News UK Optimisation DG Khan visit CO2 Grinding Vibration IEEE-IAS/PCA Review Global Slag Crushing Alternative fuels www.globalcement .com gl bal TM Contents Subscribe Ad Index cement JUNE 2018 MAGAZINE WE OPTIMIZE PRECISELY EVEN OUR NAME KIMA ECHTZEITSYSTEME IS NOW KIMA PROCESS CONTROL Experts for the bulk material handling industry Chains & Sprockets made by KettenWulf For over 90 years, KettenWulf, as an expanding global company, has stood for quality, reliability and flexibility. More than 1400 employees develop, manufacture and market customized solutions in the field of conveying and drive technology at ten locations across Europe, America, Australia and Asia. All around the globe, KettenWulf is your strategic partner when it comes to delivering cutting edge product quality. Order our new catalogue online NEW HIGH SPEED CONVEYING FATIGUE STRENGTH LOW MAINTENANCE ENERGY EFFICIENCY MAXIMUM LOAD Central bucket elevator Sprockets for chain with forged link plates bucket elevator KettenWulf Betriebs GmbH T + 49.(0)2973.801-0 [email protected] Zum Hohenstein 15 F + 49.(0)2973.801-228 www.kettenwulf.com 59889 Eslohe-Kückelheim Germany Subscribe Ad Index GLOBAL CEMENT MAGAZINE: DEARNOVEMBER READERS2013 KIMA Echtzeitsysteme GmbH (KIMA Process Control) News UK Optimisation DG Khan visit CO2 Grinding Vibration IEEE-IAS/PCA Review Global Slag Crushing Alternative fuels www.globalcement .com June 2018 gl bal TM TM .com cement gl bal Attention! There are two cement sector companies called JUNE 2018 MAGAZINE cement global ‘KIMA’ from Germany, one called ‘KIMA Automation’ from www. Gronau (automation and electrical systems) and one called WE OPTIMIZE PRECISELY ‘KIMA Echtzeitsysteme’ from Juelich (Advanced Process Control fuels Alternative EVEN OUR NAME Crushing cement MAGAZINE 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 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 MAGAZINE MAGAZINE unexpected kiln stops. Actually KIMA Echtzeitsysteme GmbH cement CemProcess, Global CemPower. global 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 feed- ing system, installed at the Essroc Nazareth plant, USA. 32 Global Slag Conference 2018 - Reviewed Robert McCaffrey reports on the successful 13th edition of the Global Slag Conference, which took place in Prague, Czechia. 37 SCHÜTTGUT now called SOLIDS Dortmund 38 Products and contracts Plug&Grind Vertical for Dunbar; Dangote orders for Gebr. Pfeiffer and Loesche. 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 Hillhead Quarrying & Recycling Show 2018 26-28 June 2018, Buxton, UK www.hillhead.com FICEM Technical Congress 2018 INTER- 3-5 September 2018, Panama City, Panama NATIONAL www.congresotecnico2018.ficem.org RWM Recycling Exhibition 12-13 September 2018, Birmingham, UK VDZ www.rwmexhibition.com 8th International VDZ Congress CONGRESS 26-28 September 2018, Düsseldorf, Germany www.vdz-congress.org BULKEX 2018 Conference & Exhibition 26 – 28 18-19 October 2018, Eastwood, UK September Duesseldorf www.bulkex.co.uk SOLIDS Dortmund 2018 2018 Germany 7-8 November 2018, Dortmund, Germany www.solidsdortmund.com 23rd Arab-International Cement Conference & Exhibition 20-22 November 2018, Amman, Jordan www.aucbm.org 4th Global CemPower Conference & Exhibition 22-23 January 2019, London, UK www.CemPower.com 13th Global CemFuels Conference & Exhibition 20-21 February 2019, Amsterdam, Netherlands www.CemFuels.com 14th Global Slag Conference & Exhibition The VDZ Congress is an international scientifi c forum 3-4 April 2019, Aachen, Germany of the cement industry and its suppliers.