utilisation rate
• High demand/high price
segment
• Extended customer reach
REVENUE
• 10 percentage point higher
utilisation rate with an estimated
increase in revenue of EGP 493m
in 2012-2013.
EBITDA
• 10 percentage point higher
utilisation rate is estimated
to have increased EBITDA
by EGP 178m in 2012-2013
HEALTH and SAFETY
• Lost Time Injury Frequency (LTIFR)
2012-13 too high
• Lost Time Injury Frequency (LTIFR)
2014 improved
LOCAL JOBS
• 99% of employees are Egyptians
TRAINING
• Own training; FLS-Institute
• 85% of all employees trained
• 35-65% jump in knowledge
• Change in job behaviour after
training rated as satisfactory or
very satisfactory
EDUCATION
• Together with Helwan University,
FLSmidth established a post-
graduate diploma degree in
cement engineering
Job creation
Ramliya/FLSmidth Egypt
• Direct jobs: 272/937 jobs
• Indirect jobs: 695/2,335 jobs
• Induced jobs: 264/887 jobs
SUPPLY OF DOMESTIC
CEMENT
• Use of coal will secure domestic
cement production
• If 30% of domestic cement
production is replaced by import,
it is expected to result in the loss
of nearly 19,000 jobs and EGP
16.5bn in Gross Value Added
GROSS VALUE ADDED
from cement industry
• Direct: EGP 24bn
• Indirect: EGP 23bn
• Induced: EGP 8bn
• Total GVA: EGP 55bn
CUSTOMER
IMPACTS
SOCIAL
IMPACTS
ECONOMIC
IMPACTS
ENVIRONMENTAL
IMPACTS
Positive impact
Negative impact
WE ARE HIGHLY SATISFIED
THAT THIS STUDY SHOWS
THAT ACC RAMLIYA IS
DELIVERING VALUE TO ITS
OWNER AS WELL AS THE
SOCIETY IN WHICH IT
OPERATES. THIS IS, AFTER ALL,
WHY WE ARE IN BUSINESS.
Per Mejnert Kristensen
Group Executive Vice President, FLSmidth
About Arabian Cement Company
Arabian Cement Company (ACC) was established in 1997 by a group of Egyptian
entrepreneurs, who aspired to establish a leading Egyptian cement company.
The cement factory is located in the Suez Governorate. It produces five million
tonnes of first quality cement, approximately 10 percent of Egypt's production.
The company is a joint venture between Cememtos La Union, a Spanish investor
holding the majority of shares, and a group of Egyptian investors. The company
was listed on the Egyptian stock exchange in May 2014.
Impact assessment
Deloitte and Qbiz conducted a socio-
economic impact assessment of the
operations and maintenance of the ACC
Ramliya cement plant in Egypt. The overall
objective was to determine the total
impact of FLSmidth’s products and
services, including the impact on a cement
plant’s competitiveness and financial
performance, on the supply and value
chain, and on society as a whole.
14. 14 HIGHLIGHTS CEMENT – APRIL 2015 15HIGHLIGHTS CEMENT – APRIL 2015
The toothed components are
manufactured in-house to the strictest
quality standards and are made from case-
hardened and heat-treated steel. In-house
heat treatment gives complete control over
the hardening processes and material
properties. After assembly, each gearbox is
tested on the internal test bed.
Installation
The first gearbox of the latest PPU
generation was installed in India.
Machine ............. FLSmidth Roller Press
(HRP R-3.00)
Drive power ....................... 2 x 1600kW
Gearbox type ....................... 2 x PPU-44
Gearbox weight ........................6.300kg
Ratio .............................................50.23
The other parts of the drive train, such as
the torque arm, overload coupling,
driving shafts, shrink disks and oil supply
systems, were also supplied by FLSmidth
MAAG Gear. The customer benefitted
from FLSmidth's ability to deliver a full
range of products from one source.
A local team of technicians installed the
gearbox under the supervision of a
MAAG service engineer. The crew was
well-trained and the individual drive train
components were assembled quickly.
MAAG Gear
Revival of a classic
Roller presses in cement plants are used for
the primary reduction of the grinding
stock. For this application, FLSmidth
MAAG Gear offers a special series of
gearboxes for roller presses (read more
about FLSmidth's new roller press concept
on pages 34-37).
The gearboxes are always used in pairs for
the drive of the two grinding rollers. They
can be used in both directions of rotation.
The gearboxes for roller presses have been
designed as two-stage planetary reducers
with spur pre-stages. This ensures optimal
design of the planetary stages with good
load distribution and adaptation to the
required gearbox ratio.
The new version
Experience gained over the last 25 years
was analysed in order to fully redesign the
PPU gearbox. The following objectives
were met:
• Weight reduction of 25%
• 15% smaller outer diameter
• Diversity of parts reduced by 20%
The main focus of the redesign was in the
toothing and the bearing system of the
individual components. The choice of an
25 years down the line and FLSmidth MAAG
Gear has revamped a classic and created a
state-of-the-art gearbox: the PPU gearbox for
roller presses and other applications.
WITH A BEARING LIFETIME
IN EXCESS OF 100,000
HOURS, THE PPU IS LIKE A
MARATHON RUNNER WHO
LEAVES THE COMPETITION
WAY BEHIND.
CONTACT RUDOLF WARTENWEILER
RUDOLF.WARTENWEILER@FLSMIDTH.COM
INNOVATION
optimum bearing system and good sizing
has resulted in a high level of reliability.
With a bearing lifetime in excess of
100.000 hours, the PPU is like a marathon
runner who leaves the competition way
behind. Compared with other gearboxes in
the same application class, the new PPU
uses just five different types of antifriction
bearings instead of up to eight, which
simplifies the management of spare parts.
Operating costs are reduced thanks to
efficiency and optimised maintenance
intervals. Lubrication oil consumption has
been optimised. The ideal oil level reduces
churning losses and improves efficiency.
The dimensions and configuration of the
gearbox were aligned to the application
and other components in the drive train,
such as shrink disk, overload coupling and
cardan shaft.
Top gearing quality
The tooth geometry was designed
following the well-proven MAAG®
standard and recalculated according to the
latest ISO and AGMA standards. This
guarantees optimum load distribution
across the teeth and therefore maximum
power transmission.
PPU IN ASSEMBLY
Applications
Alongside classic roller press
applications, the PPU is flexible enough
for other uses:
• Central drive for small ball mills
• Furnace drives
• Industrial drives (sugar)
Through the use of a wide range of
options and components, the modular
gearbox design allows the adaption of
the drive train precisely to the
customer's needs. The drive train for a
ball mill application is being supplied as
a complete system by FLSmidth MAAG
Gear for a customer in the Far East:
• PPU gearbox unit with limited end
float
• Gearbox foot for transferring load
into the foundation
• Oil supply system
• Low speed ZCF gear coupling with
intermediate flange for ball mill
• Water injection unit via the coupling
• Torsionally flexible high speed
coupling
• Auxiliary drive for maintenance work
• Main drive motor
INSTALLATION OF PPU
15. 14 HIGHLIGHTS CEMENT – APRIL 2015 15HIGHLIGHTS CEMENT – APRIL 2015
The toothed components are
manufactured in-house to the strictest
quality standards and are made from case-
hardened and heat-treated steel. In-house
heat treatment gives complete control over
the hardening processes and material
properties. After assembly, each gearbox is
tested on the internal test bed.
Installation
The first gearbox of the latest PPU
generation was installed in India.
Machine ............. FLSmidth Roller Press
(HRP R-3.00)
Drive power ....................... 2 x 1600kW
Gearbox type ....................... 2 x PPU-44
Gearbox weight ........................6.300kg
Ratio .............................................50.23
The other parts of the drive train, such as
the torque arm, overload coupling,
driving shafts, shrink disks and oil supply
systems, were also supplied by FLSmidth
MAAG Gear. The customer benefitted
from FLSmidth's ability to deliver a full
range of products from one source.
A local team of technicians installed the
gearbox under the supervision of a
MAAG service engineer. The crew was
well-trained and the individual drive train
components were assembled quickly.
MAAG Gear
Revival of a classic
Roller presses in cement plants are used for
the primary reduction of the grinding
stock. For this application, FLSmidth
MAAG Gear offers a special series of
gearboxes for roller presses (read more
about FLSmidth's new roller press concept
on pages 34-37).
The gearboxes are always used in pairs for
the drive of the two grinding rollers. They
can be used in both directions of rotation.
The gearboxes for roller presses have been
designed as two-stage planetary reducers
with spur pre-stages. This ensures optimal
design of the planetary stages with good
load distribution and adaptation to the
required gearbox ratio.
The new version
Experience gained over the last 25 years
was analysed in order to fully redesign the
PPU gearbox. The following objectives
were met:
• Weight reduction of 25%
• 15% smaller outer diameter
• Diversity of parts reduced by 20%
The main focus of the redesign was in the
toothing and the bearing system of the
individual components. The choice of an
25 years down the line and FLSmidth MAAG
Gear has revamped a classic and created a
state-of-the-art gearbox: the PPU gearbox for
roller presses and other applications.
WITH A BEARING LIFETIME
IN EXCESS OF 100,000
HOURS, THE PPU IS LIKE A
MARATHON RUNNER WHO
LEAVES THE COMPETITION
WAY BEHIND.
CONTACT RUDOLF WARTENWEILER
RUDOLF.WARTENWEILER@FLSMIDTH.COM
INNOVATION
optimum bearing system and good sizing
has resulted in a high level of reliability.
With a bearing lifetime in excess of
100.000 hours, the PPU is like a marathon
runner who leaves the competition way
behind. Compared with other gearboxes in
the same application class, the new PPU
uses just five different types of antifriction
bearings instead of up to eight, which
simplifies the management of spare parts.
Operating costs are reduced thanks to
efficiency and optimised maintenance
intervals. Lubrication oil consumption has
been optimised. The ideal oil level reduces
churning losses and improves efficiency.
The dimensions and configuration of the
gearbox were aligned to the application
and other components in the drive train,
such as shrink disk, overload coupling and
cardan shaft.
Top gearing quality
The tooth geometry was designed
following the well-proven MAAG®
standard and recalculated according to the
latest ISO and AGMA standards. This
guarantees optimum load distribution
across the teeth and therefore maximum
power transmission.
PPU IN ASSEMBLY
Applications
Alongside classic roller press
applications, the PPU is flexible enough
for other uses:
• Central drive for small ball mills
• Furnace drives
• Industrial drives (sugar)
Through the use of a wide range of
options and components, the modular
gearbox design allows the adaption of
the drive train precisely to the
customer's needs. The drive train for a
ball mill application is being supplied as
a complete system by FLSmidth MAAG
Gear for a customer in the Far East:
• PPU gearbox unit with limited end
float
• Gearbox foot for transferring load
into the foundation
• Oil supply system
• Low speed ZCF gear coupling with
intermediate flange for ball mill
• Water injection unit via the coupling
• Torsionally flexible high speed
coupling
• Auxiliary drive for maintenance work
• Main drive motor
INSTALLATION OF PPU
16. 16 HIGHLIGHTS CEMENT – APRIL 2015 17HIGHLIGHTS CEMENT – APRIL 2015
One of the biggest challenges facing cement plant owners in
Russia lies in the type and quality of the raw material extracted
from quarries. It is no different for JSC Sebryakovcement, whose
raw material has a moisture content of approximately 20 percent.
Traditionally, the raw materials (chalk and clay) need to be ground
with water to produce a slurry with a 36 percent moisture content
making it easy to pump into the kilns.
But this is an energy-consuming process. An economically viable
solution was needed to replace two of JSC Sebryakovcement’s
wet-process kiln lines that dated back to 1953. Sergey P.
Rogachev, General Director at JSC Sebryakovcement explains the
reasons behind the construction of a new dry process line with a
The ‘dreamline’ vision
The idea of a dry line at JSC Sebryakovcement is in fact not new.
The plant’s first director and his colleagues had wanted to
transform the plant into a dry line. It was their common dream.
That's why today, more than sixty years later, the line is
affectionately known as the ‘dreamline’. But achieving the dream
needed to be based on real business objectives, explains Sergey P.
Rogachev: “Our objectives included upgrading the plant
infrastructure to achieve a steep reduction of fuel consumption
and, consequently, production costs at the same time as
maintaining the quality of clinker production. The clinker burning
equipment had become inefficient, obsolete and worn-out, and
we also saw the opportunity for taking it out of service.
JSC Sebryakovcement needed to find an equally visionary partner
who could meet the requirements of a demanding environment.
The company had worked with FLSmidth on various projects since
2005, and it was a natural decision to continue the partnership.
From wet to dry in a
cold climate
SITE REPORT
clinker-producing capacity of 3,575 tpd: “The plant is located
between two large cement markets in the European part of
Russia. In order to sell a significant amount of cement on the
markets, even competing with wet plants, it is essential for us to
ensure the lowest production cost, since the transportation cost
makes up a large part of the cement price.
New dry cement plants have emerged recently on the same
markets, so it is vital our plant is as competitive as possible.
Therefore, as part of the plant upgrade programme and
reconstruction of all departments, the best means to bring down
the fuel cost in the plant’s production cost structure was to
convert the pyro-section from a wet to dry process.”
CONTACT CLAUS HAGEN JENSEN
CHJ@FLSMIDTH.COM
CONTACT PALLE E. GRYDGAARD
PEG@FLSMIDTH.COM
Stacker
Reclaimer
Crusher
Clay
Additive
Additive
Chalk
PGNAA
Reclaimer
Filter dust silo
Seperator
Crusher
Filter
Dryer crusher
Kiln feed silo
Cooler
Kiln Klinker
FLOW SHEET OF THE NEW DRY
CEMENT PLANT AT JSC
SEBRYAKOVCEMENT
FIRST DIRECT FEED
KILN SYSTEM IN
THE WORLD
Lower fuel consumption
Where the new dry line sets itself apart is in the concept of direct
feeding to the kiln. The plant owners worked closely with the
team at FLSmidth to design a solution that did not require the use
of a raw meal storage silo, such as a CF-silo. This was one of the
key reasons JSC Sebryakovcement chose FLSmidth, partly because
of FLSmidth’s experience and reputation, but also because of its
proven track record in producing innovative solutions to meet
specific requirements.
The concept involved feeding the raw materials with their natural
moisture content directly into the kiln system without grinding
them to slurry. Since no further water is added as before, the overall
heat consumption was reduced from the expected 1450-1500
kcal/kg clinker to less than 900 kcal/kg, which is the equivalent of
more than 40 percent in fuel consumption savings.
17. 16 HIGHLIGHTS CEMENT – APRIL 2015 17HIGHLIGHTS CEMENT – APRIL 2015
One of the biggest challenges facing cement plant owners in
Russia lies in the type and quality of the raw material extracted
from quarries. It is no different for JSC Sebryakovcement, whose
raw material has a moisture content of approximately 20 percent.
Traditionally, the raw materials (chalk and clay) need to be ground
with water to produce a slurry with a 36 percent moisture content
making it easy to pump into the kilns.
But this is an energy-consuming process. An economically viable
solution was needed to replace two of JSC Sebryakovcement’s
wet-process kiln lines that dated back to 1953. Sergey P.
Rogachev, General Director at JSC Sebryakovcement explains the
reasons behind the construction of a new dry process line with a
The ‘dreamline’ vision
The idea of a dry line at JSC Sebryakovcement is in fact not new.
The plant’s first director and his colleagues had wanted to
transform the plant into a dry line. It was their common dream.
That's why today, more than sixty years later, the line is
affectionately known as the ‘dreamline’. But achieving the dream
needed to be based on real business objectives, explains Sergey P.
Rogachev: “Our objectives included upgrading the plant
infrastructure to achieve a steep reduction of fuel consumption
and, consequently, production costs at the same time as
maintaining the quality of clinker production. The clinker burning
equipment had become inefficient, obsolete and worn-out, and
we also saw the opportunity for taking it out of service.
JSC Sebryakovcement needed to find an equally visionary partner
who could meet the requirements of a demanding environment.
The company had worked with FLSmidth on various projects since
2005, and it was a natural decision to continue the partnership.
From wet to dry in a
cold climate
SITE REPORT
clinker-producing capacity of 3,575 tpd: “The plant is located
between two large cement markets in the European part of
Russia. In order to sell a significant amount of cement on the
markets, even competing with wet plants, it is essential for us to
ensure the lowest production cost, since the transportation cost
makes up a large part of the cement price.
New dry cement plants have emerged recently on the same
markets, so it is vital our plant is as competitive as possible.
Therefore, as part of the plant upgrade programme and
reconstruction of all departments, the best means to bring down
the fuel cost in the plant’s production cost structure was to
convert the pyro-section from a wet to dry process.”
CONTACT CLAUS HAGEN JENSEN
CHJ@FLSMIDTH.COM
CONTACT PALLE E. GRYDGAARD
PEG@FLSMIDTH.COM
Stacker
Reclaimer
Crusher
Clay
Additive
Additive
Chalk
PGNAA
Reclaimer
Filter dust silo
Seperator
Crusher
Filter
Dryer crusher
Kiln feed silo
Cooler
Kiln Klinker
FLOW SHEET OF THE NEW DRY
CEMENT PLANT AT JSC
SEBRYAKOVCEMENT
FIRST DIRECT FEED
KILN SYSTEM IN
THE WORLD
Lower fuel consumption
Where the new dry line sets itself apart is in the concept of direct
feeding to the kiln. The plant owners worked closely with the
team at FLSmidth to design a solution that did not require the use
of a raw meal storage silo, such as a CF-silo. This was one of the
key reasons JSC Sebryakovcement chose FLSmidth, partly because
of FLSmidth’s experience and reputation, but also because of its
proven track record in producing innovative solutions to meet
specific requirements.
The concept involved feeding the raw materials with their natural
moisture content directly into the kiln system without grinding
them to slurry. Since no further water is added as before, the overall
heat consumption was reduced from the expected 1450-1500
kcal/kg clinker to less than 900 kcal/kg, which is the equivalent of
more than 40 percent in fuel consumption savings.
18. 18 HIGHLIGHTS CEMENT – APRIL 2015
FROM WET TO DRY
IN A COLD CLIMATE
A world first
A special feature of the raw materials, chalk and clay, is that they
are relatively homogeneous, regardless of where they are
extracted in the quarry. It was this feature that led to the idea of
producing the final mixture in storage. The chemical composition
of the mixture is controlled by measuring the weight and
analysing the bulk on the conveyor belt before storage.
The intended chemical composition needs to be met before
completion of a pile because no further chemical correction
is possible.
In storage, the materials are stacked according to the windrow
method made up of 10 layers split into some 20 rows. Cutting
across these approximately 200 rows produces a high
homogenising effect. Not only does this unique concept eliminate
the need for a costly raw meal blending silo, but this combination
of direct kiln feed with blending of all raw materials in storage has
not been seen before.
First clinker was achieved in September 2013, less than three
years after the contract was signed with FLSmidth. By December
2013, the performance guarantees were confirmed for the entire
upgraded clinker line. The plant has now been running for more
than one year with very high reliability.
Local expertise
Satisfied that the plant can run at 3,700 tpd, above the 3,575 tpd
target originally agreed, Claus Hagen Jensen, Project Manager at
FLSmidth, reveals why the issue of a cold climate is not actually a
problem for the line’s performance: “All parties took time during
the design phase to ensure that lessons from other cold climate
sites were taken on board. Everything was thought through very
carefully to minimise any areas of doubt. The team at JSC
Sebryakovcement took an extremely professional approach to all
aspects of the project. They went to great lengths to look ahead
in order to foresee potential issues. This plant means a lot to the
people who work there, and to the local community, which is why
the plant’s management adopted a mindset of wanting to prevent
problems before they occur.”
All performance guarantees achieved
Sergey P. Rogachev is pleased that his colleagues at JSC
Sebryakovcement have quickly developed the necessary skills to
operate the new dry cement line. And he is equally satisfied that
all performance guarantees have been achieved. He puts this
down to the experience and helpfulness of FLSmidth’s experts
during the design, construction and commissioning of the plant:
“FLSmidth believed in our experience and jointly developed a
unique production flow sheet enabling a significant reduction of
the construction costs. The first year’s operation has proved that
the flow sheet not only delivers the required clinker quality and a
considerable reduction of the fuel consumption, but also lowers
electric power costs compared to the ‘classic’ dry and wet
processes.”
“ALL PARTIES TOOK TIME DURING THE
DESIGN PHASE TO ENSURE THAT LESSONS
FROM OTHER COLD CLIMATE SITES WERE
TAKEN ON BOARD. EVERYTHING WAS
THOUGHT THROUGH VERY CAREFULLY TO
MINIMISE ANY AREAS OF DOUBT.“
Claus Hagen Jensen
Project Manager, FLSmidth
Operations have outperformed
performance guarantees
Main equipment
of JSC Sebryakovcement line 5
Crushers Guaranteed Achieved Equipment Type
Chalk crusher 600 tph (dry) 620t/h (dry) Chalk crusher EH Double Roller - 150x200
Clay crusher 250 tph (dry) 261tph (dry) Clay crusher MHC Twin Shaft Breaker 630 x 2,1
Kiln Guaranteed Achieved Mix storage –
Kiln production 3575 tph (dry) 3618 t/d Stacker Windrow stacking
Heat consumption 949 tph (dry) 807 kcal/kg clinke Reclaimers 2 Bucket excavators
Power consumption 36.31 34.56 kWg/t Raw Mill ET Drier Crusher 450 x 330
Clinker temperature 82 °C + ambient 29 °C + ambient Preheater Single string 3 cyclone stages
Free lime 1% 0.3% Calciner Low NOx
In-Line
Dust emissions Guaranteed Achieved Kiln 2 Piers – 4.35 x 54m
Main EP filter 34 mg/Nm3
(dry) 25 mg/Nm3
(dry) Cooler SF CrossBar 3 x 5
Cooler bag filter 30 mg/Nm3
(dry) 19 mg/Nm3
(dry)
Bypass bag filter 30 mg/Nm3
(dry) 26 mg/Nm3
(dry)
19HIGHLIGHTS CEMENT – APRIL 2015
19. 18 HIGHLIGHTS CEMENT – APRIL 2015
FROM WET TO DRY
IN A COLD CLIMATE
A world first
A special feature of the raw materials, chalk and clay, is that they
are relatively homogeneous, regardless of where they are
extracted in the quarry. It was this feature that led to the idea of
producing the final mixture in storage. The chemical composition
of the mixture is controlled by measuring the weight and
analysing the bulk on the conveyor belt before storage.
The intended chemical composition needs to be met before
completion of a pile because no further chemical correction
is possible.
In storage, the materials are stacked according to the windrow
method made up of 10 layers split into some 20 rows. Cutting
across these approximately 200 rows produces a high
homogenising effect. Not only does this unique concept eliminate
the need for a costly raw meal blending silo, but this combination
of direct kiln feed with blending of all raw materials in storage has
not been seen before.
First clinker was achieved in September 2013, less than three
years after the contract was signed with FLSmidth. By December
2013, the performance guarantees were confirmed for the entire
upgraded clinker line. The plant has now been running for more
than one year with very high reliability.
Local expertise
Satisfied that the plant can run at 3,700 tpd, above the 3,575 tpd
target originally agreed, Claus Hagen Jensen, Project Manager at
FLSmidth, reveals why the issue of a cold climate is not actually a
problem for the line’s performance: “All parties took time during
the design phase to ensure that lessons from other cold climate
sites were taken on board. Everything was thought through very
carefully to minimise any areas of doubt. The team at JSC
Sebryakovcement took an extremely professional approach to all
aspects of the project. They went to great lengths to look ahead
in order to foresee potential issues. This plant means a lot to the
people who work there, and to the local community, which is why
the plant’s management adopted a mindset of wanting to prevent
problems before they occur.”
All performance guarantees achieved
Sergey P. Rogachev is pleased that his colleagues at JSC
Sebryakovcement have quickly developed the necessary skills to
operate the new dry cement line. And he is equally satisfied that
all performance guarantees have been achieved. He puts this
down to the experience and helpfulness of FLSmidth’s experts
during the design, construction and commissioning of the plant:
“FLSmidth believed in our experience and jointly developed a
unique production flow sheet enabling a significant reduction of
the construction costs. The first year’s operation has proved that
the flow sheet not only delivers the required clinker quality and a
considerable reduction of the fuel consumption, but also lowers
electric power costs compared to the ‘classic’ dry and wet
processes.”
“ALL PARTIES TOOK TIME DURING THE
DESIGN PHASE TO ENSURE THAT LESSONS
FROM OTHER COLD CLIMATE SITES WERE
TAKEN ON BOARD. EVERYTHING WAS
THOUGHT THROUGH VERY CAREFULLY TO
MINIMISE ANY AREAS OF DOUBT.“
Claus Hagen Jensen
Project Manager, FLSmidth
Operations have outperformed
performance guarantees
Main equipment
of JSC Sebryakovcement line 5
Crushers Guaranteed Achieved Equipment Type
Chalk crusher 600 tph (dry) 620t/h (dry) Chalk crusher EH Double Roller - 150x200
Clay crusher 250 tph (dry) 261tph (dry) Clay crusher MHC Twin Shaft Breaker 630 x 2,1
Kiln Guaranteed Achieved Mix storage –
Kiln production 3575 tph (dry) 3618 t/d Stacker Windrow stacking
Heat consumption 949 tph (dry) 807 kcal/kg clinke Reclaimers 2 Bucket excavators
Power consumption 36.31 34.56 kWg/t Raw Mill ET Drier Crusher 450 x 330
Clinker temperature 82 °C + ambient 29 °C + ambient Preheater Single string 3 cyclone stages
Free lime 1% 0.3% Calciner Low NOx
In-Line
Dust emissions Guaranteed Achieved Kiln 2 Piers – 4.35 x 54m
Main EP filter 34 mg/Nm3
(dry) 25 mg/Nm3
(dry) Cooler SF CrossBar 3 x 5
Cooler bag filter 30 mg/Nm3
(dry) 19 mg/Nm3
(dry)
Bypass bag filter 30 mg/Nm3
(dry) 26 mg/Nm3
(dry)
19HIGHLIGHTS CEMENT – APRIL 2015
20. 20 HIGHLIGHTS CEMENT – APRIL 2015 21HIGHLIGHTS CEMENT – APRIL 2015
Fabric filters are used across a variety of different industries as they
are very efficient in securing emissions at extreme low dust levels.
In many applications, they are used as a final purification step to
remove particulate matter from the flue gas. FLSmidth is a market
leader in this field with extensive experience and in-house
knowledge on how to design, manufacture and operate fabric
filters.
Reduced CAPEX and OPEX
Capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one cost-effective process, EnviroTex
provides compelling opportunities for CAPEX savings (initial
investment needed) and OPEX savings (ongoing operating cost).
Since the filter bag requires less space than alternative solutions, it
also provides opportunities to reduce the physical footprint.
Ole Bøegh, CEO, FLSmidth Air Pollution Control says, “We believe
the catalytic filter bag will be a game-changer because it enables
cement plant owners to clean industrial off-gases and meet
stricter legislation at a fraction of the cost compared with best
available technologies today.”
Ole Bøegh explains the bag’s uniqueness: “It doesn’t just provide
us with the flexibility to tailor different catalytic combinations for
different industries; it also makes it possible to handle the removal
of several critical compounds in one integrated process. This can
significantly reduce the cost of off-gas cleaning. Remember that
today’s standard is to use separate stand-alone systems to remove
specific compounds.”
Fast-tracking innovation potential
Denmark-based Haldor Topsoe is a highly successfully
manufacturer and researcher within catalysis and surface science.
Over the past four years, FLSmidth and Haldor Topsoe have
worked closely together on developing the patent-pending
EnviroTex™
technology. The product has been thoroughly tested
and proven efficient for several industrial applications.
Key to the development of this unique product is the combination
of FLSmidth's expertise and market leadership in filters for
industrial processes as well as process integration and Haldor
Topsoe’s leadership in catalysis.
A game-changing filter bag based on
catalytic technology provides significant
CAPEX and OPEX reductions.
FLSmidth has teamed up with the Danish catalyst specialist Haldor
Topsoe to release a new type of filter bag. Called EnviroTex™
, it is
capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one integrated and cost-effective process.
It has been designed for use at cement plants, but it can just as
easily be used in power production, biomass, waste incineration,
glass and metal production, and similar.
The key differentiating factor about the patent-pending catalytic
filter bag lies in its three layers of filter fabric. Each layer contains a
tailored catalyst optimised for the removal of specific kinds of
compounds from the off-gas that passes through it.
Smashing the costs
of removing gaseous
emissions and dust
“WE BELIEVE THE CATALYTIC FILTER BAG
WILL BE A GAME-CHANGER BECAUSE IT
ENABLES CEMENT PLANT OWNERS TO
CLEAN INDUSTRIAL OFF-GASES AND MEET
STRICTER LEGISLATION AT A FRACTION OF
THE COST COMPARED WITH BEST
AVAILABLE TECHNOLOGIES TODAY.”
Ole Boegh, CEO, FLSmidth Air Pollution Control
INNOVATION
CONTACT KARSTEN POULSEN
KSP@FLSMIDTH.COMFLSMIDTH AND HALDOR TOPSØE
REPRESENTATIVES GATHERED AT HALDOR
TOPSØE HEAD QUARTER IN LYNGBY,
DENMARK DURING THE SIGNING
CEREMONY, JANUARY 2015
21. 20 HIGHLIGHTS CEMENT – APRIL 2015 21HIGHLIGHTS CEMENT – APRIL 2015
Fabric filters are used across a variety of different industries as they
are very efficient in securing emissions at extreme low dust levels.
In many applications, they are used as a final purification step to
remove particulate matter from the flue gas. FLSmidth is a market
leader in this field with extensive experience and in-house
knowledge on how to design, manufacture and operate fabric
filters.
Reduced CAPEX and OPEX
Capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one cost-effective process, EnviroTex
provides compelling opportunities for CAPEX savings (initial
investment needed) and OPEX savings (ongoing operating cost).
Since the filter bag requires less space than alternative solutions, it
also provides opportunities to reduce the physical footprint.
Ole Bøegh, CEO, FLSmidth Air Pollution Control says, “We believe
the catalytic filter bag will be a game-changer because it enables
cement plant owners to clean industrial off-gases and meet
stricter legislation at a fraction of the cost compared with best
available technologies today.”
Ole Bøegh explains the bag’s uniqueness: “It doesn’t just provide
us with the flexibility to tailor different catalytic combinations for
different industries; it also makes it possible to handle the removal
of several critical compounds in one integrated process. This can
significantly reduce the cost of off-gas cleaning. Remember that
today’s standard is to use separate stand-alone systems to remove
specific compounds.”
Fast-tracking innovation potential
Denmark-based Haldor Topsoe is a highly successfully
manufacturer and researcher within catalysis and surface science.
Over the past four years, FLSmidth and Haldor Topsoe have
worked closely together on developing the patent-pending
EnviroTex™
technology. The product has been thoroughly tested
and proven efficient for several industrial applications.
Key to the development of this unique product is the combination
of FLSmidth's expertise and market leadership in filters for
industrial processes as well as process integration and Haldor
Topsoe’s leadership in catalysis.
A game-changing filter bag based on
catalytic technology provides significant
CAPEX and OPEX reductions.
FLSmidth has teamed up with the Danish catalyst specialist Haldor
Topsoe to release a new type of filter bag. Called EnviroTex™
, it is
capable of removing ammonia, nitrogen oxides, volatile organic
compounds and dust in one integrated and cost-effective process.
It has been designed for use at cement plants, but it can just as
easily be used in power production, biomass, waste incineration,
glass and metal production, and similar.
The key differentiating factor about the patent-pending catalytic
filter bag lies in its three layers of filter fabric. Each layer contains a
tailored catalyst optimised for the removal of specific kinds of
compounds from the off-gas that passes through it.
Smashing the costs
of removing gaseous
emissions and dust
“WE BELIEVE THE CATALYTIC FILTER BAG
WILL BE A GAME-CHANGER BECAUSE IT
ENABLES CEMENT PLANT OWNERS TO
CLEAN INDUSTRIAL OFF-GASES AND MEET
STRICTER LEGISLATION AT A FRACTION OF
THE COST COMPARED WITH BEST
AVAILABLE TECHNOLOGIES TODAY.”
Ole Boegh, CEO, FLSmidth Air Pollution Control
INNOVATION
CONTACT KARSTEN POULSEN
KSP@FLSMIDTH.COMFLSMIDTH AND HALDOR TOPSØE
REPRESENTATIVES GATHERED AT HALDOR
TOPSØE HEAD QUARTER IN LYNGBY,
DENMARK DURING THE SIGNING
CEREMONY, JANUARY 2015
22. 23HIGHLIGHTS CEMENT – APRIL 201522 HIGHLIGHTS CEMENT – APRIL 2015
SMASHING THE COSTS
OF REMOVING GASEOUS
EMISSIONS AND DUST
“Developing this product has been a combination of the very best
that Topsoe and FLSmidth have to offer from an RD perspective.
By combining FLSmidth's expertise in filtration in industrial
processes with Topsoe’s leadership in catalysis, we have created a
unique product that will allow customers to meet increasingly
stringent environmental legislation” says Bjerne S. Clausen, CEO
at Haldor Topsoe.
Thomas Schulz, CEO of FLSmidth says, “It is an imperative for
FLSmidth to retain technology leadership with innovative new
solutions increasing energy efficiency and lowering cement plants’
environmental impact at a competitive lifecycle cost.”
He adds, “The EnviroTex™
catalytic filter bags will enable cement
plants to upgrade their environmental equipment to fulfill
tightened legislation at low cost and with minimum influence on
existing production equipment.”
Efficient removal of gaseous emissions and
particulate matter
Whereas a normal filter bag is a one-layer filter of textile, EnviroTex
has a three-layer porous woven structure with various catalyst
formulas customised for each layer through which gases are sent,
leaving the dust on the outer surface and removing the gaseous
pollutants when passing through the layers. Typically, the filter
bags are six to ten meters long and have a diameter of 127 mm.
It will easily remove dust below 5mg/Nm3
. At the same time, it
converts nitrogen oxides (NOx
) and ammonia (NH3
) into harmless
nitrogen (N2
) and water (H2
O). Organic hazardous air pollutants
(O-HAP), including toluene, benzene and formaldehyde, are
converted into carbon dioxide (CO2
) and water (H2
O). Dioxin,
furans and CO are also removed if it is present in the flue gas.
Immediate opportunities in the US
“Initially we believe the US market will benefit from the product,
because cement producers here are faced with immediate
challenge in order to meet new regulatory requirements that
have been issued by the US Environmental Protection Agency
and will take effect 1 September 2015,” says Thomas Schulz,
CEO at FLSmidth.
He points out that, in the longer term, China may hold an even
greater market potential as the country is also imposing stricter
emission legislation.
As part of the agreement between FLSmidth and Topsoe, the
new product will be manufactured at FLSmidth’s bag production
facilities in Georgia, USA. The high quality filter bags will then be
embedded with catalyst and assembled at Topsoe’s catalyst
production site in Houston, Texas.
EMBEDDED CATALYST IN WOVEN FIBER GLASS BAG
Newpyro system and cement
mills for Manikgarh Cement
The cement producer first announced its
plans to build a brownfield integrated
cement plant in 2010. Located in
Gadchandur, a town in the Chandrapur
District in the State of Maharashtra,
Manikgarh Cement is a division of
Century Textiles Industries Ltd., owned
by the BK Birla Group, which operates
within a variety of industries, including
textiles, rayon, chemicals, paper pulp,
and cement.
Following a lengthy series of technical
and commercial negotiations, during
which many different solutions were
weighed up, Manikgarh Cement awarded
the contract for supply of pyro processing
system and cement mills to FLSmidth. The
project kicked off immediately after the
signing of the contracts for both projects
in May 2010.
Modern pyro processing system
The scope of the 8,000 tpd pyro
processing system includes the design,
engineering, manufacture and supply of
the complete array of equipment.
It features a CF silo for homogenising and
storing raw meal with a capacity of
24,000 tonnes and bulk density of
0.9 t/m3
. With a six-stage twin string
Inline Calciner (ILC), its preheater was
designed to optimise fuel and power
consumption and minimise emissions.
The rotary kiln was lit up on 17 August
2014 and was soon producing the desired
clinker output of 8,000 tpd.
SITE REPORT
CONTACT RAZAL ALI
RAZAL.ALI@FLSMIDTH.COM
Project timeline
26 May 2010
Contract signed
May 2011
Completion of engineering
November 2011
Site mobilisation (mechanical)
September 2012
Supply of major equipment
17 August 2014
Plant commissioning
Manikgarh Cement Limited, owned by India’s BK Birla Group of
Companies, has successfully commissioned a three million tpy
cement plant.
Scope of supply - Pyro process
• CF silo – 22.4m in diameter, 55m
in height
• Kiln feed system
• ILC preheater – 8m in diameter, 160m
in height
• 3-base rotary kiln – 5.5m in diameter,
87m in length
• SF Cross Bar®
5x7F clinker cooler, with
heavy-duty roller breaker MF 418
• Coal dozing and firing system
• Clinker transport to storage
Cement mill
The cement mill contract included the
complete design, engineering,
manufacturing and supply of equipment.
The UMS ball mills supplied as part of the
contract grind at the rate of 150 tph.
All three mills have been commissioned
and are currently running at the expected
production rate, while performance
guarantee tests are currently in progress.
Scope of supply - Cement grinding
• UMS Ball mill - 4.6m dia x 15.5 m long
• Dynamic separator Sepax 500 M-22
Razal Ali, Project Manager, was
responsible for the project delivery from
FLSmidth. He is very pleased that the
project ran smoothly, saying, “There was
no delay in deliveries, which is one of the
most essential aspects of completing a
project on time and at the expected level
of perfection.” He adds that the
cooperation between FLSmidth and
Manikgarh’s cement execution teams was
highly efficient.
PREHEATER VIEW
