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Article World cement - april2018 - Cem'In'Eu - A European Network


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Cem'In'Eu - A European Network

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Article World cement - april2018 - Cem'In'Eu - A European Network

  1. 1. A EUROPEAN NETWORKIntroduction Cem’In’Eu is an industrial start-up, developing new cement production and marketing concepts in Europe, with a flexible approach to the business and strong breakthroughs in supply, logistics, production, and the selling of cement. Current projects Cem’In’Eu has launched several identical cement grinding projects that will cover part of the European market. France Aliénor Ciments Built on a fully-owned property located in Tonneins and connected to the rail network by a private junction, Aliénor Ciments will serve the markets of southwest France. Vincent Lefebvre, Cem’In’Eu, discusses the growth of cement plants in Europe. CimSaRo Located in the Port of Chalon-sur-Saône, on a plot with a long‑term lease directly connected to the rail network and the Saône river, CimSaRo will offer its products in Auvergne-Rhone-Alps, Burgundy-Franche Comté, and French-speaking Switzerland. Rhône Ciments Located on land of the Port of Valence with a long-term lease, using rail and the Rhône river, Rhône Ciments will supply the customers of Rhône Alpes, Auvergne, and the Mediterranean Coast. Ciments des Trois Frontières (C3F) Located on land off the Port of Mulhouse‑Ottmarsheim with a long-term lease, using rail and the Rhine river, Ciments des Trois Frontières will supply customers in Alsace, Baden-Württemberg, and German-speaking Switzerland. Val de Loire Ciments Val de Loire Ciments is located in Montreuil Bellay, in western France, on fully‑owned land with its private rail branch, and will deliver to the markets of western and central France. Poland Pomorski Cement Pomorski Cement is located in the Port of Gdynia, with a long-term lease on a plot at 800 m from the bulk docks. It will deliver to the markets of northern Poland around Gdansk.
  2. 2. Reprinted from April 2018 World Cement UK Cem’In’Eu’s project will be on the River Thames, in the east of the Greater London area. It will deliver to the souteastern part of England, where 50% of the national GNP is concentrated. Industrial and production model The modular grinding plants of Cem’In’Eu are highly versatile and adapt themselves to a large variety of possible installations. They occupy a reduced land area (about 2.5 ha), are modular, removable, entirely above ground, and built on simplified civil engineering. As such, they are adaptable to a variety of topographic configurations, and allow the installation of two grinding mills with an output of 30 tph each. The second mill is designed from the very beginning, but not built in the first phase, allowing a smooth ramp-up to a production of 250 000 tpy before eventually doubling the capacity, depending on market demand. The use of the best technologies available in terms of environmental protection (dust and noise) and the supply of raw materials by environmental friendly logistics (maritime, river, or rail) allows Cem’In’Eu to implement plants in places where a bigger and traditional cement mill would never be possible. Cem’In’Eu conducts the engineering of the plants internally, working with talented manufacturers from the EU to ensure the highest standards in term of safety, environmental protection, and cement quality. Each grinding plant will employ around 30 people, including local administration and sales. The CAPEX involved for the various French plants varies from e18 − 20 million, depending on the size and design of the clinker hall as well as the following civil engineering conditions: ll Raw materials storage of 5000 – 10 000 t (Serru, France). ll Cement ball mill of 30 tph with the lastest generation of cement separator to ensure high‑efficiency particle separation (Intercem, Switzerland). ll Six cement silos of 500 t each for bulk loading with two weighbridges (Orhand, France). ll A cement bag hall with a third weighbridge (Serru, France). ll An Adams packing machine for polyethylene bags production (clean and waterproof) and a Batipal palletiser with paletless stretching technology (Haver & Boecker and Newtec, Germany). ll An electric crane bridge and automatic tilting tray (Secam, France). ll An electric and fully automatised control system (Ibitek, France). For the bagging process, Cem’In’Eu has chosen polyethylene sealed plastic bags, using an Adams Chalon Montreuil Bellay Tonneins Portes Ottmarsheim Sète Figure 1. France project map. Poland Project in Gdynia Figure 2. Poland project map. UK Project Figure 3. UK project map.
  3. 3. Reprinted from April 2018 World Cement system coupled with a palletless Haver & Boecker. This will allow a direct supply of cement at the jobsite, with self‑discharging trucks, regardless of the weather. Logistic model In France, Cem’In’Eu imports the clinker by sea freight, thanks to its large-capacity storage in the port of Sète (60 000 t). The discharging of the clinker from the boats is completed by a hydraulic crane (Liebherr, Germany) into the dedusted hopper of Cem’In’Eu (RBL, France). In Poland and the UK, the port sites are at the heart of the targeted markets. The clinker storage capacity of the two sites will be optimised by combining their supply and by benefiting from the return freights available. Due to the high density of 1.4 t/m3 of the clinker, Cem’In’Eu decided to containerise it in order to use container trains instead of bulk car wagons. Cem’In’Eu has designed a specific 20 ft container, reinforced with two manholes and a tilt door. This allows the loading of 32.8 t per container and a total payload of 1350 t per train. This train, which consists of 21 wagons and is 290 ml long, is much smaller than a 400 ml conventional bulk carriage train, allowing the use of private junctions on much smaller pieces of land. At the plant, the train is unloaded by a reach-stacker on tyres, operated by the ports. On the sites only connected by rail, where reach-stackers are not available, there is a fully‑automatic electric crane bridge that discharges and recharges full and empty containers efficiently. The transfer to bulk storage is completed by an automatic tilting tray, which drains through the tilting door of the container. Commercial model Cem’In’Eu implements its grinding plants at the heart of the targeted markets, minimising the outbound logistics by truck comparative to integrated plants that have to reply on geography. Locations are selected in mature markets where two to three international cement players currently share a volume of 3 − 4 million t. Therefore, the plant of 250 000 tpy will capture a 7 − 8% market share, not enough to destabilise it. The company divides its targeted market into three equal segments: prefab concrete, ready-mixed concrete, and bags. Thanks to its fully‑sealed and waterproof plastic bags and palletless technology, Cem’In’Eu can deliver its bags directly to the end user (Masons) at the job site. Figure 4. Aliénor plant. Figure 5. Plans for Cimsaro plant. Figure 6. 3D view of Séte.
  4. 4. Reprinted from April 2018 World Cement Therefore, Cem’In’Eu is able to avoid a lot of inefficiencies linked to the traditional model of selling bagged cement through building material distribution chains. These inefficiencies include the following: ll No double transport (cement plant to warehouse, warehouse to jobsite). ll No cost for handling and dry storage. ll No cost for commercial intermediaries, ll Direct access to the end user for more efficient marketing. The digital package offers precise geo-tracking and personalised quotes, as well as the benefit of a dynamic pricing linked with Cem’In’Eu’s logistic planning and savings. Planning The company started in summer 2014. During the first 18 months, it developed the design and engineering of the plants, and selected the various markets it wanted to be in. It secured the land for its first three French plants during 1Q16. The process to obtain the construction licence and the environmental and operating licence lasted roughly one year in France, after at least 6 months of preliminary studies. All permits for Aliénor Ciments were obtained in June 2017, and the civil engineering started in September. The commissioning of the plant is due mid‑May 2018. The CimSaRo plant has obtained all its necessary permits, and plans to start its construction are due to commence during the summer of 2018, just after the start of Alienor plant. C3F already has the construction permit, has passed all the steps of public enquiries, and expected to receive the final environmental and operation licence during 1Q18. The two other French projects (Rhône Ciments and Val de Loire Ciments) are at an earlier stage of development. The land is secured, and the process of licencing and permitting will start in early 2018, with all permits expected to be granted by the end of the year. In Poland, the land was secured at the end of 2016. After a long process of detailed engineering, the construction permit and environmental licence are expected to be obtained 2H18, with a construction period of 10 − 12 months, dependent of the weather conditions. In the UK, the land is almost secured, with a permitting and licensing process of 6 − 8 months, and a similar timeframe for construction. Conclusion By 2020, Cem’In’Eu expects to have built a network of seven identical cement grinding plants, in strong markets currently served by very few established cement players. With its innovative concepts, it aims at offering an alternative to its future customers. About the author Vincent Lefebvre has been the Founder and Executive Chairman of Cem’In’Eu since 2014. Previously, he worked for Holcim for more than 20 years, as Executive Committee Member and CEO in France, Belgium, and Spain. Figure 7. Lastest workshop plan for the containurisation of Séte plant. Figure 8. Plan for the bridge crane.