February 2020 HOT STUFF A REVOLUTION IN HOT-GAS FILTRATION 200120-world-cement-cover.indd 3 22.01.2020 11:14:59 WE MOVE INDUSTRIES HEKO off ers the whole range of chains and other wear parts for bucket elevators and chain conveyors. Proven in thousands of elevators and conveyors, worldwide. Our components for the cement industry: MORE central chains, link chains, sprockets, belts, THAN bucket elevators and clinker conveyors. WWW.HEKO.COM YEARS CONVEYOR SOLUTIONS CCONTENTSONTENTS 03 Comment 55 Fuelling Change 05 News Samuel Zühlsdorf, thyssenkrupp, considers the fuel substitution technologies that are set to help the cement industry conserve REGIONAL REPORT: SOUTHEAST ASIA natural resources and decrease CO2 emissions. 10 Success in the Southeast Danny Richards, GlobalData, provides a comprehensive MATERIALS HANDLING overview of the booming Southeast Asian construction sector. 59 Tightening the Belt Leslie David provides insight into how taking a different 17 At a Crossroads of Growth approach can signifi cantly reduce replacement conveyor Manas Tamotia and George Woods, L.E.K. Consulting, belt expenditure. provide an overview of the key trends expected to shape the Southeast Asian cement market in the coming years. SAMPLING & ANALYSIS 65 Cementing a Reputation AIR POLLUTION CONTROL Ivo Nemetz, Elementar, considers the essential role of 21 DSI System Optimisation elemental analysis in creating high-quality cement. Dr. Ian Saratovsky, Martin Dillon and Gerald Hunt, Lhoist, examine dry sorbent injections (DSI) as a cost-effective solution ADDITIVES & GRINDING AIDS for complying with acid gas emission control requirements. 68 Changing the Approach Martyn Whitehead, Fosroc International, addresses how 28 The Future of Filtration and when grinding aids and cement additives can be Georg Lechner, Scheuch, outlines the advantages of hot effectively used for the production of good quality cement. gas fi ltration with ceramic fi lter elements and explains how this technology may be able to meet the demand for more TRAINING/SAFETY energy effi cient systems. 73 Pushing the Limits of Training Scott Thomas, Argos USA, considers the importance of 33 Done and Dedusted improved driver training and the benefi ts to be gained from Eduardo Sauto, Gorco, identifi es the common errors made implementing virtual reality technology. in dedusting installations and outlines how to prevent them from occurring. GENERAL INTEREST 76 The Path to Sustainability 38 Optimising for Alternative Fuels David Bizley, Editor of World Cement, spoke with Jean-Michel Charmet, Rani Hanna and Sami Zellagui, Francesco Caltagirone Jr., Chairman & CEO Fives FCB, discuss the use of high level CFD modelling of Cementir Group, to discuss sustainability and the to optimise calciner systems for the use of alternative fuels company’s ‘Industrial Plan’ for 2020 – 22. and reduced CO2 and NOx emissions. ALTERNATIVE FUELS 47 Adding Alternative Fuel to the Fire Tahir Abbas and Michail P. Akritopoulos, Cinar, discuss the February 2020 pros and cons of using alternative fuels (AF) for fi ring in kilns and calciners. ON THE COVER The Austrian Scheuch Group with subsidiaries all around the world, is known to be one of the leading global players in the area of air and environmental technology. For more than 55 years, Scheuch has been providing innovative solutions such as dedusting and exhaust gas cleaning for industrial applications. The focus is set on extensive research and development in order to further HOT STUFF extend its technological leadership position. As with emc, deconox and xmercury, Scheuch is now A REVOLUTION IN HOT-GAS FILTRATION breaking new ground in hot-gas fi ltration. For more information, visit: www.scheuch.com We know the way forward. Axians Industrial Applications & Services – your IT partner for: dispatch automation process security smart industry Axians Industrial Applications & Services GmbH Hoervelsinger Weg 17 · 89081 Ulm · Germany [email protected] · www.axians-ias.com CCOMMENTOMMENT Managing Editor: James Little DAVID BIZLEY, EDITOR [email protected] Editor: David Bizley ust recently, I found myself wondering how [email protected] people would characterise this new decade Editorial Assistant: Emily Thomas in years to come. How will the 2020s be [email protected] remembered by people living in the 2120s? Contributing Editor: Paul Maxwell-Cook HopefullyJ better than how we remember the 1920s – a decade that began with a lethal pandemic and Production: Gabriella Bond [email protected] ended with almost complete economic collapse. We have at least, thus far, avoided the fate predicted Sales Director: Rod Hardy [email protected] by 1982’s Blade Runner (an actual cinematic gem – 84% on Metacritic), which depicted a Los Angeles of 2019 as a dystopian nightmare struggling in the Sales Manager: Ian Lewis [email protected] aftermath of global war and environmental collapse. Although it’s diffi cult to know for certain at this early stage (barely a month in Website Manager: Tom Fullerton [email protected] to the decade), there are two main areas that I think will mark the 2020s out for historians of the future: 1) the global adoption of digital technologies, and 2) how Digital Editorial Assistant: Imogen Poole [email protected] the world reacts to the challenge of climate change. Administration Manager: Laura White Many of our daily lives are already heavily infl uenced by digital technology: [email protected] more than 57% of the global population (4.33 billion people) have access to Reprints the internet, and 45% of all people (3.5 billion) have a smartphone. In any major [email protected] population centre, the air is permeated with radio and microwaves transmitting endless streams of data, often to and from the devices in our pockets. If the 2000s and 2010s oversaw the birth of the digital age, the 2020s look set to see it come to fruition as billions more people around the world get online. Technologies that once seemed like science fi ction not long ago – artifi cial SUBSCRIPTIONS intelligence, virtual reality, and even quantum computing – took their fi rst steps Annual subscription (published monthly): £160 UK in the last decade and will see further development and integration in both the including postage/£175 (245) overseas (postage commercial and industrial sectors in the next. airmail)/US$280 USA/Canada (postage airmail). Two year subscription (published monthly): £256 UK The cement industry is already adapting to the digital age. To give just a few including postage/£280 (392) overseas (postage airmail)/US$448 USA/Canada (postage airmail). examples: Starlinger recently announced the launch of its GRAFiT 4.0 software, Claims for non receipt of issues must be made within 4 months of publication of the issue or they will not which uses artifi cial intelligence and machine learning to automate processes be honoured without charge. and predict potential machine downtime – OSIsoft’s PI System allows users to Applicable only to USA and Canada: collect, analyse, and share large amounts of data from multiple sources across WORLD CEMENT (ISSN No: 0263-6050, USPS No: 020-996) is published monthly by an operation, providing real-time operational intelligence – and FIVES FCB uses Palladian Publications, GBR and is distributed in the USA by Asendia USA, 17B S Middlesex Ave, state-of-the-art CFD simulation to optimise calciner systems for alternative fuels Monroe NJ 08831. (p. 38). Periodicals postage paid New Brunswick, NJ As for the challenge of climate change, there’s certainly growing consumer and additional mailing offices. POSTMASTER: send address changes to World Cement, 701C pressure for the development of greener technologies and the adoption Ashland Ave, Folcroft PA 19032 of more environmentally friendly lifestyles, but whether this translates into Copyright © Palladian Publications Ltd 2019. All rights reserved. No part of this publication may political will across the globe remains to be seen. We can at least point to be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, numerous examples from the cement industry where emissions reduction mechanical, photocopying, recording or otherwise, and environmental sustainability is being taken seriously: HeidelbergCement without the prior permission of the copyright owner. All views expressed in this journal are those of the was recently awarded an ‘A’ rating by the CDP (formerly Carbon Disclosure respective contributors and are not necessarily the opinions of the publisher, neither do the publishers Project) for its commitment to climate action – FLSmidth has launched its endorse any of the claims made in the articles or the advertisements. Uncaptioned images courtesy of ‘MissionZero’ sustainability initiative – thyssenkrupp has its green polysius Adobe Stock. Printed in the UK. cement plant scheme and has developed a range of fuel substitution Palladian Publications Ltd 15 South Street, Farnham, Surrey technologies (p. 50) – and Cementir Group has placed sustainability as a key GU9 7QU, UK part of its Industrial Plan for 2020 – 2022 (p. 76). Tel +44 (0)1252 718999 Fax +44 (0)1252 718992 However this decade turns out, it’s clear that much of the cement sector is Email: [email protected] Website: www.worldcement.com working hard to become an industry fi t for the future. February 2020 World Cement 3 The answer to your bulk handling questions Ship unloaders