Global Cement Magazine - June 2018 - Ximang.vn

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KIMA ECHTZEITSYSTEME IS NOW KIMA PROCESS CONTROL

WE OPTIMIZE PRECISELYEVEN OUR NAME

JUNE 2018

News UK Optimisation DG Khan visit CO2 Grinding Vibration IEEE-IAS/PCA Review Global Slag Crushing Alternative fuels

gl bal cement MAGAZINE

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For over 90 years, KettenWulf, as an expanding global company, has stood for quality, reliability and flexibility. More than 1400 employees develop, manufacture and market customized solutions in the field of conveying and drive technology at ten locations across Europe, America, Australia and Asia. All around the globe, KettenWulf is your strategic partner when it comes to delivering cutting edge product quality.

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Welcome to the June 2018 issue of Global Cement Magazine - the world’s most widely-read cement magazine - which will be distributed at the biennial Hillhead Quarrying and Recycling Show in Buxton, UK on 26-28 June 2018. The event attracted 18,655 visitors from 71 countries to 476 exhibitors last time out in 2016 and once again promises to be very busy indeed. To tie in with the location and themes of the event, this issue carries a review of the past 12 months in the UK cement sector from Edwin Trout of the Cement Industry Suppliers’ Forum (Page 42). There is also a look at crushing limestone to raw feed size in a single step (Page 20) and an article on alternative fuel feeding (Page 28). Global Cement will be in attendance as always - Come and say ‘hello’ to us on stand PC45 in the main pavilion.

This issue has a detailed visit report from the DG Khan Cement plant at Khairpur, Punjab, Pakistan (Page 62). Robert McCaffrey reports on this ‘self-sufficient’ cement plant, with a full process run-down and details of the plant’s waste heat recovery plant, use of alternative fuels and even the on-site orchards used to provide its canteen! Also in this issue we have a detailed look at how large cement producers are looking more deeply into their global operations and optimising ‘group-wide’ (Page 8). As Angus Maclean from management consultant Proudfoot explains, this is not about just optimising individual cement plants in isolation, but developing a group-wide approach to how they should be optimised uniformly to the benefit of the group as a whole. This holistic approach can also be applied to finance, health and safety and environmental aspects of operation by facilitating in-depth knowledge-sharing across a group. Elsewhere there are further technical contributions on vibration monitoring (Page 24), how vertical roller mill performance can be improved using grinding aids (Page 14) and reviews of the recent Global Slag Conference & Exhibition (2) and IEEE-IAS/PCA Conference (Page 51).

We hope that you enjoy this issue of Global Cement Magazine - the world’s most widely-read cement magazine!

Peter EdwardsEditor

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GLOBAL CEMENT MAGAZINE: DEAR READERS

Global Cement Magazine June 2018 3


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KIMA Echtzeitsysteme GmbH (KIMA Process Control) Attention! There are two cement sector companies called ‘KIMA’ from Germany, one called ‘KIMA Automation’ from Gronau (automation and electrical systems) and one called ‘KIMA Echtzeitsysteme’ from Juelich (Advanced Process Control and Instrumentation Development – that’s who we are!)For 22 years KIMA Echtzeitsysteme has been working in the field of high performance closed loop controls, innovative sensor systems and databases for processing industries. With SmartFill, it sets new worldwide standards regarding the precision and reliability of measuring the fill level of ball mills. With the ‘KilnCooler’ another intelligent solution is provided that treats heated spots on the kiln shell and avoids unexpected kiln stops. Actually KIMA Echtzeitsysteme GmbH has changed its brand and has started up a new website under the new name KIMA Process Control. Visit www.kima-process.de, where you will find more details about products and case studies. Have a look into it! Contact: Mr Dirk Schmidt, DirectorTel: +49 2463 9967 – 0

Fax: +49 2463 9967 – 99Email: [email protected]: www.kima-process.de / www.kimaE.de




JUNE 2018



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GLOBAL CEMENT MAGAZINE: CONTENTS

4 Global Cement Magazine June 2018

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Features 8 Realising potential from quarry to lorry

Global Cement speaks to Angus Maclean of management consulting firm Proudfoot about the Target Operating Model (TOM) tool for optimisation across a cement group.

12 Cement companies must more than double efforts to meet Paris climate goals

A new report analyses 13 of the world’s largest publicly-listed cement companies, and reveals that they need to more than double their emissions reductions if they are to limit global warming to below 2°C.

14 Progress with grinding aids for VRMs

Sika’s Matthias Dietrich shows the added value of carefully selected grinding aids for vertical roller mills.

20 Straight to the end product at the primary crushing stage

Crush+Size’s Matthias Dick outlines efficient single-step crushing with low content of small grain sizes.

24 Vibration goes back to basics

Understanding the underlying conditions behind machine vibrations in the cement plant has a range of benefits.

28 Pelican: Entsorga’s alternative fuel feeding system for the cement industry

Entsorga outlines its first Pelican alternative fuel feed-ing system, installed at the Essroc Nazareth plant, USA.

32 Global Slag Conference 2018 - Reviewed

Robert McCaffrey reports on the successful 13th edition of the Global Slag Conference, which took place in Prague, Czechia.

37 SCHÜTTGUT now called SOLIDS Dortmund

38 Products and contracts

Plug&Grind Vertical for Dunbar; Dangote orders for Gebr. Pfeiffer and Loesche.

GLOBAL CEMENT MAGAZINE: CONTENTS


Europe 39 News - HeidelbergCement strong despite winter; Buzzi and Cementir tumble; New Russian plant.

42 The UK cement sector in 2017-2018

Edwin Trout from the Cement Industry Suppliers’ Forum provides his take on the UK cement sector over the past 12 months.

Americas 48 News - Colombian woes weigh on Cementos Argos;

ANCAP restarts; Votorantim on the rebound?

51 Review: 60th IEEE-IAS/PCA Cement Industry Technical Symposium

Our review of the 60th IEEE-IAS/PCA Cement Industry Technical Symposium in Nashville, US.

Asia58 News - Afghan plant to be

re-tendered; Dewan rejects Mega bid;.

62 DG Khan Khairpur: The self-sufficient cement plant

Robert McCaffrey heads to Pakistan to visit the DG Khan cement plant at Khairpur, Punjab.

Middle East & Africa69 News - CIMAF starts Ivory Coast project; Algeria’s GICA

starts exports to Europe; New plant in Morocco.

Regulars & Comment

61 Subscription form

72 Global Cement prices

Cement prices from around the world. Subscribers get additional information.

73 The Last Word - What are the upcoming risks to the global cement sector?

74 Advertiser Index & Forthcoming issue features

Hillhead Quarrying & Recycling Show 201826-28 June 2018, Buxton, UKwww.hillhead.com

FICEM Technical Congress 20183-5 September 2018, Panama City, Panamawww.congresotecnico2018.ficem.org

RWM Recycling Exhibition12-13 September 2018, Birmingham, UKwww.rwmexhibition.com

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BULKEX 2018 Conference & Exhibition18-19 October 2018, Eastwood, UKwww.bulkex.co.uk

SOLIDS Dortmund 20187-8 November 2018, Dortmund, Germanywww.solidsdortmund.com

23rd Arab-International Cement Conference & Exhibition20-22 November 2018, Amman, Jordanwww.aucbm.org

4th Global CemPower Conference & Exhibition 22-23 January 2019, London, UK www.CemPower.com

13th Global CemFuels Conference & Exhibition 20-21 February 2019, Amsterdam, Netherlands www.CemFuels.com

14th Global Slag Conference & Exhibition 3-4 April 2019, Aachen, Germany www.GlobalSlag.com

61st IEEE-IAS/PCA Cement Industry Technical Conference28 April - 2 May 2019, St Louis, USAwww.cementconference.org

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Global Cement (GC): What is a Target Operating Model (TOM)?

Angus Maclean (AM): Target Operating Models develop and ensure that behaviours, underpinned by processes and management tools, are optimised, from ‘quarry-to-lorry’ across a cement producer’s business. TOMs go beyond simply optimising each cement plant at a local level. Instead they define how each plant should be optimised uniformly across a group.

The result for cement producers is an improved return on net assets and higher earnings before interest, tax, debt and amortisation derived from improvements across the industrial value stream at the right cost and within the right time-frame. Now that many producers have cut every possible cost that they can, a TOM allows producers to save money across all plant locations. It also makes plant managers’ lives easier by simplifying their day-to-day operations. TOM now becomes the foundation for fi-nancial benefits, and with Proudfoot Transformation know-how, you can link behavioural transformation through people to real financial results tracked on a weekly basis.

GC: Which kinds of companies is it for?

AM: Proudfoot has developed TOMs specifically for large cement, ready-mix concrete and aggregate producers like Lafarge Holcim, HeidelbergCement, CRH, and regional groups like Secil and Vicat.

GC: Why have the TOMs been developed now?

AM: We developed TOMs to help the major groups keep up with the consolidation we have seen lately in the cement sector. Due to the various mergers, acquisitions and divestments, there are now several different ways of working within many of the large cement multinationals.

A multinational may have older plants that have strong personnel and working practices in the devel-oped markets like North America or Europe. They may also have brand new plants in developing regions that might not have such strong technical personnel or may have less effective working practices. On top of this there is increasing pressure from sharehold-ers to ‘squeeze’ assets. These situations make it tricky for the big players to optimise their operations on a global scale.

What a TOM does is develop an optimal way of working for each producer that can be applied around the world. We have, for example, recently helped design, develop and implement new ways of

GLOBAL CEMENT: OPTIMISATION

Interview by Peter Edwards, Global Cement Magazine

Realising potential from quarry to lorry


Cement producers around the world have been on a cost-cutting drive over the past decade due to the global economic conditions and overcapacity in many markets. Once all costs have been cut, what else can be done? Now the largest groups are looking more deeply at how their plants operate to understand, optimise and unify their assets globally, often across wide technological and cultural divides. To find out more, Global Cement recently spoke to Angus Maclean of management consulting firm Proudfoot about the company’s Target Operating Model (TOM) tool for group-wide optimisation.


Right: TOMs allow cement producers to optimise their operations globally from quarry-to-lorry (truck).

working for LafargeHolcim and for Secil. Each TOM is different but it has been arrived at by a similar col-laborative process. As well as the financial benefits there are benefits for environmental performance and health and safety. TOMs also facilitate movement of personnel across a group’s global operations. We also help businesses ready themselves for increased digitisation of business processes, often known as ‘Industry 4.0.’

GC: How does the TOM process work?

AM: Generally it splits down into defining criteria for three different areas: Technical performance, busi-ness performance and people management.

The technical performance side takes in eve-rything you can imagine in terms of how a plant should run and be optimised, right from the quarry, to the crushers, the mills, the kilns, the coolers and dispatch.

Business performance optimisation, often domi-nated by financial aspects, looks at everything that the business must do to streamline its non-technical working practices. For example, these large groups have very onerous financial reporting requirements in different jurisdictions around the world. A TOM asks and answers questions like, ‘What is the most ef-ficient way for our individual businesses to report to the rest of the group?’

Last but not least, the management of personnel is now a critical issue for global cement producers. The importance of optimising how people are man-aged, especially with respect to succession planning, cannot be overstated. I’ve seen some risky situations lately. In one case there were 90 people working in the cement plant and 33 were due to retire in the next two years. In another case there were 16 people in a quarry, with 15 retiring in the next 18 months! It doesn’t matter how good the plant or group per-forms right now, since if it ‘plans’ like this, it won’t be equipped for the future.

Performance across these three pillars varies by company and country. We find that some groups and countries have poor financial performance but have great technical performance and people plan-ning systems. Others have fantastic financial metrics but terrible technical performance. This might be the case in developing markets where producers are breaking their kit for a quick buck.

GC: How is a TOM designed?

AM: The team at Proudfoot works with in-house teams separately on the three main pillars: Techni-cal performance, business performance and people management. On top of the pillars there are 10-12 topics that cover different aspects of each. Within those topics the cement producer will then identify 50-80 elements that it considers ‘the best way’ to achieve its stated aims for each topic. Each element looks at quite a specific area, for example: preventa-tive maintenance, automation or the best way to blast, load and haul in the quarry.

For one of the major cement producers we worked remotely via video conference with ~150 operational, technical, commercial and supply chain staff. We designed 32 elements that stated, according to that group of people, how a cement plant should be run. Another firm wanted 72 elements!

These meetings involve a lot of discussion and diplomacy. However, by including staff from every part of the group and every region, our approach eliminates the perception that the decisions are being taken by the ‘powers that be.’ The team goes back to its different plants and says ‘This is what we decided.’ That helps the programme to gain acceptance from the wider workforce. The success of any TOM is the understanding by all employees of how the process works and what it is supposed to achieve. The imple-mentation is key.

GC: How is a TOM implemented?

AM: The TOM allows the producer, along with us, to evaluate the plants that are performing well overall, as well as in each area. This kind of holistic approach is different to what we saw previously, when certain financial or performance aspects dominated many analyses. Each plant will be evaluated using a



Left: Succession planning is a big issue for cement producers

in developed markets. TOMs can be used to help globalise a

group’s approach and plan more effectively for future demands.

“TOMs go beyond simply optimising each cement plant at a local level. Instead they

define how each plant should be optimised uniformly

across a group...”

maturity assessment checklist against the various ele-ments. For each element the producer will rank its plants on a scale of ‘0-5,’ ‘not implemented’ to ‘excel-lent’ or ‘red, amber, green.’ This shows how well each plant is performing.

Crucially, the checklist also shows the plant what must be done to reach the next level. The plant then works out its own performance improvement plan based on the requirements of the checklist. Many groups carry out fresh assessments every year. This eventually results in the standardisation of working practices across the group.

To help show plant managers how the TOM works, the producer will often set up regional exam-ples. From those plants, its regional teams will then visit other plants to carry out the checklist process and advise the management.

Proudfoot can also show the group how the plants are performing on an x-y-z scatter plot, where each axis represents a different pillar. This is a great visual tool that quickly identifies outlying plants, both under-performers and best cases.

GC: How do TOMs help on the personnel side?

AM: They can help with many aspects, for example with succession planning. Previously we found that HR departments operated on a country-by-country basis in a lot of the big groups. Now they are becom-ing more global. How TOMs help is by properly defining the capabilities and competencies for people employed in a number of key roles within the plant. This could be plant manager, production manager, maintenance manager, quarry manager, and so on. It also defines the necessary abilities of others that may be suited to the different roles in the future. TOMs make it easier for groups to move people around be-tween plants due to the reduction in ‘culture-shock.’

GC: Does Proudfoot advise the best approach for the producer?

AM: Proudfoot does not advise its clients on the end goals or how to achieve them. The number of pillars, topics and elements is up to them. Some won’t use all three pillars. Some will only use a few topics and elements in each pillar. There can be a lot of variation.

GC: Opinions play a reasonably significant role in defining a TOM. Does that mean that, however well-implemented it may be, a TOM could lead a group in the wrong destination?

AM: On the technical side this is unlikely. While each multinational has a variety of plants, there are only a few ways to run each type of plant optimally. There is therefore the most similarity between groups on the technical side. They are not likely to get this pillar wrong in the TOM.

There is more variety in performance and dif-ferent choices made in business performance and people management. However, I would argue that the vast majority of TOMs lead to actually the largest improvement in these pillars, even if the TOMs are quite different from each other. The very act of mak-ing the approach uniform introduces efficiencies and it would certainly be hard for a TOM to make the group less efficient overall.

GC: In the case of a newly-acquired plant, would a group ever seek to reduce the emphasis of one of the three pillars?

AM: This has happened in some cases.

GC: Does that mean the plant becomes weaker in terms of that pillar because it moved group?

AM: Not necessarily. If a plant is very good at envi-ronmental performance, it may no longer need any investment on that side. Indeed it might have a very good local team that’s actually costing the plant a lot in terms of salaries. The plant might also be making no money for the group.

In such circumstances, questions then arise that, on the face of it, appear paradoxical: Does that plant really need to be that excellent? Answer: Maybe not. Dig deeper and we get other questions: Can we better use the plant team’s knowledge over a larger number of plants? In many cases the answer is ‘Yes’ - It could reap huge rewards globally. And of course, the invest-ments that have been made at the excellent plant will continue to be used.

GC: It seems that a lot of the major players are now rolling out TOMs. Are regional players next?

AM: We are in the process of helping some of the smaller and regional players around the world. The focus is sometimes on fewer pillars at a time, perhaps with fewer elements, but TOMs can help such players to grow. Once they have a TOM, it provides a set of blueprints that can be used for new plants and acqui-sitions around the world.

GC: Many thanks for your time today Angus.

AM: You are very welcome indeed!



Right: Financial aspects are an important aspect within TOMs, but are not the whole story.

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Cement production is the second most polluting industrial sector and cement is the second-most

consumed product in the world after water. The built environment, which includes offices and residential buildings, uses concrete extensively and accounts for over a third of global emissions. Regulation of the sector so far has been light but rising ambitions for low-carbon cities and tightening building regulations could drive change up the chain.

Indian companies top a new CDP league table of current climate performance thanks to reducing their carbon footprint during the cement making process, in part due to better access to alternative raw materials from other carbon intensive sectors. They also benefit from newer and more efficient cement plants driven by high market growth in the region, in contrast to their European peers, which rely on older cement plants.

Paul Simpson, CEO of CDP comments, “Cement is a heavy and largely invisible polluter, yet cement is taken for granted as a necessary building block of basic civilisation. With potential pressure coming from multiple sources, including down the value chain in the form of building and city regulation, cement companies need to invest and innovate in

order to avoid impending risks to their operations and the wider world. This may seem challenging at first, but every year it is delayed, the cost becomes greater. Management teams, regulators and investors need to think long term. There is a solution - cement companies just need to invest properly to find it.”

There are opportunities for companies that act early on climate risk. Companies can reduce costs by making their cement plants more energy efficient and secure their position in future sustainable ce-ment markets by investing in low-carbon products. Governments can facilitate the development of these markets through regulation and incentives.

Other findingsThe report also highlights other potential risks and opportunities for the sector:

• Carbon Capture and Storage (CCS) is an impor-tant technology for creating low-carbon cement, yet CCS projects are still largely at pilot stage in the sector. HeidelbergCement shows some investment in CCS across various technologies, but otherwise progress is limited;

GLOBAL CEMENT: EMISSIONS

CDP

Cement companies must more than double efforts to meet Paris climate goals


Building Pressure, a new report that analyses 13 of the world’s largest publicly-listed cement companies, reveals that they need to double the emissions reductions efforts to date if they are to limit global warming to below 2°C, as agreed in the Paris Climate Deal. The companies analysed in the report from CDP have a total market capitalisation of US$150bn and represent 16% of global cement production. The cement sector itself accounts for 6% of global CO2 emissions.


Right: The Orient Cement plant in Chittapur, Karnataka. Indian producers were found by CDP to benefit from using alternative raw materials from other sectors. Source: FLSmidth Pvt Ltd, entrant to the Global Cement Photography Competition.

• European players benefit from alternative fuels sourced from organised waste collection sys-tems. Emerging market producers are behind, due to limited infrastructure;

• Five companies do not use an internal carbon price, which is a significant risk in a sector where carbon pricing legislation could have a material impact;

• Carbon regulation such as the EU’s Emissions Trading Scheme (ETS) is the key mechanism to regulate emissions from the sector in Europe. However, structural issues and lobbying of policymakers have undermined the potential for change for the sector;

• Cement companies are generally not incentivis-ing long-term climate risk management through executive level remuneration, with only Cemen-tos Argos doing so.

The CDP report assesses companies across four key areas aligned with the recommendations from Mark Carney’s Task Force on Climate-related Financial Disclosures (TCFD). As the TCFD rec-ommendations become mainstream, investors will increasingly expect cement companies to disclose how they are adjusting their business models to manage transition risks, while taking advantage of the opportunity to generate revenue from the global transition to a low-carbon economy.

The CDP’s summary League Table for cement companies is shown in Table 1. Marco Kisic, Senior Analyst at CDP commented, “Cement companies have made some progress towards reducing their

emissions, but they need to do a huge amount more. It is clearly a complicated story because of our global reliance on cement, and the inherent emissions of the sector, but there are things that can be done. Cement companies should be looking at ways to further use alternative materials and fuels, improve the energy efficiency of their plants, and accelerate investments in low-carbon technologies such as carbon capture and storage, which is crucial for their long-term vi-ability. Regulation may be the key driver for change here and, interestingly, this may come from down-stream as building regulators and owners shift their focus from operational emissions, to those associated with creating the buildings themselves.”

Anhui Conch, Siam Cement, Dangote Cement and China National Building Materials did not re-spond to CDP’s 2017 climate change questionnaire and are therefore not included in this report. CDP encourages investors to raise this lack of transpar-ency in discussions with company management.

As cement companies look to the future, signifi-cant investments in innovation and technology will need to be made in order to more than double their emissions reductions and play their part in limiting global warming to below 2°C, as agreed in the Paris climate deal.

GLOBAL CEMENT: EMISSIONS

Rank Producer Country Market Capitalisation

in 2017 (US$bn)

Cement Production

in 2016 (Mt)

League Table Weighted

Rank

Transition Risks Rank

Physical Risks Rank

Transition Opportunities

Rank

Climate Governance & Strategy Rank

1 Dalmia Bharat India 3.4 15 4.64 1 9 2 4

2 Ambuja Cement India 7.7 21 5.62 3 11 12 1

3 Cementos Argos Colombia 5.3 14 5.90 7 2 7 2

4 Shree Cement India 9.4 20 5.91 2 13 3 7

5 LafargeHolcim Switzerland 34.8 233 6.03 8 6 4 3

6 HeidelbergCement Germany 19.3 125 6.08 9 7 1 5

7 CRH Ireland 29.7 34 6.85 6 4 5 9

8 ACC India 4.7 23 7.02 4 10 6 10

9 Ultratech Cement India 17.0 48 7.32 5 12 10 8

10 Cemex Mexico 12.6 67 8.04 12 8 8 6

11 Taiheiyo Cement Japan 4.7 32 8.58 11 1 11 12

12 Cementir Holding Italy 1.1 10 9.00 10 5 9 13

13 Asia Cement Corporation Taiwan 3.1 34 9.80 13 3 13 11

Weighting 35% 10% 25% 30%

Above: CDP’s summary league table of 13 cement producers’

current emissions leaders. Green indicates that producer

will be able to deal with risks of transitioning to a lower carbon

economy, while orange and red indicate a lack of preparedness.

Below left: European players benefit from alternative fuels

sourced from organised waste collection systems.

CDP is an interna-tional non-profit organisation that drives companies and governments

to reduce their greenhouse gas

emissions, safeguard water resources and

protect forests. Voted number one climate research provider by investors and work-

ing with institutional investors with assets

of US$87tn, CDP leverages investor

and buyer power to motivate companies

to disclose and manage their envi-ronmental impacts.


GLOBAL CEMENT: GRINDING

Matthias Dietrich, Sika Services AG

Progress with grinding aids for VRMs

The effect of grinding aids on the comminution of cement is based on the dispersion of fine

particles. It is a misunderstanding that grinding aids for vertical roller mills (VRMs) should stabilise the material bed between the rollers and the table by adhesive forces between the particles. Grinding aids reduce the polarity of the cleaved surface and the attraction forces between particles. This means that agglomerates of fine particles and the packing of fine particles around a larger particle are dissipated, re-sulting in an improved efficiency of the separator. The internal circulation of fine particles is reduced and the clinker on the grinding track becomes coarser. The interparticle friction and thereby the effective-ness of the comminution process is increased. In this way, grinding aids stabilise the material bed on the grinding table, facilitate compaction and de-aeration, increase the production rate and reduce vibration of vertical roller mills (See Figure 1).

The adhesion forces between particles decisively affects the flowability of powders. They are propor-tional to the particle size: the smaller the particle, the lower the powder flowability. Grinding aids reduce the adhesion forces between particles without a nega-tive impact on the stability of the material bed and fluidisation. In ball mills, where the grinding time is longer than in a VRM, excessive powder flowa-bility can lead to insufficient or inefficient grinding because the material flows too fast through the mill. In contrast to ball mills, VRMs have a very high in-ternal circulation, a short mill retention time and a huge number of classifying steps that carry the well-dispersed fines out of the mill system.

The conclusion? Grinding aids for VRMs increase the powder flowability of the finished cement with-out reduction of the stability of the material bed. The impact of grinding aids depends strongly on the fine-ness of the cement: The higher the surface area, the bigger the attraction force and therefore the bigger the benefit from an appropriate grinding aid.

The optimum grinding aid is still, to a large extent, selected empirically. However, Sika has found that a deeper understanding of the mechanism of grind-ing aids from tests in a laboratory or pilot mills,1 are helpful for selection.

Testing at Loesche

Loesche GmbH is a leading VRM manufacturer for the cement sector. It operates a technical centre for the development of new technologies, new materials and for the optimisation of mill settings. Sika has used this excellent facility to increase the knowledge about mechanisms and to test advanced grinding aids.2 During these tests, the pilot mill worked with the following parameters and dimensions:

•Tablediameter:36cm •NumberofrollersTwo •Freshfeed,clinkeralone:130kg/hr •Tablespeed:98rpm •Workingpressure:150bar •Separatorspeed:650rpm •Freshair:480m3/hr •Temperature(afterseparator):90°C •∆Pmill 21mBar •Fineness(Blaine)target:4200cm2/g


Sika AG’s Matthias Dietrich shows the added value of carefully selected grinding aids for vertical roller mills (VRMs)...


Right: The Loesche pilot mill used by Sika.

The differential pressure between the inlet and outlet of the mill (∆Pmill) is an important process variableforthetestingofgrindingaids.∆Pmill reflects the load and the filling level of the mill. At unchanged separator settings, the increase of ∆Pmill indicates more internal circulations and more fines. As a re-sultofthehigher∆Pmill, the mill vibration increases (8-10mm/s),whichresultsinagoodopportunityto

test the effect of the grinding aid. In contrast to tests with ball mills, the effect of grinding aids in a VRM is alreadyvisibleandaudibleafter10-20min.

Before the addition of the grinding aid, a blank test was run to confirm reproducibility (See Figure 2). Starting from this baseline, the new grinding aids were added onto the transport belt of the clinker, right in front of the mill. Unfortunately, at that time

Left - Figure 1: Mode of action of grinding aids.



Higher grinding efficiency

More inter-particle friction

Fewer fines on grinding track

Lower internal circulation

More fresh feed

Better de-aeration Lower vibration

Reduced addition of water

Less pre-hydration: Faster setting

and higher mech. strength

1 2 3

0

20

40

60

80

100

120

1404500

4000

3500

3000

2500

2000

1500

1000

500

0

Spec

ific a

rea (

cm2 /g

)

Prod

uctiv

ity (k

g/hr

) / Pr

op. o

f 3-3

0μm

(%)/

Vibr’n

(mm

/s)

Left - Figure 2: Blank tests show excellent reproducibility.

Specific area (Blaine) Specific area (Laser) Productivity (kg/hr)

Content 3-30μm Vibration (mm/s)

it was not possible to spray or sprinkle the grinding aid into the mill close to the rollers. Each grinding aid was added until constant mill parameters were achieved,withinamaximumof20min.Tocleanthemill from remaining grinding aid, the mill was run blankinbetween.Ittookupto90minstocomebackto the base line. The chemical structure of the added grinding aids was previously carefully selected, based on practical experiences in industrial VRMs, in combination with new molecules. A certain class of chemicals with the same functional group showed verypromisingtestresults(SeeFigure3andTable1).

The most promising results were achieved with the Grinding Aids N° 4, 5 and 6. Their chemi-

cal structure is very similar. The achievements of ProductN°5,comparedwithblankare:

Productivity:+14%Fineness:+12%Vibration:-72%

The pack set of the finished cement, measured two daysaftergrinding,wasreducedfrom28to1revolu-tion. It should not be disregarded that the pack set is measured with the finished cement, not with the material on the grinding track! Besides, pack-set is a standard term that refers to the condition in bulk cement, which inhibits ‘the start of flow.’ It can be



Right - Figure 3: Grinding results and cement properties using new grinding aids.

Specific area (Laser) Productivity Slope n (RRSB) x 20 (-) Pack set (-) Vibration (mm/s)

Blank Water 1

0

5

10

15

20

25

30

35400

350

300

250

200

100

50

0

Prod

uctiv

ity (k

g/hr

), Sp

ecifi

c are

a(m

2 /kg)

Vibr’n

(mm

/s), P

ack s

et (-

), Slo

pe n

(RRS

B) x

20 (-

)

2 3 4 5 6 7

Right - Table 1: Data used to produce Figure 3.

Water Blank 1 2 3 4 5 6 7

Productivity (kg/hr)

132 123 149 139 150 148 151 147 126

Vibration (mm/s) 9.2 8.6 9 8 4.5 3.6 2.6 2.9 9.1

Specific area (Laser) (m2/kg)

345 340 367 364 368 384 388 392 370

Pack set (-) 28 23 17 13 11 2 1 2 16

Slope n (RRSB) x 20 (-)

29.6 30.2 27.6 27 27.2 25.8 25 25.2 27.4

Right - Table 2: Comparison in cement properties and VRM operating parameters for blank, SikaGrind-455 and SikaGrind VRM-40.

150

Blank SikaGrind-455 Δ (%) SikaGrind VRM-40 Δ (%)

Cement OPC (CEM I) OPC (CEM I) - OPC (CEM I) -

Dosage (%) 0.00 0.05 - 0.05 -

Water addition (%) 3.8 2.4 -37 1.8 -53

Vibration (mm/s) 5.1 4.7 -8 3.9 -24

Production (t/hr) 143 156 +9 159 +11

Specific energy (kWh/t) 38.0 34.9 -8 34.2 -10

Surface area (Blaine) (cm2/g) 4110 4140 +1 4390 +7

Slope n (RRSB) - 0.97 - 0.93 -

www.loesche.com

SOLI

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LM 26.3 DNallalingayapalli, India

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ENT

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ERIA

L

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ALL MILL TYPES FROM A SINGLE SOURCE

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Loesche June 2018.indd 1 29/05/2018 15:33

http://www.loesche.com



Right - Figure 4: Slope n (RRSB) (-).

Blank Water 1

1.60

1.55

1.50

1.45

1.40

1.35

1.30

1.25

1.20

Slope

n (R

RSB)

(-)

2 3 4 5 6 7

Right - Figure 5: Particle size distribution of cements made using different grinding aids.

Blank Water SikaGrind-455 SikaGrind VRM-40

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.0

Volum

e (%

)

10 1001

Particle size (μm)

viewed as comparable to static friction and not as ‘flowability’.3

Theparticlesizedistribution(PSD)alsobenefitsfromthenewgrindingaid.ThePSDbecomesbroaderas shown in the slope ‘n’ according to RRSB (See Figure5).Thepotentialforstrengthdevelopmentis

decreasedas the cementPSDbecomesbroaderbutthe workability of mortar and concrete is improved.

Industrial trial with molecule N° 5Oneofthenewmolecules(N°5-SikaGrindVRM-40)wastestedinanindustrialVRMincomparisontoacommongrindingaid(SeeTable2).TheOPC(CEMI)made,withasurfaceareaof4100cm2/gBlaine,wasof higher quality and quantity. The reductions seen in the need for water injection and the reductions in vibration are remarkable.

The construction industry demands improve-ments of the performance and evenness of the cement properties. The speed of strength develop-ment is decisive, good and long workability as well asdurabilityisrequired.Withrespecttothespecialproperties of cement which is ground with VRM, in-novative grinding aids make a contribution to fulfil these requirements.

References1. Mishra, R.K.; Weibel, M.; Müller, T.; Heinz, H.; & Flatt, R.J.

‘Energy-effective grinding of Inorganic solids using organic additives,’

Chimia, 2017, 71,No. 7/8.2. PatentWO2016/055376A1;3. ‘In-

novations in Portland Cement Manufacturing,’ PCA,2011,pp.744.

Right - Table 3: Summary of benefits of grinding aids for vertical roller mills.

Effect De-agglomeration

Influence on separator Higher efficiency, recirculation

Effects on material bed Fewer fines

Consequences on grinding

Increased internal frictionEase of de-aerationReduced vibration, less wearLower water addition

Effect on productivity Reduced ΔPmill

Increased productionReduced specific energy demand

Effects on cement Broader particle size distributionIncreased power flowabilityReduced pre-hydrationFaster intial setting

Consequences for concrete

Improved workabilityFast strength development

3-59569-VRMI-A10013-00-7600 cement-advertisement-a4-en.indd 13-59569-VRMI-A10013-00-7600 cement-advertisement-a4-en.indd 1 25.04.18 08:3625.04.18 08:36

http://www.siemens.com/cement

GLOBAL CEMENT: CRUSHING

Matthias Dick, Crush + Size Technology GmbH & Co. KG

Straight to the end product at the primary crushing stage

Crush + Size Technology (CST) is developing double roll crushers based on a new crushing

tool concept. The geometric design of the crush-ing tools with large crusher teeth and synchronous running of the rolls achieves an extraordinarily high crushing ratio of up to 1:10, which is due to the direct infeed action of the crushing tools. At the same time, this prevents the formation of oversize material and flat, elongated particles. The materials introduced are directly broken down to the target size in the crush-ing gap and immediately exit the crushing chamber. The result is a grading curve that shows a very low content of small grain fractions and a higher content of medium and coarse fraction (see below).

These process characteristics are typical of the CST series. This crushing tool geometry is very effec-tive for reducing the material to the target grain size

of, for example, <120mm. The synchronised rotation of the rolls, which ensure efficient material intake, is also crucial. Extensive tests have shown that the additional content of the smaller grain fractions, for example < 11mm for limestone, is at 4% to maximum of 10% if a grain size of 600mm edge length is fed and a grain size less than 120mm is produced.

When producing cement, where coarse-grained limestone is required, the process characteristic of the CST series is especially important. It is even possible to omit one crushing stage during the crush-ing process. This saves investment and maintenance costs, including the energy input for running an ad-ditional crusher and conveyor belts.

A wide range of different machine sizes means that throughputs from at least 80t/hr up to several 1000t/hr can be offered. Different crushing tools for


Efficient single-step crushing with low content of small grain sizes...


Right: Screening line for limestone.

Crusher = CST 500 (14t) Material = Limestone Feed edge length <600mm Feed thickness <400mm Crushing in one stage

Grain size (mm)

100

90

80

70

60

50

40

30

20

10

Scre

ening

(%)

0

10 100

100

120 500

Crushed Material

50

<11.2mm - 9.0%

<1.0mm - 1.4% Feed Material

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various target grain sizes are available in a range from 4mm to 200mm or even larger. If the target grain size is, for example <200mm, throughputs as high as 10,000t/hr can be reached. Crushers for the tertiary stage are also offered for smaller grain sizes, achiev-ing sizes of <4mm.

The machine design is particularly robust and was designed for the toughest operating conditions, such as hard rock. Despite the mechanical synchro-nisation of the rotation of the rolls, a hydraulic gap adjustment is available. This allows the crushing gap to be automatically adjusted to the desired grain size, so that the operator can control the process results during the crushing process. At the same time, the crusher is protected against overload damage caused by foreign substances. In case of a blockage, the rolls are moved against the hydraulic retention force so that the complete drivetrain remains undamaged.

All in all, the CST series is a powerhouse consid-ering the combination of dead weight, throughput and crushing ratio. With the same installation space and weight, a performance increase of up to 200% can be achieved compared to conventional double-roll crushers.

To keep the maintenance effort as low as possi-ble, a quick-release system has been developed that allows the crushing tools to be radially removed from the crusher shaft. A complete roll can also be replaced quickly with low effort, as the upper housing frame can be hydraulically opened and swivelled out.

A control system with control cabinet is also avail-able. This provides a well-rounded product range and a coordinated system. Connecting conveyor systems can also be implemented into the control and special customer requests can be taken into account.

Left: The CST series of crushers can produce a wide range of material sizes in a single step.

Above: A CST crusher.

GLOBAL CEMENT: CRUSHING


GLOBAL CEMENT: MONITORING

Martin Armson, Hansford Sensors

Vibration goes back to basics

Condition monitoring has become widespread in the cement industry as a way of ensuring that

machinery stays in prime condition for as long as possible. Techniques such as vibration monitoring are commonly used to underpin a regime of pre-dictive maintenance, where equipment is assessed constantly in order to detect problems as early as possible. Overall, this minimises maintenance costs, extends plant operating life and protects both assets and staff.

Most maintenance personnel are familiar with vibration monitoring: they are comfortable taking readings using sensors and meters, and know what steps to take if conditions move outside operat-ing parameters. However, not all staff understand the conditions that cause vibrations to arise in the first place.

This article will look at some of the reasons why vibration occurs, including different types of vibra-tion and their common causes. It also details how

vibration is measured, using instruments like velocity transducers, proximity probes and accelerometers, and how acceleration, velocity and displacement can be used in practical terms.

Background basicsAll mechanical parts vibrate, but in the context of machine diagnosis ‘vibration’ is the motion of a mechanical part when it strays outside its ‘natural’ position. For instance, when a bearing begins to wear down, this affects the way that it moves along the raceway. This will eventually be detected by the human ear through increased noise. However, it can be picked up far earlier using vibration monitor-ing technology. The harmful effects of vibration are well known. What starts with an increased load on bearings, for instance, can spiral into component fa-tigue, reduced equipment efficiency and, potentially, catastrophic failure, expensive repairs and extensive downtime.


Understanding the underlying conditions behind machine vibrations gives maintenance staff a better understanding of what causes machine failure as Martin Armson, Vice President of Sales at Hansford Sensors, explains...


Right: A bearing that has suffered catastrophic failure. Such incidents can be predicted and avoided using vibration sensors and preventative maintenance.

There are three main vibration parameters: frequency, amplitude and phase. Measuring the frequency of the vibration will identity the vibrat-ing component, as each will have a characteristic frequency. Adding signal processing techniques like acceleration enveloping helps to separate the fre-quency of one component, such as a bearing, from the frequencies of all other parts of a machine, such as its casing.

The amplitude of the vibration describes the extent of the defect in a particular component. The elements of the amplitude are its displacement, veloc-ity and acceleration. The greater these are, the more severe the problem, which will be evidenced by either louder or more vigorous vibration.

The phase describes how the component is ro-tating in comparison with the norm. Knowing, for

instance, how far ‘off ’ a component is will be vital when re-balancing or adjusting the system. For rotat-ing elements, it is described in terms of an angular difference between a known ‘mark’ and the actual conditions. Phase also describes how the component deviates from standard conditions. For instance, it can determine between a shaft centre line moving up and down in a planar or ‘rocking’ fashion.

Another useful measurement is the ‘overall vibra-tion’ of a system, in a given frequency range. This is compared with the equivalent ‘nominal’ figure to give an indication of machine health. If overall vibra-tion is higher than normal, it indicates some kind of problem: the next step is to identify exactly what the problem is.

Bearing damageThe main moving component in any machine is usu-ally the bearing. Problems here are often the root cause of excess vibration. Bearings fail for a number of reasons. The main ones are inadequate lubrica-tion, poor installation or handling, age and excessive loads.

Inadequate lubrication is usually thought to mean lack of lubrication, and this can be the case. How-ever, over-lubrication can also be a problem and is a common cause of failure. Another lubricant-related problem is contamination, which is caused by factors such as leaking seals.

Poor installation is self-explanatory. If a bearing is not installed correctly in its housing, it will not perform in the way it was designed, so is likely to fail at some point. A multitude of factors can be behind this, whether it is operator inexperience, rushing the installation or using the wrong tools. In similar fash-ion, the age of the bearing needs no explanation: one comforting factor is that, with preventative mainte-nance in place, an ageing (and failing) bearing will quickly be identified and replaced.

Finally, excessive bearing load is usually brought on by imperfections elsewhere, such as misaligned shafts, imbalance or looseness. This puts excessive force on parts of the bearing, which can then cause tiny cracks on the bearing and raceway that later de-velop into more serious flaws caused by wear.

Types of vibrationExcessive wear is considered the main cause of fail-ure in machinery. Maintenance teams work hard to prevent it. However, a few other conditions need to be closely monitored, especially imbalance, mis-alignment and looseness. If left unchecked, they can damage components and machinery.

Imbalance is when the centre of mass differs from the centre of rotation. This creates a centrifugal force, leading to high vibration amplitudes at frequencies equal to 1 x rpm (1 x rotational speed) in spectral data, with a sinusoidal waveform in the time do-main. On rigidly mounted machines, amplitudes



Left: The Hansford HS-100 accelerometer has many

applications in cement plants.

Left: An accelerometer being used in a cement

sector application.

are typically highest in the horizontal rather than vertical direction.

Misalignment occurs when the shaft centre lines of two directly mating components meet at an angle, or are offset from one another. Misalignment of couplings and bearings typically cause high radial or axial vibration. There are several types of misalign-ment, which are angular, offset, or a combination of the two, which is most common.

Mechanical looseness occurs when rotating components have been fitted incorrectly. A number of running speed harmonics will dominate spectral data (i.e. 1-1 0x rpm). In some cases, and in some stages of deterioration, spectral data may also show sub-harmonic multiples of 0.5 x rpm.

All three conditions can cause machine failure and lost production. However, they can be detected early using vibration monitoring and are relatively easy to correct.

Combined measurementWhile accelerometers are most commonly used to measure vibrations, they may only pick up part of the overall picture. However, they can be combined with other devices that measure velocity and displacement to ensure that all aspects of vibration are picked up. This is because acceleration, velocity and displace-ment are all critical parts of the vibration amplitude. Together, they help to pinpoint the location and na-ture of any vibration problem.

In cement manufacturing, the key components to monitor in kiln drives, crushers, screens, conveyor belts, raw mills, elevators, separators and blowers, are the motor and gearbox assemblies. In each case it is critical that the correct type of sensor be selected, for ease of installation and access, and for reliable opera-tion and data collection.

An accelerometer is usually a piezo-electric crystal bonded to a mass, that generates an electrical signal when subjected to a force. Vibration accelerometers

are generally of two types: AC accelerometers, for measuring higher value assets; and 4-20mA ac-celerometers, which are more general-purpose. The cement industry typically uses 4-20mA accelerom-eters connected to PLC systems.

Velocity transducers, which measure angular velocity, are generally less expensive than acceler-ometers, and easy to install. Because of this, they are good for general-purpose applications. It generally has three elements: a permanent magnet, a coil and spring supports for the coil. Those for horizontal and vertical axis mounting are designed differently.

Proximity sensors detect the location of a component, such as a bearing, in relation to its ‘normal’ position. It uses either capacitance or inductance, the latter being more accurate, to de-termine distances very accurately, so can indicate the extent to which a bearing or shaft is ‘out of true’ during operation.

A combination of all three results will give an ac-curate picture of, for instance, bearing speed, velocity and position in relation to the conditions for which it was designed.

Vibration and velocity sensors are generally used to detect high frequency signals emanating from structures such as bearings and bearing supports. Proximity sensors, meanwhile, are more appropriate for finding displacement in rotating shafts, for condi-tions such as misalignment or shaft bending.

In the cement sector, a combination of all three could be used in any number of applications, from crushers and mills to precipitators, kilns or silos. The sector is well known as an aggressive production environment, conditions that can help to accelerate component failure and potential bearing damage. Using a broad set of vibration sensors, coupled with a predictive maintenance regime, can help to identify potential component failure as early as possible, and so avoid the expense and potential hazards of cata-strophic failure.



Right: Vibration signal indicative of misalignment.

Acce

lerat

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)

-22

-11

22

11

0

0.038 0.076 0.114 0.152 0.1900.000

Time (s)

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GLOBAL CEMENT: ALTERNATIVE FUELS

EntsorgaFin SpA

Pelican: Entsorga’s alternative fuel feeding system for the cement industry

Nazareth is the heart of the Lehigh Valley, an area with a long tradition of cement production. It is

also adjacent to and serves one of the most developed areas of the world, the US East Coast, in particular New York City and New Jersey. It is therefore un-derstandable that a cement plant located in the area would be sensitive to new strategies and trends.

Despite a more relaxed attitude to environmental policies under the current US Administration than in the past, cement plants across the country are still looking to increase the use of alternative fuels. This is particularly the case for fuels derived from munici-pal solid waste (MSW) that has a biogenic content of more than 55%. Such fuels offer the perfect way to reduce a cement plant’s CO2 emissions. Indeed, since 2011 pre-engineered fuels (PEFs) produced by Entsorga from MSW have even obtained ‘non-waste’ status and can be traded as a commodity.

The Nazareth project

The feeding plant installed by Entsorga at the Naza-reth plant is one of the first of its kind in the US. It is designed to receive the PEF and pneumatically feed it at up to 7t/hr to the main burner. This requires a precise dosing system that has been developed by the company. It is a step towards higher alternative fuel substitution rates for the plant. It comprises:

• Two docking stations that receive waste from US walking floor trailers. They are equipped with hydraulic units that allow operators to manage the unloading of trailers without the need for the tractor to stay in the bay;

• A Redler chain conveyor that conveys the alternative fuel to the required height in order to feed the dosing system;


The strong trend towards alternative fuels in the global cement sector has pushed Entsorga to provide a means to feed alternative fuel to the burners, in addition to its waste-to-fuel production plants. A specific technology, named the Pelican, has been designed and fine-tuned, with the first installation now installed at the Essroc Nazareth plant in Pennsylvania, part of HeidelbergCement. This installation project runs in parallel with the Entsorga’s construction of a 118,000t/yr waste-to-fuel conversion plant in Martinsburg, West Virginia, which will produce about 50,000t/yr of high-quality pre-engineered fuel for a nearby Cementos Argos plant.


Right: Panoramic view of the Pelican system and Essroc Nazareth cement plant.

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• A screw dosing system;

• A pneumatic system made up of blowers, rotary valve and pipeline, and;

• A Supervisory control and data acquisition (SCADA) system based on a new Entsorga pro-prietary sorting system. The system is capable of managing the AF dosing with the highest preci-sion and reliability.

As safety is highest priority, the feeding system is ATEX and NFPA compliant, with extensive means to avoid fire and explosion hazards.

The system requires minimal civil works and can be easily relocated if required. Having two docking stations that can operate either simul-taneously or separately is great for reliability and flexibility. This solution avoids the need to quickly switch trucks on a single docking station. When the first truck is emptied, the second can continue to feed as the first truck is switched for a third, and so on.

Shaking up the status quoThe US alternative fuels market was currently dominated by waste liquids, such as solvents and oils, and tyres. The replacement rate is different from plant to plant. On average substi-tution rates are quite low and far from the levels reached in Europe. However, Entsorga believes that alternative fuel use will spread in the US. There are many steps being taken by cement

producers and forthcoming legis-lation that will drive the use of AF.

In this field, Entsorga can take advantage of its 20 years of en-gineering experience by making available to the market its portfolio of proven, bankable and referenced technologies. Entsorga hopes to be able to help the cement industry to implement its alternative fuel strategies.

This is not just a business opportunity. For Entsorga it repre-sents an ideal way to help improve the environmental performance of an entire industrial sector. Furthermore, the uniqueness of the Nazareth project is its flex-ibility and adaptability to a range of market environments. It allows Entsorga to deliver viable solu-tions, successfully bridging needs of different industries and to pro-vide complete integrated solutions

up to the kiln feed inlet.For Entsorga the Nazareth plant, in combination

with its Mechanical Biological Treatment (MBT) plant at Martinsburg, represents the start of the spread of its technology in the US. It hopes to see many of these installations throughout the country in the coming years. The Nazareth project will now be replicated at the Cementos Argos Martinsburg ce-ment plant and elsewhere.

In the US, it may well be that the adoption of alternative fuels is driven by economic feasibilty, convenience and profit, rather than environmental regulations, as in Europe. Entsorga believes that the US conditions are predominant in other world re-gions, offering a model that can easily be replicated throughout the rest of the global cement industry.

Right: View of the Entsorga Pelican system installed at the Nazareth plant in Pennsylvania.

Right: Municipal solid waste of the kind transformed into pre-engineered fuel by Entsorga’s mechanical biological treatment plant in Martinsburg.

GLOBAL CEMENT: ALTERNATIVE FUELS


2021 FEBRUARY 2019 AMSTERDAM, NETHERLANDS

CONFERENCE • EXHIBITION • AWARDS

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Global, regional and national market trends

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GLOBAL CEMENT: EVENT REVIEW

Robert McCaffrey, Global Cement Magazine

Global Slag Conference 2018 - Reviewed

Adam Smith of Kallanish Commodities started the conference by speaking about trends in the

global steel industry. Donald Trump’s imposition of tariffs on steel and aluminium imports caused a spike in steel prices in North America at the start of 2018, but these have fallen back after most countries were given waivers from the tariffs. However, an ongoing Trump-led crusade on Chinese intellectual property ‘acquisitions’ is still dampening market sentiment. The EU exemption from the tariffs ends on 1 May 2018, and European steel association Eurofer fears that around 13Mt of US-bound global steel exports may soon be diverted to Europe instead. The EU is now considering its own external tariffs as well. Two major mergers are in the pipeline, between Tata Steel Europe and thyssenkrupp, as well as the ArcelorMit-tal takeover of Italian producer Ilva. Adam suggested that with the EU’s trade defence measures, that the mergers may raise steel consumers’ sourcing costs (meaning that steel prices are set to rise). The World Steel Association has published forecasts for 2018-2019, suggesting that there will be a mild economic deceleration in the Chinese economy (leading to a fall in steel demand), and that developing econo-mies will once again lead global growth. Developed nations including the EU will attain steady but mod-erate growth, while India is readying to be a standout growth region for the coming years.

Doug Haynes of Smithers Apex next gave an ex-ecutive summary of the Smithers report ‘The future

of ferrous slag to 2027.’ Doug suggested that around 50% of global slag production is used in the cement industry, with 32% used in road construction, 10% used in ‘other applications,’ 3% used in embankments and 2% in internal recycling. These figures exclude disposal to landfill. Doug points out that drivers for slag use include construction demand in India, China and Asia, construction market demand, a trend towards sustainability, the technical proper-ties of cement and concrete with slag, environmental pressures on primary rock extraction and the de-velopment of processes capable of mitigating Basic Oxygen Furnace (BOF) slag free-lime expansion. However, there are many barriers, including potential decreases in slag production capacity, the financial cost of installing new technology and environmental regulations restricting the use of ferrous slag.

Charles Zeynel of ZAG International next gave an update on granulated blast furnace slag (GBFS), other supplementary cementitious materials (SCMs) and the global cement industry. He started by say-ing that “after having forecast for years that we are going to run out of slag, the day has finally arrived.” He recounted a story of a company that had signed a five-year contract with a Chinese state-owned steel company for significant tonnages of slag: six months later, the price tripled despite the contract terms. “But just try and sue a state-owned company in China - you will not get far.” The value of slag, he concluded, has increased dramatically. The slag producers have


The 13th Global Slag Conference & Exhibition has taken place in Prague, with 120 delegates in attendance from 30 different countries. The 14th Global Slag Conference will take place on 3-4 April 2019 in Aachen, Germany.


1: Pieter Van Mierloo (left) receives Global Slag awards for ‘slag plant of the year’ (Recoval Dria) and ‘slag product of the year’ (Carbstone blocks) from conference convenor Dr Robert McCaffrey (right), who is seen in a number of other photos in this article, presenting awards and prizes.

2: Victoria Masaguer Torres of ArcelorMittal Spain speaks on the use of slag as a passive mine water treatment medium.

3: Dr York Reichardt of KHD Hum-boldt Wedag giving operational results of the KHD roller press.

4: Andreas Jungmann speaking on behalf of Loesche on the processing of steel slag.

1 2 3 4


concluded that they want a larger share of the value of slag, so that prices have increased. Charlie pointed out that there is a global oversupply of clinker, but that there is a positive overall outlook for the cement industry due to population growth and urbanisation. Countries are starting to stipulate non-clinker com-ponents in cement (some of the emirates in the UAE now stipulate at least 60% fly ash or slag in cement). Due to the continuing closure of coal-fired power stations, particularly in the US and EU, flyash sup-plies are effectively reducing: slag is the next ‘go-to’ SCM on the list. There is no current global growth in blast furnace slag production, due to the rise of Electric Arc Furnace (EAF) steel production. Only around 75% of globally-produced blast furnace slag (BFS) is granulated, creating around 250Mt of GBFS, albeit with 150Mt in China, 30Mt in Japan and 70Mt in the rest of the world. China is now auctioning slag supplies for export each week, with the ‘winner’ hav-ing to pay cash ‘up-front.’ Now around 25Mt of slag is

traded internationally, of which 12Mt is Japanese slag, and around 5-6Mt is Chi-nese slag. Freight rates are rising from their historic lows, and will eventually become a major factor in slag use and pricing. From being a buyer’s market, slag is becoming a seller’s market.

Michael Connolly of TMS Inter-national next gave an update on the regulatory approach to slag and slag products in the USA. In the US around 20Mt of iron and steel slag is produced and marketed each year. Eleven states

14: It’s a thumbs up from Jitka Halamová (left) and Andrey

Korablin (right).


5: Andreas Ehrenberg of the FEhS speaking on the storability and

reactivity of granulated blast furnace slag.

8: Patrick Lecherf (left) of Euragglo in discussion with Frank

Henning (VDZ).

6+7: Nick Jones of Harsco (6) was a co-author/presenter

on a paper with Mark Tilley of Lixivia (7), who between them presented on the possibility of

extracting valuable components from slag.

9: Left to right: Philip Hempel of Gebr. Pfeiffer, Tobias Braun of

Gebr. Pfeiffer, and Frank Henning of the VDZ toasting the success of

the Global Slag Conference.

5 6 7 8

9

10

12 13

14

11: Delegates from ARGO-IPS and Metallo Belgium NV were

happy at the prospect of visiting Aachen in 2019.

10: Delegates enjoying the Global Slag Awards dinner cruise

along the Vltava River.

11

13: Andreas Jungmann picks up Loesche’s Global Slag award for

technological innovation.

12: Nick Jones of Harsco picks up his company’s award for ‘slag

producer of the year.’

have now decided that slag is a product rather than a waste, ‘if it is not discarded and is distributed for use in commerce.’ Industry and the US National Slag As-sociation are busy trying to persuade the remaining states to adopt the same approach to slag. Steel slag is actually the preferred aggregate in high-demand road surface applications, due to its higher coefficient of friction, high resistance to rutting and its high compressive strength, leading to superior skidding resistance. This has led to its use as the track surface for the Indianapolis Motor Speedway, home of the Indy 500. “When properly segregated from ladle slag, steel slag is an excellent high-density aggregate ideal for use in concrete. The only drawback is its high

density, but when mixes are properly designed using a mix of natural ag-gregates and slag, a high efficiency mix can be achieved. These mixes usually have a slightly higher strength and durabil-ity than mixes with just natural aggre-gate stone.” Steel slag has also been used as an SCM, while TMS also supplies EAF slag to several ce-ment companies as a cement raw feed.

Andrey Korablin of Russian company SmartScrap Ltd, celebrated his birthday by giving an overview of the Russian steel and slag markets. Russia is the fifth largest steel producer in the world, just behind the US, producing around 70Mt, concentrated in the ‘Central Federal District,’ around Moscow, in the south west and also around the Urals. The largest producers are Evraz, NLMK, MMK and Severstal. Many slag pro-ducers process their own slag, but others use either subsidiary companies or independent processors. Only around 50% of metallurgical waste is recycled. Federal laws are being tightened on waste dumping, while the goal of the Ministry of Industry is to bring the level of municipal solid waste recycling to 80%



19: Amir Shakurov of Ecoslag gives a presentation on the beneficiation of molten slag using the Ecoslag ‘drum crystalliser.’

20: Left to right: Andreas Jungmann and Paul Erwerth of Loesche speak with Al Popp of Edw. C. Levy Co., on Loesche’s prize-winning exhibition stand.

15 16

17 18

19 20

15: Philip Hempel of Gebr. Pfeiffer delivers his presentation on the MVR slag mill.

16: Fernando Dueñas of Cemengal outlines his company’s reference list of projects around the world.

17: Jürgen Haunstetter of the German Aerospace Centre gave a talk on the use of slag as a heat energy storage medium.

18: David Algermissen of FEhS - Institut für Baustoff-Forschung e.V. - receives a prize for his paper on the use of BOF slag as a raw material for the cement industry.

21: Adam Smith of Kallanish Commodities gave the keynote opening presentation, on global steel market trends.

22: Dr York Reichardt (KHD, left) and Roger Cockram (RCS Group, right), discussing slag matters on the KHD Humboldt Wedag exhibition stand.

23: Tsuyoshi Ikawa of JFE Shoji Trade Corporation (left) and Michael Connolly of TMS International LLC enjoy the chilled-out ambience of the Global Slag Awards dinner cruise along the Vltava River.

21 22 23

by 2030, while there are also potential tax breaks for slag use. Road construction and use in the cement industry are the areas, Andrey concluded, with the most potential for increased slag use in Russia.

At the start of the second session, on slag benefi-ciation, Victoria Masaguer Torres of ArcelorMittal Spain spoke about the use of steelmaking slag in the passive neutralisation of mine waters. The project started a decade ago when a highway construction project allowed the interaction between groundwa-ter and pyritic materials that caused an acid water problem. A laboratory-scale anoxic trial using steel-making slag was used to prove the efficacy of the slag as a neutralisation agent: calcium content of the slag was reduced during the trial, while the pH of the acidic waters was reduced. In a pilot scale trial, 50t of ladle slag was used in one pit, while limestone was used in a control pit. It was found that limestone achieves an acidity reduction of around 90%, com-pared to around 80% for slag. The slag has a half-life of around two years, and following the exhaustion of the slag as a neutralising material, the pit would be closed and left in place.

Patrick Lecherf of Euragglo next spoke about the agglomeration and briquetting of steel-plant byprod-

ucts. Particles are briquetted by first squeezing out the air between particles. Then, if the particles are not self-compacting, by using a binder (such as molas-ses and lime in the case of steel plant byproducts), the materials are formed into briquettes by being squeezed between patterned rollers. Other bind-ers can be used, such as bentonite, sodium silicate, lignosulfonate, polymers and hardeners, starch and cement. The abrasiveness of the material to be bri-quetted will determine the frequency of maintenance of the forming rollers.

Amir Shakurov of Ecoslag Recycling of Russia then gave details of molten slag beneficiation using an innovative drum crystalliser. Amir pointed out that a number of different slags have similar viscosity, melting points and enthalpy over a similar tempera-ture range (1500-1800°C). The Ecoslag solution is the accelerated cooling and solidification of molten slag (including carbon, stainless, ferro alloys, copper and nickel slags) using a continuously-rotating drum crystalliser to stabilise dicalcium silicate into a stable form. Amir suggested that the slag crystalliser is built of heat-resistant materials that can withstand the wear-and-tear of 100,000 melts. The Ecoslag drum crystalliser has been successfully installed by Bao


24: Visitors to the Cemengal stand hear details of the com-

pany’s modular grinding plants.


24 25 26

27 28 29

25: Andreas Ehrenberg of the FEhS receives his prize for

the best presentation at the conference, on the storage,

grindability and reactivity of granulated blastfurnace slag.

26: Dr York Reichardt receives his well-deserved prize as ‘Global

Slag personality of the year.’

27: Andreas Ehrenberg (FEhS, left) and York Reichardt (KHD,

right) enjoy Czech food and drink on board the yacht Grand

Bohemia.

28: (L to R) Charles Zeynel (ZAG International), Walid Irani of

Cimenterie Nationale SAL (CN), Lebanon, Milan Vranes (ZAG) and

Adib El-Hachem, also of CN.

29: (L to R) Dan Rogers (Smithers PIRA), Juha Koskinen (Tapojärvi Oy), David Perilli (Global Slag),

Henry Pilventö (Tapojärvi Oy).

30 31 32

30: (L to R) Susanne Schüler and Dirk Mudersbach of Max

Aicher Umwelt GmbH, Dominik Wohlmuth of voestalpine Stahl

Donawitz GmbH, Joe Bartholmé of Paul Wurth S.A. and David Al-germissen of the FEhS, enjoying

the event’s popular dinner cruise through the heart of Prague.

31: Paul Erwerth of Loesche picks up the company’s award for ‘Global Slag (equipment) supplier

of the year.’

32: Dan Rogers of Smithers Pira held the lucky questionnaire and so was very happy to have won a

box of local Prague chocolates.

Steel in China. Amir mentioned a previous Russian invention for slag cooling and crystallisation with steel balls and water sprays, which he claimed has been copied by Chinese firms and has now been re-exported around the world.

Jitka Halamová and Jiří Pyš of ArcelorMittal Ostrava, a company that will soon become an in-dependent unit, next spoke on the efficient use of slag resources. Starting in 2012, the company com-menced a series of small steps towards improving the recycling rates of its slag materials. Better internal communication, benchmarking, cross-exchange of ideas from other units, logistics optimisation, and some equipment upgrades allowed the beneficiation and significant addition of value to slag.

Global Slag Awards Dinner

At the end of the first day of the conference, delegates gathered on the dining yacht Grand Bohemia for a cruise along the Vltava River, among the fabulous sights of historic Prague. During the cruise the Global Slag Awards 2018 were presented. Global Slag company of the year (slag/slag product producer) was Harsco Metals and Minerals, and the slag user of the year was CRH Group. The ‘supplier of the year’ for technology, equipment or services was Loesche. The Recoval Dria unit in Belgium was named as the Global Slag plant of the year, and, fittingly, Carbstone blocks...



33 34 3533: Andrey Korablin of Russian company SmartScrap gives his presentation on Russian steel production and slag markets.

36

37

38

39

34: David Haynes and his wife Angela enjoying the dinner cruise.

35: Patrick Lecherf of Euragglo is all smiles during his presentation on briquetting of steel plant by-products.

36: Michael Connolly of TMS International presents his paper on the status of slag and slag products in the US.

38: (R to L) Jitka Hala-mová and Jiří Pyš, both of ArcelorMittal Ostrava a.s., gave a joint paper on the steps that the steelworks has taken to improve the reuse and recycling rate of its slag and slag products.

37: Gilles Franceschini of ArcelorMittal Europe SA receives a small prize at the Global Slag farewell reception.

39: Paul Erwerth of Loesche receives the prize for the best exhibition stand at Global Slag, on behalf of Loesche.

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Easyfairs

SCHÜTTGUT now called SOLIDS Dortmund

On 7 - 8 November 2018, the ninth trade show for

granules, powders and bulk solids technologies – and the first to run officially under the ‘SOLIDS’ brand – will take place at the Messe Dortmund. Over the years since its premiere in 2006, the share of international exhibi-tors has risen to nearly 20%, and among visitors to about 12%.

“With the new name SOLIDS Dortmund, we are recognising the consistent growth and ever-increasing internationalisation that has taken place over the course of the last eight editions of Schüttgut,” emphasises Daniel Eisele, Group Event Director for organiser Easyfairs.

The new name, SOLIDS Dortmund, also under-scores the show’s affiliation with Europe’s largest series of trade shows for granules, powders and bulk solids technologies. Together with its sister events SOLIDS Antwerp, SOLIDS Rotterdam, SOLIDS Zurich, SOLIDS Krakow and SOLIDS Russia, Dort-mund has long been a pillar of the SOLIDS European Series (SES).

The new name will be accompanied by a new logo for SOLIDS Dortmund. It consists of three nested hexagons, representing the three types of bulk sol-ids, i.e. stone, granules and powders. Its six corners stand for the six SES shows. The broad approval with which the new name and logo have been received is summarised by Professor Rainer Barnekow from the Life Science Technologies Department of the Hochschule Ostwestfalen-Lippe. “I’m delighted with the new name SOLIDS. SOLIDS includes not only

coarse bulk goods but also powders and finer-grained materials, and this is exactly what you’ll find at the trade show. Since the show has become more international, an English name is the ideal choice.”

Along with SOLIDS Dortmund, the fifth edition of RECYCLING-TECHNIK Dortmund will also open its doors in Dortmund’s exhibition halls in November 2018. The two shows will be accompanied by the 4th German Fire and Explosion Protection Congress and the 8th URBAN MINING® Congress, which will both be held in parallel.

As of 2018, Germany’s pre-eminent trade show for granules, powders and bulk solids technologies will also be known domestically as SOLIDS Dortmund. With this name change, organiser Easyfairs acknowledges the show’s growth as well as its increased international significance. More than 500 exhibitors and some 7000 visitors are expected on 7-8 November 2018, when the spotlight is focused on the latest technology for the production and handling of bulk materials.

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SOLIDS Dortmund & RECYLING-TECHNIK Dortmund

Date: Opening hours:Ticket price:

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Euro30 for both shows

Messe Dortmund, Halls 4, 5, 6 + 7 Rheinlanddamm 200, 44139 Dortmund

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GLOBAL CEMENT NEWS: PRODUCTS & CONTRACTS

Philippines: Starlinger installs 300th conversion line for Ad*Star bags

Austria’s Starlinger has installed its 300th con-version line for Ad*Star bags at Sakomoto

International Packaging’s plant in Caloocan City near Manila. The Ad*StarKON line was delivered as part of two sack conversion lines for the client. Sakomoto International Packaging supplies the local cement industry with Ad*Star sacks made of polypropylene fabric.

Netherlands: Van Beek introduces eggshell to lime equipment

Van Beek has developed an eggshell dryer for drying crushed eggshells in a continuous industrial process. This

dryer heats the eggshells to 130°C degrees to give a patho-gen-free, fine-grained and high quality lime with a maximum moisture content of 1%.

The eggshell dryer, marketed under the Celsius name, is a machine with a single screw and operates as a paddle dryer. The machine requires little installation space in an automated line that breaks the eggs to separate the contents from the shells. After dehumidification the line crushes the shells, after which they land in the eggshell dryer.


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Above: The Van Beek Celsius turns egg shells into high quality lime.

Nigeria: Gebr. Pfeiffer sells first mills to Dangote Cement

Germany’s Gebr. Pfeiffer has struck a deal to sell an MVR 6000 R-4 mill for raw material grind-

ing and an MPS 3350 BK mill for processing coal for kiln firing for Dangote Cement’s new plant at Okpella in Edo State. The mill order is the first for Gebr. Pfeiffer from the Nigerian cement producer. The order was placed via China’s Sinoma Interna-tional Engineering.

UK: Cemengal supplies modular vertical mill to Dunbar

Spain’s Cemengal is supplying a 0.5Mt/yr Plug&Grind Vertical mill to Tarmac’s Dunbar cement plant. Work

started in April 2018. The unit follows the Plug&Grind product line’s modular format and it includes an FLSmidth OK Mill 37.3. The mill will be used to grind clinker at the cement plant, although the subsidiary of CRH may also use the mill to grind slag. The order is Cemengal’s first Plug&Grind Vertical in Europe.

Nigeria: Dangote to use Loesche mills at Obajana

Dangote Cement will use two vertical roller mills (VRM) from Germany’s Loesche for a new production line at

its Obajana plant in Kogi State. The order comprises a six-roller mill for raw cement meal with a capacity of 580t/hr, the largest roller mill for raw material in the Loesche range, and a three-roller mill with a modular design featuring a drive power range of 1000kW for grinding hard coal and lignite with a throughput of up to 70t/hr.

India: Tancem project update

Commissioning of the new 3000t/day production line at Tancem’s Ariyalur plant in Tamil Nadu is expected

to take place in the second quarter of 2018. Construction work is reported as almost complete. Larsen & Toubro (L&T) is the lead contractor on the project with Denmark’s FLSmidth hired by L&T to provide the design, engineering, manufacturing and supply of all equipment. FLSmidth’s scope of supply includes providing key components for the line, including raw material crushing equipment, limestone storage, raw and coal grinding, single-string ILC pyro processing system with cooler, cement grinding and packing and loading systems.


NEWS


Germany: HeidelbergCement strong despite winter weather

HeidelbergCement increased its sales volumes of cement in the first quarter of

2018 despite facing poor weather and coping with reduced working days. Sales volumes of cement rose by 2% year-on-year to 28.2Mt from 27.5Mt in the same period in 2017. Falling sales volumes in Europe and North America were offset by growth in Asia-Pacific and Africa-Eastern Mediterranean Basin. In Asia, Indonesia and India contributed strongly to its growth, the cement producer said. In Africa, increases in sales volumes were recorded in Egypt, Ghana and Tanzania. Its sales revenue increased on a like-for-like basis by 2% to Euro3.78bn.

The group completed its acquisition of Cementir Italia in Italy and the Alex Fraser Group in Australia in the reporting period. It also finished the sale of the sand-lime brick operating line in Germany and its white ce-ment business in the US.

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Italy: Buzzi and Cementir take a tumble in first quarter

Buzzi Unicem’s sales fell by 8.4% year-on-year to Euro539m in the first quarter of 2018

from Euro589m in the same period in 2017. Its cement sales fell by 1.6% to 5.1Mt from 5.2Mt. It blamed poor weather and reduced working days in the reporting period. Sales volumes in Eastern Europe performed well due to favour-able trends in Czechia and Russia. Sales in Italy improved due to the consolidation of Cemen-tizillo into the group.

Meanwhile, Cementir’s sales and earnings also fell in the first quarter of 2018. Its sales dropped by 1.6% year-on-year to Euro242m from Euro246 in the same period of 2017 when adjusted for the divestment of Cementir Italia to HeidelbergCement. Earnings before interest, taxation, depreciation and amortisa-tion (EBITDA) fell by 12.4% to Euro241m from Euro27.5m. Cement sales volumes increased by 4.1% to 2.08Mt from 2Mt.

http://www.hardtop-gmbh.com

GLOBAL CEMENT NEWS: EUROPE


France: ArcelorMittal to increase Ecocem France stake

ArcelorMittal planned to increase its stake in Ecocem France to 49% from 30% by the end of May 2018.

The transaction is subject to the approval of the Irish Competition Authority. The French subsidiary of Ire-land’s Ecocem was set up in 2007 by ArcelorMittal and Ecocem Materials.

Switzerland: Poor start to 2018 for LafargeHolcim

LafargeHolcim has blamed falling earnings in the first quarter of 2018 on poor weather in

North America and Europe. Its recurring earnings before interest, taxation, depreciation and amorti-sation (EBITDA) fell by 7.7% on a like-for-like basis year-on-year to Euro587m from Euro678m in the same period in 2017. Its net sales rose by 3.1% to Euro4.89bn and its cement sales volumes rose by 3.2% to 47.7Mt on a like-for-like basis.

Czechia: Hranice sales rise by 9%

Cement Hranice’s cement sales rose by nearly 9% year-on-year in 2017 due to despatches to fellow subsidiaries of

Buzzi Unicem in Czechia and Slovakia. Its overall sales rose by 6.3% to Euro61.5m from Euro57.9m, according to the Czech News Agency. Board member Roman Michalcik said that the local construction sector had grown in 2017 due to good weather towards the end of the period and large local infra-structure projects.

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Spain: Alicante port expansion

The Port of Alicante is undergoing a Euro3m up-grade to build a new dock that can support larger

vessels. Once completed the upgrade will allow ships with a length of up to 240m to dock, according to the Diario Informacion newspaper. Previously the port could only support ships of up to 165m. The site pro-cesses large volumes of cement and clinker and dust mitigation measures are also being installed.

Above: The Port of Alicante at sunset.

Russia: New plant at Sibay

An investment deal has been signed be-tween the Government of Bashkortostan,

the Sichuan-Sibay Industrial Park and Jiunghe Sichuan Environmental Protection Company to build a Euro168m, 1.8Mt/yr cement plant in Sibay. Once operational the unit is expected to create around 200 jobs. The project was originally scheduled to open in 2018 but con-struction work at the site has not started yet. Further reporting by the Russian Construction trade magazine says that the general contrac-tor for the project will be Sinoma.

UK: Bhatia on Breedon board

Breedon Group appointed Amit Bhatia as its non-executive deputy chairman on 1 May

2018. Bhatia joined Breedon’s board as a non-executive director in August 2016, following the group’s acquisition of Hope Construction Materials.

France: HGH stake could be sold

The Carlyle Group has started talks with HGH Infrared Systems to acquire a majority

stake. The deal is expected to be completed by the end of 2018. No value has been disclosed.

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CEMENT NEWS


France: Vicat’s markets pick up

Vicat’s sales in Turkey, the US and Kazakhstan have driven its growth in the first quarter of

2018. Its sales revenue for its cement business rose by 10.9% year-on-year at constant scope and exchange rates to Euro290m in the first quarter of 2018. Its cement sales volumes rose by 6.5% to 5.2Mt from 4.9Mt.

“We posted significant business growth in Turkey, the US and Kazakhstan, excluding cur-rency effects. The gradual recovery continued in France, and India was boosted by the start-up of new infrastructure projects. Conversely, we recorded a business contraction in Switzerland during the first quarter as a result of adverse weather conditions, especially in March 2018, and the completion of a number of major projects. The group’s business trends in Egypt were hampered by the military operations underway to restore se-curity in its production area,” said group chairman and chief executive officer (CEO) Guy Sidos.

Norway: Government to fund Norcem CCS project

The Norwegian government has proposed continuing funding for Norcem’s CO2 cap-

ture and storage project at its Brevik cement plant. The announcement follows an assess-ment by the Ministry of Petroleum and Energy of local carbon capture, transport and storage (CCS) projects. The government has proposed to fund FEED studies (Front End Engineering and Design studies) with around Euro8m in 2018. The total funding for the demonstra-tion project in 2018 amounts to Euro29m, including funds transferred from 2017. The proposed funds for 2018 will cover FEED stud-ies of CO2 transport, storage and up to two capture facilities.

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Continued uncertainty over the implications of Brexit on the future shape of the economy has

contributed to a plateau in economic activity across a range of sectors in the UK economy, not least construction. The fundamentals are strong enough: house-building remains a pressing need and both housing policy and major infrastructure remain Government priorities with major spending commit-ments. Universities continue to build, both academic facilities and student accommodation.

However, where investment is discretionary – in commercial office building and industrial units, for instance, and high-end luxury accommodation in London – spending levels are static or falling. De-mand is far from even across the country. Analysis by the Mineral Products Association (MPA) revealed ‘massive differences in recovery’ since the recession. Data for ready-mixed concrete (which we can regard as a proxy for cement) shows a 50% increase in the London market since 2007, while sales volumes in every other region remained at least 20% below 2007

levels, with some down by as much as 54%. The measures of economic well-being in construction paint a rather patchy picture.

Indeed, a Construction Index article from Au-gust 2017 summed up the situation by highlighting the ‘mixed messages’ from statisticians. While industry-wide state-of-trade surveys revealed a 17th consecutive quarter of growth, second quarter output data from the Office for National Statistics (ONS) for the second quarter of 2017 showed a 1.3% fall, the largest since 2012. Meanwhile, the IHS Markit PMI suggests that sector workloads and orders are on the rise.

The ONS figures for 2017 reveal contraction in the second to fourth quarters, the first time there have been two or more consecutive quarters of decline since 2012. However, there was sufficient growth in the first quarter for the year as a whole to register, perhaps misleadingly, overall growth. More recently January 2018 saw contraction of -3.4%, the worst figure since June 2012 (-3.9%). For the first quarter of 2018, construction output fell 3.3%, caused in part by the late winter weather in February and March.

The IHS Markit/CIPS Construction Purchasing Managers’ Index (PMI), in which 50 signals a state of no change, has hovered just above the threshold since mid 2016. For the period of this review, it opened at its highest level and fell, slipping below 50 twice, as shown in Table 1.

Reports from the Construction Products Asso-ciation indicate a slowing of sales and a lowering of expectations. The latest forecasts suggest a plateau in 2018, fed by political uncertainty and the fallout from the collapse of the major construction firm Carillion. It expects output to rise by 2.7% in 2019 and 1.9% in 2020. Infrastructure and private housing remain the most positive sectors, though 90% of product manu-facturers are reporting higher raw material costs.

The MPA’s quarterly statistics reflect a level of de-mand for building materials in the third quarter of

Edwin Trout, Cement Industry Suppliers’ Forum

The UK cement sector in 2017 and 2018

This article outlines the major developments affecting the UK cement industry over the past year, a period characterised by a market sluggishness born of political and economic uncertainty. It highlights the rapid growth of the Breedon Group, culminating in its recent acquisition of Lagan Cement. With little capital investment in greater capacity by most producers this year, Hanson’s new mill at Padeswood stands out, while across the industry a greater emphasis on technological innovation has consciously emerged. Surprisingly, in an industry not known for labour disputes, a number of strikes have been called in recent months, but have been peaceably resolved.

SubscribeContents Ad IndexGLOBAL CEMENT: UK

Above: Edwin Trout, Secretary of the Cement Industry Suppliers’ Forum.


Right: The Breedon Group Hope plant, as seen from the road to the limestone quarry. The group’s cement operations were rebranded from Hope Cement to Breedon Cement in August 2017. Breedon acquired Ireland’s Lagan Cement in April 2018.

2017 that was lower than both the previous quarter and the third quarter of 2016. When the full year returns were published in February 2018, sales of concrete, crushed rock and sand and gravel were all flat. Only mortar saw a rise. Figures for cement sales were not available, but with concrete its principal outlet, they are likely to be in line with the pat-tern above. As mineral building products are seldom stocked on site for long, such statistics can be seen as an immediate indication of construction activity.

Company performanceThe static state of the market is reflected in individual company results. Increased global turnover at Cemex in 2017 contrasted with a 6% fall in cement deliveries in Britain, though this was offset by a 1% increase in the average selling price. Sales of aggre-gates and concrete were also down, with higher prices.

CRH’s statements give little away about Tarmac in the UK, apart from the latest, which advised of ‘poor weather’ in the first quarter of 2018. The coffers of Hanson’s parent company Heidel-bergCement swelled with the addition of Italcementi, and chairman Bernd Schiefele claimed the company had ‘never sold more cement, concrete, gravel and sand than in 2017.’ How-ever, performance in the UK ‘Suffered from the uncertainties arising from the Brexit vote: sales volumes declined across all product lines.’ LafargeHolcim’s otherwise positive results for 2017 note that earnings in the UK were lower as a result of project delays and a general economic slowdown.

Breedon, the only cement producer solely focused on the UK market, saw an exceptional 99% increase in concrete sales due to its ac-quisition of Hope Construction Materials in 2016. Full year results for 2017 were published in March 2018 and reveal pre-tax profits of Euro84.5m, up by 52% from Euro53.6m in 2016. Revenue was up Euro49.2m to Euro746m.

Mergers and acquisitionsOne of the underlying developments of the year has been the creation of Breedon Cement and the expansion of its parent Breedon Group as an integrated mineral products business. Fol-lowing its purchase of Hope, the then Breedon Aggregates had acquired a cement producing

capability of its own, with the eponymous Derbyshire works becoming the cornerstone of a third Breedon business unit, Hope Cement. The branding of this unit changed in July 2017 to accommodate the ac-quisition of Sherburn Stone, the portfolio of which included a cement import operation in the north east

of England. ‘Breedon Cement’ signalled the broadening of the business away from a focus on cement produced at Hope alone.

This was rapidly followed by the bolt-on acquisition of Humberside Aggregates Ltd

and further activity was announced in December 2017, in the form of a pro-posed asset swap with Tarmac. Breedon

was to take over four of Tarmac’s quarries and an asphalt plant, valued at Euro18.9m,

while transferring to Tarmac 27 of its ready-mixed concrete plants and a pay-

ment of Euro5.6m. With regulatory clearance required, the likely impact

was considered by the Competi-tion & Markets Authority and

a public consultation held in February 2018. The proposals

were revised and at the time of writing the CMA

has indicated that it is minded to ap-prove. Staffordshire Concrete Ltd was

also acquired in April 2018.

Breedon’s rise has now reached new heights

with the recently announced acquisition of Ireland’s Lagan Cement.

That the two groups were in talks was confirmed in February 2018, building on the cooperation that already existed between them. The acquisition went ahead and Lagan became a Breedon Group business on 20 April 2018. Its incorporation has prompted a further restructuring with two additional divisions:

GLOBAL CEMENT: UK


78 45

6

10

11

1

2

3

9

Left: The UK’s integrated cement plants.

TOTAL = 10.3Mt/yr.

Tarmac (CRH) 1. Cookstown, 0.5Mt/yr.

2. Dunbar, 1.0Mt/yr. 3. Aberthaw, 0.6Mt/yr. 4. Tunstead, 0.8Mt/yr.

Aggregate Industries (LafargeHolcim)

5. Cauldon,1.0Mt/yr.

Cemex UK 6. Rugby, 1.3Mt/yr.

7. South Ferriby, 0.8Mt/yr.

Breedon Cement 8. Hope, 1.3Mt/yr.

Hanson (HeidelbergCement)

9. Ribblesdale, 0.9Mt/yr. 10. Padeswood, 0.8Mt/yr.

11. Ketton, 1.3Mt/yr.

Year Mon PMI Comments

2017

Jun 54.8 Political uncertainties blamed for the weakening market

Jul 51.9 11-month low with falling commercial construction, but housebuilding firm

Aug 51.1 Weakest overall performance since August 2016 (orders not replacing completions)

Sep 48.1 First fall below 50 in 13 months

Oct 50.8 Lowest expectations of growth since December 2012

Nov 53.1 Five-month high, driven by housebuilding activity

Dec 52.2 Down due to weaker housebuilding, falling commercial, slower infrastructure

2018

Jan 50.2 A four-month low: housebuilding into decline, commercial returning to growth

Feb 51.4 Civil engineering worst performing; housebuilding weak

Mar 47.0 Below 50 for the first time in six months and the fastest fall since July 2016

Apr 52.5 Housebuilding growing at its fastest pace for more than two years

Below - Table 1: Construction Purchasing Managers’ Index

(PMI) for the UK. Values over 50 indicate growth, with values

under 50 indicating contraction.

Breedon Northern Ireland and Breedon Republic of Ireland.

Significantly, Breedon now controls cement pro-duction in the Republic of Ireland as well as in the UK, and the expanded Breedon Cement business in-cludes both the Hope and Kinnegad plants, as well as the Sherburn import operation, all under the control of Jude Lagan.

Other mineral products groups have bought and sold too, though in a smaller way. Aggregate In-dustries – LafargeHolcim’s UK business – acquired Kendall Group in February 2018; the formerly inde-pendent producer operated marine aggregate wharfs in Portsmouth and Shoreham-by-Sea, and five ready-mixed concrete plants in Hampshire and Sussex.

Tarmac’s parent company CRH has made deals abroad and the UK business was strengthened by the acquisition of Scottish Power’s 50% share of their joint venture ash company in October 2017. This will continue to operate under the ScotAsh name and will maintain its current range of products from power station ash. Cemex UK remains as it was, except for a change at the top. Michel Andre was appointed Country President in September 2017, succeeding Jesus Gonzalez, who has been promoted to the execu-tive team in Mexico.

InvestmentHanson’s Euro23m project at Padeswood is the prin-cipal investment in expanded production facilities in the UK cement industry at present. With four age-ing mills having significantly less capacity than the kiln, Hanson currently has to transport clinker to be ground off site, with all the environmental and trans-port costs that that entails.

A planning application to construct a new mill was submitted to Flintshire County Council in August 2017, with Hanson also committed to invest-ing in new railway loading facilities. When details were released, it transpired that the new installation would be a re-used 0.65Mt/yr vertical roller mill shipped from a plant in Bilbao, Spain. Hanson would mothball three of the older mills while retaining one for continued use. The plans were accepted and work has since commenced. The mill is expected to be fully operational during 2019.

Tarmac started work in April 2018 to install a 0.5Mt/yr Plug&Grind Vertical mill at Dunbar, the first such installation by Cemengal in Europe. The project should be completed in July 2019.

On a smaller scale, Ecocem Ireland has invested Euro2.5m in opening the second of its import termi-nals, this one at Sheerness in the Port of Medway in south-east England. Bulk ground granulated blast-furnace slag is now being imported into the UK from Ecocem’s newly opened plant at Dunkirk, France. Selected investments made by the sector over the past 12 months are shown in Table 2.

Research and innovationWhile there has been lower investment, there has been an increased emphasis on innovation. Aggre-gate Industries might claim to be to the fore in this endeavour, appointing Pablo Libreros as Growth & Innovation Director in September 2017, responsible for development and recommending opportuni-ties for the business. These, it was envisaged, would include greater cross-promotion of products through-out the LafargeHolcim group. In January, Aggregate Industries launched its 2018 Innovation Strategy, setting out priorities for the year ahead. Key areas of interest included robotics and artificial intelligence; virtual and augmented reality; digital engineering, offsite construction and ‘blockchain’. Putting its aspi-rations into practice, the company has entered into a partnership with Open Energi, that firm having just launched its Dynamic Demand 2.0 platform, which uses artificial intelligence to connect, aggregate and optimise energy assets to reduce power costs. Aggre-gate Industries has also commented publicly on the possible future use of driverless lorries.

Perhaps less overtly, Cemex has introduced a number of significant innovations over the past few

GLOBAL CEMENT: UK


Client Plant Equipment / Service Supplier Date

Hanson Padeswood L586 XPower wheeled loaders Liebherr Jul 2017

Lafarge Cookstown Quarry machinery maintenance UPS Jun 2017

TarmacTunstead Vibration monitoring Schaeffler UK Jan 2018

Dunbar Plug&Grind Vertical mill Cemengal Apr 2018

Above - Table 2: Major contracts signed by UK cement producers in 2017 and 2018.

Right: The Hanson Padeswood cement plant is the most modern of Hanson Cement’s UK plants, thanks to the commissioning of Kiln 4. It is cur-rently being upgraded with the addition of a 0.65Mt/yr vertical roller mill shipped from a plant in Bilbao, Spain.

Cemengal June 2018.indd 1 29/05/2018 15:39

http://www.cemengal.com

months, each of them part of a multi-national initia-tive. In September 2017 the company announced it was participating in the EU-supported EPOS pro-ject aimed at enabling cross-sector symbiosis. The project highlights case studies exemplifying ways to use waste from other industries to deliver greater efficiency and contribute to more sustainable pro-cesses. As part of the project the UK’s South Ferriby plant has worked on ways to incorporate wastes from chemical company Ineos into the cement produc-tion process. In March Cemex claimed to be the first company to successfully operate cement plants by remote control. Based at group headquarters in Monterrey, the Centro de Control Cemento oper-ates in real time, tracking live data for the operation of 14 cement plants, 25 kilns and 86 grinding mills across three countries. And at the other end of the process, under the headline ‘Cemex delivers the fu-ture’, Cemex Go was launched in 2017 as a seamless customer experience for order placement and live tracking of shipments, and is now being trialled with 12 customers in the UK.

Tarmac, in similar vein, has just introduced an innovative Track-and-Trace system across its 1800-strong fleet, aiming to improve efficiency and boost customer service.

In a project that has similarities with the EPOS programme, Hanson’s parent company Heidel-bergCement has signed a three-year collaboration with the European Molecular Biology Laboratory to exchange scientific and technical knowledge in areas related to emissions reduction and recovery, and ‘innovation in general.’ LafargeHolcim has also appointed a new Group Head of Reasearch and De-velopment. Dr Heike Faulhammer took up her post at the company’s global research and development centre at Lyon in July 2017.

TransportTransport and logistics have been an ongoing focus for investment, perhaps more for safety and efficiency improvements than for an expansion of use. The sid-ings at Padeswood cement plant are an exception to this last remark, as are developments in the related aggregates sector.

Quinn Building Products has highlighted its new approach to distribution. The company’s ‘blended lo-gistics’ offers combined loads of heavyweight cement or concrete blocks with lighter insulation materials, to enable its fleet to operate at full capacity and avoid unused space.

Health and safetyChanges to vehicle design to improve road safety have been explored over the past couple of years, particularly since the spate of cyclist deaths in 2014 prompted regulatory changes to truck use in London. DAF and Mercedes Benz have been at the forefront of high-visibility cab design and industry fleet operators have been investing in new vehicles of this type. In June last year Cemex flagged up the greater visibility provided by N3 vehicles from both manufacturers. Hanson meanwhile has taken delivery of the first of 40 new Mercedes Benz lorries fitted with low-entry cabs, panoramic windscreens and 360° cameras. These too are for service in the capital.

The concern for health and safety extends not just to vehicle design, but safe operation and road user awareness too. It is an ongoing concern, though new initiatives continue to be introduced. In October 2017, for instance, Quinn Building Products opened a vehicle inspection centre in County Fermanagh, Northern Ireland, to maintain its fleet of 300 trucks and trailers. The company took the opportunity to re-state its commitment to ensuring the safety of its vehicles and operators.

In December 2017, Aggregate Industries in-troduced a points-based policy known as ‘Fair & Just’, designed to improve driving standards among its hauliers. Then following the installation of the Teletrac Navman GPS system in all of its vehicles, the company introduced a driving style rewards programme to reward drivers who are committed to safety, and achieve operational best practice. Ag-gregate Industries has also partnered with the Fleet Operator Recognition Scheme (FORS) to ensure its subcontractor fleet attains the benchmark. Likewise Tarmac is working with FORS and has been re-ac-credited to undertake the audit process for its entire fleet, including subcontractors. Since the scheme was introduced in 2014, more than 1800 Tarmac vehicles have been FORS-accredited.

Health and safety policy on companies’ own sites continues to be pursued with as much vigour as it has for many years. Hanson held a ‘safety stand-down’ throughout the group on 16 October 2018, allowing an hour to carry out health, safety and well-being activities. The key messages to employees and contractors alike was: ‘Always challenge unsafe be-haviour and stop a job if they think it is unsafe.’ Such attitudes are rewarded annually at the MPA Health & Safety Awards.

Right: The Brexit ‘game’ is still afoot. The exact terms of the UK’s departure from the EU have the potential to affect cement demand. Exactly how remains to be seen.

GLOBAL CEMENT: UK


Industrial relations

In a development uncharacteristic of the UK cement industry in recent times, the past 12 months has seen the calling or threat of, strikes and other industrial action. These have affected delivery drivers and, in a closely related sector, workers at Tarmac Build-ing Product’s block-making plant at Stanford Le Hope. Here the dispute revolved around terms and conditions for new starters and 24hr strikes were announced for several dates in February and March 2018. The dispute was resolved amicably in April 2018, with Tarmac announcing plans to upgrade and reopen a second factory on the site.

As for deliveries, drivers working for Cemex’s cement and aggregates operations were the first to threaten strike action, over pay and allowances, though that was resolved in May 2017. Similarly, the threat of a strike by drivers working at eight Hanson depots, followed by refusal to stay in cabs overnight, was averted by a deal with Unite in February 2018.

New products launchedMuch of the new product lines of the past few months relate to packed cements, closely associated with changes in branding and presentation. The Lafarge range from Aggregate Industries was ex-tended to include six new products. To enhance the range, a Lafarge-branded pallet hood has been de-veloped for product displays at builders’ merchants. Then launched just weeks ago was TerraCem, the UK’s first hydraulic road binder formulated for use in soil stabilisation.

Quinn Building Products launched three lines of bagged cement in the spring of 2018, including General Purpose Cement, Master Grade Cement and Premium Grade Cement.

SustainabilityThe emphasis placed on sustainability by the UK and its regulators over the past 20 years, and quantified in annual sustainability reports from the MPA, is part of a wider national commitment that has had reason to celebrate success in the past year. The UK is now seen

by the EU as a leading country for the substitution of coal by renewable energy sources, particularly wind and solar power.

According to National Grid figures, 2017 was the greenest year ever in terms of electricity generation. The rise of renewable energy helped break 13 clean energy records during the year. Indeed, in April 2018 electricity generation ran without the use of coal for 72 consecutive hours. Moreover figures from Carbon Brief show that 2017 was the fifth consecutive year in which CO2 emissions had fallen, with the level now 38% below that of 1990. Emissions fell 2.6% in 2017, driven by a 20% reduction in the use of coal for electricity generation, and are now at levels last seen in the 1890s.

That said, the 164-page Clean Growth Strategy published in October 2017, which sets out how the UK intends to reach its targets, has been queried by the Committee on Climate Change. The Committee has warned that targets are likely to be missed, espe-cially without funding for the introduction of carbon capture technology in heavy industry.

Another warning comes in the wake of the recent Chinese ban on importation of waste plastics. The UK Recycling Association has commented that, ‘we simply don’t have the markets in the UK.’ The eco-nomics of recycling might well have an impact on the supply of alternative fuels to the cement industry.

ConclusionsAs mentioned at the top of this article, the UK is in the midst of a plateau in terms of economic and con-struction growth. Given the continued uncertainty surrounding the exact terms of the UK’s departure from the EU - now only nine months away - this un-easy situation could remain for some time to come, despite the strong need for cement and allied build-ing materials. This will be my last report before the UK leaves the EU on 29 March 2019. By the time of my next report in June 2019 the picture may - or indeed may not be - a little bit clearer. See you on the other side!

Left: The Cemex South Ferriby plant is located

where the Humber Estuary meets the River Ancholme in

North Lincolnshire.

GLOBAL CEMENT: UK


GLOBAL CEMENT NEWS: THE AMERICAS



Brazil: Votorantim on the rebound?

Votorantim’s sales from its cement business have grown due to increased sales volumes in Brazil,

Turkey, India and Latin America. Higher prices in North America and Europe, Asia and Africa also contributed to the result. Votorantim Cimentos’ sales revenue grew by 11% year-on-year to US$682m in the first half of 2018 from US$613m in the same period in 2017. Local sales in Brazil grew by 13% to US$417m due to concrete and mortar sales. Its adjusted earnings before interest, taxa-tion, depreciation and amortisation (EBITDA) rose by 28% to US$65.3m from US$50.8m.

Paraguay: President inaugurates Vallemi upgrade

President Horacio Cartes has inaugurated a kiln upgrade to Industria Nacional del Cemento’s

(INC) Vallemi cement plant. The project has con-verted the unit’s third production line to petcoke usage from fuel oil, according to La Nación newspa-per. The upgrade work cost US$45m. The plant has three production lines but only one is used.

Colombia: Cementos Argos weighed down by local market and US

Cementos Argos’ sales have fallen due to decreased cement sales volumes in Colombia and the US. It

blamed poor weather in the US and a large number of holidays in Colombia for the situation. Its sales rev-enue dropped by 8.2% year-on-year to US$677m from US$737m. However, its adjusted earnings before inter-est, taxation, depreciation and amortisation (EBITDA) rose by 2% to US$107m from US$104m.

“The growth of EBITDA throughout all our regions is proof that the strategy we established is beginning to reap the benefits of the best efficiency programme and to focus our initiatives in continuing to provide the best experiences to our clients,” said Juan Esteban Calle, president of Cementos Argos.

Cement sales volumes fell by 4.1% overall to 3.69Mt. Volume drops were noted in Colombia and the US but in the rest of the world they rose by 11%.

Uruguay: ANCAP restarts following strike action

Production has resumed at the Administración Nacional de Combustibles, Alcoholes y Port-

land’s (ANCAP) Minas and Paysandú cement plants following a strike, according to the El Espectador newspaper. The disruption ended following ne-gotiation between management, the union, the Ministry of Industry, Energy and Mining and the Ministry of Labour and Social Security. In April 2018 it was reported that production at the Minas plant had stopped for two months due to union action.

Above: Skyline of Bogotá, capital of Colombia, at dusk. Source: hinterhof / Shutterstock.com

Colombia: Production down 3.3%

Colombian cement production fell by 3.3% year-on-year to 2.9Mt in the first quarter of 2018 from

3Mt in the same period in 2017. Local despatches fell by 5.5% to 2.84Mt from 3Mt, according to data from the National Administrative Department of Statistics.

Dominican Republic: Falling sales

Cement sales fell slightly by 1.5% year-on-year to 4.18Mt in 2017 from 4.24Mt in 2018. Adocem,

the Dominican Portland Cement Producers Associa-tion, blamed the slowdown on a slowdown in the general economy. It also reported that exports grew in 2017 to 20.1% of production from 17.3% in 2016.

Paraguay: Méndez resigns from INC

Jorge Méndez has resigned as the president of Industria Nacional del Cemento (INC). He had been in

post since 2013.

Below: Votorantim Cimentos cement plant at Santa Helena, São Paulo, Brazil. Source: Votorantim website.



US: PCA announces 2018 Safety Innovation Awards winners

The Portland Cement Association (PCA) has announced the winners of the 2018 Safety

Innovation Awards. Cemex USA’s Miami plant Florida won the milling/

grinding category with its new process to load ball mills. The site developed a new mill loading process that uses a small hopper for grinding media, and an inclined transport system with buckets to convey the grinding media directly to the mill. This new system eliminates the interaction between the employee and the machine, reduces the number of people needed to load the mill from five to two, and eliminates the need for employees to stand on top of the mill.

Cemex USA’s Houston operations in Texas won the pyroprocessing category for its use of drones for hazardous inspections. It has implemented a system for using protected air drones to inspect enclosed and confined spaces. Visual inspections of enclosed areas (preheater towers, tanks, silos, process ducts, etc) normally require intrusive equipment, long delays for

system cooling, and placement of employees on scaf-folding in confined spaces.

LafargeHolcim US’ Corporate Program in Chicago won the distribution category for its X-Factor barge cover. It has developed a process for barge cover re-moval that reduces the risk of falls from employees stepping on to the barge.

Ash Grove Cement’s Louisville plant in Nebraska won the general facility category for its use of mag-nets as duct hole patches. Ash Grove has developed a hole-patch technique using magnets. Magnetic patches are quick, simple, and effective at prevent-ing or limiting the release of materials from holes created in ducts caused by abrasion, leading to a cleaner plant, reduced slip, trip and fall risks, and fewer related Mine Safety and Health Administration housekeeping citations.

Cemex USA’s Brooksville in Florida also won the general facility category for its filters moved to ground level project. It redesigned the blower housings to move the filter from the top of the blower housings to an easily accessible location at ground level.

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Canada: CSL Group buys 50% of pneumatic cement vessel business

CSL Group has agreed to buy 50% of Eureka Ship-ping, SMT Shipping’s pneumatic cement vessel

business. The new joint venture will allow Eureka and CSL to expand services to customers in the seaborne cement powder and fly ash transportation markets around the world. CSL’s Australian cement shipping business is not included in the joint venture.

“The joint venture represents an important step in CSL’s strategy to increase its presence in the global construction material sector,” said Louis Martel, Presi-dent and chief executive officer (CEO) of CSL Group.

The companies say that the partnership is a strong strategic fit, leveraging the companies’ respective strengths in the shipping and handling of dry bulk cargos. There will be no change in the day-to-day management and operation of vessels in the Eureka fleet. The transaction is subject to regulatory ap-proval and is expected to be completed by the end of June 2018.

Eureka Shipping operates a fleet of self-unloading cement carriers in the Baltic Sea, the Atlantic Ocean, the Mediterranean Sea, the Caribbean and Asia. SMT Shipping Group has, over the past 30 years, built a fleet of about 45 vessels through a number of joint venture companies operating in various bulk commodities markets, focusing on geared bulk carriers, floating storage/transhipment terminals and belt-unloaders.

Mexico: Cemex Ventures invests in health and safety startup Prysmex

Cemex Ventures has invested in Prysmex, a Mexico-based startup that offers a product capable of

detecting and helping to prevent workplace accidents through the Internet of Things and real-time data col-lection. Following a successful trial period, Cemex has installed Prysmex’s product at all its cement plants in Mexico.

Prysmex’s product features a web platform with a collaborative management app that monitors the environmental and geolocation variables of unsafe acts and conditions on customised 3D maps, enabling real-time decision-making and increased industry safety and productivity. Through the Internet of Things, Prysmex enables an analysis of data such as impacts, light and noise levels, locations, temperatures and the presence of toxic gases. Placed on the workers’ hel-mets, Prysmex devices monitor and communicate in real time users’ conditions, alerting them to potential situations and high-risk areas. In addition, its web ap-plication provides an analytical report of workers’ and plant conditions, enabling better workplace decision-making and accident prevention at all times.

Founded by chemical engineer Susana Ruiz and civil engineer Patricio de Villa in Monterrey, Mexico, Prysmex was the finalist of Cemex Ventures Startup Competition 2017 and is now part of the company’s portfolio.

Barbados/Trinidad & Tobago: Dispute over cheap Turkish imports

Trinidad Cement and its Barbadian subsidiary Arawak Cement have

taken legal action against the Govern-ment of Barbados over allegedly breaking the Caribbean Community Single Market and Economy. The complaint relates to accusations that the country broke import duties on cement, according to Barbados Today. The government has been accused of reducing import tariffs to 5% from 60%.

Arawak Cement and its competitor Rock Hard Cement have battled for the local market since the entry of the latter company in the market in 2015.

Union members from the Trinidad Cement branch of the Oilfields Workers Trade Union had earlier protested at the Port of Chaguaramas over cement imports from Turkey. A union member claimed that a batch of imported cement had no import duties paid, according to the Trinidad Guardian newspaper.

Trinidad Cement has taken legal action in the Caribbean Court of Justice against Turkey’s Sonmez Cimento for

breaking local tariff rules. In 2016 Trinidad Cement made an official complaint to Caricom, the

Caribbean Community organisation, about tax concerns for a cement import from Turkey.

Jamaica: Caribbean Cement to buy equipment from parent

Caribbean Cement has signed an agreement to buy plant

equipment from its parent company Trinidad Ce-

ment. The US$118m deal includes kiln and mill equipment being used at Carib-

bean Cement’s Rockfort plant in Kingston. The equipment was previ-

ously leased to Caribbean Cement in 2010.

Massimo Toso, CEO of Buzzi Unicem USA, started the conference by comparing and

contrasting the European and US cement industries, pointing out that in Europe cement producers are obliged to take CO2 very seriously, but that there is a ‘clear gap’ between this approach and that of the US. Additionally, he suggested that European heavy manufacturers might be guilty of the sin of hubris over the perception of the cement industry by the public - it is increasingly the case that the public re-gards the cement industry as an ‘outdated relic,’ or, as another speaker put it, belonging in ‘the cemetery of dinosaurs.’ Massimo exhorted the listening delegates to reach out and to promote the industry. “It might be just a grey powder,” he said, “but many of the greatest accomplishments of humankind in the last two cen-turies would not have been possible without cement and concrete.”

Ed Sullivan of the PCA next gave his ‘State of the industry’ address. With more than 2m jobs created each year and with the unemployment rate lower than 4.5%, Ed suggested that there may be a further strengthening of US economic growth. This comes despite already tight labour markets and a worsening skills shortage, which will lead to increased wages. The situation might start to unbalance the economy, in terms of inflation, leading to interest rate rises, but at much lower levels than historically. Ed reiterated his forecast of cement demand growth of around 2.5% annually, even in the absence of fiscal stimulus. Some states are still experiencing fiscal problems despite rising tax incomes, since entitlement programmes are growing more quickly than state incomes, and this is squeezing state construction budgets. Ed suggests that there is unlikely to be a Trump Infrastructure Bill before 2019, but even then, the majority of the

Robert McCaffrey, Global Cement Magazine

Event Review: 60th IEEE-IAS/PCA Conference

Over 1000 delegates gathered at the Gaylord Opryland Resort and Convention Centre in Nashville, Tennessee, on 6-10 May, for the 60th IEEE-IAS/PCA Cement Industry Technical Conference. An exhibition of over 180 vendors took place. The 61st event in the series will take place in St Louis in 2019.


1: Ryan Preis (left) and Mark Glover (right) of fan expert Air-Stream proudly man the stand.



3: Busy Aumund stand with Ingo Mirbach, facing camera, and Wes

Allen, far right. Inset: Aumund USA president Geoff Conroy seen

at Global Cement’s dart board shortly before he enters

his well-earned retirement.

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4: Henrik Nilsson (left) and Vinny Matthews (right) of drive and control expert Bosch Rexroth.

5: Josh Carlegis poses happily for the camera at refractory gurus Calderys.

6: Environmental professional BWF Envirotec’s Angi Hamlin

(left) and Mike Beetem (right).

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5

3

5 6

2: Xavier d’Hubert of CMI Energy (right) in discussion

with a visitor to his stand.

14: Smiles from Di Matteo and KIMA Process: Left to right, Dirk Schmidt, KIMA, and Di Matteo’s Svetoslav Chopov, Rafael Castan, Andreas Sennekowski.

13. DALOG Diagnosesysteme’s condition monitoring team spearheaded by left to right: Franz Muschaweck, Birgit Muschaweck and Christoph Muschaweck.



purported US$1tn earmarked for construction will come from states rather than from the federal gov-ernment. States and local governments are currently US$3trn in debt so the money might not materialise in the end. The cement intensity of the infrastructure spending is also in some doubt. Ed, in summary, was not optimistic on the real near-term cement industry effects of any Trump Infrastructure Bill. However, he forecast that without significant new capacity in the US, even with imports, that around 2030 the country may face shortages of cement.

The rest of the conference featured parallel sessions, and here we concentrate on selected pres-entations.

John Kline of Kline Consulting next spoke on the capture of CO2 from the cement industry and its reuse in the concrete industry. Carbon pricing covers around 25% of the world’s emissions, and John sug-

gested that carbon prices will inexorably rise around the world. He suggested that there are a number of different ways of capturing CO2 from the cement pro-duction (sorbent technology, membrane, cryogenic) and many uses for the CO2 captured (fuels, plastics, fertilisers, enhanced oil recovery, aggregates), in-cluding accelerating the strength gain of concrete through the formation of nano-scale nucleation sites in the concrete mix. Through dosing around 200g of CO2 into a concrete mix, the use of around 9kg of cement per cubic metre of concrete can be avoided.

Lance Clarke, environmental manager at the Roanoke cement plant, next spoke about environ-mental initiatives at the plant. He suggested that the first and most important step to maintaining a licence to operate is transparency: don’t avoid the neighbours, welcome them; hold open houses- it forces good housekeeping at the plant; provide local

7: Doug Sibersky of Christian Pfeiffer America (left) and Cornelia Cretiu of Solvay (right)smile for the camera during the exhibition reception.

8: CCC Group’s team proudly awaiting more visitors to their stand. Left to right: Randy Shepler, Arvid Oehlke, John Love and Peter Banak. CCC also hosted an evening hospitality suite during the show.

9: Cement Alliance: left to right, Josef Keuschnig (PM-Technol-ogies), Andreas Anderl (M.A.L. Umwelttechnik), stand visitor Kevin Blankenship (Saxum Engi-neering), Thomas Hacker, Carlos Chavez (Refractarios Altran), Reinhard Ringdorfer (Unitherm), Emanuele Stancenelli (Euromecc)and Alex Lederer (Unitherm).

10: Cement and gypsum experts Claudius Peters Americas. Left to right: Ryan Hogan, Rob Hetrick and Henrik Wetegrove.

12: D&L Weld Inc’s. team. Left to right: Tom Teter, Don DeHaven & Dustin DeHaven.

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11: Dave Galloway (right) and Terry Baum (left) of Canadian bulk professionals Advanced Materials Handling, Ltd.

AMH Test May 2018.indd 1 24/05/2018 13:28

http://www.advancedmaterial.ca

information and outreach through regular commu-nications. The plant has also stocked an old quarry pond with trout and keeps bees on the plant site, as well as operating an outdoor classroom facility for local children. The plant continues to have good rela-tions with its close neighbours and stakeholders.

Stefan Laux of Praxair next spoke on the use of a lance to inject hot oxygen into the kiln to reduce NOx and CO emissions. A small amount of fuel is used to preheat the oxygen, to around 1370-1650°C, to form a high-momentum highly-reactive hot oxygen jet. The high velocity oxygen jet, positioned at the kiln inlet, rapidly entrains surrounding gases, oxidising CO and reducing the levels of NOx. The approach can be used alongside SNCR or SCR but has a low capex and no toxic ammonia reagents.

The first presenter in a session on ‘engineered fuels’ was Frederick De Raedt of Alterros, who quoted European standard EN15359 in order to

define SRF, which is ‘intentionally produced with respect to quality criteria,’ whereas RDF is usually a remaining fraction from waste treatment operations. Producers of SRF control the production process so that the fuel meets the desired specifications, while RDF is a non-specified waste. SRF has an energy value of 16-20MJ/kg.

Xavier d’Hubert next gave an overview of kiln burners with an eye on the possibility of using more alternative fuels (AF). Burners have evolved over the years, and since the 2000s they have trended towards increased use of AF. A bewildering array of options are available and the choice of burners will depend on the alternative fuels that are avail-able. The Notar gasification reactor is an option for non-direct combustion of alternative fuels, which is perhaps the next step onwards from the Hotdisk and Polysius Step Combustor options for burning bulky alternative fuels.



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15: Ugras Akay (centre) of cooler guru Fons Technology International and Samim Cenk Alpaslan (right), in discussion with a visitor to plant expert DAL Technik Makina’s stand.

16: Juan Quintero (left) and John Stewart (right), of emissions monitoring specialist ENOTEC GmbH smile for the camera.

17: FCT Combustion’s managing director Con Manias (far left) in discussion while FCT Combus-tion’s Adriano Greco (centre, facing away) and David Rapson of FCT ACTech, (centre facing) welcome numerous visitors.

18: All smiles from France’s cement expert The Fives Group! Left to right: Max Vaccaro, Yan Huerre, Julien Rickeboer, Lars Hansen and Philippe Martineau.

19: Gebr.Pfeiffer Inc. welcoming Redecam’s Alberto Pedrinoni, second from left. From right: Blaz Jurko, Volkan Ündeğer (Quad Plus), Chris Oesch and Tania Vitery.

20: FLSmidth manned a busy exhibition stand throughout the show.

21: Laboratory specialist Herzog Automation’s stand: Yolanda Escalante (right) and Bruce Weak-land (left) had a successful event in Nashville.

22: John King Chain Ltd’s Oliver Wadsworth (left) and Will Wadsworth (right) reported a pleasing number of enquiries at the show.

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Ty Howard, plant manager of the LafargeHolcim Devil’s Slide plant in Utah, spoke about the consid-erations for the use of engineered fuels at the plant, which include air permit conditions, the heat value of the availability of the fuel, market conditions, effects on process parameters and performance in conjunc-tion with other fuels. The plant uses a variety of AFs including tyre chips, nylon fluff and waste plastics.

In an ‘automation’ session, Alistair Brown spoke on behalf of Thermoteknix, on video storage chal-lenges with high-frame-rate high-definition video. In fact, his company’s kiln camera generates 105MB of data per second, or 7TB per day. Compression helps by reducing data volume by 97.5%, down to 2.5MB per second, although this still means 50-100TB of data to store per year. In fact, using ‘intelligent stor-age management’ to manage and automate storage, the full resolution data is retained for a week, and

then one frame per second is retained for 60 days, unless an ‘event’ marker is placed on the system, whereupon the event will be retained in full.

Thomas Walter of Siemens AG pointed out five mega-trends that will influence the cement in-dustry: urbanisation, population growth, climate change, globalisation and digitalisation. By 2020, 40Zettabytes of data will be created each year, with a zettabyte being 1 billion terabytes, from 50 billion connected devices. Alongside these trends other drivers will influence the cement industry, including health and safety, costs and production efficiency. The Internet of Things (IoT) response to these chal-lenges is increased automation and instrumentation, engineering software for the entire plant lifecycle, improved networks, secure data storage and trans-mission, and software platforms to store and analyse the data. At the moment there are distinct ‘data

23: The team from HMC Gears made some good contacts.

25: Kurt Robinson, left, and Erik Matheson, right, manned the much-visited Webster Industries stand.

26: During a coffee break between lectures Felix Bartknecht, left, of Sick AG and Karsten Horn, right, of Inform GmbH pause for Global Cement’s camera.

29: Chain expert KettenWulf was flying the flag again this year. The stand was manned by Diego Herrero (left) and Scott Martin (right).

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24: Grinding gurus Loesche were flying the flag with, left to right, Jürgen Triep, Eduardo Garcia and Thomas Leppak.

27: Wear protection experts Wear-Con proudly manned the stand at this year’s show: Front row, Dennis Todd, right, Cindy Todd, left. Back row left to right, Lisa Huey, James Huey, Chris Booz, Corey Booz.

28: Tomas Zrostlik of gearbox specialist Wikov Gear, Czechia. The company has opened a new office in the US.

30: Filtration specialist Gore’s smiling team paused briefly for the camera during what was a busy show for them.

islands’ that do not talk to each other, in terms of raw materials, suppliers, production and maintenance, logistics and real-time information about supply and demand from customers. Upon full digitalisa-tion, these islands will be fully connected, and able to talk to each other in real time. Application of big data analysis and artificial intelligence to the digital-ised system will enable optimisation ‘from quarry to customer.’

Second dayOn the second day of the conference, the Portland Cement Association’s chairman Allen Hamblen spoke about the importance of resilience - an attrib-ute that concrete construction has in abundance. The 2017 cost of damage from floods, hurricanes, torna-dos and fires in the US was over US$300bn and Allen strongly advocated the use of resilient...

1: BEUMER G



34: Environmental specialist Scheuch’s Alois Hermandinger (left) and Andreas Gangl (right) in perfect colour-coding at their stand.

31: Charley Kinsey of McDonough’s Elevators, neighbour to Global Cement this year, recently completed installation of a new elevator

system at a cement plant in North West USA.

32: Michael Thiel of NGC Transmissions reported good footfall at the stand with some interesting enquiries received.

37: Anis Haider of ITECA (left) in discussion with Daniel Uttelbach,

KHD Humboldt Wedag (right).

34

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Scan the QR code below or enter the bit.ly code into your browser to read more about the IEEE-IAS/PCA Cement Industry Technical Conference and see the conference video...

31 32 33

35 36

37 38 39

35: Joe Riley (centre) of STM EcoSystems, flanked by STM’s Michael Kelaher (right) and Cornelia Cretiu of Solvay (left).

36: UNICAST’s Steve Kirschner (far right) and Dan Kowarski (second from left), welcome

visitors to their stand.

33: Multi Queen’s Award for Export winner Thermoteknix

Systems Ltd exhibited and presented successfully at the

event. Right, Alistair Brown, left, Bob Blocksidge.

38: Davide Gambarotta of bulk handling expert MDG Handling Systems, poses for the camera.

39: Dominik Stracke, right, and left, Carlos Soteldo of chain

professional Kobo USA had a successful exhibition.

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GLOBAL CEMENT NEWS: ASIA



Japan: Sumitomo Osaka sales pick up

Sumitomo Osaka Cement’s net sales rose by 4.6% year-on-year to US$2.24bn in the financial year

that ended on 31 March 2018 from US$2.14bn in the same period of the previous year. It attributed the in-crease to higher sales volumes of cement. However, its operating income fell by 15.6% to US$92m from US$113m due to higher coal prices. The company said that overall local demand in the country rose by 0.2% to 42Mt during the reporting period. Exports rose by 2.4% to 11.8Mt.

Thailand: SCG helped by rising prices

SCG’s cement business earnings have risen due to higher local prices and cost savings in the first

quarter of 2018. Its earnings before interest, taxation, depreciation and amortisation (EBTIDA) rose by 7% year-on-year to US$201m in the first quarter of 2018 from US$195m in the same period of 2017. The com-pany said that local demand for cement remained flat in the reporting period as increased demand from the government sector balanced out declines elsewhere. Local exports rose by 20% to 1.2Mt.

Philippines: Eagle Cement’s first quarter grows on efficiency gains

Eagle Cement’s profit for the first quarter of 2018 grew due to higher sales volume and efficiency gains. Its

net profit rose by 3% year-on-year to US$21.3m. Its sales revenue rose by 6% to US$77.4m. The cement pro-ducer attributed its increase in sales volume to efficient production methods at its plant.

Indonesia: Semen Indonesia’s profit falls due to fuel costs

Semen Indonesia’s net profit fell by 45% year-on-year to US$29.6m in the first quarter of 2018 from

US$54m in the same period in 2017. It blamed the de-cline on fuel costs and rising debt payments, according to Reuters. Despite this, its sales revenue rose by 3.4% to US$476m from US$460m. Its cement sales volumes rose by 4% to 6.79Mt from 6.53Mt. The majority of this rise came from exports, which increased by 44.9% to 0.6Mt from 0.41Mt.

Indonesia: Lucky earnings fall

Lucky Cement’s earn-ings before interest,

taxation, depreciation and amortisation (EBITDA) fell by 21.6% year-on-year to US$114m in the nine months of its financial year to the end of March 2018 from US$145m in the same period in 2016. It noted that its cost of sales rose by 16.9% due to rising coal and other fuel prices. Its gross rev-enue rose by 7.1% to US$439m from US$410m. Cement production rose by 11.1% to 5.79Mt from 5.2Mt.

The cement producer added that it is expanding production at its Pezu plant by 2.6Mt/yr due to delays with its expansion plans elsewhere in the north of the country. Approvals from the government have been secured. The US$152m upgrade project is scheduled to be completed by the fourth quarter of 2019. It is also building a US$109m integrated cement plant at Samawah in Iraq. The joint-venture project with a local partner will have a cement production capacity of 1.2Mt/yr when operational. Commercial produc-tion is currently scheduled for end of 2019.

India: Ultratech’s sales up 34% in Q4

Ultratech Cement’s consolidated net sales rose by 34% year-on-year to US$1.39bn in the fourth

quarter of its 2017 financial year from US$1.04bn in the same period in the previous year. Its profit before interest, depreciation and taxation increased by 20% to US$283m from US$236m.

The group benefitted from its acquisition of assets from Jaiprakash Associates in mid-2017. Its cement production capacity grew by 28% to 85Mt/yr from

66.3Mt/yr. However, its capac-ity utilisation rate fell slightly to 80% from 82%. Its local sales rose by 32% to 17.6Mt from 13.4Mt and exports increased by 15% to 0.82Mt from 0.72Mt. The cement producer also warned that a rise in petcoke and coal prices following a government ban had caused its input costs to inflate during the quarter.

China: CNBM rev-enue rises by 40%

China National Building Materials’ operating reve-

nue rose by 40% year-on-year to US$394m in the first quarter of 2018 from US$281m in the same period of 2017. Its net profit more than tri-pled to US$77.4m from US$23.6m.

NEWS: ASIA

Kyrgyzstan: Production rises

Data from the National Statistics Com-mittee shows that cement producers

in Kyrgyzstan manufactured 1.5Mt of cement in 2017. The country produced 1.3Mt in 2016 and 1.5Mt in 2015.

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Afghanistan: Plant tender

The Ministry of Mines & Petroleum plans to re-issue a tender for the Jabal Saraj

cement plant. The winning company will have to invest US$170m into the project to build a 1Mt/yr plant, according to Tolo News. Previously, a local company won the tendering process to renovate the unit but the High Economic Council decided to find a company with more experience of the cement sector.

South Korea: Tongyang to sell Sampyo stake

Tongyang Networks plans to sell its stake in Sampyo Cement for US$12.7m,

according to Reuters. The sale covers 3,000,000 shares. Tongyang Cement & Energy changed its name to Sampyo Ce-ment in 2017 following its purchase by Sampyo Corporation in 2015.

New Zealand: Golden Bay shipping switch

Golden Bay Cement plans to start shipping cement directly from its in-

tegrated plant at Whangarei, Northland in the North Island. Previously, cement from the plant was being shipped to the South Island via Auckland. After the change around 11% of Whangarei’s output will be shipped to the South Island.

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GLOBAL CEMENT NEWS: ASIA


Bangladesh: Two dead at Crown

Two workers were killed and a third critically injured at Crown Cement’s grinding plant in

Paschim Muktarpur in Munshiganj on 14 May 2018. They died after being struck by falling material when entering a room at the site to clean it.

Vietnam: New plant for Vinaconex

A joint venture between Vinaconex Engineering Con-struction and Investment and Lilama will supply

US$66m of equipment for the Tan Thang cement plant in Nghe An province. The new plant will have a cement production capacity of 2Mt/yr. Vinaconex and Lilama will join European companies Bedeschi and FLSmidth on the project.

The National Company Law Tribunal (NCLT) has asked the Committee of Creditors (CoC) of Binani Cement to con-

sider Ultratech Cement’s revised offer. It has also set 24 June 2018 as the completion deadline of the insolvency resolution process, according to the Press Trust of India. The NCLT also asked the CoC to reconsider the resolution plan of Rajputana Properties if the subsidiary of Dalmia Bharat Group was willing to raise its offer over that of UltraTech Cement.

A consortium led by Dalmia Bharat won an auction for Binani Cement with a bid of US$974m in early March 2018. UltraTech Cement then made a direct bid to Binani Cement a few weeks later. However, the Supreme Court blocked Ul-traTech Cement’s offer in mid-April 2018. UltraTech Cement has since made a raised offer to the resolution professional handling the insolvency process of Binani Cement.

Pakistan: GE Power to supply Power Cement

GE Power has won a contract to design, manu-facture and deliver a 132/6.3kV air-insulated

switchgear (AIS) grid station to support a new production line being built at Power Cement’s plant in Nooriabad. The project is expected to be completed in early 2019. It will supply the cement plant with a reliable electricity supply from the Hyderabad Electric Supply Company.

India: Binani Cement asked to reconsider Ultratech’s offer by NCLT

Pakistan: Gharibwal starts mill

Gharibwal Cement has started commercial operation of a 250t/hr vertical cement mill

for grinding cement. It says it is the single largest cement grinding mill in the country. The cement producer operates a 2.1Mt/yr integrated plant at Ismailwal in Chakwal.

Sri Lanka: Tokyo launches resource-planning software

Tokyo Cement has launched resource-planning soft-ware across its business. The software was developed

by Abas and implemented by Providence Global, accord-ing to the Daily News newspaper. The software is being deployed across all of Tokyo Cement’s operations, includ-ing its cement plant at Trincomalee, its ready-mix concrete plants and its bulk cement import terminal and biomass power generation units. The new software is intended to fully integrate supply chain management and warehouse operations.

India: Shree plan moves forward

The Ministry of Environment, Forest and Climate Change has awarded terms of

reference for Shree Cement’s proposed plant at Bhuj in Gujarat. The proposed 3.5Mt/yr integrated plant project will include a waste heat recovery unit, a captive power plant, a synthetic gypsum unit and a railway terminal. The unit will be built near Maldo, Lakhpat tehsil in Kachchh district. Limestone for the plant will come from a quarry next to the proposed site.

Pakistan: Dewan rejects Mega bid

Dewan Cement has rejected a takeover bid by Mega Conglomerate to buy a 87.5% stake in it. Chairman

Dewan Mohammad Yousuf Farooqui turned down the offer following a valuation of the company. The valua-tion reported that the value of the cement producer was below the initial offer made by Mega Conglomerate due to low capacity utilisation rates at Dewan’s plants and the need for investment at the sites. The company reports that negotiations with Mega are continuing.




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The mineral-rich Salt Range is certainly not just composed of salt, although it contains three

large and famous salt mines of Khewra, Kalabagh and Warcha. Coal is also found in the Salt Range, but what brings cement producers to the region is its high-quality limestone, as well as its strategic posi-tion in the developing north of Pakistan and the fact that it is now well-connected with the world-class M2 motorway, which winds it way up steep inclines into the hills around the famous salt-water lake and nature reserve at Kallar Kahar from the vast plain of the Punjab below. Indeed, so rich are the hills in limestone that the twin cement plants of Bestway Ce-ment, and the Dandot Cement Factory near Tobar, are within a long stone’s throw of the DG Khan Ce-ment plant at Khairpur. DG Khan Cement Company is a member of the Nishat group of companies, with businesses including cement, textiles and banking. Global Cement recently visited the Khairpur plant site and was kindly hosted by plant manager Col (r) Hashmat Ali Khan and his colleagues.

DG Khan Cement’s site was established in 2004, and started production in 2007. The plant was of-ficially inaugurated by the then prime minister of Pakistan, Shaukat Aziz. The plant capacity is around 6700t/day of clinker, or 2.21Mt/year, with cement production capacity of 2.43Mt/year.

Cement plant process walk-through

The plant has its own limestone quarry, with a lease area of 6798 acres, as well as an argillaceous clay quarry on site. The present working area of the quarry is 1.35km2, and total reserves of limestone are around 646Mt.

The limestone crusher at Khairpur has a capacity of 1500t/hr, sending material to a limestone storage shed with total capacity of 90,000t. An FLSmidth 52.5 Atox mill, fitted with an RAR-LVT 52.5 air-separator, is used for grinding raw materials at a rate of 500t/hr. Prior to the pyro-system, materials are stored and homogenised in a CF silo with capacity of 25,500t of raw meal. The plant uses a two-pier Rotax-2 kiln with

Robert McCaffrey, Global Cement Magazine, with kind assistance from DG Khan Cement staff

DG Khan Khairpur: The ‘self-sufficient’ cement plant


Below: An overview of the plant and of part of the quarry, set in the deeply-incised landscape of the Salt Range.

GLOBAL CEMENT: PLANT VISIT


Right: A Caterpillar dump truck being filled with limestone in the plant’s quarry, by a Caterpil-lar tracked back-hoe excavator.

Global Cement recently visited the Khairpur cement plant of DG Khan Cement Company, situated at Chakwal in a rural area in Punjab State, northern Pakistan, between Lahore and Islamabad. Despite the remote location, the cement plant is a model of modernity, demonstrating admirable self-sufficiency in a number of areas and boasting many impressive features.

tertiary air-duct and an FLSmidth SF 4 x 7F Cross Bar cooler for clinker cooling. A Brokk 330 remote-controlled demolition robot is used to de-brick the kiln during shutdowns. Clinker is transported by pan conveyor to the mammoth clinker storage silo, with a capacity of 110,000t of clinker. The two OK 36-4 vertical roller mills used for clinker milling are each rated at 175t/hr. The three cement silos at the site have a storage capacity of 21,000t each.

Cement quality control is facilitated with the use of technology such as PGNAA and X-ray analysers (PANalytical CubiX Pro XRD and CubiX XRF). The packing house can bag cement at 600t/hr, using six Ventomatic rotary packers operating at 12,000 50kg bags per hour, while there are also 12 loading posi-tions for trucks. Three bulk loaders are available for delivery of 600t/hr of bulk cement, in parallel.

Waste heat power generationThe DG Khan Cement plant at Khairpur has a total power requirement of 31MW, which cannot always reliably be supplied by the national grid. In order to give the manufacturing facility an uninterrupted supply of power, DG Khan Cement has installed two captive power plants. Firstly, the plant features a Kalina Cycle-based waste heat recovery plant with power production capacity of 8.6MW, manufactured by FLSmidth of Denmark. Wasabi Energy provided FLSmidth with front-end engineering design (FEED), procurement and commissioning services in relation to the Kalina Cycle® technology. The Kalina Cycle1 process uses a binary working fluid of ammonia and water with proprietary and patented processes for varying the ammonia concentration throughout the system and for heat-recuperative stages for increased efficiency. The use of ammonia permits efficient use of waste heat streams allowing boiling to start at lower temperatures. A binary fluid allows the composition of the working fluid to be varied through the use of distillation, providing a richer concentration through the Heat Recovery Vapour Generator (HRVG) and leaner composition in the low-pressure condenser. As the molecular weight of ammonia is close to that of

water, a standard back-pressure turbine can be used.In contrast to the Rankine Cycle, the non-isother-

mal boiling that results from the use of a binary fluid with variable composition gives a good match with the thermal characteristics of the HRVG so that more of the heat can be extracted from the energy source to enhance the efficiency of the process. Similar considerations apply at the condensing end of the power cycle. By selecting a suitable ratio of the two components that form the working fluid, the boiling point can be adjusted to suit the temperature of the heat source and extract the maximum amount of heat. With this characteristic, of being able to take full advantage of the temperature differential be-tween heat source and heat sink, the process is ideally suited for extraction of useful heat from low-grade sources such as is found at a cement plant. Efficiency improvements of 15-50% are claimed for this type of application.

The waste heat recovery system at Khairpur has a fluid temperature of 340°C and recovers waste heat from the preheater and from the clinker cooler using the patented Kalina Cycle KCS1-2A system specially developed for the cement industry.

Combustion-engine power plantSecondly, the plant’s other captive power generation unit was provided by Wärtsilä of Finland and consists of two 18-cylinder dual-fuel natural gas and heavy fuel oil Wärtsilä 50DF internal combustion engine electrical power generation units, with a combined

Left: The Wasabi Energy/FLSmidth 8.6MW Kalina Cycle

waste heat recovery plant at the Khairpur cement plant.



maximum power output of 33MW. Each Wärtsilä unit can produce up to 16.64MWe in continuous base-load operation with a heat rate of 7608kJ/kWh, which is equivalent to an overall thermal efficiency of 47.3% at the busbars. The Wärtsilä 50DF lean-burn dual-fuel engine has become popular for power plant installations in a number of countries. It is one of the most powerful gas-burning engines on the mar-ket today and has both low emissions and high fuel efficiency which make it a competitive alternative to gas turbines.

According to Wärtsilä, “Important factors in the choice of engine were the need for a reliable, cost-effective electricity supply to the cement-making process, with flexibility in the choice of fuel. Fuel flexibility is an important factor in Pakistan as the year-round supply of natural gas cannot be guar-anteed, particularly during high demand in winter

months. Furthermore, operating an independent power plant for a cement works is advantageous when starting the large motors commonly used in cement mills with their sudden high starting cur-rents. These requirements are all ideally met by the Wärtsilä 50DF.”

“When running on natural gas, the gas fuel is supplied at a low pressure (less than five bar) and the engine operates on the lean-burn Otto process. Gas is admitted into the air inlet channels of the individual cylinders during the intake stroke to give a lean, premixed air-gas mixture in the engine com-bustion chambers. Reliable ignition is obtained by injecting a small quantity of diesel oil directly into the combustion chambers as pilot fuel, which ignites by compression ignition as in a conventional diesel engine. This ‘micro-pilot’ injection uses less than 1% of the fuel energy required as liquid fuel at nominal

Right: The Wärtsilä 50DF lean-burn dual-fuel engine, installed at Khairpur.

Below: The view from the plant’s preheater tower at dusk, with the clinker and cement silos on the left, the plant’s orchards in the centre, raw meal silo and limestone shed at the right and the hills of the Salt Range in the distance.



load. Electronic control closely regulates the ‘micro-pilot’ injection system and air-gas ratio to keep each cylinder at its correct operating point between the knock and misfir-ing limits.

In the ‘diesel’ mode, the engines run on liquid fuel oil such as heavy fuel oil as in a conventional diesel engine. The engines are fully capa-ble of switching over from gas to back-up liquid fuel instantly and automatically should the gas supply be interrupted or in the event of any other alarm, while continuing to de-liver full power. When the situation returns to normal it is then possible to switch back to gas mode.”

Alternative fuels useKhairpur is also a leader in Pakistan in the use of alternative fuels for

kiln firing, using solid munici-pal waste and other industrial and agricultural wastes. The plant uses an Eldan Recycling pre-chopper/shredder, screen, wind-sifter and a further Veco-plan shredder, fitted with SSAB

• Gwadar • Karachi

• Lahore

• Khairpur• Islamabad



Left: The plant is compact and still smart despite its high

capacity utilisation rate.

Below: Position of the Khairpur plant, in relation to the main cities of Pakistan and significant projects in the Chinese-backed Pakistan Economic Corridor.

Hardox wear-resistant steel hoppers to cope with the abrasive materials being fed into it. The alternative fuels processing facility at the Khairpur plant is large and impressive. The purpose of the project was to replace the use of imported coal with locally-available alternative fuels including agricultural waste such as rice husk, corn cob, wheat straw, bagasse; tex-tile waste; tyre waste; and refuse derived fuel (RDF) from Municipal Solid Waste (MSW). Incoming wastes are stored in separate piles and are first taken to the shredder for size reduction and then transported to the storage bin. The al-ternative fuels are then extracted using a double screw conveyor and are taken using a Vecobelt pipe conveyor to the cal-

ciner floor before being injected into the calciner combustion chamber, controlled through Schenck weigh-feeders.

Bag production at KhairpurThe plant site also has its own bag manufac-turing facility, operated by Nishat Paper Prod-ucts Company Ltd, running three lines with Windmöller & Höls-cher equipment, with a production capacity of 800,000 bags/day, for its own use and for the pro-duction of bags for other

Right: The Eldan Recycling pre-chopper/shredder used at Khairpur for processing of RDF.

Right: One of the Windmöller & Hölscher AM 2185 tuber machines in use at Khairpur.



Right: The Vecoplan shredder, fitted with SSAB Hardox wear-resistant steel hoppers to cope with abrasive RDF.

cement producers in the region. The lines are equipped with Flexa 820 flexographic end printers for in-line operation with tu-bers for multiwall applications, with a print width of up to 157cm. The AM 2185 tuber is used to make three-ply sacks (although up to four plies could be used), while the AD 2390 sack bottomer is also used on the lines. Twin Arcomat 2 robot palletising machines are used to handle the sacks produced. A Paul Maschinenfabrik bag flattening machine is used to pre-condition the bags before use. The plant produces bags not only for DG Khan’s cement plants in Pakistan, but also for

its competitors, including Bestway Cement, Falcon Cement, Dewan Cement Ltd, Lucky Cement, Kohat Cement and Maple Leaf Cement. The three lines have a capacity of 190 million bags each year.

Production and social responsibilityThe Khairpur plant produces Ordinary Portland Cement and Sulphate Resistant Cement, which are sold locally as well as being exported. The DG Khan Cement Khairpur facility is ISO certified for Quality Management Systems to ISO 9001:2015 and for Envi-ronmental Management Systems to ISO 14001:2015.

A free medical centre has been established for plant employees and for local residents, while a water reservoir on site has provided relief for locals from

the droughts which are common in the otherwise lovely area. Regular internships and training programmes are made avail-able for students and locals at the cement plant.

Green and pleasant landNotably, the plant possesses its own plant nursery, orchards, olive trees and rose gardens, including over 30 varieties of roses. It also has 20 acres of agricul-tural and fruit fields for growing its own

produce, which is used in the plant’s canteen, as well as a harvest of around 22t of wheat each year. Products are sold to employees at subsidised rates. Common Myna birds, Acridotheres tristis, enjoy nesting around the top of the preheater tower, no doubt attracted by the warmth of the pyroprocess, but perhaps also by the spectacular views of this tidy and self-sufficient cement plant, situated in an idyl-lic valley in the heights of the spectacular Salt Range in the Punjab.

1. http://www.globalcement.com/magazine/articles/721-kalina-

cycle-power-systems-in-waste-heat-recovery-applications

2. Validation of the CDM-project: substitution of coal with alternate

fuels at DG Khan Cement Company Limited, Khairpur Plant,

Report 1577385, TÜV SÜD Industrie Service GmbH

Left: A Brokk 330 remote-controlled demolition robot

is used to de-brick the kiln during shutdowns.

Left: A pair of PANalytical CubiX Pro XRD and CubiX XRF

machines for quality control at Khairpur cement plant.

Left: A view into the kiln at Khairpur.

Left: Common Myna birds gathering at dusk on the warm

preheater tower.



Clockwise from above: FLSmidth DuoFlex burner; Windmöller & Hölscher Flexa 820 flexographic end printer; Paul Maschinenfabrik bag flattener; FLSmidth Atox coal mill; DGKhan Khairpur’s control room; Wind-möller & Hölscher Arcomat 2 bag palletising machine; Olives ripen-ing in the plant’s olive groves.



Main picture: The goose-neck at the top of the precalciner, with the fields of the local farmers and other local cement plants in the distance.

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Contents

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Saudi Arabia: Southern Province’s sales down in first quarter of 2018

Southern Province Cement’s sales fell by 9.6% year-on-year to US$73m in the first quarter of 2018 from

US$80.8m in the same period in 2017. Its net profit fell by 2.9% to US$27.2m from US$28m. It blamed the falling sales and profit on decreased demand.

GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA

Qatar: Three years accident free

Alkhalij Cement, a subsidiary of Qatari Investors Group, has reached three years or 3.5 million

hours without accidents, at its plant in Umm Bab. The company said that achievement showed that its employees had followed safety rules with dedi-cation and reliability. Alkhalij Cement operates an integrated plant with a clinker production capacity of 6000t/day.

Saudi Arabia: UCC resumes exports to Bahrain

The United Cement Company (UCC) has resumed im-porting cement from Saudi Arabia to Bahrain. UCC

chief executive Faisal Shehab said that since the Saudi government lifted cement tariffs in February 2018 it had imported up to 60,000t of cement. Shehab estimated that his company supplies 70% of the construction market in Bahrain.

Egypt: New cement bag plant proposed

A Saudi Arabian company plans to build a US$28m paper bag plant at Borg El-Arab in Alexandria. The plant will

have three production lines, including one exclusively for manufacturing cement bags. Ahmed Abdel Razek, head of the Industrial Development Authority (IDA), said that the company plans to start production a year-and-a half after land for the unit is allocated.

Syria: Lafarge security chief charged with financing terrorism

Jacob Waerness, the former security chief at Lafarge Syria, was arrested by French Police in early May

2018 while transferring between planes at the Charles de Gaulle airport on charges of financing terrorism. The arrest follows a number of arrests of high-profile employees of the former Lafarge as part of an ongo-ing investigation into the alleged financing of armed groups, including the so-called Islamic State (IS), by the company in Syria in the early 2010s. Waerness worked as the head of security for Lafarge in Syria from 2011 to 2013.

Alongside the investigation two non-governmental organisations, Sherpa and the European Center for Constitutional and Human Rights (ECCHR), are now arguing that Lafarge should be indicted for complic-ity in crimes against humanity. They have made the argument for the accusation in a memorandum to the investigative judges examining Lafarge Syria’s conduct. Despite the indictment of several Lafarge executives the NGOs want the charges to apply to Lafarge itself as a company.

Syria: France sought to protect Lafarge

The French government reportedly asked the US not to target Lafarge Syria’s Jalabiya cement plant

during military operations in 2014. Emails seen and reported upon by Reuters suggest that France’s Syria envoy, Franck Gellet, asked the French Foreign Ministry to protect the cement plant while it was in Islamic State controlled territory. The request to ‘not to do anything about this site without checking with us first’ was then passed to US officials. Reuters reports that neither the French Foreign Ministry nor LafargeHolcim commented on the emails when asked.

Malawi: Shayona to double capacity

Shayona Cement plans to more than double production at its integrated plant at Kasungu

in Lilongwe from 1200t/day to 3000t/day. It is also considering expansion to other countries in Africa.


Nigeria: Dangote exports 0.2Mt in Q1

Dangote Cement exported 0.21Mt of cement to Ghana, Togo and Niger from Nigeria in the first quarter of

2018. The company’s revenue for the quarter grew by 16% year-on-year to US$668m from US$575m. Its profit in-creased by 29% to US$199m from US$154m a year earlier. Cement sales for the quarter rose by 2.8% to 6.2Mt from 6.03Mt in the first quarter of 2018.

Uganda: Rail project trouble

Local cement producers are facing a challenge to meet the specification required for cement

being used by the Standard Gauge Railway (SGR) project. Project coordinator Kasingye Ky-amugambi said at a procurement conference in Kampala that the project was facing issues with cement, reinforcement steel and sand, according to the Daily Monitor newspaper. Hima Cement is producing one specific product for the project following discussions with the SGR. However, the railway needs eight different types of cement.

Kyamugambi has called for legal cover for the infrastructure project to bypass local product sourcing laws. He has asked for new legislation to cover projects with a lifecycle of over a century.

The SGR is being built by China’s China Harbour Engineering Company. The project is intended to link up to Kenya’s railway project at Tororo with proposed links to Rwanda and South Sudan.

Ivory Coast: CIMAF starts project

Morocco’s Ciments de l’Afrique (CIMAF) has started work on a 0.3Mt/yr cement plant at

Bouake. The company has acquired land for the project and is currently preparing the necessary permits to begin construction, according to the African Press Agency.

CIMAF built its first 0.5Mt grinding plant in Abidjan in 2013. The production capacity at this unit was then increased to 1Mt/yr in 2016. In late 2017 the cement producer started building a sec-ond 1Mt/yr plant at San Pedro. The latest project at Bouake will be its third plant in the country.

Uganda: FCKS sells Yetu cement in Luau

Fabrica de Cimento do Kwanza Sul (FCKS) has started selling its Yetu cement product in Luau, Moxico prov-

ince. 400t of the product has been transported via the Benguela railway as part of a sales expansion drive.

Ghana: Cimpor and ETE Group work together on clinker shipments

Cimpor and ETE Group have collaborated to export 55,900t of clinker from Portugal to Ghana. The clinker

was transferred via barges from the river terminal of Cimpor’s Alhandra cement plant before being loaded into a bulk carrier at the Port of Lisbon.

Morocco: CBMI plant for LafargeHolcim

China’s CBMI has signed a contract with LafargeHolcim to build a cement grinding plant near Agadir. The deal

for the SSS 13 & 14 Grinding Plant EPC Contract was signed on 21 March 2018 at the LafargeHolcim Technology Centre in Lyon, France. Once operational the plant will be run by LafargeHolcim Maroc.

Kenya: First fall in cement consumption since 2000

Cement consumption in Kenya has fallen for the first time since 2000. It fell by 8.2% year-on-year to 6.2Mt in 2017 from 6.7Mt in 2016, ac-

cording to data from the Kenya National Bureau of Statistics. Reduced demand for building materials in the construction sector occurred at the same time as a fall in the value of building plans approved in 2017.

Algeria: GICA exports to Europe

Groupe des Ciments d’Algérie’s (GICA) has made its first export to Europe. The Ministry of

Industry and Mines said that 45,000t of cement was exported to Europe via GICA’s building ma-terials distribution subsidiary. The consignment was the last part of a contract to export 0.2Mt of cement to Europe.


GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA

AUCBM June 2018.indd 1 22/05/2018 16:03

http://www.aucbm.org/LogIn.aspx

Egypt: Ordinary Portland Cement prices as of 21 May 2018: Arabian Cement (Al

Mosalah) = US$46.08/t; Arabian Ce-ment (Al Nasr) = US$44.69/t; Cemex

(Al Muhandis) = US$45.80/t; Building Materials Industries (Altaamir) = US$44.97/t; Elnahda Cement (Al Sakhrah) = US$44.58/t; Wadi El Nile Cement = US$44.97/t; Lafarge (Al Makhsous) = US$45.25/t; Arish

Cement (Alaskary) = US$45.25/t; Arish Cement (Askary Bany Suef ) =

US$45.25/t; Sinai Cement = US$44.97/t; Suez Cement = US$45.81/t; Tourah Port-

land Cement = US$46.53/t; Helwan Cement = US$46.53/t; Misr Beni Suef = US$46.09/t; El

Sewedy Cement = US$46.53/t; South Valley Cement = US$44.86/t; Misr Cement Qena = US$44.58/t.

White cement prices as of 21 May 2018: Sinai White Cement (Alabid Elnada) = US$124.57/t; Sinai White Cement (Super Sinai) = US$125.42/t; El Menya Cement (Super Royal) = US$122.90/t; Menya Helwan Cement = US$122.90/t.

Blended cement prices as of 21 May 2018: Sinai Cement (Alnakheel) = US$41.90/t; Helwan Cement (Alwaha) = US$42.62/t. Sulphate-resistant cement prices as of 21 May 2018: Cemex (Almukawem) = US$46.19/t; Lafarge (Kaher Albehar) = US$48.26/t; Suez Cement (Al Suez Sea Water) = US$47.86/t; El Sewedy Cement = US$47.86/t.

Rwanda: In just a matter of weeks the price of a 50kg bag of Cimerwa cement in Kigali rose from US$10.00/bag to US$13.80/bag. Imported ce-ment prices also increased from US$9.78/bag to US$12.08/bag.

Outside of the capital in areas such as Gat-sibo District, Cimerwa cement prices rose from US$10.00/bag to US$14.95/bag, while imported cement increased in price from US$9.78/bag to US$12.65/bag.

Cimerwa said that the shortage was caused by temporary shutdown of its plant in Bugarama, in Rusizi District due to annual maintenance. Bheki

Mthembu, Cimerwa’s chief executive officer, said, “The upgrade and maintenance caused a lot of anxiety and pressure in the market place, with some people taking advantage to speculate on cement prices.”

There is a backlog of nearly 5000t of unmet de-mand from consumers that had requested cement during the shutdown.

Guinea: A shortage of cement at the start of May 2018 led to prices in Mamou rising to US$8.36/bag (50kg), rather than the previous level of US$6.71/bag, a 25% rise in just a week. This has led to stop-page of work at many sites in the city.

Some cement dealers have claimed a lack of raw materials, as only three of the four cement plants in the country are currently making cement.

Zambia: The average price of 32.5 N cement across Zambia at the start of May 2018 was US$7.08/bag (50kg), according to our correspondent. The price of 42.5 N cement was US$7.28/bag. Prices have been broadly stable in local currency terms since February 2018, although they have changed sig-nificantly in US Dollar terms due to currency fluctuations.

Bahrain: The price of cement in Bahrain is roughly US$71.53-79.48/t.

Kyrgyzstan: Cement is sold at US$3.36/bag to US$4.97/bag (50kg) in Kyrgyzstan, de-pending on the location and type of cement.

Here Global Cement Magazine presents its monthly review of global cement prices, in US$ for easy comparison. Additional price information is only available to subscribers to Global Cement Magazine. Subscribe on Page 96. In this issue subscribers receive information from more countries, including Uzbekistan, Uganda, India, South Africa, Pakistan and China.

Prices are for metric tonnes (Mt), unless stated otherwise. US$ conversions from local currencies are correct at the time of original publication.

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GLOBAL CEMENT: THE LAST WORD

What are the future risks for the cement industry? LafargeHolcim points the way...

Company annual reports can sometimes be a turgid read, but every now and again they may include an

exciting flash of something interesting, almost like see-ing the flash of a metallic-blue kingfisher darting along a non-descript and over-grown ditch. However, the recent LafargeHolcim (LH) Annual Report 2017 was a very interesting read throughout, and nowhere more so than in the section on ‘Risk management,’ especially after its recent and ongoing travails in regards to the operation of its cement plant in Syria (see Page 69).

The company explains that the Group’s ‘risk map’ is established on the basis of ‘strategic, operational and topical risk assessments’ to form a Group risk report, on the basis of several steps; Risks are assessed and priori-tised according to their significance and likelihood: Top risks are analysed more deeply regarding their causes; Risk mitigating actions are defined. Risk management is a line-manager’s responsibility, backed-up by Group Risk Management and with ‘internal audit’ as a third line of defence.

In its annual report, LafargeHolcim lays out the re-sults of this risk management exercise for us all to see. In no particular order, the company’s greatest risks are:

Market demand risks: changes in demand leading to changes in pricing and/or industry structure - LH says that it maintains a globally-diversified portfolio, with top-3 positions in 80% of its markets, and that it trades in clinker, cement and other products to take advantage of shifting demand between countries;

Legal and compliance risk: such as being found to have violated law covering business conduct such as bribery, corruption, terrorism and unfair competition - LH says that it maintains a comprehensive risk-based compliance programme with dedicated resources, alongside comprehensive training;

Energy prices: the risk being that energy costs rise, or that certain alternative fuels become unavailable - LH says that fuel mix and energy efficiency are key areas of focus for all plants, and that it uses ‘derivative instruments’ to hedge part of its exposure to these risks;

Raw materials risk: ‘That raw materials cannot be supplied at economical cost or suitable quality’ (eg sand and limestone) - LH says that ‘We apply a range of tactics including strategic sourcing, changing input mixtures and maintaining minimum long-term reserve levels. At Group level our R&D is devoted to find-ing ways to mitigate this risk while at the same time lowering our environmental footprint, eg by using waste-derived materials’;

Sustainability risk: ‘The cement industry is associ-ated with significant negative externalities, notably high CO2 emissions - By 2030 LH aims to reduce net CO2/tonne of cement by 40% compared to 1990 levels, and advocates a carbon price, while increasingly aiming the business towards sustainable products and solutions;

Political risk: Due to political instability in its op-erating markets - LH believes that diversification is the key response, and is politically neutral;

Talent risks: Does the company have enough of a ‘talent pipeline’ for its global ambitions? - LH evaluates talent in its staff and invests in talent development;

Cyber risk: LH has established a Group cyber-security roadmap to protect critical assets from cyber attacks and to improve its cyber resilience;

JV and associate risks: LH says that where it does not have a controlling interest, there may be a restric-tion of its ability to generate adequate returns and to ensure its compliance programmes are adhered-to - which it says it seeks to manage through formal agree-ments with the companies in question;

Goodwill and asset impairment: Significant under-performance of any unit - LH says it monitors units on a timely basis, or when a ‘triggering event materialises;’

Financial risks: Including liquidity, interest rates, foreign exchange and credit risk, possibly causing a downgrade of the Group’s credit rating and the avail-ability and cost of future funding - buried deep in the Annual Report, it says that a 1% change in interest rates would cost the group CHF34m (Euro29m);

Insurance risks: Not all risks can be insured - LH monitors its status to determine if additional insurance is required;

Defined benefit pension risk: These pensions are volatile and the Group may have to pay into them to ‘top them up’ - Where possible, LH has closed such pension schemes and actively manages the remainders.

LafargeHolcim says that ‘additional risks and un-certainties not presently known to LH or that it deems immaterial’ may develop into issues as well.

What, I wonder, would be the impact of a carbon emission floor price in Europe of Euro20/t of CO2? What if the price was set at US$123/t of CO2, according to a December 2016 ‘worst-case’ estimate of the ‘social cost’ economic impact of the emission of CO2 accord-ing to the US EPA and other agencies? How would LH cope? How would any cement company in the world?

1 https://www.epa.gov/sites/production/files/2016-12/documents/

social_cost_of_carbon_fact_sheet.pdf






JUNE 2018



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GLOBAL CEMENT MAGAZINE: ADVERTISER INDEX

Advertisers - June 2018Advanced Material Handling Ltd. 53 [email protected] • www.advancedmaterial.ca

Aixergee Aixprocess 29 [email protected] • www.aixergee.de

23rd Arab-International Cement Conference, Amman, Jordan 71 [email protected] • www.aucbm.org

Cemengal 45 [email protected] • www.cemengal.com

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Coal Mill Safety Pte Ltd 40 [email protected] • www.coalmillsafety.com

Global CemFuels Conference 2019, Amsterdam, Netherlands 21,31 [email protected] • www.cemfuels.com

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Hillhead Quarrying & Recycling Show 2018 23 [email protected] • www.hillhead.com

Intercem Engineering GmbH 41 [email protected] • www.intercem.de

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Refractories WORLDFORUM 27 [email protected] • www.refractories-worldforum.com

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Testing Bluhm & Feuerherdt GmbH 59 [email protected] • www.testing.de

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Reports: Top 10 Cement Producers; China Technical: Grinding, Fans, Block-chain, Microgrids, Silos, Material Handling

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http://www.voestalpine.com/welding

https://www.vdz-online.de/en/latest-news/events/vdz-congress-2018/

http://www.testing.de

http://www.stmecosystems.com

http://www.siemens.com/cement

http://www.sicit2000.it

http://www.refractories-worldforum.com

http://www.le-international.com

http://www.loesche.com

http://www.korfez-eng.de

http://www.kima-process.de

http://www.keithwalkingfloor.com

http://www.kettenwulf.com

http://www.intercem.de


http://www.hardtop-gmbh.de



http://www.coalmillsafety.com

http://www.christianpfeiffer.com

http://www.cemengal.com

http://www.aucbm.org

http://www.aixergee.de

http://www.advancedmaterial.ca

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