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

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and Instrumentation Development – that’s who we are!) Global Slag For 22 years KIMA Echtzeitsysteme has been working in the field of high performance closed loop controls, innovative IEEE-IAS/PCA Review www.globalcement .com Vibration Vibration sensor systems and databases for processing industries. With Grinding CO2 CO2 SmartFill, it sets new worldwide standards regarding the Exclusive Official Magazine for DG Khan visit precision and reliability of measuring the fill level of ball Optimisation Optimisation Global Cement Conferences: Global CemFuels, UK mills. With the ‘KilnCooler’ another intelligent solution is News Global Slag, Global CemTrans, Global GypSupply KIMA ECHTZEITSYSTEME IS NOW provided that treats heated spots on the kiln shell and avoids KIMA PROCESS CONTROL FutureCem, Global Boards, Global Well Cem, Global unexpected kiln stops. Actually KIMA Echtzeitsysteme GmbH MAGAZINE CemProcess, Global CemPower. global cement 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! Editorial Director Fax: +49 2463 9967 – 99 Dr Robert McCaffrey Email: [email protected] Contact: Mr Dirk Schmidt, Director [email protected] Web: www.kima-process.de / www.kimaE.de Tel: +49 2463 9967 – 0 (+44) (0) 1372 840951

Editor Peter Edwards [email protected] (+44) (0) 1372 840967

Web Editor Welcome to the June 2018 issue of Global Cement Magazine - the world’s most widely- David Perilli [email protected] read cement magazine - which will be distributed at the biennial Hillhead Quarrying and (+44) (0) 1372 840952 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 Commercial Director Paul Brown carries a review of the past 12 months in the UK cement sector from Edwin Trout [email protected] of the Cement Industry Suppliers’ Forum (Page 42). There is also a look at crushing Mobile: (+44) (0) 7767 475998 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 Business Development Executive ‘hello’ to us on stand PC45 in the main pavilion. Sören Rothfahl [email protected] This issue has a detailed visit report from the DG Khan Cement plant at Khairpur, Mobile: (+44) (0) 7850 669169 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! Company manager Sally Hope Also in this issue we have a detailed look at how large cement producers are looking [email protected] 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 Subscriptions Amanda Crow approach to how they should be optimised uniformly to the benefit of the group as [email protected] 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 Office administration (Page 24), how vertical roller mill performance can be improved using grinding aids Jane Coley [email protected] (Page 14) and reviews of the recent Global Slag Conference & Exhibition (Page 32) and IEEE-IAS/PCA Conference (Page 51). The views expressed in feature articles are those of the named author or authors. For full details on article submission, please We hope that you enjoy this issue of Global Cement Magazine see: www.GlobalCement.com Peter Edwards - the world’s most widely-read cement magazine! Editor ISSN: 1753-6812 Published by Pro Global Media Ltd Ground Floor, Sollis House, 20 Hook Road, Epsom, Surrey, UK KT19 8TR Tel: +44 (0)1372 743837 (switchboard) Cement Printed on Forest Stewardship Council Fax: +44 (0)1372 743838 Industry (FSC®) certified papers by Pensord, Suppliers’ a company with ISO 14001:2004 Forum environmental certification.

Global Cement Magazine June 2018 3 GLOBAL CEMENT MAGAZINE: CONTENTS Subscribe Ad Index

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 feeding 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.

4 Global Cement Magazine June 2018 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.

Asia

58 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 & Africa

69 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

Global Cement Magazine June 2018 5 GLOBAL CEMENT

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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.

Global Cement (GC): What is a Target Operating AM: Proudfoot has developed TOMs specifically Model (TOM)? for large cement, ready-mix concrete and aggregate producers like Lafarge Holcim, HeidelbergCement, Angus Maclean (AM): Target Operating Models CRH, and regional groups like Secil and Vicat. develop and ensure that behaviours, underpinned by processes and management tools, are optimised, GC: Why have the TOMs been developed now? from ‘quarry-to-lorry’ across a cement producer’s business. TOMs go beyond simply optimising each AM: We developed TOMs to help the major groups cement plant at a local level. Instead they definehow keep up with the consolidation we have seen lately each plant should be optimised uniformly across in the cement sector. Due to the various mergers, a group. acquisitions and divestments, there are now several The result for cement producers is an improved different ways of working within many of the large return on net assets and higher earnings before cement multinationals. interest, tax, debt and amortisation derived from A multinational may have older plants that have improvements across the industrial value stream strong personnel and working practices in the devel- at the right cost and within the right time-frame. oped markets like North America or Europe. They Now that many producers have cut every possible may also have brand new plants in developing regions cost that they can, a TOM allows producers to save that might not have such strong technical personnel money across all plant locations. It also makes plant or may have less effective working practices. On top managers’ lives easier by simplifying their day-to-day of this there is increasing pressure from sharehold- operations. TOM now becomes the foundation for fi- ers to ‘squeeze’ assets. These situations make it tricky nancial benefits, and with Proudfoot Transformation for the big players to optimise their operations on a know-how, you can link behavioural transformation global scale. through people to real financial results tracked on a What a TOM does is develop an optimal way weekly basis. of working for each producer that can be applied around the world. We have, for example, recently GC: Which kinds of companies is it for? helped design, develop and implement new ways of

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

8 Global Cement Magazine June 2018 GLOBAL CEMENT: OPTIMISATION

“TOMs go beyond simply Left: Succession planning is a optimising each cement plant big issue for cement producers at a local level. Instead they in developed markets. TOMs can be used to help globalise a define how each plant should group’s approach and plan more be optimised uniformly effectively for future demands. across a group...”

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 planning systems. Others have fantastic financial metrics but terrible technical performance. This might be the case in developing markets where producers are working for LafargeHolcim and for Secil. Each TOM breaking their kit for a quick buck. is different but it has been arrived at by a similar collaborative process. As well as the financial benefits GC: How is a TOM designed? there are benefits for environmental performance and health and safety. TOMs also facilitate movement AM: The team at Proudfoot works with in-house of personnel across a group’s global operations. We teams separately on the three main pillars: Techni- also help businesses ready themselves for increased cal performance, business performance and people digitisation of business processes, often known as management. On top of the pillars there are 10-12 ‘Industry 4.0.’ topics that cover different aspects of each. Within those topics the cement producer will then identify GC: How does the TOM process work? 50-80 elements that it considers ‘the best way’ to achieve its stated aims for each topic. Each element AM: Generally it splits down into defining criteria for looks at quite a specific area, for example: preventa- three different areas: Technical performance, busi- tive maintenance, automation or the best way to ness performance and people management. blast, load and haul in the quarry. The technical performance side takes in eve- For one of the major cement producers we worked rything you can imagine in terms of how a plant remotely via video conference with ~150 operational, should run and be optimised, right from the quarry, technical, commercial and supply chain staff. We to the crushers, the mills, the kilns, the coolers designed 32 elements that stated, according to that and dispatch. group of people, how a cement plant should be run. Business performance optimisation, often domi- Another firm wanted 72 elements! nated by financial aspects, looks at everything that These meetings involve a lot of discussion and the business must do to streamline its non-technical diplomacy. However, by including staff from every working practices. For example, these large groups part of the group and every region, our approach have very onerous financial reporting requirements eliminates the perception that the decisions are being in different jurisdictions around the world. A TOM taken by the ‘powers that be.’ The team goes back to asks and answers questions like, ‘What is the most ef- its different plants and says ‘This is what we decided.’ ficient way for our individual businesses to report to That helps the programme to gain acceptance from the rest of the group?’ the wider workforce. The success of any TOM is the Last but not least, the management of personnel understanding by all employees of how the process is now a critical issue for global cement producers. works and what it is supposed to achieve. The imple- The importance of optimising how people are man- mentation is key. aged, especially with respect to succession planning, cannot be overstated. I’ve seen some risky situations GC: How is a TOM implemented? lately. In one case there were 90 people working in the cement plant and 33 were due to retire in the AM: The TOM allows the producer, along with next two years. In another case there were 16 people us, to evaluate the plants that are performing well in a quarry, with 15 retiring in the next 18 months! overall, as well as in each area. This kind of holistic It doesn’t matter how good the plant or group per- approach is different to what we saw previously, when forms right now, since if it ‘plans’ like this, it won’t be certain financial or performance aspects dominated equipped for the future. many analyses. Each plant will be evaluated using a

Global Cement Magazine June 2018 9 GLOBAL CEMENT: OPTIMISATION

maturity assessment checklist against the various elements. For each element the producer will rank its plants on a scale of ‘0-5,’ ‘not implemented’ to ‘excel- Right: Financial aspects are an important aspect within TOMs, lent’ or ‘red, amber, green.’ This shows how well each but are not the whole story. 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 There is more variety in performance and dif- practices across the group. ferent choices made in business performance and To help show plant managers how the TOM people management. However, I would argue that works, the producer will often set up regional exam- the vast majority of TOMs lead to actually the largest ples. From those plants, its regional teams will then improvement in these pillars, even if the TOMs are visit other plants to carry out the checklist process quite different from each other. The very act of mak- and advise the management. ing the approach uniform introduces efficiencies and Proudfoot can also show the group how the plants it would certainly be hard for a TOM to make the are performing on an x-y-z scatter plot, where each group less efficient overall. axis represents a different pillar. This is a great visual tool that quickly identifies outlying plants, both GC: In the case of a newly-acquired plant, would under-performers and best cases. a group ever seek to reduce the emphasis of one of the three pillars? GC: How do TOMs help on the personnel side? AM: This has happened in some cases. AM: They can help with many aspects, for example with succession planning. Previously we found that GC: Does that mean the plant becomes weaker in HR departments operated on a country-by-country terms of that pillar because it moved group? basis in a lot of the big groups. Now they are becoming more global. How TOMs help is by properly AM: Not necessarily. If a plant is very good at envi- defining the capabilities and competencies for people ronmental performance, it may no longer need any employed in a number of key roles within the plant. investment on that side. Indeed it might have a very This could be plant manager, production manager, good local team that’s actually costing the plant a lot maintenance manager, quarry manager, and so on. It in terms of salaries. The plant might also be making also defines the necessary abilities of others that may no money for the group. be suited to the different roles in the future. TOMs In such circumstances, questions then arise that, make it easier for groups to move people around be- on the face of it, appear paradoxical: Does that plant tween plants due to the reduction in ‘culture-shock.’ really need to be that excellent? Answer: Maybe not. Dig deeper and we get other questions: Can we better GC: Does Proudfoot advise the best approach use the plant team’s knowledge over a larger number for the producer? of plants? In many cases the answer is ‘Yes’ - It could reap huge rewards globally. And of course, the invest- AM: Proudfoot does not advise its clients on the end ments that have been made at the excellent plant will goals or how to achieve them. The number of pillars, continue to be used. topics and elements is up to them. Some won’t use all three pillars. Some will only use a few topics and GC: It seems that a lot of the major players are now elements in each pillar. There can be a lot of variation. rolling out TOMs. Are regional players next?

GC: Opinions play a reasonably significant role AM: We are in the process of helping some of the in defining a TOM. Does that mean that, however smaller and regional players around the world. The well-implemented it may be, a TOM could lead a focus is sometimes on fewer pillars at a time, perhaps group in the wrong destination? with fewer elements, but TOMs can help such players to grow. Once they have a TOM, it provides a set of AM: On the technical side this is unlikely. While each blueprints that can be used for new plants and acqui- multinational has a variety of plants, there are only a sitions around the world. few ways to run each type of plant optimally. There is therefore the most similarity between groups on GC: Many thanks for your time today Angus. the technical side. They are not likely to get this pillar wrong in the TOM. AM: You are very welcome indeed!

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Sicit 2000 March 2016.indd 1 12/05/2016 14:40 GLOBAL CEMENT: EMISSIONS Contents Subscribe Ad Index

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.

ement production is the second most polluting order to avoid impending risks to their operations Cindustrial sector and cement is the second-most and the wider world. This may seem challenging at consumed product in the world after water. The built first, but every year it is delayed, the cost becomes environment, which includes offices and residential greater. Management teams, regulators and investors buildings, uses concrete extensively and accounts for need to think long term. There is a solution - cement over a third of global emissions. Regulation of the companies just need to invest properly to find it.” sector so far has been light but rising ambitions for There are opportunities for companies that act low-carbon cities and tightening building regulations early on climate risk. Companies can reduce costs could drive change up the chain. by making their cement plants more energy efficient Indian companies top a new CDP league table and secure their position in future sustainable ce- of current climate performance thanks to reducing ment markets by investing in low-carbon products. their carbon footprint during the cement making Governments can facilitate the development of these process, in part due to better access to alternative raw markets through regulation and incentives. materials from other carbon intensive sectors. They also benefit from newer and more efficient cement Other findings plants driven by high market growth in the region, in The report also highlights other potential risks and contrast to their European peers, which rely on older opportunities for the sector: cement plants. Paul Simpson, CEO of CDP comments, “Cement • Carbon Capture and Storage (CCS) is an impor- is a heavy and largely invisible polluter, yet cement tant technology for creating low-carbon cement, is taken for granted as a necessary building block of yet CCS projects are still largely at pilot stage basic civilisation. With potential pressure coming in the sector. HeidelbergCement shows some from multiple sources, including down the value investment in CCS across various technologies, chain in the form of building and city regulation, but otherwise progress is limited; cement companies need to invest and innovate in

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.

12 Global Cement Magazine June 2018 GLOBAL CEMENT: EMISSIONS

Rank Producer Country Market Cement League Table Transition Physical Transition Climate Capitalisation Production Weighted Risks Rank Risks Rank Opportunities Governance & in 2017 (US$bn) in 2016 (Mt) Rank Rank 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%

• European players benefit from alternative fuels emissions, but they need to do a huge amount more. Above: CDP’s summary league table of 13 cement producers’ sourced from organised waste collection sys- It is clearly a complicated story because of our global current emissions leaders. tems. Emerging market producers are behind, reliance on cement, and the inherent emissions of the Green indicates that producer due to limited infrastructure; sector, but there are things that can be done. Cement will be able to deal with risks of companies should be looking at ways to further use transitioning to a lower carbon economy, while orange and red • Five companies do not use an internal carbon alternative materials and fuels, improve the energy indicate a lack of preparedness. price, which is a significant risk in a sector where efficiency of their plants, and accelerate investments carbon pricing legislation could have a material in low-carbon technologies such as carbon capture impact; and storage, which is crucial for their long-term vi- ability. Regulation may be the key driver for change • Carbon regulation such as the EU’s Emissions here and, interestingly, this may come from down- Below left: European players Trading Scheme (ETS) is the key mechanism to stream as building regulators and owners shift their benefit from alternative fuels sourced from organised waste regulate emissions from the sector in Europe. focus from operational emissions, to those associated collection systems. However, structural issues and lobbying of with creating the buildings themselves.” policymakers have undermined the potential for Anhui Conch, Siam Cement, Dangote Cement change for the sector; and China National Building Materials did not re- spond to CDP’s 2017 climate change questionnaire • Cement companies are generally not incentivis- and are therefore not included in this report. CDP CDP is an interna- ing long-term climate risk management through encourages investors to raise this lack of transpar- tional non-profit executive level remuneration, with only Cemen- ency in discussions with company management. organisation that drives companies As cement companies look to the future, signifi- tos Argos doing so. and governments cant investments in innovation and technology will to reduce their The CDP report assesses companies across need to be made in order to more than double their greenhouse gas four key areas aligned with the recommendations emissions reductions and play their part in limiting emissions, safeguard water resources and global warming to below 2°C, as agreed in the Paris from Mark Carney’s Task Force on Climate-related protect forests. Voted Financial Disclosures (TCFD). As the TCFD rec- climate deal. number one climate ommendations become mainstream, investors will research provider by increasingly expect cement companies to disclose investors and working with institutional how they are adjusting their business models to investors with assets manage transition risks, while taking advantage of of US$87tn, CDP the opportunity to generate revenue from the global leverages investor transition to a low-carbon economy. and buyer power to motivate companies The CDP’s summary League Table for cement to disclose and companies is shown in Table 1. Marco Kisic, Senior manage their envi- Analyst at CDP commented, “Cement companies ronmental impacts. have made some progress towards reducing their

Global Cement Magazine June 2018 13 GLOBAL CEMENT: GRINDING Contents Subscribe Ad Index

Matthias Dietrich, Sika Services AG

Progress with grinding aids for VRMs

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

Testing at Loesche he effect of grinding aids on the comminution Tof cement is based on the dispersion of fine Loesche GmbH is a leading VRM manufacturer for particles. It is a misunderstanding that grinding aids the cement sector. It operates a technical centre for for vertical roller mills (VRMs) should stabilise the the development of new technologies, new materials material bed between the rollers and the table by and for the optimisation of mill settings. Sika has adhesive forces between the particles. Grinding aids used this excellent facility to increase the knowledge reduce the polarity of the cleaved surface and the about mechanisms and to test advanced grinding attraction forces between particles. This means that aids.2 During these tests, the pilot mill worked with agglomerates of fine particles and the packing of fine the following parameters and dimensions: particles around a larger particle are dissipated, re- sulting in an improved efficiency of the separator. The • Table diameter: 36 cm internal circulation of fine particles is reduced and • Number of rollers Two the clinker on the grinding track becomes coarser. • Fresh feed, clinker alone: 130kg/hr The interparticle friction and thereby the effective- • Table speed: 98rpm ness of the comminution process is increased. In this • Working pressure: 150bar way, grinding aids stabilise the material bed on the • Separator speed: 650rpm grinding table, facilitate compaction and de-aeration, • Fresh air: 480m3/hr increase the production rate and reduce vibration of • Temperature (after separator): 90°C vertical roller mills (See Figure 1). • ∆Pmill 21mBar The adhesion forces between particles decisively • Fineness (Blaine) target: 4200cm2/g 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 negative 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 flowability 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 internal circulation, a short mill retention time and a Right: The Loesche pilot mill used by Sika. 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 without reduction of the stability of the material bed. The impact of grinding aids depends strongly on the fineness 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 grinding aids from tests in a laboratory or pilot mills,1 are helpful for selection.

14 Global Cement Magazine June 2018 GLOBAL CEMENT: GRINDING

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

More inter- Lower internal particle friction circulation

Fewer fines on More fresh grinding track feed

Better de-aeration Lower vibration

Less pre-hydration: Faster setting Reduced addition and higher of water mech. strength

The differential pressure between the inlet and test the effect of the grinding aid. In contrast to tests outlet of the mill (∆Pmill) is an important process with ball mills, the effect of grinding aids in a VRM is variable for the testing of grinding aids. ∆Pmill reflects already visible and audible after 10-20min. the load and the filling level of the mill. At unchanged Before the addition of the grinding aid, a blank separator settings, the increase of ∆Pmill indicates test was run to confirm reproducibility (See Figure more internal circulations and more fines. As a re- 2). Starting from this baseline, the new grinding aids sult of the higher ∆Pmill, the mill vibration increases were added onto the transport belt of the clinker, (8-10mm/s), which results in a good opportunity to right in front of the mill. Unfortunately, at that time

4500 140 4000 120 3500 Left - Figure 2: Blank tests 100 show excellent reproducibility. 3000 /g)

2 Specific area (Blaine) 2500 80 Specific area (Laser) Productivity (kg/hr) 2000 60 Content 3-30μm Vibration (mm/s)

Specific area (cm Specific area 1500 40 1000 20 500

0 0 (mm/s) Vibr’n of 3-30μm (%)/ / Prop. Productivity (kg/hr)

1 2 3

Global Cement Magazine June 2018 15 GLOBAL CEMENT: GRINDING

400 35

350 30 /kg) Right - Figure 3: Grinding 2 300 results and cement properties 25 using new grinding aids. 250 20 Specific area (Laser) 200 Productivity 15 Slope n (RRSB) x 20 (-) 150 Pack set (-) 10 Vibration (mm/s) 100 Productivity (kg/hr), Specific area(m Productivity (kg/hr), 50 5 Vibr’n (mm/s), Pack set (-), Slope n (RRSB) x 20 (-) (mm/s), Pack Vibr’n 0 0

Blank Water 1 2 3 4 5 6 7

Water Blank 1 2 3 4 5 6 7 Productivity 132 123 149 139 150 148 151 147 126 (kg/hr) Vibration (mm/s) 9.2 8.6 9 8 4.5 3.6 2.6 2.9 9.1 Right - Table 1: Data used to produce Figure 3. Specific area 345 340 367 364 368 384 388 392 370 (Laser) (m2/kg) Pack set (-) 28 23 17 13 11 2 1 2 16 Slope n (RRSB) 29.6 30.2 27.6 27 27.2 25.8 25 25.2 27.4 x 20 (-)

it was not possible to spray or sprinkle the grinding cal structure is very similar. The achievements of aid into the mill close to the rollers. Each grinding Product N° 5, compared with blank are: aid was added until constant mill parameters were achieved, within a maximum of 20min. To clean the Productivity: +14% mill from remaining grinding aid, the mill was run Fineness: +12% blank in between. It took up to 90mins to come back Vibration: -72% to the base line. The chemical structure of the added grinding aids was previously carefully selected, The pack set of the finished cement, measured two based on practical experiences in industrial VRMs, days after grinding, was reduced from 28 to 1 revolu- in combination with new molecules. A certain class tion. It should not be disregarded that the pack set of chemicals with the same functional group showed is measured with the finished cement, not with the very promising test results (See Figure 3 and Table 1). material on the grinding track! Besides, pack-set is The most promising results were achieved with a standard term that refers to the condition in bulk the Grinding Aids N° 4, 5 and 6. Their chemi- cement, which inhibits ‘the start of flow.’ It can be

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 - Right - Table 2: Comparison Water addition (%) 3.8 2.4 -37 1.8 -53 in cement properties and VRM operating parameters Vibration (mm/s) 5.1 4.7 -8 3.9 -24 for blank, SikaGrind-455 and Production (t/hr) 143 156 +9 159 +11 SikaGrind VRM-40. 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 -

16 Global Cement Magazine June 2018 ALL MILL TYPES FROM A SINGLE SOURCE

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

1.60 1.55 1.50 1.45 1.40 Right - Figure 4: Slope n (RRSB) (-). Slope n (RRSB) (-) 1.35 1.30 1.25 1.20

Blank Water 1 2 3 4 5 6 7

viewed as comparable to static friction and not as decreased as the cement PSD becomes broader but ‘flowability’.3 the workability of mortar and concrete is improved. The particle size distribution (PSD) also benefits from the new grinding aid. The PSD becomes broader Industrial trial with molecule N° 5 as shown in the slope ‘n’ according to RRSB (See One of the new molecules (N° 5 - SikaGrind VRM- Figure 5). The potential for strength development is 40) was tested in an industrial VRM in comparison to a common grinding aid (See Table 2). The OPC (CEM I) made, with a surface area of 4100cm2/g Blaine, was Effect De-agglomeration of higher quality and quantity. The reductions seen Influence on separator Higher efficiency, recirculation in the need for water injection and the reductions in Effects on material bed Fewer fines vibration are remarkable. The construction industry demands improve- Consequences on Increased internal friction ments of the performance and evenness of the grinding Ease of de-aeration cement properties. The speed of strength develop- Reduced vibration, less wear ment is decisive, good and long workability as well Lower water addition as durability is required. With respect to the special Right - Table 3: Summary of Effect on productivity Reduced ΔP benefits of grinding aids for mill properties of cement which is ground with VRM, in- vertical roller mills. Increased production novative grinding aids make a contribution to fulfil Reduced specific energy demand these requirements. Effects on cement Broader particle size distribution Increased power flowability References Reduced pre-hydration 1. Mishra, R.K.; Weibel, M.; Müller, T.; Heinz, H.; & Flatt, R.J. Faster intial setting ‘Energy-effective grinding of Inorganic solids using organic additives,’ Consequences for Improved workability Chimia, 2017, 71, No. 7/8. 2. Patent WO 2016/055376 A1; 3. ‘In- concrete Fast strength development novations in Portland Cement Manufacturing,’ PCA, 2011, pp. 744.

9.0 8.0 7.0 Right - Figure 5: Particle size distribution of 6.0 cements made using 5.0 different grinding aids. 4.0

Blank (%) Volume Water 3.0 SikaGrind-455 2.0 SikaGrind VRM-40 1.0 0.0

1 10 100

Particle size (μm)

18 Global Cement Magazine June 2018 3-59569-VRMI-A10013-00-7600 cement-advertisement-a4-en.indd 1 JUDWHERWKHQJLQHHULQJDQGRSHUDWLRQV$UH\RXUHDG\WRJRGLJLWDO" PDQDJHPHQWDQGOLIHF\FOHHQJLQHHULQJ6LHPHQVKHOSV\RXLQWH VROXWLRQVIRUDGYDQFHGSURFHVVFRQWUROSURFHVVVLPXODWLRQDVVHW UDLVHSURGXFWLYLW\WRDQHZOHYHO/HYHUDJLQJLQGXVWU\VSHFLILF &HPHQWZLOODOZD\VVWD\FHPHQW²EXWZLWKGLJLWDOL]DWLRQ\RXFDQ DQHZFRPSHWLWLYHHGJH +RZFHPHQWFRPSDQLHVWXUQGLJLWDODQGJDLQ WKHWLPHWRGHFLGHLVQRZ 'LJLWDOL]DWLRQ² VLHPHQVFRPFHPHQW 25.04.18 08:36

950,$ GLOBAL CEMENT: CRUSHING Contents Subscribe Ad Index

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

Straight to the end product at the primary crushing stage

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

rush + Size Technology (CST) is developing of, for example, <120mm. The synchronised rotation Cdouble roll crushers based on a new crushing of the rolls, which ensure efficient material intake, tool concept. The geometric design of the crush- is also crucial. Extensive tests have shown that the ing tools with large crusher teeth and synchronous additional content of the smaller grain fractions, for running of the rolls achieves an extraordinarily high example < 11mm for limestone, is at 4% to maximum crushing ratio of up to 1:10, which is due to the direct of 10% if a grain size of 600mm edge length is fed and infeed action of the crushing tools. At the same time, a grain size less than 120mm is produced. this prevents the formation of oversize material and When producing cement, where coarse-grained flat, elongated particles. The materials introduced are limestone is required, the process characteristic directly broken down to the target size in the crush- of the CST series is especially important. It is even ing gap and immediately exit the crushing chamber. possible to omit one crushing stage during the crush- The result is a grading curve that shows a very low ing process. This saves investment and maintenance content of small grain fractions and a higher content costs, including the energy input for running an ad- of medium and coarse fraction (see below). ditional crusher and conveyor belts. These process characteristics are typical of the A wide range of different machine sizes means CST series. This crushing tool geometry is very effec- that throughputs from at least 80t/hr up to several tive for reducing the material to the target grain size 1000t/hr can be offered. Different crushing tools for

100 120 500 90

80 100 70

60 Crushed Right: Screening line Material for limestone. 50 Crusher = CST 500 (14t) Material = Limestone (%) Screening Feed edge length <600mm 40 Feed thickness <400mm 50 Crushing in one stage 30 <11.2mm - 9.0% 20 <1.0mm - 1.4% Feed Material 10

10 100

Grain size (mm)

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Lub Eng - Böhler - House June 2018.indd 1 29/05/2018 15:34 GLOBAL CEMENT: CRUSHING

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

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 considering 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 possible, 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 available. 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.

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Martin Armson, Hansford Sensors

Vibration goes back to basics

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...

ondition monitoring has become widespread in vibration is measured, using instruments like velocity Cthe cement industry as a way of ensuring that transducers, proximity probes and accelerometers, machinery stays in prime condition for as long as and how acceleration, velocity and displacement can possible. Techniques such as vibration monitoring be used in practical terms. are commonly used to underpin a regime of predictive maintenance, where equipment is assessed Background basics constantly in order to detect problems as early as All mechanical parts vibrate, but in the context of possible. Overall, this minimises maintenance costs, machine diagnosis ‘vibration’ is the motion of a extends plant operating life and protects both assets mechanical part when it strays outside its ‘natural’ and staff. position. For instance, when a bearing begins to Most maintenance personnel are familiar with wear down, this affects the way that it moves along vibration monitoring: they are comfortable taking the raceway. This will eventually be detected by the readings using sensors and meters, and know what human ear through increased noise. However, it can steps to take if conditions move outside operat- be picked up far earlier using vibration monitoring parameters. However, not all staff understand ing technology. The harmful effects of vibration are the conditions that cause vibrations to arise in the well known. What starts with an increased load on first place. bearings, for instance, can spiral into component fa- This article will look at some of the reasons why tigue, reduced equipment efficiency and, potentially, vibration occurs, including different types of vibra- catastrophic failure, expensive repairs and extensive tion and their common causes. It also details how downtime.

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

24 Global Cement Magazine June 2018 GLOBAL CEMENT: MONITORING

instance, how far ‘off’ a component is will be vital when re-balancing or adjusting the system. For rotating 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 Left: An accelerometer can determine between a shaft centre line moving up being used in a cement and down in a planar or ‘rocking’ fashion. sector application. Another useful measurement is the ‘overall vibration’ 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 vibration is higher than normal, it indicates some kind of problem: the next step is to identify exactly what the problem is.

Bearing damage There are three main vibration parameters: The main moving component in any machine is usu- frequency, amplitude and phase. Measuring the ally the bearing. Problems here are often the root frequency of the vibration will identity the vibrat- cause of excess vibration. Bearings fail for a number ing component, as each will have a characteristic of reasons. The main ones are inadequate lubrica- frequency. Adding signal processing techniques like tion, poor installation or handling, age and excessive acceleration enveloping helps to separate the fre- loads. quency of one component, such as a bearing, from Inadequate lubrication is usually thought to mean the frequencies of all other parts of a machine, such lack of lubrication, and this can be the case. How- as its casing. ever, over-lubrication can also be a problem and is a The amplitude of the vibration describes the common cause of failure. Another lubricant-related extent of the defect in a particular component. The problem is contamination, which is caused by factors elements of the amplitude are its displacement, veloc- such as leaking seals. ity and acceleration. The greater these are, the more Poor installation is self-explanatory. If a bearing severe the problem, which will be evidenced by either is not installed correctly in its housing, it will not louder or more vigorous vibration. perform in the way it was designed, so is likely to fail The phase describes how the component is ro- at some point. A multitude of factors can be behind tating in comparison with the norm. Knowing, for this, whether it is operator inexperience, rushing the installation or using the wrong tools. In similar fashion, the age of the bearing needs no explanation: one comforting factor is that, with preventative maintenance 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 develop into more serious flaws caused by wear.

Types of vibration Left: The Hansford HS-100 accelerometer has many Excessive wear is considered the main cause of fail- applications in cement plants. ure in machinery. Maintenance teams work hard to prevent it. However, a few other conditions need to be closely monitored, especially imbalance, misalignment 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

Global Cement Magazine June 2018 25 GLOBAL CEMENT: MONITORING

Right: Vibration signal 0 indicative of misalignment. Acceleration (G) Acceleration

-11

-22 0.000 0.038 0.076 0.114 0.152 0.190

Time (s)

are typically highest in the horizontal rather than are generally of two types: AC accelerometers, for vertical direction. measuring higher value assets; and 4-20mA ac- Misalignment occurs when the shaft centre lines celerometers, which are more general-purpose. The of two directly mating components meet at an angle, cement industry typically uses 4-20mA accelerom- or are offset from one another. Misalignment of eters connected to PLC systems. couplings and bearings typically cause high radial or Velocity transducers, which measure angular axial vibration. There are several types of misalign- velocity, are generally less expensive than acceler- ment, which are angular, offset, or a combination of ometers, and easy to install. Because of this, they are the two, which is most common. good for general-purpose applications. It generally Mechanical looseness occurs when rotating has three elements: a permanent magnet, a coil and components have been fitted incorrectly. A number spring supports for the coil. Those for horizontal and of running speed harmonics will dominate spectral vertical axis mounting are designed differently. data (i.e. 1-1 0x rpm). In some cases, and in some Proximity sensors detect the location of a stages of deterioration, spectral data may also show component, such as a bearing, in relation to its sub-harmonic multiples of 0.5 x rpm. ‘normal’ position. It uses either capacitance or All three conditions can cause machine failure inductance, the latter being more accurate, to de- and lost production. However, they can be detected termine distances very accurately, so can indicate early using vibration monitoring and are relatively the extent to which a bearing or shaft is ‘out of true’ easy to correct. during operation. A combination of all three results will give an ac- Combined measurement curate picture of, for instance, bearing speed, velocity While accelerometers are most commonly used to and position in relation to the conditions for which measure vibrations, they may only pick up part of the it was designed. overall picture. However, they can be combined with Vibration and velocity sensors are generally used other devices that measure velocity and displacement to detect high frequency signals emanating from to ensure that all aspects of vibration are picked up. structures such as bearings and bearing supports. This is because acceleration, velocity and displace- Proximity sensors, meanwhile, are more appropriate ment are all critical parts of the vibration amplitude. for finding displacement in rotating shafts, for condi- Together, they help to pinpoint the location and nations such as misalignment or shaft bending. ture of any vibration problem. In the cement sector, a combination of all three In cement manufacturing, the key components to could be used in any number of applications, from monitor in kiln drives, crushers, screens, conveyor crushers and mills to precipitators, kilns or silos. The belts, raw mills, elevators, separators and blowers, are sector is well known as an aggressive production the motor and gearbox assemblies. In each case it is environment, conditions that can help to accelerate critical that the correct type of sensor be selected, for component failure and potential bearing damage. ease of installation and access, and for reliable opera- Using a broad set of vibration sensors, coupled with tion and data collection. a predictive maintenance regime, can help to identify An accelerometer is usually a piezo-electric crystal potential component failure as early as possible, and bonded to a mass, that generates an electrical signal so avoid the expense and potential hazards of cata- when subjected to a force. Vibration accelerometers strophic failure.

26 Global Cement Magazine June 2018

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EntsorgaFin SpA

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

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.

azareth is the heart of the Lehigh Valley, an area The Nazareth project Nwith a long tradition of cement production. It is The feeding plant installed by Entsorga at the Naza- also adjacent to and serves one of the most developed reth plant is one of the first of its kind in the US. It is areas of the world, the US East Coast, in particular designed to receive the PEF and pneumatically feed New York City and New Jersey. It is therefore unit at up to 7t/hr to the main burner. This requires a derstandable that a cement plant located in the area precise dosing system that has been developed by the would be sensitive to new strategies and trends. company. It is a step towards higher alternative fuel Despite a more relaxed attitude to environmental substitution rates for the plant. It comprises: policies under the current US Administration than in the past, cement plants across the country are still • Two docking stations that receive waste from US looking to increase the use of alternative fuels. This is walking floor trailers. They are equipped with particularly the case for fuels derived from munici- hydraulic units that allow operators to manage pal solid waste (MSW) that has a biogenic content the unloading of trailers without the need for the of more than 55%. Such fuels offer the perfect way tractor to stay in the bay; to reduce a cement plant’s CO2 emissions. Indeed, since 2011 pre-engineered fuels (PEFs) produced by • A Redler chain conveyor that conveys the Entsorga from MSW have even obtained ‘non-waste’ alternative fuel to the required height in order to status and can be traded as a commodity. feed the dosing system;

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

28 Global Cement Magazine June 2018 ENERGY INTENSIVE INDUSTRIES / INNOVATIVE TECHNOLOGIES Fuels, Combustion, & Air Pollution Control

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Aixergee - Xavier June 2018.indd 1 22/05/2018 16:20

aixergee_105x210mm_140610b.indd 1 10.06.14 14:13 GLOBAL CEMENT: ALTERNATIVE FUELS

producers and forthcoming legislation that will drive the use of AF. In this field, Entsorga can take advantage of its 20 years of engineering experience by making available to the market its portfolio of proven, bankable and referenced technologies. Entsorga hopes to be Right: View of the Entsorga able to help the cement industry Pelican system installed at the Nazareth plant in Pennsylvania. to implement its alternative fuel strategies. This is not just a business opportunity. For Entsorga it represents an ideal way to help improve the environmental performance of an entire industrial sector. Furthermore, the uniqueness of the Nazareth project is its flexibility and adaptability to a range of market environments. It allows Entsorga to deliver viable solutions, successfully bridging needs of different industries and to provide complete integrated solutions • A screw dosing system; up to the kiln feed inlet. For Entsorga the Nazareth plant, in combination • A pneumatic system made up of blowers, rotary with its Mechanical Biological Treatment (MBT) valve and pipeline, and; plant at Martinsburg, represents the start of the spread of its technology in the US. It hopes to see • A Supervisory control and data acquisition many of these installations throughout the country (SCADA) system based on a new Entsorga pro- in the coming years. The Nazareth project will now prietary sorting system. The system is capable of be replicated at the Cementos Argos Martinsburg ce- managing the AF dosing with the highest preci- ment plant and elsewhere. sion and reliability. In the US, it may well be that the adoption of alternative fuels is driven by economic feasibilty, As safety is highest priority, the feeding system is convenience and profit, rather than environmental ATEX and NFPA compliant, with extensive means to regulations, as in Europe. Entsorga believes that the avoid fire and explosion hazards. US conditions are predominant in other world regions, offering a model that can easily be replicated The system requires minimal civil works and throughout the rest of the global cement industry. 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 Right: Municipal solid waste of second can continue to feed as the first truck is the kind transformed into pre- switched for a third, and so on. engineered fuel by Entsorga’s mechanical biological treatment Shaking up the status quo plant in Martinsburg. The 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 substitution 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

30 Global Cement Magazine June 2018 2021 FEBRUARY 2019 AMSTERDAM, NETHERLANDS 13th cemfuels.com gl bal #cemfuels cemfuels CONFERENCE • EXHIBITION • AWARDS Global CemFuels Enquiries

Alternative fuels for cement and lime Exhibition and sponsorship: [email protected] Global, regional and national market trends Programme and speakers: Technological developments and case studies robert.mcca [email protected] AMSTERDAM

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Including CemFuels Awards Gala Dinner

cemfuels2019 fullpage.indd 1 22/05/2018 15:47 GLOBAL CEMENT: EVENT REVIEW Contents Subscribe Ad Index

Robert McCaffrey, Global Cement Magazine

Global Slag Conference 2018 - Reviewed

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.

dam Smith of Kallanish Commodities started of ferrous slag to 2027.’ Doug suggested that around Athe conference by speaking about trends in the 50% of global slag production is used in the cement global steel industry. Donald Trump’s imposition of industry, with 32% used in road construction, 10% tariffs on steel and aluminium imports caused a spike used in ‘other applications,’ 3% used in embankments in steel prices in North America at the start of 2018, and 2% in internal recycling. These figures exclude but these have fallen back after most countries were disposal to landfill. Doug points out that drivers given waivers from the tariffs. However, an ongoing for slag use include construction demand in India, Trump-led crusade on Chinese intellectual property China and Asia, construction market demand, a 1: Pieter Van Mierloo (left) ‘acquisitions’ is still dampening market sentiment. trend towards sustainability, the technical proper- receives Global Slag awards for ‘slag plant of the year’ (Recoval The EU exemption from the tariffs ends on 1 May ties of cement and concrete with slag, environmental Dria) and ‘slag product of the 2018, and European steel association Eurofer fears pressures on primary rock extraction and the de- year’ (Carbstone blocks) from that around 13Mt of US-bound global steel exports velopment of processes capable of mitigating Basic conference convenor Dr Robert may soon be diverted to Europe instead. The EU is Oxygen Furnace (BOF) slag free-lime expansion. McCaffrey (right), who is seen in a number of other photos in now considering its own external tariffs as well. Two However, there are many barriers, including potential this article, presenting awards major mergers are in the pipeline, between Tata Steel decreases in slag production capacity, the financial and prizes. Europe and thyssenkrupp, as well as the ArcelorMit- cost of installing new technology and environmental tal takeover of Italian producer Ilva. Adam suggested regulations restricting the use of ferrous slag. that with the EU’s trade defence measures, that the Charles Zeynel of ZAG International next gave 2: Victoria Masaguer Torres of mergers may raise steel consumers’ sourcing costs an update on granulated blast furnace slag (GBFS), ArcelorMittal Spain speaks on the use of slag as a passive mine (meaning that steel prices are set to rise). The World other supplementary cementitious materials (SCMs) water treatment medium. Steel Association has published forecasts for 2018- and the global cement industry. He started by say- 2019, suggesting that there will be a mild economic ing that “after having forecast for years that we are deceleration in the Chinese economy (leading to going to run out of slag, the day has finally arrived.” 3: Dr York Reichardt of KHD Hum- a fall in steel demand), and that developing econo- He recounted a story of a company that had signed a boldt Wedag giving operational mies will once again lead global growth. Developed five-year contract with a Chinese state-owned steel results of the KHD roller press. nations including the EU will attain steady but mod- company for significant tonnages of slag: six months erate growth, while India is readying to be a standout later, the price tripled despite the contract terms. “But growth region for the coming years. just try and sue a state-owned company in China - 4: Andreas Jungmann speaking on behalf of Loesche on the Doug Haynes of Smithers Apex next gave an ex- you will not get far.” The value of slag, he concluded, processing of steel slag. ecutive summary of the Smithers report ‘The future has increased dramatically. The slag producers have

1 2 3 4

32 Global Cement Magazine June 2018 GLOBAL CEMENT: EVENT REVIEW

5 6 7 8

5: Andreas Ehrenberg of the FEhS concluded that they want a larger share of the value 9 speaking on the storability and of slag, so that prices have increased. Charlie pointed reactivity of granulated blast out that there is a global oversupply of clinker, but furnace slag. 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- 6+7: Nick Jones of Harsco (6) was a co-author/presenter ponents in cement (some of the emirates in the UAE on a paper with Mark Tilley of now stipulate at least 60% fly ash or slag in cement). Lixivia (7), who between them Due to the continuing closure of coal-fired power presented on the possibility of stations, particularly in the US and EU, flyash sup- extracting valuable components from slag. 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 10 8: Patrick Lecherf (left) of Electric Arc Furnace (EAF) steel production. Only Euragglo in discussion with Frank around 75% of globally-produced blast furnace slag Henning (VDZ). (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 9: Left to right: Philip Hempel supplies for export each week, with the ‘winner’ hav- of Gebr. Pfeiffer, Tobias Braun of Gebr. Pfeiffer, and Frank Henning ing to pay cash ‘up-front.’ Now around 25Mt of slag is of the VDZ toasting the success of the Global Slag Conference.

10: Delegates enjoying the Global Slag Awards dinner cruise along the Vltava River.

11: Delegates from ARGO-IPS and Metallo Belgium NV were 11 12 13 happy at the prospect of visiting Aachen in 2019.

traded internationally, of which 12Mt is 12: Nick Jones of Harsco picks up his company’s award for ‘slag 14 Japanese slag, and around 5-6Mt is Chi- producer of the year.’ nese slag. Freight rates are rising from their historic lows, and will eventually become a major factor in slag use and 13: Andreas Jungmann picks up pricing. From being a buyer’s market, Loesche’s Global Slag award for slag is becoming a seller’s market. technological innovation. Michael Connolly of TMS Inter- national next gave an update on the regulatory approach to slag and slag 14: It’s a thumbs up from Jitka Halamová (left) and Andrey products in the USA. In the US around Korablin (right). 20Mt of iron and steel slag is produced and marketed each year. Eleven states

Global Cement Magazine June 2018 33 GLOBAL CEMENT: EVENT REVIEW

15: Philip Hempel of Gebr. Pfeiffer delivers his presentation 15 16 density, but when on the MVR slag mill. mixes are properly designed using a mix of natural ag- 16: Fernando Dueñas of gregates and slag, a Cemengal outlines his company’s high efficiency mix reference list of projects around the world. can be achieved. These mixes usually have a slightly higher 17: Jürgen Haunstetter of the strength and durabil- German Aerospace Centre gave a ity than mixes with talk on the use of slag as a heat just natural aggre- energy storage medium. 17 18 gate stone.” Steel slag has also been used as 18: David Algermissen of FEhS an SCM, while TMS - Institut für Baustoff-Forschung also supplies EAF e.V. - receives a prize for his paper slag to several ce- on the use of BOF slag as a raw ment companies as a material for the cement industry. cement raw feed.

19: Amir Shakurov of Ecoslag gives a presentation on the beneficiation of molten slag using the Ecoslag ‘drum 19 20 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.

have now decided that slag is a product rather than a Andrey Korablin of Russian company SmartScrap waste, ‘if it is not discarded and is distributed for use Ltd, celebrated his birthday by giving an overview of in commerce.’ Industry and the US National Slag As- the Russian steel and slag markets. Russia is the fifth sociation are busy trying to persuade the remaining largest steel producer in the world, just behind the US, states to adopt the same approach to slag. Steel slag producing around 70Mt, concentrated in the ‘Central is actually the preferred aggregate in high-demand Federal District,’ around Moscow, in the south west road surface applications, due to its higher coefficient and also around the Urals. The largest producers are of friction, high resistance to rutting and its high Evraz, NLMK, MMK and Severstal. Many slag pro- compressive strength, leading to superior skidding ducers process their own slag, but others use either 21: Adam Smith of Kallanish resistance. This has led to its use as the track surface subsidiary companies or independent processors. Commodities gave the keynote for the Indianapolis Motor Speedway, home of the Only around 50% of metallurgical waste is recycled. opening presentation, on Indy 500. “When properly segregated from ladle slag, Federal laws are being tightened on waste dumping, global steel market trends. steel slag is an excellent high-density aggregate ideal while the goal of the Ministry of Industry is to bring for use in concrete. The only drawback is its high the level of municipal solid waste recycling to 80% 22: Dr York Reichardt (KHD, left) and Roger Cockram (RCS Group, right), discussing slag matters on the KHD Humboldt Wedag exhibition stand. 21 22 23

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.

34 Global Cement Magazine June 2018 GLOBAL CEMENT: EVENT REVIEW

24 25 26

24: Visitors to the Cemengal 27 28 29 stand hear details of the company’s modular grinding plants.

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 by 2030, while there are also potential tax breaks for ucts. Particles are briquetted by first squeezing out well-deserved prize as ‘Global slag use. Road construction and use in the cement the air between particles. Then, if the particles are not Slag personality of the year.’ industry are the areas, Andrey concluded, with the self-compacting, by using a binder (such as molas- most potential for increased slag use in Russia. ses and lime in the case of steel plant byproducts), 27: Andreas Ehrenberg (FEhS, At the start of the second session, on slag benefi- the materials are formed into briquettes by being left) and York Reichardt (KHD, ciation, Victoria Masaguer Torres of ArcelorMittal squeezed between patterned rollers. Other bind- right) enjoy Czech food and drink on board the yacht Grand Spain spoke about the use of steelmaking slag in the ers can be used, such as bentonite, sodium silicate, Bohemia. passive neutralisation of mine waters. The project lignosulfonate, polymers and hardeners, starch and started a decade ago when a highway construction cement. The abrasiveness of the material to be bri- project allowed the interaction between groundwa- quetted will determine the frequency of maintenance 28: (L to R) Charles Zeynel (ZAG International), Walid Irani of ter and pyritic materials that caused an acid water of the forming rollers. Cimenterie Nationale SAL (CN), problem. A laboratory-scale anoxic trial using steel- Amir Shakurov of Ecoslag Recycling of Russia Lebanon, Milan Vranes (ZAG) and making slag was used to prove the efficacy of the then gave details of molten slag beneficiation using Adib El-Hachem, also of CN. slag as a neutralisation agent: calcium content of the an innovative drum crystalliser. Amir pointed out slag was reduced during the trial, while the pH of that a number of different slags have similar viscosity, 29: (L to R) Dan Rogers (Smithers the acidic waters was reduced. In a pilot scale trial, melting points and enthalpy over a similar tempera- PIRA), Juha Koskinen (Tapojärvi 50t of ladle slag was used in one pit, while limestone ture range (1500-1800°C). The Ecoslag solution is Oy), David Perilli (Global Slag), was used in a control pit. It was found that limestone the accelerated cooling and solidification of molten Henry Pilventö (Tapojärvi Oy). achieves an acidity reduction of around 90%, com- slag (including carbon, stainless, ferro alloys, copper pared to around 80% for slag. The slag has a half-life and nickel slags) using a continuously-rotating drum 30: (L to R) Susanne Schüler of around two years, and following the exhaustion of crystalliser to stabilise dicalcium silicate into a stable and Dirk Mudersbach of Max the slag as a neutralising material, the pit would be form. Amir suggested that the slag crystalliser is built Aicher Umwelt GmbH, Dominik Wohlmuth of voestalpine Stahl closed and left in place. of heat-resistant materials that can withstand the Donawitz GmbH, Joe Bartholmé Patrick Lecherf of Euragglo next spoke about the wear-and-tear of 100,000 melts. The Ecoslag drum of Paul Wurth S.A. and David Al- agglomeration and briquetting of steel-plant byprod- crystalliser has been successfully installed by Bao germissen of the FEhS, enjoying the event’s popular dinner cruise through the heart of Prague.

30 31 32 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.

Global Cement Magazine June 2018 35 GLOBAL CEMENT: EVENT REVIEW

33: Andrey Korablin of Russian company SmartScrap gives his presentation on Russian steel 33 34 35 production and slag markets.

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

35: Patrick Lecherf of 36 Euragglo is all smiles during his presentation 36: Michael Connolly of TMS on briquetting of steel International presents his plant by-products. paper on the status of slag and slag products in the US. 38

38: (R to L) Jitka Hala- mová and Jiří Pyš, both 37 of ArcelorMittal Ostrava a.s., gave a joint paper 37: Gilles Franceschini of on the steps that the ArcelorMittal Europe SA steelworks has taken to receives a small prize at the improve the reuse and Global Slag farewell reception. recycling rate of its slag and slag products.

Global Slag Awards Dinner 39 At the end of the first day of the conference, delegates gathered on the dining yacht Grand Bohemia for a 39: Paul Erwerth of Loesche cruise along the Vltava River, among the fabulous receives the prize for the best sights of historic Prague. During the cruise the exhibition stand at Global Slag, Global Slag Awards 2018 were presented. Global Slag on behalf of Loesche. 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, Steel in China. Amir mentioned a previous Russian Carbstone blocks... 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. Scan the QR code below or enter the bit.ly Jitka Halamová and Jiří Pyš of ArcelorMittal code into your browser to read more about the Ostrava, a company that will soon become an in- Global Slag Conference & Exhibition and see the dependent unit, next spoke on the efficient use of conference photo gallery... slag resources. Starting in 2012, the company commenced a series of small steps towards improving the recycling rates of its slag materials. Better internal See more communication, benchmarking, cross-exchange of http://bit.ly/ GlobalSlag18 ideas from other units, logistics optimisation, and some equipment upgrades allowed the beneficiation and significant addition of value to slag.

36 Global Cement Magazine June 2018 Contents Subscribe Ad Index GLOBAL CEMENT: EVENT PREVIEW

Easyfairs

SCHÜTTGUT now called SOLIDS Dortmund

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.

n 7 - 8 November 2018, Othe ninth trade show for SOLIDS Dortmund & granules, powders and bulk RECYLING-TECHNIK Dortmund solids technologies – and the first to run officially under the Date: 7-8 November 2018 ‘SOLIDS’ brand – will take place Opening hours: 09:00 - 17:00 at the Messe Dortmund. Over the Ticket price: Euro30 for both shows years since its premiere in 2006, the share of international exhibi- Venue: Messe Dortmund, Halls 4, 5, 6 + 7 tors has risen to nearly 20%, and Rheinlanddamm 200, 44139 Dortmund among visitors to about 12%. “With the new name SOLIDS Websites: www.solids-dortmund.com Dortmund, we are recognising www.recycling-technik.com 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 The new name will be accompanied by a new logo Director for organiser Easyfairs. for SOLIDS Dortmund. It consists of three nested The new name, SOLIDS Dortmund, also under- hexagons, representing the three types of bulk sol- scores the show’s affiliation with Europe’s largest ids, i.e. stone, granules and powders. Its six corners series of trade shows for granules, powders and bulk stand for the six SES shows. The broad approval with solids technologies. Together with its sister events which the new name and logo have been received SOLIDS Antwerp, SOLIDS Rotterdam, SOLIDS is summarised by Professor Rainer Barnekow from Zurich, SOLIDS Krakow and SOLIDS Russia, Dort- the Life Science Technologies Department of the mund has long been a pillar of the SOLIDS European Hochschule Ostwestfalen-Lippe. “I’m delighted with Series (SES). 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.

Global Cement Magazine June 2018 37 GLOBAL CEMENT NEWS: PRODUCTS & CONTRACTS

Contents Netherlands: Van Beek introduces eggshell Subscribe to lime equipment an Beek has developed an eggshell dryer for drying Ad Index Vcrushed 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. Above: The Van Beek Celsius turns egg shells into high quality lime.

Nigeria: Dangote to use Loesche Nigeria: Gebr. Pfeiffer sells first mills mills at Obajana to Dangote Cement angote Cement will use two vertical roller mills (VRM) ermany’s Gebr. Pfeiffer has struck a deal to sell Dfrom Germany’s Loesche for a new production line at Gan MVR 6000 R-4 mill for raw material grind- its Obajana plant in Kogi State. The order comprises a six- ing and an MPS 3350 BK mill for processing coal roller mill for raw cement meal with a capacity of 580t/hr, for kiln firing for Dangote Cement’s new plant at the largest roller mill for raw material in the Loesche range, Okpella in Edo State. The mill order is the first for and a three-roller mill with a modular design featuring a Gebr. Pfeiffer from the Nigerian cement producer. drive power range of 1000kW for grinding hard coal and The order was placed via China’s Sinoma Interna- lignite with a throughput of up to 70t/hr. tional Engineering.

UK: Cemengal supplies modular vertical Philippines: Starlinger installs 300th mill to Dunbar conversion line for Ad*Star bags

pain’s Cemengal is supplying a 0.5Mt/yr Plug&Grind ustria’s Starlinger has installed its 300th con- SVertical mill to Tarmac’s Dunbar cement plant. Work Aversion line for Ad*Star bags at Sakomoto started in April 2018. The unit follows the Plug&Grind International Packaging’s plant in Caloocan City product line’s modular format and it includes an FLSmidth near Manila. The Ad*StarKON line was delivered OK Mill 37.3. The mill will be used to grind clinker at the as part of two sack conversion lines for the client. cement plant, although the subsidiary of CRH may also Sakomoto International Packaging supplies the use the mill to grind slag. The order is Cemengal’s first local cement industry with Ad*Star sacks made of Plug&Grind Vertical in Europe. polypropylene fabric.

India: Tancem project update

ommissioning of the new 3000t/day production line Cat 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.

38 Global Cement Magazine June 2018 Contents Subscribe Ad Index NEWS

Germany: HeidelbergCement strong despite winter weather The hottest option eidelbergCement increased its sales Hvolumes of cement in the first quarter of 2018 despite facing poor weather and coping in Bi-Metal and 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 Wear Castings! 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 HARDTOP® Bi-Metal Castings provide Egypt, Ghana and Tanzania. Its sales revenue increased on a like-for-like basis by 2% to high wear resistance Euro3.78bn. The group completed its acquisition of increased durability Cementir Italia in Italy and the Alex Fraser reduced overall costs Group in Australia in the reporting period. It high efficiency also finished the sale of the sand-lime brick operating line in Germany and its white ce- reduced expense for maintenance ment business in the US. minimised downtime raised production added profit

Italy: Buzzi and Cementir take a tumble in first quarter uzzi Unicem’s sales fell by 8.4% year-on-year Bto 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 Reichelstrasse 23 when adjusted for the divestment of Cementir D-39124 Magdeburg Italia to HeidelbergCement. Earnings before interest, taxation, depreciation and amortisa- Germany tion (EBITDA) fell by 12.4% to Euro241m from Euro27.5m. Cement sales volumes increased phone: +49 (0) 391 532969-0 by 4.1% to 2.08Mt from 2Mt. fax: +49 (0) 391 532969-21 e-mail: [email protected] Global Cement Magazine June 2018 39 web: www.hardtop-gmbh.com GLOBAL CEMENT NEWS: EUROPE

Switzerland: Poor start to 2018 for Spain: Alicante port expansion LafargeHolcim he Port of Alicante is undergoing a Euro3m up- afargeHolcim has blamed falling earnings in Tgrade to build a new dock that can support larger Lthe first quarter of 2018 on poor weather in vessels. Once completed the upgrade will allow ships North America and Europe. Its recurring earnings with a length of up to 240m to dock, according to the before interest, taxation, depreciation and amorti- Diario Informacion newspaper. Previously the port sation (EBITDA) fell by 7.7% on a like-for-like basis could only support ships of up to 165m. The site pro- year-on-year to Euro587m from Euro678m in the cesses large volumes of cement and clinker and dust same period in 2017. Its net sales rose by 3.1% to mitigation measures are also being installed. Euro4.89bn and its cement sales volumes rose by 3.2% to 47.7Mt on a like-for-like basis.

France: ArcelorMittal to increase Ecocem France stake rcelorMittal planned to increase its stake in Ecocem AFrance 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. Above: The Port of Alicante at sunset.

Czechia: Hranice sales rise by 9% Russia: New plant at Sibay

ement Hranice’s cement sales rose by nearly 9% year-on- n investment deal has been signed be- Cyear in 2017 due to despatches to fellow subsidiaries of Atween the Government of Bashkortostan, Buzzi Unicem in Czechia and Slovakia. Its overall sales rose by the Sichuan-Sibay Industrial Park and Jiunghe 6.3% to Euro61.5m from Euro57.9m, according to the Czech Sichuan Environmental Protection Company News Agency. Board member Roman Michalcik said that the to build a Euro168m, 1.8Mt/yr cement plant in local construction sector had grown in 2017 due to good Sibay. Once operational the unit is expected weather towards the end of the period and large local infra- to create around 200 jobs. The project was structure projects. originally scheduled to open in 2018 but construction work at the site has not started yet. Further reporting by the Russian Construction trade magazine says that the general contrac- Your vice-president conducts the negotiations tor for the project will be Sinoma. with the suppliers of your new line. Yes No You can be sure that the contract with the P UK: Bhatia on Breedon board supplier will lead to an efficient plant. reedon Group appointed Amit Bhatia as its You can be sure that the contract with the P supplier will lead to an efficient pyroprocess. Bnon-executive deputy chairman on 1 May You can be sure that the contract with the 2018. Bhatia joined Breedon’s board as a non- supplier will lead to an efficient and safe P executive director in August 2016, following coal mill system with an up-to-date design the group’s acquisition of Hope Construction concept. Materials. Ask for assistance before you sign the P contract. France: HGH stake could be sold

Coal Mill Safety Pte Ltd he Carlyle Group has started talks with www.coalmillsafety.com THGH Infrared Systems to acquire a majority [email protected] stake. The deal is expected to be completed by the end of 2018. No value has been disclosed.

40 Global Cement Magazine June 2018

CEMENT NEWS

Norway: Government to fund Norcem CCS project

he Norwegian government has proposed Tcontinuing funding for Norcem’s CO2 capture and storage project at its Brevik cement plant. The announcement follows an assessment 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.

Your project, our solution

We deliver customised solutions for operators and investors of cement plants throughout the world. Intercem is the competent and experienced partner for planning, detail engineering, project handling of greenfield projects and the conversion/modernisation France: Vicat’s markets pick up of production systems. Our 3-level system makes it possible for us to offer both used icat’s sales in Turkey, the US and Kazakhstan and modernised products, to compile new Vhave driven its growth in the first quarter of 2018. Its sales revenue for its cement business solutions made rose by 10.9% year-on-year at constant scope and from used exchange rates to Euro290m in the first quarter and new of 2018. Its cement sales volumes rose by 6.5% to components 5.2Mt from 4.9Mt. or to create “We posted significant business growth in completely Turkey, the US and Kazakhstan, excluding currency effects. The gradual recovery continued new systems. in France, and India was boosted by the start-up of new infrastructure projects. Conversely, we recorded a business contraction in Switzerland And all that: FastFairFlexible 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 Intercem Engineering GmbH by the military operations underway to restore se- Intercem Installation GmbH curity in its production area,” said group chairman Carl-Zeiss-Straße 10 | 59302 Oelde and chief executive officer (CEO) Guy Sidos. Germany | Tel.: +49 2522 92058-0 E-Mail: [email protected] | www.intercem.de Global Cement Magazine June 2018 41

Intercem_Imageanzeige_1/2_102x297_EN.indd 3 29.09.15 09:48 GLOBAL CEMENT: UK Contents Subscribe Ad Index

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.

ontinued uncertainty over the implications of levels, with some down by as much as 54%. The CBrexit on the future shape of the economy has measures of economic well-being in construction contributed to a plateau in economic activity across paint a rather patchy picture. a range of sectors in the UK economy, not least Indeed, a Construction Index article from Au- construction. The fundamentals are strong enough: gust 2017 summed up the situation by highlighting house-building remains a pressing need and both the ‘mixed messages’ from statisticians. While housing policy and major infrastructure remain industry-wide state-of-trade surveys revealed a 17th Government priorities with major spending commit- consecutive quarter of growth, second quarter output ments. Universities continue to build, both academic data from the Office for National Statistics (ONS) for facilities and student accommodation. the second quarter of 2017 showed a 1.3% fall, the However, where investment is discretionary – in largest since 2012. Meanwhile, the IHS Markit PMI commercial office building and industrial units, for suggests that sector workloads and orders are on Above: Edwin Trout, instance, and high-end luxury accommodation in the rise. Secretary of the Cement London – spending levels are static or falling. De- The ONS figures for 2017 reveal contraction in the Industry Suppliers’ Forum. mand is far from even across the country. Analysis second to fourth quarters, the first time there have by the Mineral Products Association (MPA) revealed been two or more consecutive quarters of decline ‘massive differences in recovery’ since the recession. since 2012. However, there was sufficient growth in Data for ready-mixed concrete (which we can regard the first quarter for the year as a whole to register, as a proxy for cement) shows a 50% increase in the perhaps misleadingly, overall growth. More recently London market since 2007, while sales volumes in January 2018 saw contraction of -3.4%, the worst every other region remained at least 20% below 2007 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 Right: The Breedon Group shown in Table 1. Hope plant, as seen from the Reports from the Construction Products Asso- road to the limestone quarry. ciation indicate a slowing of sales and a lowering of The group’s cement operations expectations. The latest forecasts suggest a plateau in were rebranded from Hope Cement to Breedon Cement 2018, fed by political uncertainty and the fallout from in August 2017. Breedon the collapse of the major construction firm Carillion. acquired Ireland’s Lagan It expects output to rise by 2.7% in 2019 and 1.9% in Cement in April 2018. 2020. Infrastructure and private housing remain the most positive sectors, though 90% of product manufacturers 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

42 Global Cement Magazine June 2018 GLOBAL CEMENT: UK

2017 that was lower than both the previous quarter capability of its own, with the eponymous Derbyshire and the third quarter of 2016. When the full year works becoming the cornerstone of a third Breedon returns were published in February 2018, sales of business unit, Hope Cement. The branding of this concrete, crushed rock and sand and gravel were all unit changed in July 2017 to accommodate the ac- flat. Only mortar saw a rise. Figures for cement sales quisition of Sherburn Stone, the portfolio of which were not available, but with concrete its principal included a cement import operation in the north east outlet, they are likely to be in line with the pat- of England. ‘Breedon Cement’ signalled the tern above. As mineral building products are broadening of the business away from a focus seldom stocked on site for long, on cement produced at Hope alone. such statistics can be seen as This was rapidly followed by the bolt-on an immediate indication of acquisition of Humberside Aggregates Ltd Left: The UK’s integrated construction activity. and further activity was announced in cement plants. December 2017, in the form of a pro- TOTAL = 10.3Mt/yr. Company performance posed asset swap with Tarmac. Breedon The static state of the market is was to take over four of Tarmac’s quarries Tarmac (CRH) reflected in individual company and an asphalt plant, valued at Euro18.9m, 1. Cookstown, 0.5Mt/yr. results. Increased global turnover while transferring to Tarmac 27 of its 2. Dunbar, 1.0Mt/yr. 3. Aberthaw, 0.6Mt/yr. at Cemex in 2017 contrasted with ready-mixed concrete plants and a pay- 4. Tunstead, 0.8Mt/yr. a 6% fall in cement deliveries 2 ment of Euro5.6m. With regulatory in Britain, though this was clearance required, the likely impact Aggregate Industries offset by a 1% increase was considered by the Competi- (LafargeHolcim) in the average selling 1 tion & Markets Authority and 5. Cauldon,1.0Mt/yr. price. Sales of aggre- a public consultation held in Cemex UK gates and concrete 9 February 2018. The proposals 6. Rugby, 1.3Mt/yr. were also down, with 7 were revised and at the time 7. South Ferriby, 0.8Mt/yr. higher prices. of writing the CMA 10 8 4 CRH’s statements give little away about has indicated that Breedon Cement 5 8. Hope, 1.3Mt/yr. Tarmac in the UK, apart from the latest, 11 it is minded to ap- which advised of ‘poor weather’ in 6 prove. Staffordshire Hanson the first quarter of 2018. The coffers Concrete Ltd was (HeidelbergCement) of Hanson’s parent company Heidel- 3 also acquired in April 9. Ribblesdale, 0.9Mt/yr. 10. Padeswood, 0.8Mt/yr. bergCement swelled with the addition 2018. 11. Ketton, 1.3Mt/yr. of Italcementi, and chairman Bernd Breedon’s rise has Schiefele claimed the company had now reached new heights ‘never sold more cement, concrete, with the recently announced gravel and sand than in 2017.’ How- acquisition of Ireland’s Lagan Cement. ever, performance in the UK ‘Suffered That the two groups were in talks was confirmed in from the uncertainties arising from the Brexit February 2018, building on the cooperation that vote: sales volumes declined across all product lines.’ already existed between them. The acquisition went Below - Table 1: Construction Purchasing Managers’ Index LafargeHolcim’s otherwise positive results for 2017 ahead and Lagan became a Breedon Group business (PMI) for the UK. Values over note that earnings in the UK were lower as a result on 20 April 2018. Its incorporation has prompted a 50 indicate growth, with values of project delays and a general economic slowdown. further restructuring with two additional divisions: under 50 indicating contraction. Breedon, the only cement producer solely focused on the UK market, saw an exceptional 99% increase in concrete sales due to its acquisition of Hope Construction Materials in Year Mon PMI Comments 2016. Full year results for 2017 were published Jun 54.8 Political uncertainties blamed for the weakening market in March 2018 and reveal pre-tax profits Jul 51.9 11-month low with falling commercial construction, but housebuilding firm of Euro84.5m, up by 52% from Euro53.6m Aug 51.1 Weakest overall performance since August 2016 (orders not replacing completions) in 2016. Revenue was up Euro49.2m to 2017 Sep 48.1 First fall below 50 in 13 months Euro746m. Oct 50.8 Lowest expectations of growth since December 2012 Mergers and acquisitions Nov 53.1 Five-month high, driven by housebuilding activity One of the underlying developments of the year Dec 52.2 Down due to weaker housebuilding, falling commercial, slower infrastructure has been the creation of Breedon Cement and Jan 50.2 A four-month low: housebuilding into decline, commercial returning to growth the expansion of its parent Breedon Group as Feb 51.4 Civil engineering worst performing; housebuilding weak an integrated mineral products business. Fol- 2018 Mar 47.0 Below 50 for the first time in six months and the fastest fall since July 2016 lowing its purchase of Hope, the then Breedon Aggregates had acquired a cement producing Apr 52.5 Housebuilding growing at its fastest pace for more than two years

Global Cement Magazine June 2018 43 GLOBAL CEMENT: UK

Client Plant Equipment / Service Supplier Date On a smaller scale, Ecocem Ireland has invested Hanson Padeswood L586 XPower wheeled loaders Liebherr Jul 2017 Euro2.5m in opening the second of its import termi- Lafarge Cookstown Quarry machinery maintenance UPS Jun 2017 nals, this one at Sheerness in the Port of Medway in Tunstead Vibration monitoring Schaeffler UK Jan 2018 south-east England. Bulk ground granulated blast- Tarmac furnace slag is now being imported into the UK from Dunbar Plug&Grind Vertical mill Cemengal Apr 2018 Ecocem’s newly opened plant at Dunkirk, France. Selected investments made by the sector over the past 12 months are shown in Table 2. Above - Table 2: Major Breedon Northern Ireland and Breedon Republic of contracts signed by UK cement Ireland. Research and innovation producers in 2017 and 2018. Significantly, Breedon now controls cement pro- While there has been lower investment, there has duction in the Republic of Ireland as well as in the been an increased emphasis on innovation. Aggre- UK, and the expanded Breedon Cement business in- gate Industries might claim to be to the fore in this cludes both the Hope and Kinnegad plants, as well as endeavour, appointing Pablo Libreros as Growth & the Sherburn import operation, all under the control Innovation Director in September 2017, responsible of Jude Lagan. for development and recommending opportuni- Other mineral products groups have bought and ties for the business. These, it was envisaged, would sold too, though in a smaller way. Aggregate In- include greater cross-promotion of products through- dustries – LafargeHolcim’s UK business – acquired out the LafargeHolcim group. In January, Aggregate Kendall Group in February 2018; the formerly inde- Industries launched its 2018 Innovation Strategy, pendent producer operated marine aggregate wharfs setting out priorities for the year ahead. Key areas of in Portsmouth and Shoreham-by-Sea, and five ready- interest included robotics and artificial intelligence; mixed concrete plants in Hampshire and Sussex. virtual and augmented reality; digital engineering, Tarmac’s parent company CRH has made deals offsite construction and ‘blockchain’. Putting its aspi- abroad and the UK business was strengthened by rations into practice, the company has entered into a the acquisition of Scottish Power’s 50% share of their partnership with Open Energi, that firm having just joint venture ash company in October 2017. This will launched its Dynamic Demand 2.0 platform, which continue to operate under the ScotAsh name and will uses artificial intelligence to connect, aggregate and maintain its current range of products from power optimise energy assets to reduce power costs. Aggre- station ash. Cemex UK remains as it was, except for gate Industries has also commented publicly on the a change at the top. Michel Andre was appointed possible future use of driverless lorries. Country President in September 2017, succeeding Perhaps less overtly, Cemex has introduced a Jesus Gonzalez, who has been promoted to the execu- number of significant innovations over the past few tive team in Mexico.

Investment Hanson’s Euro23m project at Padeswood is the principal investment in expanded production facilities in the UK cement industry at present. With four ageing 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- Right: The Hanson Padeswood port costs that that entails. cement plant is the most modern of Hanson Cement’s A planning application to construct a new mill UK plants, thanks to the was submitted to Flintshire County Council in commissioning of Kiln 4. It is cur- August 2017, with Hanson also committed to invest- rently being upgraded with the ing in new railway loading facilities. When details addition of a 0.65Mt/yr vertical roller mill shipped from a plant were released, it transpired that the new installation in Bilbao, Spain. 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.

44 Global Cement Magazine June 2018 Cemengal June 2018.indd 1 29/05/2018 15:39 GLOBAL CEMENT: UK

Quinn Building Products has highlighted its new approach to distribution. The company’s ‘blended lo- Right: The Brexit ‘game’ is still gistics’ offers combined loads of heavyweight cement afoot. The exact terms of the or concrete blocks with lighter insulation materials, UK’s departure from the EU have to enable its fleet to operate at full capacity and avoid the potential to affect cement unused space. demand. Exactly how remains to be seen. Health and safety Changes 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 months, each of them part of a multi-national initia- have been investing in new vehicles of this type. In tive. In September 2017 the company announced it June last year Cemex flagged up the greater visibility was participating in the EU-supported EPOS pro- provided by N3 vehicles from both manufacturers. ject aimed at enabling cross-sector symbiosis. The Hanson meanwhile has taken delivery of the first of project highlights case studies exemplifying ways to 40 new Mercedes Benz lorries fitted with low-entry use waste from other industries to deliver greater cabs, panoramic windscreens and 360° cameras. efficiency and contribute to more sustainable pro- These too are for service in the capital. cesses. As part of the project the UK’s South Ferriby The concern for health and safety extends not just plant has worked on ways to incorporate wastes from to vehicle design, but safe operation and road user chemical company Ineos into the cement produc- awareness too. It is an ongoing concern, though new tion process. In March Cemex claimed to be the initiatives continue to be introduced. In October first company to successfully operate cement plants 2017, for instance, Quinn Building Products opened by remote control. Based at group headquarters in a vehicle inspection centre in County Fermanagh, Monterrey, the Centro de Control Cemento oper- Northern Ireland, to maintain its fleet of 300 trucks ates in real time, tracking live data for the operation and trailers. The company took the opportunity to of 14 cement plants, 25 kilns and 86 grinding mills re-state its commitment to ensuring the safety of its across three countries. And at the other end of the vehicles and operators. process, under the headline ‘Cemex delivers the fu- In December 2017, Aggregate Industries in- ture’, Cemex Go was launched in 2017 as a seamless troduced a points-based policy known as ‘Fair & customer experience for order placement and live Just’, designed to improve driving standards among tracking of shipments, and is now being trialled with its hauliers. Then following the installation of the 12 customers in the UK. Teletrac Navman GPS system in all of its vehicles, Tarmac, in similar vein, has just introduced the company introduced a driving style rewards an innovative Track-and-Trace system across its programme to reward drivers who are committed 1800-strong fleet, aiming to improve efficiency and to safety, and achieve operational best practice. Ag- boost customer service. gregate Industries has also partnered with the Fleet In a project that has similarities with the EPOS Operator Recognition Scheme (FORS) to ensure its programme, Hanson’s parent company Heidel- subcontractor fleet attains the benchmark. Likewise bergCement has signed a three-year collaboration Tarmac is working with FORS and has been re-ac- with the European Molecular Biology Laboratory credited to undertake the audit process for its entire to exchange scientific and technical knowledge in fleet, including subcontractors. Since the scheme was areas related to emissions reduction and recovery, introduced in 2014, more than 1800 Tarmac vehicles and ‘innovation in general.’ LafargeHolcim has also have been FORS-accredited. appointed a new Group Head of Reasearch and De- Health and safety policy on companies’ own sites velopment. Dr Heike Faulhammer took up her post continues to be pursued with as much vigour as at the company’s global research and development it has for many years. Hanson held a ‘safety stand- centre at Lyon in July 2017. down’ throughout the group on 16 October 2018, allowing an hour to carry out health, safety and well- Transport being activities. The key messages to employees and Transport and logistics have been an ongoing focus contractors alike was: ‘Always challenge unsafe be- for investment, perhaps more for safety and efficiency haviour and stop a job if they think it is unsafe.’ Such improvements than for an expansion of use. The sid- attitudes are rewarded annually at the MPA Health & ings at Padeswood cement plant are an exception to Safety Awards. this last remark, as are developments in the related aggregates sector.

46 Global Cement Magazine June 2018 GLOBAL CEMENT: UK

Industrial relations

In a development uncharacteristic of the UK cement by the EU as a leading country for the substitution of industry in recent times, the past 12 months has seen coal by renewable energy sources, particularly wind the calling or threat of, strikes and other industrial and solar power. action. These have affected delivery drivers and, in According to National Grid figures, 2017 was the a closely related sector, workers at Tarmac Build- greenest year ever in terms of electricity generation. ing Product’s block-making plant at Stanford Le The rise of renewable energy helped break 13 clean Hope. Here the dispute revolved around terms and energy records during the year. Indeed, in April 2018 conditions for new starters and 24hr strikes were electricity generation ran without the use of coal for announced for several dates in February and March 72 consecutive hours. Moreover figures fromCarbon 2018. The dispute was resolved amicably in April Brief show that 2017 was the fifth consecutive year 2018, with Tarmac announcing plans to upgrade and in which CO2 emissions had fallen, with the level reopen a second factory on the site. now 38% below that of 1990. Emissions fell 2.6% in As for deliveries, drivers working for Cemex’s 2017, driven by a 20% reduction in the use of coal for cement and aggregates operations were the first electricity generation, and are now at levels last seen to threaten strike action, over pay and allowances, in the 1890s. though that was resolved in May 2017. Similarly, the That said, the 164-page Clean Growth Strategy threat of a strike by drivers working at eight Hanson published in October 2017, which sets out how the depots, followed by refusal to stay in cabs overnight, UK intends to reach its targets, has been queried by was averted by a deal with Unite in February 2018. the Committee on Climate Change. The Committee has warned that targets are likely to be missed, espe- New products launched cially without funding for the introduction of carbon Much of the new product lines of the past few capture technology in heavy industry. months relate to packed cements, closely associated Another warning comes in the wake of the recent with changes in branding and presentation. The Chinese ban on importation of waste plastics. The Lafarge range from Aggregate Industries was ex- UK Recycling Association has commented that, ‘we tended to include six new products. To enhance the simply don’t have the markets in the UK.’ The eco- range, a Lafarge-branded pallet hood has been de- nomics of recycling might well have an impact on the veloped for product displays at builders’ merchants. supply of alternative fuels to the cement industry. Then launched just weeks ago was TerraCem, the UK’s first hydraulic road binder formulated for use Conclusions in soil stabilisation. As mentioned at the top of this article, the UK is in Quinn Building Products launched three lines the midst of a plateau in terms of economic and con- of bagged cement in the spring of 2018, including struction growth. Given the continued uncertainty General Purpose Cement, Master Grade Cement and surrounding the exact terms of the UK’s departure Premium Grade Cement. from the EU - now only nine months away - this un- easy situation could remain for some time to come, Sustainability despite the strong need for cement and allied build- The emphasis placed on sustainability by the UK and ing materials. This will be my last report before the its regulators over the past 20 years, and quantified in UK leaves the EU on 29 March 2019. By the time annual sustainability reports from the MPA, is part of of my next report in June 2019 the picture may - or a wider national commitment that has had reason to indeed may not be - a little bit clearer. See you on the celebrate success in the past year. The UK is now seen other side!

Left: The Cemex South Ferriby plant is located where the Humber Estuary meets the River Ancholme in North Lincolnshire.

Global Cement Magazine June 2018 47 GLOBAL CEMENT NEWS: THE AMERICAS Contents Subscribe Ad Index

Colombia: Production down 3.3% olombian cement production fell by 3.3% year- Con-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.

Above: Skyline of Bogotá, capital of Colombia, at dusk. Source: hinterhof / Shutterstock.com Colombia: Cementos Argos weighed down by local market and US “The growth of EBITDA throughout all our regions ementos Argos’ sales have fallen due to decreased is proof that the strategy we established is beginning Ccement sales volumes in Colombia and the US. It to reap the benefits of the best efficiency programme blamed poor weather in the US and a large number and to focus our initiatives in continuing to provide the of holidays in Colombia for the situation. Its sales rev- best experiences to our clients,” said Juan Esteban Calle, enue dropped by 8.2% year-on-year to US$677m from president of Cementos Argos. US$737m. However, its adjusted earnings before inter- Cement sales volumes fell by 4.1% overall to 3.69Mt. est, taxation, depreciation and amortisation (EBITDA) Volume drops were noted in Colombia and the US but rose by 2% to US$107m from US$104m. in the rest of the world they rose by 11%.

Paraguay: President inaugurates Paraguay: Méndez resigns from INC Vallemi upgrade orge Méndez has resigned as the president of resident Horacio Cartes has inaugurated a kiln JIndustria Nacional del Cemento (INC). He had been in Pupgrade to Industria Nacional del Cemento’s post since 2013. (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- Brazil: Votorantim on the rebound? per. The upgrade work cost US$45m. The plant has three production lines but only one is used. otorantim’s sales from its cement business have Vgrown due to increased sales volumes in Brazil, Turkey, India and Latin America. Higher prices in North Uruguay: ANCAP restarts following America and Europe, Asia and Africa also contributed to strike action the result. Votorantim Cimentos’ sales revenue grew by 11% year-on-year to US$682m in the first half of 2018 roduction has resumed at the Administración from US$613m in the same period in 2017. Local sales PNacional de Combustibles, Alcoholes y Port- in Brazil grew by 13% to US$417m due to concrete and land’s (ANCAP) Minas and Paysandú cement plants mortar sales. Its adjusted earnings before interest, taxa- following a strike, according to the El Espectador tion, depreciation and amortisation (EBITDA) rose by 28% newspaper. The disruption ended following ne- to US$65.3m from US$50.8m. gotiation between management, the union, the Ministry of Industry, Energy and Mining and the Below: Votorantim Cimentos cement plant at Santa Helena, São Paulo, Brazil. Source: Votorantim website. 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.

Dominican Republic: Falling sales

ement sales fell slightly by 1.5% year-on-year to C4.18Mt 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.

48 Global Cement Magazine June 2018 GLOBAL CEMENT NEWS: THE AMERICAS

US: PCA announces 2018 Safety system cooling, and placement of employees on scaf- Innovation Awards winners folding in confined spaces. he Portland Cement Association (PCA) has LafargeHolcim US’ Corporate Program in Chicago Tannounced the winners of the 2018 Safety won the distribution category for its X-Factor barge Innovation Awards. cover. It has developed a process for barge cover re- Cemex USA’s Miami plant Florida won the milling/ moval that reduces the risk of falls from employees grinding category with its new process to load ball stepping on to the barge. mills. The site developed a new mill loading process Ash Grove Cement’s Louisville plant in Nebraska that uses a small hopper for grinding media, and an won the general facility category for its use of mag- inclined transport system with buckets to convey the nets as duct hole patches. Ash Grove has developed grinding media directly to the mill. This new system a hole-patch technique using magnets. Magnetic eliminates the interaction between the employee and patches are quick, simple, and effective at prevent- the machine, reduces the number of people needed to ing or limiting the release of materials from holes load the mill from five to two, and eliminates the need created in ducts caused by abrasion, leading to a for employees to stand on top of the mill. cleaner plant, reduced slip, trip and fall risks, and Cemex USA’s Houston operations in Texas won fewer related Mine Safety and Health Administration the pyroprocessing category for its use of drones for housekeeping citations. hazardous inspections. It has implemented a system Cemex USA’s Brooksville in Florida also won the for using protected air drones to inspect enclosed and general facility category for its filters moved to ground confined spaces. Visual inspections of enclosed areas level project. It redesigned the blower housings to (preheater towers, tanks, silos, process ducts, etc) move the filter from the top of the blower housings to normally require intrusive equipment, long delays for an easily accessible location at ground level.

Global Cement Magazine June 2018 49 GLOBAL CEMENT NEWS: THE AMERICAS

Barbados/Trinidad & Tobago: Dispute over cheap Turkish imports

rinidad Cement and its Barbadian Trinidad Cement has taken legal action in the Caribbean Tsubsidiary Arawak Cement have Court of Justice against Turkey’s Sonmez Cimento for taken legal action against the Govern- breaking local tariff rules. In 2016 Trinidad Cement ment of Barbados over allegedly breaking made an official complaint to Caricom, the the Caribbean Community Single Market Caribbean Community organisation, and Economy. The complaint relates to about tax concerns for a cement import accusations that the country broke import from Turkey. duties on cement, according to Barbados Today. The government has been accused of reducing import tariffs to 5% from 60%. Jamaica: Caribbean Cement to Arawak Cement and its competitor Rock buy equipment from parent Hard Cement have battled for the local market since the entry of the aribbean Cement has signed latter company in the market Can agreement to buy plant in 2015. equipment from its parent Union members from company Trinidad Ce- the Trinidad Cement branch ment. The US$118m of the Oilfields Workers Trade deal includes kiln Union had earlier protested at the Port and mill equipment of Chaguaramas over cement imports being used at Carib- from Turkey. A union member claimed that bean Cement’s Rockfort a batch of imported cement had no import duties plant in Kingston. The equipment was previ- paid, according to the Trinidad Guardian newspaper. ously leased to Caribbean Cement in 2010.

Canada: CSL Group buys 50% of Mexico: Cemex Ventures invests in pneumatic cement vessel business health and safety startup Prysmex SL Group has agreed to buy 50% of Eureka Ship- emex Ventures has invested in Prysmex, a Mexico- Cping, SMT Shipping’s pneumatic cement vessel Cbased startup that offers a product capable of business. The new joint venture will allow Eureka and detecting and helping to prevent workplace accidents CSL to expand services to customers in the seaborne through the Internet of Things and real-time data col- cement powder and fly ash transportation markets lection. Following a successful trial period, Cemex has around the world. CSL’s Australian cement shipping installed Prysmex’s product at all its cement plants business is not included in the joint venture. in Mexico. “The joint venture represents an important step Prysmex’s product features a web platform with in CSL’s strategy to increase its presence in the global a collaborative management app that monitors the construction material sector,” said Louis Martel, Presi- environmental and geolocation variables of unsafe dent and chief executive officer (CEO) of CSL Group. acts and conditions on customised 3D maps, enabling The companies say that the partnership is a strong real-time decision-making and increased industry strategic fit, leveraging the companies’ respective safety and productivity. Through the Internet of Things, strengths in the shipping and handling of dry bulk Prysmex enables an analysis of data such as impacts, cargos. There will be no change in the day-to-day light and noise levels, locations, temperatures and the management and operation of vessels in the Eureka presence of toxic gases. Placed on the workers’ hel- fleet. The transaction is subject to regulatory ap- mets, Prysmex devices monitor and communicate in proval and is expected to be completed by the end of real time users’ conditions, alerting them to potential June 2018. situations and high-risk areas. In addition, its web ap- Eureka Shipping operates a fleet of self-unloading plication provides an analytical report of workers’ and cement carriers in the Baltic Sea, the Atlantic Ocean, plant conditions, enabling better workplace decision- the Mediterranean Sea, the Caribbean and Asia. SMT making and accident prevention at all times. Shipping Group has, over the past 30 years, built a fleet Founded by chemical engineer Susana Ruiz of about 45 vessels through a number of joint venture and civil engineer Patricio de Villa in Monterrey, companies operating in various bulk commodities Mexico, Prysmex was the finalist of Cemex Ventures markets, focusing on geared bulk carriers, floating Startup Competition 2017 and is now part of the storage/transhipment terminals and belt-unloaders. company’s portfolio.

50 Global Cement Magazine June 2018 Contents Subscribe Ad Index GLOBAL CEMENT: EVENT REVIEW

Robert McCaffrey, Global Cement Magazine

Event Review: 60th IEEE-IAS/PCA Conference

1: Ryan Preis (left) and Mark Glover (right) of fan expert Air- Stream proudly man the stand. 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 2: Xavier d’Hubert of take place in St Louis in 2019. CMI Energy (right) in discussion with a visitor to his stand.

3: Busy Aumund stand with Ingo Mirbach, facing camera, and Wes assimo Toso, CEO of Buzzi Unicem USA, Ed Sullivan of the PCA next gave his ‘State of the Allen, far right. Inset: Aumund Mstarted the conference by comparing and industry’ address. With more than 2m jobs created USA president Geoff Conroy seen contrasting the European and US cement industries, each year and with the unemployment rate lower at Global Cement’s dart board pointing out that in Europe cement producers are than 4.5%, Ed suggested that there may be a further shortly before he enters his well-earned retirement. obliged to take CO2 very seriously, but that there is strengthening of US economic growth. This comes a ‘clear gap’ between this approach and that of the despite already tight labour markets and a worsening US. Additionally, he suggested that European heavy skills shortage, which will lead to increased wages. 4: Henrik Nilsson (left) and Vinny manufacturers might be guilty of the sin of hubris The situation might start to unbalance the economy, Matthews (right) of drive and over the perception of the cement industry by the in terms of inflation, leading to interest rate rises, but control expert Bosch Rexroth. public - it is increasingly the case that the public re- at much lower levels than historically. Ed reiterated gards the cement industry as an ‘outdated relic,’ or, as his forecast of cement demand growth of around 2.5% another speaker put it, belonging in ‘the cemetery of annually, even in the absence of fiscal stimulus. Some 5: Josh Carlegis poses dinosaurs.’ Massimo exhorted the listening delegates states are still experiencing fiscal problems despite happily for the camera at refractory gurus Calderys. to reach out and to promote the industry. “It might be rising tax incomes, since entitlement programmes are just a grey powder,” he said, “but many of the greatest growing more quickly than state incomes, and this accomplishments of humankind in the last two cen- is squeezing state construction budgets. Ed suggests 6: Environmental professional turies would not have been possible without cement that there is unlikely to be a Trump Infrastructure BWF Envirotec’s Angi Hamlin and concrete.” Bill before 2019, but even then, the majority of the (left) and Mike Beetem (right).

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Global Cement Magazine June 2018 51 GLOBAL CEMENT: EVENT REVIEW

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7: Doug Sibersky of Christian purported US$1tn earmarked for construction will gested that carbon prices will inexorably rise around Pfeiffer America (left) and come from states rather than from the federal gov- the world. He suggested that there are a number of Cornelia Cretiu of Solvay (right) smile for the camera during the ernment. States and local governments are currently different ways of capturing CO2 from the cement pro- exhibition reception. US$3trn in debt so the money might not materialise duction (sorbent technology, membrane, cryogenic) in the end. The cement intensity of the infrastructure and many uses for the CO2 captured (fuels, plastics, 8: CCC Group’s team proudly spending is also in some doubt. Ed, in summary, was fertilisers, enhanced oil recovery, aggregates), in- awaiting more visitors to their not optimistic on the real near-term cement industry cluding accelerating the strength gain of concrete stand. Left to right: Randy Shepler, Arvid Oehlke, John Love effects of any Trump Infrastructure Bill. However, he through the formation of nano-scale nucleation sites and Peter Banak. CCC also hosted forecast that without significant new capacity in the in the concrete mix. Through dosing around 200g of an evening hospitality suite US, even with imports, that around 2030 the country CO2 into a concrete mix, the use of around 9kg of during the show. may face shortages of cement. cement per cubic metre of concrete can be avoided. 9: Cement Alliance: left to right, The rest of the conference featured parallel Lance Clarke, environmental manager at the Josef Keuschnig (PM-Technol- sessions, and here we concentrate on selected pres- Roanoke cement plant, next spoke about environ- ogies), Andreas Anderl (M.A.L. entations. mental initiatives at the plant. He suggested that Umwelttechnik), stand visitor John Kline of Kline Consulting next spoke on the first and most important step to maintaining a Kevin Blankenship (Saxum Engi- neering), Thomas Hacker, Carlos the capture of CO2 from the cement industry and its licence to operate is transparency: don’t avoid the Chavez (Refractarios Altran), reuse in the concrete industry. Carbon pricing covers neighbours, welcome them; hold open houses- it Reinhard Ringdorfer (Unitherm), around 25% of the world’s emissions, and John sug- forces good housekeeping at the plant; provide local Emanuele Stancenelli (Euromecc)and Alex Lederer (Unitherm). 13. DALOG Diagnosesysteme’s condition monitoring team spearheaded by left 14: Smiles from Di Matteo and KIMA Process: Left to right, Dirk Schmidt, KIMA, to right: Franz Muschaweck, Birgit Muschaweck and Christoph Muschaweck. and Di Matteo’s Svetoslav Chopov, Rafael Castan, Andreas Sennekowski. 10: Cement and gypsum experts Claudius Peters Americas. Left to right: Ryan Hogan, Rob Hetrick 13 14 and Henrik Wetegrove.

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

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

52 Global Cement Magazine June 2018 AMH Test May 2018.indd 1 24/05/2018 13:28 GLOBAL CEMENT: EVENT REVIEW

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15: Ugras Akay (centre) of cooler guru Fons Technology information and outreach through regular commu- define SRF, which is ‘intentionally produced with International and Samim Cenk nications. The plant has also stocked an old quarry respect to quality criteria,’ whereas RDF is usually a Alpaslan (right), in discussion pond with trout and keeps bees on the plant site, as remaining fraction from waste treatment operations. with a visitor to plant expert DAL Technik Makina’s stand. well as operating an outdoor classroom facility for Producers of SRF control the production process so local children. The plant continues to have good rela- that the fuel meets the desired specifications, while tions with its close neighbours and stakeholders. RDF is a non-specified waste. SRF has an energy 16: Juan Quintero (left) and John Stefan Laux of Praxair next spoke on the use of a value of 16-20MJ/kg. Stewart (right), of emissions lance to inject hot oxygen into the kiln to reduce NOx Xavier d’Hubert next gave an overview of kiln monitoring specialist ENOTEC and CO emissions. A small amount of fuel is used to burners with an eye on the possibility of using more GmbH smile for the camera. preheat the oxygen, to around 1370-1650°C, to form alternative fuels (AF). Burners have evolved over a high-momentum highly-reactive hot oxygen jet. the years, and since the 2000s they have trended The high velocity oxygen jet, positioned at the kiln towards increased use of AF. A bewildering array 17: FCT Combustion’s managing director Con Manias (far left) in inlet, rapidly entrains surrounding gases, oxidising of options are available and the choice of burners discussion while FCT Combus- CO and reducing the levels of NOx. The approach can will depend on the alternative fuels that are avail- tion’s Adriano Greco (centre, be used alongside SNCR or SCR but has a low capex able. The Notar gasification reactor is an option for facing away) and David Rapson and no toxic ammonia reagents. non-direct combustion of alternative fuels, which is of FCT ACTech, (centre facing) welcome numerous visitors. The first presenter in a session on ‘engineered perhaps the next step onwards from the Hotdisk and fuels’ was Frederick De Raedt of Alterros, who Polysius Step Combustor options for burning bulky quoted European standard EN15359 in order to alternative fuels. 18: All smiles from France’s cement expert The Fives Group! Left to right: Max Vaccaro, Yan Huerre, Julien Rickeboer, Lars 18 19 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 21: Laboratory specialist Herzog Automation’s 22: John King Chain Ltd’s Oliver Wadsworth (left) stand throughout the show. stand: Yolanda Escalante (right) and Bruce Weak- and Will Wadsworth (right) reported a pleasing land (left) had a successful event in Nashville. number of enquiries at the show.

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27: Wear protection experts Wear-Con proudly manned the stand at 28: Tomas Zrostlik of gearbox specialist Wikov Gear, this year’s show: Front row, Dennis Todd, right, Cindy Todd, left. Back Czechia. The company has opened a new office in the US. row left to right, Lisa Huey, James Huey, Chris Booz, Corey Booz.

23: The team from HMC Gears Ty Howard, plant manager of the LafargeHolcim then one frame per second is retained for 60 days, made some good contacts. Devil’s Slide plant in Utah, spoke about the consid- unless an ‘event’ marker is placed on the system, erations for the use of engineered fuels at the plant, whereupon the event will be retained in full. which include air permit conditions, the heat value of Thomas Walter of Siemens AG pointed out the availability of the fuel, market conditions, effects five mega-trends that will influence the cement in- 24: Grinding gurus Loesche were on process parameters and performance in conjunc- dustry: urbanisation, population growth, climate flying the flag with, left to right, tion with other fuels. The plant uses a variety of AFs change, globalisation and digitalisation. By 2020, Jürgen Triep, Eduardo Garcia and including tyre chips, nylon fluff and waste plastics. 40Zettabytes of data will be created each year, with Thomas Leppak. In an ‘automation’ session, Alistair Brown spoke a zettabyte being 1 billion terabytes, from 50 billion on behalf of Thermoteknix, on video storage chal- connected devices. Alongside these trends other 25: Kurt Robinson, left, and Erik lenges with high-frame-rate high-definition video. In drivers will influence the cement industry, including Matheson, right, manned the fact, his company’s kiln camera generates 105MB of health and safety, costs and production efficiency. much-visited Webster Industries data per second, or 7TB per day. Compression helps The Internet of Things (IoT) response to these chal- stand. by reducing data volume by 97.5%, down to 2.5MB lenges is increased automation and instrumentation, per second, although this still means 50-100TB of engineering software for the entire plant lifecycle, data to store per year. In fact, using ‘intelligent stor- improved networks, secure data storage and trans- 26: During a coffee break age management’ to manage and automate storage, mission, and software platforms to store and analyse between lectures Felix Bartknecht, left, of Sick AG and the full resolution data is retained for a week, and the data. At the moment there are distinct ‘data Karsten Horn, right, of Inform GmbH pause for Global Cement’s camera. 29 30 29: Chain expert KettenWulf was flying the flag again this year. The stand was manned by Diego Herrero (left) and Scott Martin (right).

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

56 Global Cement Magazine June 2018 GLOBAL CEMENT: EVENT REVIEW

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34: Environmental specialist Scheuch’s Alois Hermandinger (left) and 35: Joe Riley (centre) of STM EcoSystems, flanked by STM’s 36: UNICAST’s Steve Kirschner (far right) and Andreas Gangl (right) in perfect colour-coding at their stand. Michael Kelaher (right) and Cornelia Cretiu of Solvay (left). Dan Kowarski (second from left), welcome visitors to their stand.

31: Charley Kinsey of McDonough’s Elevators, neighbour to 33: Multi Queen’s Award for islands’ that do not talk to each other, in terms of raw Global Cement this year, recently completed installation of a new elevator Export winner Thermoteknix system at a cement plant in North West USA. Systems Ltd exhibited and materials, suppliers, production and maintenance, presented successfully at the logistics and real-time information about supply 32: Michael Thiel of NGC Transmissions reported good footfall at the stand event. Right, Alistair Brown, left, and demand from customers. Upon full digitalisa- with some interesting enquiries received. Bob Blocksidge. tion, these islands will be fully connected, and able to talk to each other in real time. Application of big 37: Anis Haider of ITECA (left) in data analysis and artificial intelligence to the digital- discussion with Daniel Uttelbach, KHD Humboldt Wedag (right). ised system will enable optimisation ‘from quarry Scan the QR code below or enter the bit.ly to customer.’ code into your browser to read more about the IEEE-IAS/PCA Cement Industry Technical Second day 38: Davide Gambarotta of bulk Conference and see the conference video... handling expert MDG Handling On the second day of the conference, the Portland Systems, poses for the camera. Cement Association’s chairman Allen Hamblen spoke about the importance of resilience - an attrib- See more ute that concrete construction has in abundance. The http://bit.ly/ 39: Dominik Stracke, right, and 2017 cost of damage from floods, hurricanes, torna- 2shzgA6 left, Carlos Soteldo of chain professional Kobo USA had a dos and fires in the US was over US$300bn and Allen successful exhibition. strongly advocated the use of resilient...

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Global Cement Magazine June 2018 57 GLOBAL CEMENT NEWS: ASIA Contents Subscribe Ad Index

Japan: Sumitomo Osaka sales pick up India: Ultratech’s sales up 34% in Q4 umitomo Osaka Cement’s net sales rose by 4.6% ltratech Cement’s consolidated net sales rose Syear-on-year to US$2.24bn in the financial year Uby 34% year-on-year to US$1.39bn in the fourth that ended on 31 March 2018 from US$2.14bn in the quarter of its 2017 financial year from US$1.04bn in same period of the previous year. It attributed the in- the same period in the previous year. Its profit before crease to higher sales volumes of cement. However, interest, depreciation and taxation increased by 20% to its operating income fell by 15.6% to US$92m from US$283m from US$236m. US$113m due to higher coal prices. The company The group benefitted from its acquisition of assets said that overall local demand in the country rose by from Jaiprakash Associates in mid-2017. Its cement 0.2% to 42Mt during the reporting period. Exports production capacity grew by 28% to 85Mt/yr from rose by 2.4% to 11.8Mt. 66.3Mt/yr. However, its capacity utilisation rate fell slightly to 80% from 82%. Its local Indonesia: Lucky sales rose by 32% to 17.6Mt earnings fall from 13.4Mt and exports increased by 15% to 0.82Mt ucky Cement’s earn- from 0.72Mt. The cement Lings before interest, producer also warned that a taxation, depreciation rise in petcoke and coal prices and amortisation (EBITDA) following a government ban fell by 21.6% year-on-year had caused its input costs to to US$114m in the nine inflate during the quarter. months of its financial year to the end of March 2018 from US$145m in China: CNBM rev- the same period in 2016. enue rises by 40% It noted that its cost of sales rose by 16.9% due hina National Building to rising coal and other CMaterials’ operating reve- fuel prices. Its gross rev- nue rose by 40% year-on-year enue rose by 7.1% to US$439m from US$410m. to US$394m in the first quarter of 2018 from US$281m Cement production rose by 11.1% to 5.79Mt in the same period of 2017. Its net profit more than tri- from 5.2Mt. pled to US$77.4m from US$23.6m. 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 Philippines: Eagle Cement’s first country. Approvals from the government have been quarter grows on efficiency gains secured. The US$152m upgrade project is scheduled to be completed by the fourth quarter of 2019. It is agle Cement’s profit for the first quarter of 2018 grew also building a US$109m integrated cement plant Edue to higher sales volume and efficiency gains. Its at Samawah in Iraq. The joint-venture project with a net profit rose by 3% year-on-year to US$21.3m. Its local partner will have a cement production capacity sales revenue rose by 6% to US$77.4m. The cement proof 1.2Mt/yr when operational. Commercial produc- ducer attributed its increase in sales volume to efficient tion is currently scheduled for end of 2019. production methods at its plant.

Thailand: SCG helped by rising prices Indonesia: Semen Indonesia’s profit falls due to fuel costs CG’s cement business earnings have risen due to Shigher local prices and cost savings in the first emen Indonesia’s net profit fell by 45% year-on- quarter of 2018. Its earnings before interest, taxation, Syear to US$29.6m in the first quarter of 2018 from depreciation and amortisation (EBTIDA) rose by 7% US$54m in the same period in 2017. It blamed the de- year-on-year to US$201m in the first quarter of 2018 cline on fuel costs and rising debt payments, according from US$195m in the same period of 2017. The com- to Reuters. Despite this, its sales revenue rose by 3.4% pany said that local demand for cement remained to US$476m from US$460m. Its cement sales volumes flat in the reporting period as increased demand rose by 4% to 6.79Mt from 6.53Mt. The majority of this from the government sector balanced out declines rise came from exports, which increased by 44.9% to elsewhere. Local exports rose by 20% to 1.2Mt. 0.6Mt from 0.41Mt.

58 Global Cement Magazine June 2018 NEWS: ASIA

New Zealand: Golden Bay shipping switch „ olden Bay Cement plans to start The Vicat - King“ Gshipping cement directly from its in- German production tegrated plant at Whangarei, Northland in the North Island. Previously, cement from excellent performance 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. Vicat apparatus, different models acc. to EN, DIN, ASTM, BS

Automatic Vicat apparatus acc. to EN 196-3, DIN 1164, Kyrgyzstan: Production rises ASTM C187 230 V / 50 Hz, ata from the National Statistics Com- Dmittee shows that cement producers with delay timer in Kyrgyzstan manufactured 1.5Mt of cement in 2017. The country produced 1.3Mt in 2016 and 1.5Mt in 2015.

Afghanistan: Plant tender Computer controlled Vicat apparatus he Ministry of Mines & Petroleum plans with 6 or 8 measuring places Tto re-issue a tender for the Jabal Saraj acc. to EN 196-3, EN 480-2, cement plant. The winning company will have to invest US$170m into the project ASTM 191, test method B to build a 1Mt/yr plant, according to Tolo 230 V / 50 Hz 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

ongyang Networks plans to sell its Tstake 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. TESTING Bluhm & Feuerherdt GmbH Motzener Straße 26b • 12277 Berlin / Germany Phone: +49 30 710 96 45-0 Global Cement Magazine June 2018 59 www.testing.de • [email protected] GLOBAL CEMENT NEWS: ASIA

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

he National Company Law Tribunal (NCLT) has asked the TCommittee 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- India: Shree plan moves forward traTech Cement’s offer in mid-April 2018. UltraTech Cement has since made a raised offer to the resolution professional he Ministry of Environment, Forest and handling the insolvency process of Binani Cement. TClimate 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 Pakistan: Dewan rejects Mega bid heat recovery unit, a captive power plant, a synthetic gypsum unit and a railway terminal. ewan Cement has rejected a takeover bid by Mega The unit will be built near Maldo, Lakhpat tehsil DConglomerate to buy a 87.5% stake in it. Chairman in Kachchh district. Limestone for the plant will Dewan Mohammad Yousuf Farooqui turned down the come from a quarry next to the proposed site. offer following a valuation of the company. The valuation 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 Pakistan: GE Power to supply need for investment at the sites. The company reports that Power Cement negotiations with Mega are continuing. E Power has won a contract to design, manu- Gfacture and deliver a 132/6.3kV air-insulated Vietnam: New plant for Vinaconex switchgear (AIS) grid station to support a new production line being built at Power Cement’s joint venture between Vinaconex Engineering Con- plant in Nooriabad. The project is expected to be Astruction and Investment and Lilama will supply completed in early 2019. It will supply the cement US$66m of equipment for the Tan Thang cement plant plant with a reliable electricity supply from the in Nghe An province. The new plant will have a cement Hyderabad Electric Supply Company. production capacity of 2Mt/yr. Vinaconex and Lilama will join European companies Bedeschi and FLSmidth on the project. Pakistan: Gharibwal starts mill

haribwal Cement has started commercial Sri Lanka: Tokyo launches Goperation of a 250t/hr vertical cement mill resource-planning software for grinding cement. It says it is the single largest cement grinding mill in the country. The cement okyo Cement has launched resource-planning soft- producer operates a 2.1Mt/yr integrated plant at Tware across its business. The software was developed Ismailwal in Chakwal. by Abas and implemented by Providence Global, according to the Daily News newspaper. The software is being deployed across all of Tokyo Cement’s operations, includ- Bangladesh: Two dead at Crown ing its cement plant at Trincomalee, its ready-mix concrete plants and its bulk cement import terminal and biomass wo workers were killed and a third critically power generation units. The new software is intended to Tinjured at Crown Cement’s grinding plant in fully integrate supply chain management and warehouse Paschim Muktarpur in Munshiganj on 14 May 2018. operations. They died after being struck by falling material when entering a room at the site to clean it.

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

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.

Cement plant process walk-through he mineral-rich Salt Range is certainly not just Tcomposed of salt, although it contains three The plant has its own limestone quarry, with a lease large and famous salt mines of Khewra, Kalabagh area of 6798 acres, as well as an argillaceous clay and Warcha. Coal is also found in the Salt Range, quarry on site. The present working area of the but what brings cement producers to the region is its quarry is 1.35km2, and total reserves of limestone are high-quality limestone, as well as its strategic posi- around 646Mt. tion in the developing north of Pakistan and the fact The limestone crusher at Khairpur has a capacity that it is now well-connected with the world-class of 1500t/hr, sending material to a limestone storage M2 motorway, which winds it way up steep inclines shed with total capacity of 90,000t. An FLSmidth 52.5 into the hills around the famous salt-water lake and Atox mill, fitted with an RAR-LVT 52.5 air-separator, nature reserve at Kallar Kahar from the vast plain is used for grinding raw materials at a rate of 500t/ of the Punjab below. Indeed, so rich are the hills in hr. Prior to the pyro-system, materials are stored and limestone that the twin cement plants of Bestway Ce- homogenised in a CF silo with capacity of 25,500t of ment, and the Dandot Cement Factory near Tobar, raw meal. The plant uses a two-pier Rotax-2 kiln with 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 Right: A Caterpillar dump truck being filled with limestone in businesses including cement, textiles and banking. the plant’s quarry, by a Caterpil- Global Cement recently visited the Khairpur plant lar tracked back-hoe excavator. 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, Below: An overview of the plant and started production in 2007. The plant was of- and of part of the quarry, set in the deeply-incised landscape of ficially inaugurated by the then prime minister of the Salt Range. Pakistan, Shaukat Aziz. The plant capacity is around 6700t/day of clinker, or 2.21Mt/year, with cement production capacity of 2.43Mt/year.

62 Global Cement Magazine June 2018 GLOBAL CEMENT: PLANT VISIT

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 Left: The Wasabi Energy/ kiln during shutdowns. Clinker is transported by pan FLSmidth 8.6MW Kalina Cycle conveyor to the mammoth clinker storage silo, with waste heat recovery plant at the a capacity of 110,000t of clinker. The two OK 36-4 Khairpur cement plant. 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 water, a standard back-pressure turbine can be used. Ventomatic rotary packers operating at 12,000 50kg In contrast to the Rankine Cycle, the non-isother- bags per hour, while there are also 12 loading posi- mal boiling that results from the use of a binary fluid tions for trucks. Three bulk loaders are available for with variable composition gives a good match with delivery of 600t/hr of bulk cement, in parallel. the thermal characteristics of the HRVG so that more of the heat can be extracted from the energy source Waste heat power generation to enhance the efficiency of the process. Similar The DG Khan Cement plant at Khairpur has a total considerations apply at the condensing end of the power requirement of 31MW, which cannot always power cycle. By selecting a suitable ratio of the two reliably be supplied by the national grid. In order components that form the working fluid, the boiling to give the manufacturing facility an uninterrupted point can be adjusted to suit the temperature of the supply of power, DG Khan Cement has installed heat source and extract the maximum amount of two captive power plants. Firstly, the plant features heat. With this characteristic, of being able to take a Kalina Cycle-based waste heat recovery plant with full advantage of the temperature differential be- power production capacity of 8.6MW, manufactured tween heat source and heat sink, the process is ideally by FLSmidth of Denmark. Wasabi Energy provided suited for extraction of useful heat from low-grade FLSmidth with front-end engineering design (FEED), sources such as is found at a cement plant. Efficiency procurement and commissioning services in relation improvements of 15-50% are claimed for this type to the Kalina Cycle® technology. The Kalina Cycle1 of application. process uses a binary working fluid of ammonia and The waste heat recovery system at Khairpur has a water with proprietary and patented processes for fluid temperature of 340°C and recovers waste heat varying the ammonia concentration throughout the from the preheater and from the clinker cooler using system and for heat-recuperative stages for increased the patented Kalina Cycle KCS1-2A system specially efficiency. The use of ammonia permits efficient use developed for the cement industry. of waste heat streams allowing boiling to start at lower temperatures. A binary fluid allows the composition Combustion-engine power plant of the working fluid to be varied through the use of Secondly, the plant’s other captive power generation distillation, providing a richer concentration through unit was provided by Wärtsilä of Finland and consists the Heat Recovery Vapour Generator (HRVG) and of two 18-cylinder dual-fuel natural gas and heavy leaner composition in the low-pressure condenser. As fuel oil Wärtsilä 50DF internal combustion engine the molecular weight of ammonia is close to that of electrical power generation units, with a combined

Global Cement Magazine June 2018 63 GLOBAL CEMENT: PLANT VISIT

maximum power output of 33MW. Each Wärtsilä months. Furthermore, operating an independent unit can produce up to 16.64MWe in continuous power plant for a cement works is advantageous base-load operation with a heat rate of 7608kJ/kWh, when starting the large motors commonly used in which is equivalent to an overall thermal efficiency of cement mills with their sudden high starting cur- 47.3% at the busbars. The Wärtsilä 50DF lean-burn rents. These requirements are all ideally met by the dual-fuel engine has become popular for power plant Wärtsilä 50DF.” installations in a number of countries. It is one of “When running on natural gas, the gas fuel is the most powerful gas-burning engines on the mar- supplied at a low pressure (less than five bar) and ket today and has both low emissions and high fuel the engine operates on the lean-burn Otto process. efficiency which make it a competitive alternative to Gas is admitted into the air inlet channels of the gas turbines. individual cylinders during the intake stroke to give According to Wärtsilä, “Important factors in the a lean, premixed air-gas mixture in the engine com- choice of engine were the need for a reliable, cost- bustion chambers. Reliable ignition is obtained by effective electricity supply to the cement-making injecting a small quantity of diesel oil directly into process, with flexibility in the choice of fuel. Fuel the combustion chambers as pilot fuel, which ignites flexibility is an important factor in Pakistan as the by compression ignition as in a conventional diesel year-round supply of natural gas cannot be guar- engine. This ‘micro-pilot’ injection uses less than 1% anteed, particularly during high demand in winter 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.

64 Global Cement Magazine June 2018 GLOBAL CEMENT: PLANT VISIT

kiln firing, using solid municipal waste and other industrial and agricultural wastes. The Left: The plant is compact plant uses an Eldan Recycling and still smart despite its high pre-chopper/shredder, screen, capacity utilisation rate. wind-sifter and a further Veco- plan shredder, fitted with SSAB

load. Electronic control closely regulates the ‘micro-pilot’ injection Below: Position of the Khairpur plant, in relation to system and air-gas ratio to keep the main cities of Pakistan and significant projects in the Chinese-backed Pakistan Economic Corridor. each cylinder at its correct operating point between the knock and misfir- ing limits. • Islamabad In the ‘diesel’ mode, the engines run on liquid fuel oil such as heavy • Khairpur fuel oil as in a conventional diesel • Lahore engine. The engines are fully capable 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 deliver full power. When the situation returns to normal it is then possible to switch back to gas mode.”

Alternative fuels use Khairpur is also a leader in Pakistan • Gwadar • Karachi in the use of alternative fuels for

Global Cement Magazine June 2018 65 GLOBAL CEMENT: PLANT VISIT

ciner floor before being injected into the calciner combustion chamber, controlled through Schenck weigh-feeders. Right: The Vecoplan shredder, fitted with SSAB Hardox wear- Bag production at resistant steel hoppers to cope with abrasive RDF. Khairpur The plant site also has its own bag manufacturing 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- Hardox wear-resistant steel hoppers to duction of bags for other 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 Right: The Eldan Recycling pre-chopper/shredder used at husk, corn cob, wheat straw, bagasse; tex- Khairpur for processing of RDF. 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 alternative fuels are then extracted using a double screw conveyor and are taken using a Vecobelt pipe conveyor to the cal-

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

66 Global Cement Magazine June 2018 GLOBAL CEMENT: PLANT VISIT

the droughts which are common in the otherwise lovely area. Regular internships and training programmes are made available for students and locals at the cement Left: A Brokk 330 remote- plant. controlled demolition robot is used to de-brick the kiln Green and pleasant land during shutdowns. Notably, 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 agricultural and fruit fields for growing its own

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 Left: A pair of PANalytical four plies could be used), while the AD 2390 CubiX Pro XRD and CubiX XRF machines for quality control at sack bottomer is also used on the lines. Twin Khairpur cement plant. 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

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 Left: A view into the kiln at doubt attracted by the warmth of the pyroprocess, Khairpur. 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 its competitors, including Bestway Cement, Falcon 2. Validation of the CDM-project: substitution of coal with alternate Cement, Dewan Cement Ltd, Lucky Cement, Kohat fuels at DG Khan Cement Company Limited, Khairpur Plant, Cement and Maple Leaf Cement. The three lines have Report 1577385, TÜV SÜD Industrie Service GmbH a capacity of 190 million bags each year.

Production and social responsibility The Khairpur plant produces Ordinary Portland Cement and Sulphate Resistant Cement, which are sold locally as well as being exported. The DG Khan Left: Common Myna birds Cement Khairpur facility is ISO certified for Quality gathering at dusk on the warm Management Systems to ISO 9001:2015 and for Envi- preheater tower. 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

Global Cement Magazine June 2018 67 GLOBAL CEMENT: PLANT VISIT

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.

68 Global Cement Magazine June 2018 GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA

Syria: Lafarge security chief charged Alongside the investigation two non-governmental Contents with financing terrorism organisations, Sherpa and the European Center for Constitutional and Human Rights (ECCHR), are now Subscribe acob Waerness, the former security chief at Lafarge arguing that Lafarge should be indicted for complic- JSyria, was arrested by French Police in early May ity in crimes against humanity. They have made the Ad Index 2018 while transferring between planes at the Charles argument for the accusation in a memorandum to the de Gaulle airport on charges of financing terrorism. investigative judges examining Lafarge Syria’s conduct. The arrest follows a number of arrests of high-profile Despite the indictment of several Lafarge executives employees of the former Lafarge as part of an ongo- the NGOs want the charges to apply to Lafarge itself as ing investigation into the alleged financing of armed a company. groups, including the so-called Islamic State (IS), by the company in Syria in the early 2010s. Waerness worked Syria: France sought to protect Lafarge as the head of security for Lafarge in Syria from 2011 to 2013. he French government reportedly asked the US Tnot 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.

Saudi Arabia: Southern Province’s sales Malawi: Shayona to double capacity down in first quarter of 2018 hayona Cement plans to more than double outhern Province Cement’s sales fell by 9.6% year- Sproduction at its integrated plant at Kasungu Son-year to US$73m in the first quarter of 2018 from in Lilongwe from 1200t/day to 3000t/day. It is also US$80.8m in the same period in 2017. Its net profit fell considering expansion to other countries in Africa. by 2.9% to US$27.2m from US$28m. It blamed the falling sales and profit on decreased demand. Qatar: Three years accident free

Saudi Arabia: UCC resumes exports lkhalij Cement, a subsidiary of Qatari Investors to Bahrain AGroup, has reached three years or 3.5 million hours without accidents, at its plant in Umm Bab. he United Cement Company (UCC) has resumed im- The company said that achievement showed that Tporting cement from Saudi Arabia to Bahrain. UCC its employees had followed safety rules with dedi- chief executive Faisal Shehab said that since the Saudi cation and reliability. Alkhalij Cement operates an government lifted cement tariffs in February 2018 it had integrated plant with a clinker production capacity imported up to 60,000t of cement. Shehab estimated that of 6000t/day. his company supplies 70% of the construction market in Bahrain.

Egypt: New cement bag plant proposed

Saudi Arabian company plans to build a US$28m paper Abag 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.

Global Cement Magazine June 2018 69 GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA

Kenya: First fall in cement consumption since 2000

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

Nigeria: Dangote exports 0.2Mt in Q1 Algeria: GICA exports to Europe

angote Cement exported 0.21Mt of cement to Ghana, roupe des Ciments d’Algérie’s (GICA) has DTogo and Niger from Nigeria in the first quarter of Gmade its first export to Europe. The Ministry of 2018. The company’s revenue for the quarter grew by 16% Industry and Mines said that 45,000t of cement year-on-year to US$668m from US$575m. Its profit in- was exported to Europe via GICA’s building ma- creased by 29% to US$199m from US$154m a year earlier. terials distribution subsidiary. The consignment Cement sales for the quarter rose by 2.8% to 6.2Mt from was the last part of a contract to export 0.2Mt of 6.03Mt in the first quarter of 2018. cement to Europe.

Morocco: CBMI plant for LafargeHolcim Ivory Coast: CIMAF starts project

hina’s CBMI has signed a contract with LafargeHolcim orocco’s Ciments de l’Afrique (CIMAF) has Cto build a cement grinding plant near Agadir. The deal Mstarted work on a 0.3Mt/yr cement plant at for the SSS 13 & 14 Grinding Plant EPC Contract was signed Bouake. The company has acquired land for the on 21 March 2018 at the LafargeHolcim Technology Centre project and is currently preparing the necessary in Lyon, France. Once operational the plant will be run by permits to begin construction, according to the LafargeHolcim Maroc. African Press Agency. CIMAF built its first 0.5Mt grinding plant in Abidjan in 2013. The production capacity at this Ghana: Cimpor and ETE Group work unit was then increased to 1Mt/yr in 2016. In late together on clinker shipments 2017 the cement producer started building a second 1Mt/yr plant at San Pedro. The latest project at impor and ETE Group have collaborated to export Bouake will be its third plant in the country. C55,900t 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 Uganda: Rail project trouble a bulk carrier at the Port of Lisbon. ocal cement producers are facing a challenge Lto meet the specification required for cement Uganda: FCKS sells Yetu cement in Luau being used by the Standard Gauge Railway (SGR) project. Project coordinator Kasingye Ky- abrica de Cimento do Kwanza Sul (FCKS) has started amugambi said at a procurement conference in Fselling its Yetu cement product in Luau, Moxico prov- Kampala that the project was facing issues with ince. 400t of the product has been transported via the cement, reinforcement steel and sand, according Benguela railway as part of a sales expansion drive. 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.

70 Global Cement Magazine June 2018 AUCBM June 2018.indd 1 22/05/2018 16:03 GLOBAL CEMENT MAGAZINE: PRICES Contents Subscribe Ad Index

Egypt: Ordinary Portland Cement prices as of 21 May 2018: Arabian Cement (Al Here Global Cement Magazine presents its Mosalah) = US$46.08/t; Arabian Ce- monthly review of global cement prices, in ment (Al Nasr) = US$44.69/t; Cemex US$ for easy comparison. Additional price (Al Muhandis) = US$45.80/t; Building information is only available to subscribers Materials Industries (Altaamir) = to Global Cement Magazine. Subscribe on US$44.97/t; Elnahda Cement (Al Page 96. In this issue subscribers receive Sakhrah) = US$44.58/t; Wadi El information from more countries, including Nile Cement = US$44.97/t; Lafarge Uzbekistan, Uganda, India, South Africa, (Al Makhsous) = US$45.25/t; Arish Pakistan and China. Cement (Alaskary) = US$45.25/t; Arish Cement (Askary Bany Suef) = Prices are for metric tonnes (Mt), unless US$45.25/t; Sinai Cement = US$44.97/t; stated otherwise. US$ conversions from Suez Cement = US$45.81/t; Tourah Port- local currencies are correct at the time of land Cement = US$46.53/t; Helwan Cement original publication. = 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 Mthembu, Cimerwa’s chief executive officer, said, White Cement (Alabid Elnada) = US$124.57/t; “The upgrade and maintenance caused a lot of Sinai White Cement (Super Sinai) = US$125.42/t; anxiety and pressure in the market place, with El Menya Cement (Super Royal) = US$122.90/t; some people taking advantage to speculate on Menya Helwan Cement = US$122.90/t. cement prices.” Blended cement prices as of 21 May 2018: Sinai There is a backlog of nearly 5000t of unmet de- Cement (Alnakheel) = US$41.90/t; Helwan Cement mand from consumers that had requested cement (Alwaha) = US$42.62/t. Sulphate-resistant cement during the shutdown. prices as of 21 May 2018: Cemex (Almukawem) = US$46.19/t; Lafarge (Kaher Albehar) = US$48.26/t; Guinea: A shortage of cement at the start of May Suez Cement (Al Suez Sea Water) = US$47.86/t; El 2018 led to prices in Mamou rising to US$8.36/bag Sewedy Cement = US$47.86/t. (50kg), rather than the previous level of US$6.71/ bag, a 25% rise in just a week. This has led to stop- Rwanda: In just a matter of weeks the price of a page of work at many sites in the city. 50kg bag of Cimerwa cement in Kigali rose from Some cement dealers have claimed a lack of US$10.00/bag to US$13.80/bag. Imported ce- raw materials, as only three of the four cement ment prices also increased from US$9.78/bag to plants in the country are currently making cement. US$12.08/bag. Outside of the capital in areas such as Gat- Zambia: The average price of 32.5 N cement across sibo District, Cimerwa cement prices rose Zambia at the start of May 2018 was US$7.08/bag from US$10.00/bag to US$14.95/bag, while (50kg), according to our correspondent. The price imported cement increased in price from of 42.5 N cement was US$7.28/bag. Prices have US$9.78/bag to US$12.65/bag. been broadly stable in local currency terms since Cimerwa said that the shortage was caused by February 2018, although they have changed sig- temporary shutdown of its plant in Bugarama, in nificantly in US Dollar terms due to Rusizi District due to annual maintenance. Bheki currency fluctuations.

Bahrain: The price of cement in Bahrain is roughly US$71.53- Do you have your finger on the cement 79.48/t. price pulse where you are? If so, Global Cement Magazine needs you! Kyrgyzstan: Cement is sold Contact: Peter Edwards at US$3.36/ [email protected] bag to US$4.97/ bag (50kg) in Regular contributors receive a free Kyrgyzstan, de- subscription to Global Cement Magazine! pending on the location and type of cement.

72 Global Cement Magazine June 2018 Contents Subscribe Ad Index GLOBAL CEMENT: THE LAST WORD

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

Robert McCaffrey Editorial Director, Global Cement Magazine ([email protected])

ompany annual reports can sometimes be a turgid Sustainability risk: ‘The cement industry is associ- Cread, but every now and again they may include an ated with significant negative externalities, notably high exciting flash of something interesting, almost like see- CO2 emissions - By 2030 LH aims to reduce net CO2/ ing the flash of a metallic-blue kingfisher darting along tonne of cement by 40% compared to 1990 levels, and a non-descript and over-grown ditch. However, the advocates a carbon price, while increasingly aiming the recent LafargeHolcim (LH) Annual Report 2017 was business towards sustainable products and solutions; a very interesting read throughout, and nowhere more Political risk: Due to political instability in its op- so than in the section on ‘Risk management,’ especially erating markets - LH believes that diversification is the after its recent and ongoing travails in regards to the key response, and is politically neutral; operation of its cement plant in Syria (see Page 69). Talent risks: Does the company have enough of a The company explains that the Group’s ‘risk map’ is ‘talent pipeline’ for its global ambitions? - LH evaluates established on the basis of ‘strategic, operational and talent in its staff and invests in talent development; topical risk assessments’ to form a Group risk report, on Cyber risk: LH has established a Group cyber- the basis of several steps; Risks are assessed and priori- security roadmap to protect critical assets from cyber tised according to their significance and likelihood: Top attacks and to improve its cyber resilience; risks are analysed more deeply regarding their causes; JV and associate risks: LH says that where it does Risk mitigating actions are defined. Risk management not have a controlling interest, there may be a restric- is a line-manager’s responsibility, backed-up by Group tion of its ability to generate adequate returns and to Risk Management and with ‘internal audit’ as a third ensure its compliance programmes are adhered-to line of defence. - which it says it seeks to manage through formal agree- In its annual report, LafargeHolcim lays out the re- ments with the companies in question; sults of this risk management exercise for us all to see. Goodwill and asset impairment: Significant under- In no particular order, the company’s greatest risks are: performance of any unit - LH says it monitors units on Market demand risks: changes in demand leading a timely basis, or when a ‘triggering event materialises;’ to changes in pricing and/or industry structure - LH Financial risks: Including liquidity, interest rates, says that it maintains a globally-diversified portfolio, foreign exchange and credit risk, possibly causing a with top-3 positions in 80% of its markets, and that it downgrade of the Group’s credit rating and the avail- trades in clinker, cement and other products to take ability and cost of future funding - buried deep in the advantage of shifting demand between countries; Annual Report, it says that a 1% change in interest rates Legal and compliance risk: such as being found to would cost the group CHF34m (Euro29m); have violated law covering business conduct such as Insurance risks: Not all risks can be insured - LH bribery, corruption, terrorism and unfair competition monitors its status to determine if additional insurance - LH says that it maintains a comprehensive risk-based is required; compliance programme with dedicated resources, Defined benefit pension risk: These pensions are alongside comprehensive training; volatile and the Group may have to pay into them to Energy prices: the risk being that energy costs rise, ‘top them up’ - Where possible, LH has closed such or that certain alternative fuels become unavailable pension schemes and actively manages the remainders. - LH says that fuel mix and energy efficiency are key LafargeHolcim says that ‘additional risks and un- areas of focus for all plants, and that it uses ‘derivative certainties not presently known to LH or that it deems instruments’ to hedge part of its exposure to these risks; immaterial’ may develop into issues as well. Raw materials risk: ‘That raw materials cannot be What, I wonder, would be the impact of a carbon supplied at economical cost or suitable quality’ (eg emission floor price in Europe of Euro20/t of CO2? sand and limestone) - LH says that ‘We apply a range What if the price was set at US$123/t of CO2, according of tactics including strategic sourcing, changing input to a December 2016 ‘worst-case’ estimate of the ‘social mixtures and maintaining minimum long-term reserve cost’ economic impact of the emission of CO2 accord- levels. At Group level our R&D is devoted to finding to the US EPA and other agencies? How would LH ing ways to mitigate this risk while at the same time cope? How would any cement company in the world? lowering our environmental footprint, eg by using 1 https://www.epa.gov/sites/production/files/2016-12/documents/ waste-derived materials’; social_cost_of_carbon_fact_sheet.pdf

Global Cement Magazine June 2018 73 GLOBAL CEMENT MAGAZINE: ADVERTISER INDEX

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KIMA ECHTZEITSYSTEME IS NOW To advertise contact: Editorial contributions: KIMA PROCESS CONTROL MAGAZINE MAGAZINE Paul Brown: +44 (0) 7767 475 998 Peter Edwards: global cement +44 (0) 1372 840 950 [email protected] +44 (0) 1372 840 967 [email protected] Sören Rothfahl: +44 (0) 7850 669 169 [email protected] [email protected]

Advertisers - June 2018 Advanced 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 Christian Pfeiffer 7 [email protected] • www.christianpfeiffer.com Coal Mill Safety Pte Ltd 40 [email protected] • www.coalmillsafety.com Global CemFuels Conference 2019, Amsterdam, Netherlands 21,31 [email protected] • www.cemfuels.com Global Slag Conference 2019, Aachen, Germany IBC [email protected] • www.globalslag.com HARDTOP Gießereitechnologie GmbH & Co. KG 39 [email protected] • www.hardtop-gmbh.de Hillhead Quarrying & Recycling Show 2018 23 [email protected] • www.hillhead.com Intercem Engineering GmbH 41 [email protected] • www.intercem.de KettenWulf IFC [email protected] • www.kettenwulf.com Keith Mfg. Co. 49 [email protected] • www.keithwalkingfloor.com Kima Process GmbH FC [email protected] • www.kima-process.de KORFEZ Engineering OBC [email protected] • www.korfez-eng.de Loesche GmbH 17 [email protected] • www.loesche.com Lubrication Engineers International Ltd 21 [email protected] • www.le-international.com Refractories WORLDFORUM 27 [email protected] • www.refractories-worldforum.com SICIT 2000 SpA 11 [email protected] • www.sicit2000.it Siemens 19 www.siemens.com/cement STM Ecosystems 55 [email protected] • www.stmecosystems.com Testing Bluhm & Feuerherdt GmbH 59 [email protected] • www.testing.de 8th VDZ International Congress, Düsseldorf, Germany 6 [email protected] • www.vdz-congress.com voestalpine Böhler Welding 21 www.voestalpine.com/welding Xavier d’Hubert 29 [email protected]

Next issue: July-August 2018 Advertising deadline: 6 July 2018

Reports: Top 10 Cement Producers; China Technical: Grinding, Fans, Block-chain, Microgrids, Silos, Material Handling Event Preview: VDZ International Congress Event Reviews: Global CemProcess Conference; Hillhead Quarrying & Recycling Show 2018

74 Global Cement Magazine June 2018 34 APRIL 2019 AACHEN, GERMANY

14th CONFERENCE globalslag.com #globalslag gl bal EXHIBITION slag AWARDS 2019 Slag for profit Global Slag Enquiries Improving slag performance Exhibition and sponsorship: New applications for slag [email protected] Programme and speakers: Global slag markets and trading robert.mcca [email protected]

AACHENOrganised by: gl bal TM cement MAGAZINE

Including Global Slag Awards Gala Dinner

Global Slag 2019 FP.indd 1 29/05/2018 17:05 korfez-eng.de

Be open for new solutions and understand change as an opportunity.

Always placing customer needs First, keeps us focused on our mission, to continuously improve ball mills with individual designs, advanced technologies and flexible adaptations to different operating conditions at any time.

Korfez June 2018.indd 1 25/05/2018 09:18