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January 2015

F
WORLD CEMENT January 2015 www.worldcement.com
CONTENTS JANUARY

WORLD CEMENT REGULARS


20 71
05 Comment

09 News

17 Keynote: 2015 A State of Flux


Imran Akram, IA Cement, UK.

77 Product News

80 Regional Report Fact Sheet

REGIONAL REPORT: RUSSIA, CEE & CIS


20 Alternative Fuel Projects at Cement Hranice
Giovanni Battista Auxilia and Stefano Comoglio, Buzzi Unicem,
Italy.

27 Market Developments: Russia, Belarus and ADDITIVES


Kazakhstan
Denis Borodenok and Evgeni Khrustalev, EY, CIS. 55 Latest Advances in Cement Additives
Laurent Guillot and Ray Scott-Taggart, CHRYSO Group, France.
COOLERS
MILL LININGS & WEAR PARTS
34 The Next Evolution in Clinker Cooling
Andreas Hand and Ravi Saksena, KHD Humboldt Wedag, 61 Extreme Wear Resistance
Germany. Alessandro Priami, Fonderia Gelli, Italy.

ALTERNATIVE & CONVENTIONAL 64 Anti-Ageing Solutions


Simona Serban, Castolin Eutectic, Switzerland.
FUELS
39 WDF Solutions WEIGHING, FEEDING & DOSING
Matt Drew, Saxlund International, UK.
67 Grinding Aid and Dense Phase Success
45 Ensuring Consistency Todd Loudin, Flowrox, USA.
Brian McGrath, ResourceCo Asia, Malaysia.
DUST SUPRESSION & CLEAN-UP
49 Dust Explosion Prevention
Mark Dziuba, Yara Industrial GmbH, Germany. 71 Smart Sweeper Selection
Dave Panizzi, ElginSweeper, USA.

74 Silo Cleanout & Air Cannon Technology


Round-up
WORLD CEMENT

News items from Standard Industrie International, Primasonics


and Staminair.
January 2015

January 2015

THIS MONTHS COVER


Within Fives, the Cement|Minerals business line provides pioneering solutions
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in Algeria and Qatar National Cement Co. in Qatar with the signature of two new
contracts on a turnkey basis. Fives is a reliable, enterprising partner for solutions that
deliver ultimate performance.

F Palladian Publications Ltd Volume 46: Number 1


15 South Street, Farnham, Surrey
www.worldcement.com

GU9 7QU, ENGLAND January 2015


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Fax +44 (0)1252 718992
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COMMENT JANUARY

Katherine Guenioui, Editor


Katherine Guenioui@worldcement.com

January is traditionally a time limestone, which seals up the crack. This development
for looking to the future. But could mark the end of potholes a problem that has
let me take you back into the been plaguing travellers since the invention of roads. The
past for just a moment about spending on road maintenance in a little country like the
600years to be precise. The UK runs into billions of pounds annually. With the amount
Ming dynasty was continuing the of repairs needed in countries with extensive road networks
construction of the Great Wall the US, India self-healing concrete would surely be a
of China, which was originally winner, not to mention it would provide another reason to
begun in the 7thcenturyBC, or choose concrete over asphalt.
thereabouts. Life had moved on Weve got plenty more innovations in this issue. In
somewhat in the intervening particular, if youre interested in alternative fuels, we
millennia, and the rammed have articles about solid waste fuels, tyre-derived fuels,
earth and reed construction of sewage sludge and a case study from BuzziUnicem, which
the original walls could now be is utilising a variety of wastes in its process. Were also
updated with more modern technology. Stones and bricks featuring articles looking at nuisance dust, wear and
were used instead of earth and the Chinese developed a abrasion protection, additives and the latest developments
special mortar to hold it all together: a mixture of slaked in cooler technology a little something for everyone.
lime and sticky rice. Apparently the sticky rice accounts for Aside from technical innovations, 2015 is set to be an
both the mortars durability and its bright white colour. interesting year for the cement industry. This month will
Facts like these amaze me. Today we are looking at see companies make their binding bids for the assets of
the use of rice husks as an alternative fuel in cement Lafarge and Holcim being divested as part of their merger,
manufacture and it seems forward-thinking. Six hundred which is set to be finalised in the first half of this year.
years ago, they cooked up the rice and threw it in. Necessity At the time of writing, both UltraTechCementLtd and
is the mother of invention, I suppose. They needed a wall Cementos Argos had withdrawn their bids for assets in
that would hold (pre-cement) and they built one. It makes Brazil, while HeidelbergCement had announced previously
you wonder what else we could be throwing in the mix, that it would not be making a bid for any of the assets up
doesnt it? for sale. We will keep you updated with all the latest news
These days, it seems, the secret ingredient could be on this merger and all the other activity in the cement
bacteria. Scientists at several universities are working on industry at www.worldcement.com. Meanwhile, for a
a specially blended self-healing concrete that contains glimpse into the cement hot-spots for the coming year,
bacteria hidden in tiny capsules. When water drains into a turn to this months keynote article from ImranAkram of
crack in the concrete, the bacteria is released and produces IACement.

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WORLD NEWS JANUARY

USA FLSmidth signs EPC Kazakhstan Italcementi obtains


contract with Cemex EBRD loan for plant upgrade
FLSmidth has signed an EPC contract with Cemex for The Italcementi Group has signed an agreement with
the supply of a new cement production line for the the European Bank for Reconstruction and Development
companys Odessa plant in western Texas, USA. Once the (EBRD) for a loan of approximately e20 million to fund the
installation is complete, the cement production line is revamping of its Shymkent plant in southern Kazakhstan.
expected to have a capacity of approximately 2540 tpd. In addition to the loan, EBRD will invest approximately
The expansion will utilise state-of-the-art production e4 million in Shymkentcement, for an equity stake of
technology, resulting in higher fuel efficiency and around 21%.
improved productivity. The equipment scope includes The project, arranged under the EBRD policy to support
a 5-stage ILC preheater with a Low NOX Calciner, 3-pier energy efficiency initiatives in Kazakhstan, will replace the
kiln, FLSmidth Cross-Bar cooler, Duoflex burner, four wet process lines currently operating at the cement
Pfister weighing and dosing systems, gas analysers and plant with a new dry process line. The new state-of-the-art
three Fuller-Kinyon pumps. Furthermore, an FLSmidth technology will enable the plant to boost efficiency and
control system will ensure the most efficient operation. achieve a significant reduction in atmospheric emissions.
The order will contribute beneficially to FLSmidths The new 1.2 million tpy plant is expected to begin
earnings until late 2016. operations in early 2016.

Worldwide KORFEZ receives new Turkish and South African orders

Mill shell lining project in Turkey Mill conversion project in South Africa
KORFEZ ENG. has received a repeat order from a Turkish In November 2014, KORFEZ ENG. was chosen to perform
customer for first compartment mill shell lining for a a mill conversion project for a new customer in South
4.20 m dia. two-compartment cement mill. A lifting lining Africa. In close collaboration with the customer, the
with a total compartment length of approximately 4.80 m company developed an optimised solution to replace
made of durable cast steel with a chromium content of 12% the currently installed clamped mill shell lining. A bolted
has been designed in the companys technical sales office in wave lining system for the existing 3.80 m dia. slag mill
Germany. Delivery is scheduled for the beginning of 2015. was chosen due to its fine grinding media composition
In August 2014, the installation of KORFEZ ENG.s with very small grinding balls. For this lining system
second compartment mill shell lining was successfully it is considerably easier to perform the assembly and
concluded. A combination of lifting and classifying liners installation, as well as the maintenance of the wave liner
made of extremely durable cast steel with 27% chromium plates, and storage is also made easier as it has many
content were delivered to protect the mill tube from equal parts.
wear, as well as to ensure a well balanced material flow Manufacturing will be completed in less than two
throughout the complete grinding chamber. All start-up months and delivery is planned for January 2015.
tests were successful and the customer is satisfied with the Significant process improvements can be expected
current performance of the cement mill. following installation.

NEWS HIGHLIGHTS

Dalmia Bharat receives CII-ITC To read more about these


Sustainability Award for third consecutive articles go to:
year
Holcim and Lafarge name future Executive
Committee
VDMA positive about 2014 performance

January 2015
World Cement /9
Ivory Coast Cemtec receives contract from Ciments de LAfrique
Ciments de LAfrique has contracted Cemtec for the new grinding facility will have a capacity of 500 000 tpy,
construction of a new cement grinding plant at its existing which will double the existing plants production capacity.
facility located 15 km outside of Abidjan, Ivory Coast. The The scope of supply includes the raw material handling,
comprising intermediate silos, grinding section, cement silos
with bulk loading, transport to the existing packaging plant,
the electrical and control system, structural steel building,
civil works and complete erection. The key components
of the plant consist of a shell-supported 3.8 x 11.0 m ball
mill with installed motor power of 2250 kW and a CTC-110
separator with improved rotor design to reduce power
consumption and increase separation efficiency.
The main challenge is the integration of the new
grinding facility into the existing plant structure with
minimal interference and in the shortest possible timeframe.
This will be ensured by the clear vision and technical
specification of Ciments de LAfrique and the flexibility of
Cemtec towards the fulfillment of the specification. The
plant will be fully operational towards the end of 2015.

The Americas Cemex to expand production capacity at Colorado


and Tepeaca plants
Cemex Latam Holdings, S.A. (CLH) has announced new In other news, Cemex is resuming the expansion
plans to increase cement production capacity at its project at its Tepeaca plant in Mexico. This will increase
Colorado plant in Costa Rica to 1.1 million tpy by 2017. the plants capacity to 7.6 million tpy by 2017. The
The cost of the project is expected to be approximately company had already invested almost US$450 million
US$35 million over a 3-year period, and will include the by 2008, with an additional US$200 million planned,
construction of a new grinding mill, as well as several bringing the total investment in the capacity expansion to
capacity-enhancing projects on its clinker production approximately US$650 million. The expansion will enable
line. The expansion will generate approximately 90 jobs Cemex to better serve the local market. Some 100 direct
during the construction phase and around 50 jobs once and 240 indirect jobs will be generated once operations
operations begin. commence.

Canada Registration now open for 2015 IEEE-IAS/PCA Conference


Registration is now open for the 57th Annual IEEE-IAS/PCA The conference will feature a number of technical
Cement Industry Technical Conference, which will be paper presentations, tutorials (including MSHA
held at the Sheraton Centre Hotel in Toronto, Canada, recertification) and new professional training sessions
from 26 30 April 2015. The theme of the conference is ten new professional training sessions will be offered
BIG; it is the biggest in the industry and will be hosted in 2015. The topics and sponsors are listed on the
in Canadas largest city. Participants will also be given conference website: www.cementconference.org. Booth
the opportunity to visit St. Marys Bowmanville plant, the space is limited and will be sold on a first come, first
largest cement production facility in Canada. serve basis, so exhibitors are encouraged to register early.

EVENTS
2 5 February 2015 19 20 February 2015 21 24 April 2015
World of Concrete Enhanced Usage of Alternative 24th AFCM Technology
Fuels & Raw Materials Symposium & Exhibition
Las Vegas, USA
New Delhi, India Hanoi, Vietnam
www.worldofconcrete.com
www.cmaindia.org cemass@fpt.vn

26 30 April 2015 27 29 April 2015 3 7 May 2015


IEEE-IAS/PCA Conference Cementtech 2015 International Cement Microscopy
Association Conference
Toronto, Canada Beijing, China
Seattle, USA
www.cementconference.org www.cementtech.com
www.cemmicro.org

10 \ January 2015
World Cement
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+1(832) 286 - 4485 (USA)
France ContiTech and Techmi Egypt El Arish Cement places
build Europes longest conveyor repeat VRM order with Loesche
The longest conveyor belt in Europe recently went El Arish Cement
into operation at a cement plant in Montalieu. The is extending the
community of Montalieu, home to the Vicat cement clinker production
plant, lies in eastern France between Lyon and Geneva. capacity of its
To bring in limestone from the quarry 6.2 km away, existing cement
Vicat required a cost-effective solution and launched a plant by adding
project to realise its transport needs by conveyor belt. two new 5500 tpd
The company contacted Techmi about the construction lines. The company
of the entire conveyor system and in 2013, ContiTech already operates
was awarded the contract, becoming Techmis strategic two Loesche
partner. LM 56.4 vertical
The endless belt is around 13 km long and twists roller mills for
and turns on the head and tail of the system in order to cement raw
run parallel to the loaded belt on the return. Limestone material grinding
residues remain on the returning belt rather than falling in its existing lines
underneath it, making the system considerably easier to no. 1 and no. 2.
clean. The system blends into its surroundings without any El Arish Cement
difficulty. Concrete walls and a cover encase the conveyor has opted for the
belt and people, animals and vehicles can easily cross over Similar mill type LM 63.3+3 same mills for the
the construction. installed in India. two new production
The belt, as well as the steel cords for the carcass, lines. These mills will be used to grind raw meal at a
were produced by ContiTech Imas in Volos, Greece. The capacity of 450 tph and to a fineness of 12% R 90 m.
STAHLCORD ST1000-5+5 X steel cable conveyor is resistant As the new mills are the same type as the existing
to abrasion, weather and corrosion. It is also thermally ones, common spare parts can be used, keeping the
stable, highly durable and low maintenance. spare parts demand to a minimum.
ContiTech produced and delivered the belt within For cement grinding, El Arish Cement also decided
the space of just five weeks. During the first step, 13 rolls on two LM 63.3+3 vertical roller mills. The table
of 1 km belt sections weighing 20 t each were shipped diameter of the mills is equal to 6.3 m and will be
from Volos to Fos-sur-Mer on the French Mediterranean powered by a drive system with a rated capacity of
coast. From there, they were transported in a heavy-duty 6800 kW. The mills will grind various cement types with
truck convoy over 360 km to Montalieu. In Montalieu, the capacities of up to 305 tph.
team from ContiTech France and the service team from El Arishs good experience with its existing mills
HQ in Northeim, Germany, were onsite to assemble the and the very low specific energy demand of the milling
belt. They carried out the job in two stages, splicing the system were major factors in the companys decision to
13 sections of belt to each other, and spent a total of two select Loesche for the supply of their first two VRMs for
months on location. cement grinding.
The 250 t conveyor belt is now in operation, powered
by three electric motors delivering 250 kW each. In
normal conditions, the belt can transport up to 700 tph USA PCA appoints new CEO
of limestone. At maximum capacity, it can shift as much
as 1000 t. The belt has officially been in operation since At its annual meeting on 18 November 2014, the Board
mid-October 2014. of Directors of the Portland Cement Association (PCA)
named James G. Toscas as its new President and Chief
Executive Officer, effective 15 December 2014.
Toscas has decades of experience in the concrete
industry. For the past 11 years, he served as President
and CEO of the Precast/Prestressed Concrete Institute,
and from 1998 to 2002, he was Executive Vice President
and CEO at the American Concrete Institute (ACI).
Jim brings to PCA a wealth of skill and knowledge
that will serve the association and membership well,
said Cary Cohrs, PCAs immediate past Board of Directors
Chairman and Chairman of the Recruitment Committee.
John Stull, President and CEO of Lafarge North
America Inc., has been elected as Chairman of the PCA,
succeeding Cary Cohrs. Karl Watson Jr., President of
Cemex USA, has been elected as Vice-Chairman.

12 \ January 2015
World Cement
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Ecuador Holcim secures loan for Guayaquil cement project

Holcim Ecuador is continuing with the modernisation of its


Guayaquil plant, which involves the construction of a new clinker
production line, with the aim of replacing the import of clinker.
The total investment amount is US$300 million.
Holcim Ecuador has signed an A/B loan agreement for
US$125 million with Corporacin Andina de Fomento (CAF) to
finance part of the project. The A/B loans are a co-financing
mechanism established by multilateral agencies to finance
development projects, along with other international financial
institutions.
The modernisation of the plant will generate up to 3200 jobs
directly and indirectly. This investment promotes strategic import
substitution, providing added value to Ecuador and annual
currency savings above US$20 million.
In addition, the project will implement more environmentally
friendly technology, with 20% of the investment earmarked for
sustainable management. Construction continues as scheduled
and operation is expected to start in March 2015.

New Zealand Graymont to purchase shares in McDonalds Lime


Holcim (New Zealand) Limited and New Zealand Steel StphaneGodin, Graymonts President and Chief Executive
Limited have entered into an agreement for Canadas Officer. Together we will continue to reliably deliver
Graymont to purchase their shares in McDonalds Lime. quality products and services to our customers and realise
The company has also entered a separate agreement our world class vision built on a strong safety culture,
with Holcim to acquire its stake in Taylors Lime. commitment to improving environmental performance,
Graymont is North Americas second largest supplier of and engagement with the communities in which we
lime and lime-based products with facilities across the US operate.
and Canada, and has a significant investment in Grupo This acquisition reflects Graymonts confidence in the
Calidra, the largest lime producer in Mexico. long-term growth prospects for New Zealands economy
The McDonalds Lime operations are located in the and the region. The transaction is subject to obtaining
Waikato/King Country region, south of Hamilton. Taylors all the usual regulatory approvals and is expected to be
Lime operates in the Otago region, north of Dunedin. completed during 2015.
Both companies supply high quality limestone and lime Holcim New Zealands Managing Director, Jeremy
products to leading agribusinesses, resource companies and Smith, said Graymont is the right buyer for the lime
manufacturers throughout New Zealand. The agreements businesses and that it is also another step in Holcims
include the retention of all employees on their current strategic plan. Holcim is moving to an imported
terms and conditions. cement model and is investing AUS$100 million in the
We look forward to welcoming the employees construction of two import terminals in Auckland and
of McDonalds and Taylors to Graymont, said Timaru to support this.

IN BRIEF
Four of Lehigh Hansons Carbolite GmbH and CRH plc has reached an
cement plants, located in GeroHochtemperaturfen agreement to dispose
Leeds (Alabama), Union Bridge GmbH&Co. KG will merge of its clay and concrete
(Maryland), Glens Falls to form a new company, businesses in the UK and
(New York), and Redding Carbolite-Gero GmbH & its clay business in the
(California), have earned Co.KG, on 1January 2015. The US to funds managed by
the US EPAs ENERGY STAR company will offer solutions Bain Capital Europe LLP
certification for 2014. The for applications in vacuum and for an enterprise value of
company has strict operational under different atmospheres, 414 million. The transaction,
efficiency and energy as well as high temperature which excludes real
management programmes in systems with tungsten, estate assets, is subject to
place across all of its business molybdenum or graphite regulatory approvals and is
lines. insulation. expected to close in 1H15.

14 \ January 2015
World Cement
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KEYNOTE JANUARY

2015 - A STATE OF FLUX


Imran Akram, IA Cement, UK, examines 2015 cement demand
prospects around the world in this summary from the
Cement 2015 report.

Introduction time to recover from the financial crisis. While the US


IA Cement, UK, has published its Cement 2015 research now has positive momentum, much of Europe and Japan
report, a comprehensive document looking at 2015 is struggling. The once high-flying BRICs have seen a
trends. The report takes a detailed look at consumption sharp deterioration in prospects. The significant drop in
prospects around the world, as well as providing oil prices will provide a substantial boost to the world
an overview of key risks, competitive pressures and economy, at the expense of the Middle East, Russia and
trading flows. It examines the worlds cement hotspots US shale oil areas. Lower oil prices could tip low-growth
and provides a review of the worlds leading cement markets such as Europe or Japan into deflation. There
producers. This article presents a summary from the is optimism that new regimes in Indonesia and India
report of demand prospects by region. will be able to generate faster demand growth in 2015.
In 2015 growth in global cement volumes is predicted Africa is a bright spot despite the Ebola risks. The pace
to be around 3%, similar to 2014. For the first time in of US recovery will determine how quickly US and global
15 years, Chinese growth may lag behind global growth. interest rates increase. At present, higher rates appears to
The USA is clearly improving, with bright prospects be a greater risk for 2016 than 2015.
in India and Africa. Most other regions face a mixed
outlook. Western Europe converging toward zero
Ultimately, 2014 was a disappointing year growth European markets are in a precarious position. Recent
slowed over the summer in many markets including the GDP growth for 3Q14 shows almost no growth in
US, Europe, China, Brazil and the Middle East. In 2015 Germany and France, with Italy back in recession. The
it is difficult to get over-excited as many of these trends strongest economies of Germany and the UK have clearly
remain in place. The global economy is taking a long lost momentum. In France the government has missed

January 2015
World Cement / 17
budget targets and is suffering from an exit of capital. demand, based on a much better environment for
The crisis-hit countries are now showing an improved infrastructure spending. Colombia continues to
performance Spain, Ireland and Greece have all finally perform strongly, with growth in infrastructure to
come out of recession and are growing once more. accompany an already buoyant housing market.
Eurozone inflation is a low 0.4%, and will fall further IA Cement anticipates growth of 5 7% in 2015. Other
as the recent decline in oil prices filters through the markets are struggling. Brazilian economic growth has
economy. This runs the risk of tipping the region into virtually disappeared after the World Cup. Cement
deflation. One remedy for this is for the European demand and GDP growth are likely to be rooted at
Central Bank (ECB) to print money. To date, this has around 1% in 2015. High inflation and a large budget
been resisted by Germany. deficit give newly re-elected President Rousseff very
In 2015, IA Cement expects growth to return to the few options to stimulate growth. The debt crisis in
Western European cement market (albeit just 0.5%), Argentina remains in full swing at the time of writing,
marking an end to seven years of falling volumes. making a further decline in 2015 cement volumes
Forecasts have begun to converge around the zero likely.
level for most countries stronger countries have been
downgraded, while weaker economies are improving. Cautious outlook for the Middle East
Confidence in the region has dropped due to the
Eastern Europe to post weak growth plummeting oil price, as well as the ongoing political
In Eastern Europe modest growth is expected in fallout from the Arab Spring and ISIS. Forecasts for
Poland, the Czech Republic and Hungary. Poland will 2015 are therefore cautious, with a modest 2 2.5%
experience some delays in infrastructure spending until growth in demand expected. The Saudi market is likely
the new EU plan is implemented. The Russia-Ukraine to return to 5 6% growth due to major projects like
crisis continues to create the Riyadh Metro. Cement


uncertainty in the region. demand is likely to revive in
Russia is heading towards the UAE with 3 5% growth
recession. The ruble has driven by the improving
dropped almost 30% In 2015 growth in global housing market and the
against the dollar, there is restart of several projects.
a massive capital exodus, cement volumes is Iraq is difficult to predict
the lower oil price will due to ISIS. The outlook in
cost Russia US$100 billion
predicted to be around 3%, Iran is largely dependent
annually and sanctions similar to 2014. For the first on the sanctions regime.
are beginning to bite. As Elsewhere, IA Cement expects
a result, cement demand time in 15 years, Chinese solid growth in Turkey and
is expected to drop in Qatar, with stable markets in
2015. Consumption is
growth may lag behind Kuwait and Bahrain.


likely to fall sharply once global growth.
more in Ukraine. Africa another good year
Momentum in Africa is
US well placed for generally positive for 2015
growth with 4 5% growth, driven
IA Cement expects by the demand recovery in
cement demand will grow 6% in 2015, placing the the regions largest market, Egypt. The shortage of gas
US among the fastest-growing major cement markets in Egypt will mean another year of substantial clinker
in the world. Cement prices are expected to increase imports. Further solid growth is forecast for Algeria,
by 5 7% with a US$10/t price increase announced driven by government spending. Libya is in the grip
for January. This mix of higher volumes and pricing of anarchy and IA Cement therefore anticipates lower
will result in a further significant boost to US cement volumes. Prospects for Sub-Saharan Africa are positive,
margins in 2015. Considering the depth of the assuming that the Ebola crisis is contained. Overall,
downturn, cement demand is capable of growing solid growth in 2015 is likely across most Sub-Saharan
at double-digit rates. However, the housing market markets, although falling commodity prices will take
recovery has been slower than expected as buyers a few points off the growth rate in many countries.
have held back due to rising selling prices and higher IA Cement forecasts 6 8% growth in demand in
long-term interest rates. Cement imports will only the major markets of Nigeria, Kenya, Tanzania and
increase slightly as local capacity is still able to meet Ethiopia. New capacity is likely to bring selling prices
rising demand. US interest rates are likely to be down in a number of markets.
increased in 2H15, which will lead to higher global
rates. China restricted by tighter liquidity
The Chinese cement market is struggling due to a
Sluggish prospects for Latin America weak property market and tight liquidity. Funding
Prospects in Latin America are mixed. A recovery is costs have increased. The property bubble is at risk of
likely in Mexico with a solid 3 4% growth in cement bursting, with prices dropping across China this year.

18 \ January 2015
World Cement
Global cement demand outlook, 2015E. (Source: IA Cement Ltd.)

The government is spending more on infrastructure, cement demand growth in 2015, although there are
particularly in rail. However, a major new stimulus signs of overheating in private construction, as well
programme appears unlikely. Instead, the government as in the form of tight power supplies. Thailand is
has cut interest rates and injected small amounts of poised to recover from the political turmoil with 4 5%
liquidity into the banking sector. In the absence of a growth. Note that the industry will need to absorb the
fiscal stimulus, cement consumption is expected to grow TPI addition of 4.5 million t of capacity in mid-2015.
at 2.5 3% in 2015. On a more positive note, the Chinese In Vietnam, domestic demand has begun to recover
government is maintaining a very tight grip over supply. and the country is now the worlds largest exporter of
cement. With supply still outstripping demand, exports
New government in India restores confidence need to remain high in 2015. In Japan, the money
The election of the new government in May 2014 has printing and stimulus measures are helping to underpin
resulted in a sea-change in India. Confidence has soared cement demand, with growth expectations of 1.5% in
at the business and consumer level. Cement volumes 2015. Myanmar continues to grow at a double-digit
flat in the run-up to the elections are now growing at rate. IA Cement sees no reason for this growth rate to
almost double-digit rates. Cement consumption is likely change. Local producers are still exploring partnerships
to increase by 7 8% in 2015. In the private sector, with foreign companies.
IA Cement expects to see higher demand from housing
as well as a pickup in business investment. Furthermore, Conclusion
the new government is likely to kick-start infrastructure Another year of moderate growth looks likely in
spending in 2015. Cement producers are campaigning 2015. Positive drivers include a significant boost from
for new roads to be built with concrete rather than lower oil prices, a clear delay to rising rates in mature
asphalt. The cost base continues to increase, but in 2015 markets and new governments pushing reforms in
the pickup in demand will provide a better environment India and Indonesia. The role of the central banks
for price increases and higher profit margins. will be pivotal money printing looks increasingly
necessary for Japan and Europe, while availability
Solid prospects in the Far East of credit is the central question for China. The US
Prospects for the remaining Asian markets are solid recovery will eventually jeopardise emerging market
for 2015, with an average growth rate of almost 4%. growth, where numerous asset bubbles in housing and
Most countries benefit from falling oil prices. Indonesia credit can only be punctured by higher interest rates.
has the best prospects of the major markets. President The completion of the LafargeHolcim merger and the
Jokowi has a solid economic base to work from associated disposal process/consequences will be key
moderate inflation, spare capacity in several sectors, events for 2015.
substantially reduced energy subsidies and a mandate
to increase infrastructure spending. A 6% growth in Note
2015 cement demand is expected, but this could go Details of the full report are available
higher if new infrastructure projects are started quickly. at www.iacement.com or by emailing
In the Philippines, IA Cement anticipates a 5 6% publications@iacement.com.

January 2015
World Cement / 19
Introduction The family of alternative fuels includes a variety of
Some ten years ago, Buzzi Unicem decided on wastes, ranging from rubber to plastic and paper to
a radical revision of its energy management wood. These are usually available in most regions and
strategy, which involved the modification of the are desirable for cement companies due to the cost
fuel sources used at its cement manufacturing savings that burning alternative fuels offer, and for
plants. Fossil fuels have long been the industrys the communities due to the reduced environmental
main source of energy; however, there are both impact. However, the use of alternative fuels comes
economic and environmental reasons to focus on with specific problems, mainly related to the handling
the utilisation of alternative energy sources. and burning of non-homogenous, and often wet,

20 \
Alternative Fuel Projects
at Cement Hranice
Giovanni Battista Auxilia and Stefano Comoglio,
Buzzi Unicem, Italy, outline recent modernisation projects
to increase alternative fuels storage and handling
capacity at Cement Hranice in the Czech Republic.

/ 21
materials. For this reason, related projects usually require
specific storage and dosing systems, and modifications to
the calciners. This is the case at Buzzi Unicems Hranice
plant, located in the eastern Czech Republic.

Planning and preparation


The Hranice plant was founded in 1954 and
modernised and refurbished at the end of the 1980s
by the Czech company PSP, the primary supplier of
heavy equipment for Eastern Europe in the former
Czechoslovakia. Following the reconstruction, and
over the past few years, the plant has operated at an
average production rate of 700000tpy of clinker and
850000tpy of cement, burning predominantly coal
with heat substitution by alternative fuels of up to
70% heat replacement. On this basis, the specific heat
consumption has been around 3400kJ/kg of clinker.
The plant has access to a variety of burnable
materials, sourced from neighbourhoods surrounding
the facility, including tyres, animal meal and fluff.
There are no restrictions, aside from technological
ones, to prevent the company from significantly
increasing its current total annual consumption
of alternative fuels (around 30000 t). Given the
companys target for a heat source with a 30:70
ratio (coal and alternative fuels, respectively),
Tertiary air modification. the challenge was made even harder with the
introduction of new emission limits in the Czech
Republic. As of 1October2014, the limit on NOX
decreased from 800mg/m 3 to 500mg/m3.
In the second half of 2012 a project was
established to increase the plants use of alternative
fuels. The project will be realised in two steps: the
first was the calciner modernisation, during which the
company optimised the calciner combustion capability
and improved alkali removal, and the second will
involve the increase of alternative fuels storage and
handling capacity. Project assumptions for the calciner
modernisation were set to a kiln production capacity
of 3000 tpd, maintained at the present rate, a specific
heat consumption in the range of 34003500kJ/kg
of clinker, a gas retention time inside the calciner of
7seconds, differential pressure between the kiln inlet
and top cyclone of 8000Pa, and a daily NOX average
of <400mg/Nm3 at 10% O 2.

Project definition: technical solution and


structural works
As the project was a modernisation, the company
had to preserve as much of the existing equipment
as possible, while installing the new equipment
in a very limited space. A solution was developed
together with Austrian-based A TEC, which involved
saving the existing separate combustion chamber for
preheating fuels and moving the burners to the riser
duct. The calciner itself should have a total length
of approximately 95m, an internal diameter of
4250mm, and show the post-combustion chamber a
large volume at the calciner upper bend to allow for
complete combustion of larger fuel particles.
The lining of the duct, supplied by Refratechnik,
Supporting structures for calciner. needed to ensure the best protection against alkali

22 \ January 2015
World Cement
Our experts in a wide
scope of fields are ready
to answer the questions

Turnkey project BYPASS DUST STORAGE &


HANDLING at CEMENT Hranice in the
Czech republic successfully completed
in October, 2014 by ALIACEM Perov.

Technical data:
Material Chlorine bypass dust
Chlorine content 8 upto 18 %
Filter capacity 32 000 Nm3/h
Silo capacity 400 m3
Cooling screw conveyor capacity 30 m3/h
Inlet dust temperature to the cooling screw conveyor 150 C
Outlet dust temperature from the cooling screw conveyor 95 C

Three excellent technical solutions designed in the project:

1. Water cooling of bypass dust in double screw conveyor


for safe bypass dust dispatch done by trucks

2. Proportional mixing of bypass dust & raw meal 3. No chimney behind filter & no emissions all waste
dust for easy using in cement grinding plant gas used as cooling air in clinker cooler

Head office in Czech republic Representatives for Lebanon, Syria and Jordan Representatives Brasil & South America

Aliacem s.r.o. DEALTRADE LEVANT PragoTec - Projetos, Equipamentos & Servios Ltda.
Sirava 27/1295 Hadath, Adib Chidiac Street Av. Eng. Domingos Ferreira, 2391
750 02 Prerov Tohme Bldg, 2nd floor Empresarial San Marino, 10. andar
Czech rebublic Beirut, Lebanon Boa Viagem, 51020-031, Recife/PE
Tel: +420/606784778 Tel.: +961/71383003, +420/603166812 Brazil
Tel: (55) 81/33277033
Email: info@aliacem.cz Email: ok@detrag.com Email: pragotec@pragotec.com.br
www.aliacem.cz www.detrag.com www.pragotec.com.br
attack on brick porosity and brick volume expansion, The existing tertiary air duct was to be modified
characteristics found in special products with low only in its terminal portion in order to install the DeNOX
alumina content (around 20%) and no silica carbide. system, which branched to the upper part of the rising
The total amount, including existing portions to be duct and the relevant valves.
refurbished, was calculated to be in the range of 600t On the structural side, the new installation required
of refractory materials. This was the first important reinforcement of the existing preheater tower in order
project in Europe using Refratechniks new low alumina to support the 160t weight of the new calciner duct, a
content brick KRONEX 20. dedicated structure linked to the preheater tower and
laid on a new foundation block on micropiles.

Procurement phase
Once the technological solution had been
established, the project team entered the
contracting phase. Both the European community
and Czech government offered contributions to
the project costs, since it met the requirements for
inclusion in ongoing programmes for environmental
protection and plant modernisation.
The selection of the supplier followed strict
procedures. A tender was prepared and published
so that it could be made available to any company
and quotations were sent on the specified deadline
and opened in the presence of representatives of the
company, the government and the bidders themselves.
To be valid, the selection process had to include at least
three bidding companies.
The criterion for proposal evaluation was fixed
and described in the tender. Each bidder received a
score, based on economical (60%) and technological
(40%) evaluations on the proposed solution. The
complete process of the supplier selection was
successful and fulfilled all the requirements to access
public contributions. Together, the EU and Czech
government grants covered about 20% of the project
costs.

Project timeline
Erection completed. The contract was signed on 18June2013 and the
engineering was completed in November2013.
In the meantime civil mobilisation took place,
beginning with the concrete works. The mechanical
crews carried out the preparatory works and the
displacement of equipment to be removed. At
the beginning of winter, the first structural and
technological steel was delivered to the site and the
erection phase continued until February2014. Once
the company completed the electrical connections
and functional logic, the fire was lit again on
5March2014. A TEC subcontracted Aliacem Perov,
a local Czech company, to carry out the construction
and erection.
During the technical definition of the project and
the procurement phase, the company headquarters
in Italy supported the local team, who then
managed the project during erection until the
successful startup.

Line performance after new installation


After the kiln start-up, the production rate was
progressively brought up to the planned capacity
Post-combustion chamber (inside model). (Courtesy of of 3000 tpd of clinker. Process parameters were in
A TEC.) the expected ranges and the only anomalous value

24 \ January 2015
World Cement
We are setting the
standards for refractory
solutions and services
Development, engineering and
installation of refractory systems
for new and existing plants

REFRATECHNIK
Refratechnik Cement GmbH
Rudolf-Winkel-Strasse 1
37079 Gttingen
Germany
Phone +49 551 6941 0
Fax +49 551 6941 104
refra@refra.com
www.refra.com
was observed in the high temperature of the separate
combustion chamber bottom. A TEC was requested to
analyse the problem and find a solution. The company
proposed a modification of the fuel injection pipe in
order to allow for better heat exchange between the
fluff and the gas. Once this modification had been
carried out, the temperature in the chamber decreased
below the warning limit.
In its first few months of operation, the kiln
has worked with a specific heat consumption of
3410kJ/kg of clinker at 4000Nm3/h bypass. The average
coal/alternative fuel ratio is now 56:44, achieving a
saving of CZK9.5/GJ on thermal energy costs.

Conclusion
The kiln line is now in the condition to burn up to
100% of alternative fuels in the calciner, corresponding
to a total of 70% heat substitution. Limitations
include, for the time being, the capacity of fluff
storage and dosing to the combustion chamber (at
3tph).
The second stage of the Hranice modernisation
project is now in its engineering phase. As part of
the project, the company will install a new storage
hall with a total capacity of 4500m3, proper handling
equipment to clean the material of foreign objects,
and increase dosing capacity up to 10tph. This
installation will allow the kiln line to reach the target
Velocity reduction in upstream and mixing effect in Buzzi Unicem has set for the Hranice plant at the
downstream. (Courtesy of A TEC.) desired heat substitution level.

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