2007

Highlights

April
Highlights
Highlights
Editor: Anders Klinkby Godiksen
(responsible under Danish law)
Brenda Kaplan
V. Ragini Shah
Henrik Vinther
Production: Gunnar Andreasen
Translations: Martin Bojesen
Editorial office:
FLSmidth A/S
Vigerslev All 77,
DK-2500 Valby, Copenhagen, Denmark
Tel: +45 36 18 10 00
Fax: +45 36 45 44 27
Email: info@flsmidth.com
Internet: www.flsmidth.com
All rights reserved
Contents
Equipped for the future
Breaking records in Mexico
Another major project for Kazakhstan
Green cement plant for the Emerald Isle
One of largest white cement plants
Largest-scale ATOX mills on stream
Chinas leading cement producer
Americas next generation of plants
The preferred supplier for 125 years
D.G.Khan upgrades cooler
New ship unloader for Eastern Portland
KOCH strengthens FLSmidth
New workshop in China
Airtech fabric filter technology
Sanghi Cement at historic 10,500 tpd
Cost-effective shortcut to dry conversion
Thumbs-up to kiln simulator
New FLSmidth literature
Vasavadatta Cement commissioned
Take the e-highway to spare parts
Sebryakovcement sets ball rolling
On the job
Front cover: This year FLSmidth is celebrating the
125 years since the company was founded in 1882.
On pages 16-17 we have collected some of
FLSmidths major contributions to the technological
development of the cement industry for more than
a century.
Layout: Blue Business A/S ISSN 0909-8992
Equipped for
the future
Tuesday 2 January 2007 was a historical day for FLSmidth as it
celebrated the 125 years that have passed since the company
was established. The day also marked the beginning of another
exciting year for the global cement industry. Highlights asked
CEO Jrgen Huno Rasmussen to comment on the companys
anniversary.
Is FLSmidth equipped Youve also been favoured
for the future? by fortune?
My answer is definitely yes. Consider- True, when I took over the helm in
ing the success were experiencing 2004, I knew that the prospects were
just now, it may even be a challenge good. But the present size of the mar-
to keep both feet on the ground and ket has exceeded all expectations. The
not become overwhelmed by our cement industry has its ups and
good fortune. The demand for ce- downs, a fact to which the FLSmidth
2
ment machinery is at an all-time high, organisation can certainly testify. The
4
which is challenging our organisation. companys present success derives not
4 We are well equipped because we only from the size of the market, but
6 have chosen a precise strategy and also from our own history and flexibili-
7 returned to our roots within cement ty. The FLSmidth flag is planted across
8 and minerals. This focused strategy is the globe and is testament to the ac-
10 based on a solid financial platform, a tions of our predecessors at all levels
dedicated workforce and 125 years in FLSmidth. They took up the baton
12
of expertise as a global and forward- and paved the way for future success-
16
thinking engineering company. All in es. We still see old, well-maintained
18 all, we are well prepared to supply plants running seamlessly. By continu-
19 the plant and service solutions of the ing the same actions today and mak-
20 future. ing the appropriate decisions, we are
21
22
24
25
26
27
28
28
30
32
2 Highlights April 2007
also paving the way for future genera-
tions.
New ways?
FLSmidth will grow considerably over the
coming years. In Cement, our aftermar-
ket activities and the design of new
technological solutions are making good
progress. In Minerals, we have recently
taken a positive step forward by acquir-
ing KOCH Transporttechnik, the German
materials handling group. Their exten-
sive know-how will prove highly useful
to FFE Minerals, which we plan to grow
to a size comparable to Cement.
How about specific FLSmidth
values?
We dont blow our own trumpet with
trendy slogans. Our customers know
perfectly well what we stand for. We
show it in practice. And you can read
about it in this magazine. Our values can
be expressed in different ways, but I ven-
ture to say that everyone in FLSmidth is
proud of the companys reputation as
the industrys preferred partner. If you
see an FLSmidth logo on a machine,
there is no doubt that this is top-quality
equipment backed by a global organisa-
tion willing to provide top-level service
when needed.
Will the anniversary year see
any special events?
Were already busy with one of the com-
panys most important years in recent
times. Of course, our anniversary has
been highlighted in the press. Mean-
while were sticking to our normal prin-
ciple: business as usual. Thats because
we intend to remain the preferred part-
ner for at least another hundred years.
But the anniversary celebrations will
include customers. In May, well embark
on a road show with seminars in Den-
mark, Egypt, India, Indonesia and the
USA. These will be high-profile events
shared with management executives
from our customers. There is every rea-
son to celebrate.
I wish you pleasant reading of this
new issue of Highlights, which as usual
also comes in an electronic version,
eHighlights on www.flsmidth.com
J. Huno Rasmussen
CEO, FLSmidth
Highlights April 2007 3
 Breaking records
in Mexico
CEMEX S.A.B. DE C.V. (CEMEX), a global building
solutions company that provides high quality
products and reliable service to customers and
communities in more than 50 countries, has
awarded FLSmidth a contract to build the largest
kiln system in South America.
Situated at the Tepeaca plant in Mexico, the new line will have
a capacity of 10,000 metric tonnes clinker per day. The kiln sys-
tem is part of a 4.4 million tonnes per year expansion project
to mark CEMEXs 100-year anniversary. Additional equipment
packages will be tendered later on.
Meeting strict environmental standards
The USD 35.9m project demonstrates FLSmidth's leadership
and capability in designing large clinker production systems.
The contract includes the latest generation Multi-Movable
Cross-Bar Cooler. In addition, the ILC 5-stage preheater with
low NOx and CO calciner will ensure that the strict environ-
mental and efficiency demands are met.
With a strong local presence in North America, FLSmidth
was able to differentiate itself from possible competitors.
FLSmidth's US project centre based in Bethlehem, Pennsylva-
nia, which is responsible for the project, attributes the success
of the contract to its ability to act as a complete partner for
the supply of engineering services, project management, and
commissioning as well as all major machines for the clinker
production line.
Seated (l to r):Peter Westring and Hugo Bolio.
Standing (l to r):Richardt Fangel, Enrique Mendez, Elias Garza,
Edmo Gutierrez, Hector Trevino, Hector Mendez, Emiliano Quiroga.
4 Highlights April 2007
Another major
project for
Kazakhstan
The last issue of Highlights reported on
FLSmidths first major order in Kazakhstan, a
3,500 tpd modernisation project. More recently,
East Energy Company (EEC), part owner of
Kokshe Cement, has placed a EUR 90 million
contract for a complete new greenfield plant,
confirming Kazakhstan as a major new market.
Kazakhstan, a country rich in oil, gas and minerals, is see-
ing double-digit growth in construction activity. The coun-
trys 15 million people, who inhabit an area comparable to
Western Europe, need increasing volumes of cement for
roads, homes and industrial development. Several new
cement plant projects are being considered, but the first
one to begin operation will be Kokshe Cements two
million tpy plant.
Mutual trust
Most of 2006 saw a very constructive dialogue between
the customer, its German advisor and project developer
Evagor GmbH and FLSmidth, which was chosen to design
and supply the plant. The talks, which took place in an
open atmosphere of mutual trust, culminated in the sign-
ing of a contract in late 2006.
The new greenfield plant will be situated 270 km
northwest of Astana, the Kazakhstani capital. The regions
surrounding Astana, in the centre of the country, and
Almaty, the countrys commercial centre in the south-east,
together account for 60 percent of the nations cement
consumption. The decision to invest in cement production
therefore came naturally for EEC of Kazakhstan whose
current interests are mainly in oil and gas production.
EEC also has a construction business which will handle some
of the civil works for the new plant.
Kokshe Cements new 2m tpy greenfield plant will be situated way out in the
Kazakhstan steppes, some 270 km northwest of the nations capital, Astana.
The plant site is strategically located
with plenty of limestone and clay re-
serves nearby. A special railway line will
be built to the plant for deliveries of
equipment and, subsequently, additives
and other materials needed in cement
production. Distribution of cement,
mainly in bulk, will also primarily take
place by rail.
State-of-the art project
With temperatures dropping to -40o C in
the winter, building the plant and de-
signing equipment that can withstand
the cold will be a major challenge. Civil
works, plant installation and commis-
sioning are planned to take place during
the frost-free months of 2007, 2008 and
2009, respectively.
The plant will feature state-of-the-art
production equipment and control sys-
tems, all designed to achieve maximum
production efficiency and best practice
environmental performance. The con-
tract includes not only equipment sup-
plies, but also engineering, training and
spare parts. FLSmidth is responsible for
transporting the equipment to the site, a
major operation involving deliveries from
selected manufacturing plants by rail,
ship and truck. Another major assign-
ment will be to provide the bulk of tech-
nical documentation in both English and
Russian.
First modern cement plant
This contract confirms our expectations
of growing cement industry activity in
the former Soviet Union countries, and
FLSmidth is actively pursuing the vast
opportunities in this fast growing re-
gion, FLSmidth Group CEO Jrgen
Huno Rasmussen says.
Leif Kirk, Vice President, Sales, FLSmidth and Kapanov
Sailaubek, Director Kokshe Cement, sign the contract.
Scope of equipment supplies
EV 200x200 limestone crusher
Side Scraper store for limestone and clay
ATOX 47.5 raw mill
CF silo dia. 20x56 m (21,500 tonnes)
ATOX 22.5 coal mill
5-stage ILC preheater with ammonia injection to reduce NOx
Two-support kiln 5.25x62 m (5,500 tonnes per day)
SF Cross-Bar cooler 4x6
Clinker store dia. 60x46 m (100,000 t)
Two OK 33-4 cement mills
Four CFS cement silos dia. 20x40 m
MAAG Gear units
Two Ventomatic packing lines
Pfister feeders
FLSmidth Automation control system, including RoboLab
FLSmidth Airtech bag filters and electrostatic precipitators
Highlights April 2007 5
 Green cement plant for
the Emerald Isle
FLSmidth has been entrusted
with a 4,000 tpd project for Irish
Cement Ltd.s Platin Works north
of Dublin. The state-of-the-art
plant will be designed to comply
with the most stringent environ-
mental requirements.
The signing of a contract with Irish Ce-
ment Ltd. (ICL) for a new 4,000 tpd
clinker production line practically coin-
cided with FLSmidths 125th anniversary
around New Year 2007. This is not the
first time ICL and FLSmidth have cele-
brated an anniversary by signing a con-
tract. On 5 December 1996, the two
parties marked the 60th anniversary of
their mutual relationship by signing a
contract for the rehabilitation of Kiln 2
line, meeting best practice environmen-
tal standards. The new line will both
increase the overall plant capacity from
2 to 2.8 million tpy and lower carbon
dioxide emissions. Once line 3 is in oper-
ation by late 2008, it is expected that
the existing line 1 dating back to 1972
will be closed down.
FLSmidths role in the new project
consists of supplying a total package of
machinery and equipment plus engi-
neering services. The main equipment
items are:
MVT raw material store, 95 metres in
diameter
ATOX 47.5 raw mill
ATOX 25 coal mill
Pfister coal feeders
ILC preheater and ROTAX two-
support kiln dia. 5 x 60 m
MMC 11x97 cooler
OK 36-4 cement mill
MAAG gear units
Platin Cement Works is located near
Drogheda in eastern Ireland, some
50 km north of Dublin. The new produc-
tion line will be the biggest investment
ever in Ireland by Cement Roadstone
Holding (CRH), the leading international
materials group which owns ICL. Platins
expansion project will ensure adequate
supplies for Irelands thriving economy
and growing construction sector.

Signing the contract for Irish Cement Platins new 4,000 tpd line,
at ICLs Platin Works. The highlight of seated l to r: John McKeon, Jrgen Huno Rasmussen, Ken McKnight,
that project was the replacement of a Peter Thomsen. Standing l to r: Richard Cunningham, Barry Leonard,
Michael Keatings, Niels Chr. Tew, Ivor Reese.
UNAX planetary cooler by a COOLAX
grate cooler within only 47 days of kiln
downtime.
This time, the contract signed is for
a complete line 3. This will be an ultra-
modern, energy-efficient production

6 Highlights April 2007

Helping to build one of largest
white cement plants

Sinai White Cement Company has decided to add a new 1,300 tpd and documentation for local manufac-
line to its existing plant with FLSmidth supplying equipment and ture and procurement. The range of
engineering. With a total capacity of 1.1 to 1.2 million tonnes per equipment for Sinai Whites second line
year, Sinai White will become one of the worlds largest white is similar to that of the first line, but the
cement plants. new line will feature a rotary cooler in-
stead of a grate cooler, this being a more
The market for cement is booming in UMS 42 x 14.5 cement mill efficient solution which is now the stan-
the Middle East and in the countries Electrostatic precipitators from dard choice for white cement projects
around the Mediterranean. This is a re- FLSmidth Airtech from FLSmidth.
gion with a particularly high demand for Feeding equipment from Pfister Sinai White Company, which is
white cement, and the Sinai White Ce- 57 percent-owned by Aalborg Portland
ment Company is producing at capacity, The contract with FLSmidth comprises White of Denmark, expects its new
despite only being six-years-old. So the not only the supplies of mechanical and production line to be operational by the
company is investing in a new line to electrical equipment but also drawings end of 2008.
satisfy the market.
As was the case with the first line
commissioned in 2001, FLSmidth has
been chosen as supplier for the new
project. This decision was prompted by
the successful performance of the exist-
ing plant and FLSmidths great expertise
and experience in white cement technol-
ogy. The scope of FLSmidths supplies is:

ATOX 25 raw mill including MAAG

gear unit
Two UM 29 x 16.0 sand mills
ILC pyro system including 4-stage
preheater, calciner, 3.75 x 57 m
three-support kiln
Rotary cooler

Celebrating the signing of the contract for Sinai White Cement Companys second line.

Highlights April 2007 7

 Largest-scale ATOX mills come on stream
As cement production plants
continue to grow in size, there
is a corresponding demand for
larger mills. In the previous issue
of Highlights, we discussed the
increasing size of OK vertical
mills used for finish grinding
of cement and slag. This article
focuses on the ATOX vertical mill
used for raw material and coal
grinding.
More than 300 ATOX mills have been
sold since the first mills were commis-
sioned during the early to mid-1980s.
The ATOX range originally comprised of
11 sizes, the largest being an ATOX 50
a mill with a grinding table measuring
five metres in diameter.
At the beginning of this century,
FLSmidth expanded its range to meet
the industrys need for higher capacity.
Four new mill sizes were introduced:
ATOX 52.5, 55, 57.5 and 60. The total
8 Highlights April 2007
range of ATOX mills now spans from
665 to 5,931 kW installed power.
Chinese cement company
has success with mega-sized
ATOX mills
In 2003, FLSmidth sold the first of its
new larger-sized mills to the Chinese
state-owned organisation Anhui Wan-
wei Update High-Tech Material Industry
Co. Ltd (known as Wanwei). Located in
Chaohu City in the Chinese province of
Anhui, Wanwei is active in chemicals,
fabrics and cement.
Founded in the 1970s, Wanwei orig-
inally manufactured fabric. But growth
in chemical and fabric production result-
ed in an increasing amount of calcium
carbide residue which led to the
development of cement production at
Wanwei.
Wanwei now has three cement pro-
duction lines: a 1,000 tonnes per day
(tpd) line commissioned in 2000; a
1,200 tpd line commissioned in 2003;
and a 6,000 tpd line commissioned in
2005. The latter is equipped with an
ATOX 52.5 raw mill, the first of the
mega-sized vertical grinding units to
enter into operation. The mill has a main
drive of 4,266 kW, a MAAG gear and an
RAR-LVT 52.5 separator. Following its
successful commissioning, the mill com-
fortably achieved its performance expec-
tations.
Accepted by the industry
Since 2004, FLSmidth has sold nine
more mills like the one used by Wanwei,
and even some larger ATOX mills. These
will be featured in the next issue of
Highlights.
Today vertical mills are widely accept-
ed as the most efficient means of prepar-
ing kiln feed for the production of ce-
ment clinker. The mills can finely grind a
wide range of feed materials using a
highly energy-efficient process. Raw
materials vary considerably in grindability,
drying requirements and abrasion, but
the vertical roller mill has the flexibility to
handle these variations.
The ATOX mill combines the grind-
ing, separation and drying processes into
a single unit. Its excellent drying capacity
means the mill is suited to grinding ma-
terials containing up to 20 percent mois-
ture. It is also extremely compact com-
pared to other vertical mills and pro-
duces very little noise which allows for
outdoor installation.
ATOX raw mill selected for the
worlds largest production line
Further proving its versatility, the ATOX
raw mill has been chosen by Holcim for
use in the worlds biggest production
line. Located in Ste. Genevieve in Mis-
souri, USA, the plant will have a capacity
of 12,000 tpd.
Wanweis cement plant in Central Eastern China was the first to commission a
mega-size raw grinding mill (ATOX 52.5).

Since the early eighties, FLSmidth has sold 300

ATOX mills used for grinding either raw materials
or coal. In China, alone, the cement industry has
invested in 100 ATOXes. In December 2006,
FLSmidths Beijing office staff and families duly
celebrated this landmark achievement.

Highlights April 2007 9

 Chinas leading cement producer
confident of future growth
Anhui Conch Cement Co.
Tongling is one of the worlds
largest cement plants. FLSmidth
has provided vital parts of the
technology including the recent-
ly commissioned twin 10,000 tpd
pyroprocessing lines.
Large kilns have always exerted a strong
attraction on cement people, both be-
cause of their sheer size and because of
their huge production capacity.
To gain a good impression of a gi-
gantic cement facility, there is no better
place to go than Tongling, China, the
Anhui Conch Groups largest production
complex. The plant is able to produce 10
million tonnes clinker per year and con-
sists of four lines located at two inter-
connected sites a few kilometres from
the Yangtze River in the Anhui province
of eastern China. The cement plant is
close to plentiful reserves of high-grade
limestone.
10 Highlights April 2007
World leader in huge cement
plants
The two most recent lines, which are
also the largest, are very impressive with
their twin preheater towers rising 146
metres up in the horizon. By contrast,
the relative peace and quiet of this mas-
sive installation is quite remarkable, as
there are no clinker grinding facilities at
the site.
The two 10,000 tpd clinker produc-
tion lines were the first of their kind in
China. At the time, the worlds only oth-
er lines of that capacity were the three
which FLSmidth had previously supplied
to cement producers in Thailand.
This experience confirms FLSmidths
position as the leading supplier of very
large kiln systems to the global cement
industry.
A successful start
At 20:38 on 26 May 2004, Tongling
Conch ignited the first of its 10,000 tpd
kilns which on 5 June produced the first
actual clinker. A grand opening ceremo-
ny attended by cement industry execu-
tives and provincial government officials
celebrated both the first and the next
10,000 tpd pyro systems plus the four
new ATOX raw mills at Tongling.
After a brief commissioning period,
the first line was steadily producing
more than 11,000 tpd. Construction of
the first of the two new clinker lines
took only 18 months from erection to
production an impressive achievement
considering the scale of the project.
The second line entered production
six months later, boosting Tonglings to-
tal production capacity to 2 x 10,000 +
1 x 5,000 + 1 x 4,000 = 29,000 tpd.
Scope of contract
FLSmidth has a long standing and strong
relationship with Conch dating back to
the early 1990s when it signed the con-
tract for Tonglings first line (4,000 tpd).
The successful implementation of that
project led to a number of orders from
Conch over the following years. FLSmidth
has been a supplier of cement-making
machinery to China since 1906.
In 2002 Anhui Conch Cement Co.
awarded FLSmidth the contract for key
technology and equipment for the two
new lines at Tongling. The scope of sup-
ply was
Two 2-string, 5-stage ILC preheaters
Two 10,000 tpd rotary kilns
Two Duoflex kiln burners for coal
Four ATOX 50 raw mills
Four 3,800 kW planetary gears sup-
plied by MAAG Gear
Pfister coal feeders.
Distribution and boosting of exports from the pres-
The new Tongling site does not grind ent level of nearly five million tonnes per
finished cement. Instead the clinker is year. The new Tongling site has there-
transported to grinding plants located fore been designed to accommodate a
on Chinas east coast or at major cities third line, but the final decision to ex-
along the Yangtze river where cement pand the plant has yet to be made.
consumption is high. Within the next five years, Conch
A covered belt conveyor carries the hopes to boost its annual clinker produc-
clinker from the plant to the distribution tion capacity from approximately 50
terminal on the Yangtze river, a distance million tonnes to 100 million tonnes. If
of 7 km. On its way back the belt carries this growth materialises, Conch will join
coal. The pier at the busy terminal re- the worlds top ten league of cement
ceives vessels up to 5,000 dwt. It has producers.
three loading stations each with a ca-
pacity of 1,200 tph of clinker or 800 tpd
of cement from the old Tongling site.
Ambitious plans for the future
The Conch Group is already Chinas
largest cement producer, accounting for
4-5 percent of the nations current con-
sumption. Conchs plans for the future
include further expansion of production

Chinas leading cement producer, the Anhui Conch Group, successfully operates
these two 10,000 tpd production lines at the Tongling plant. FLSmidth supplied
the principal equipment, testament to the companys experience and expertise
in supplying mega-size cement production plants.

Highlights April 2007 11

 The Americas next generation of plants

The world has seen an unprece-
dented rise in new plant capacity
in the past couple of years with
North America playing a leading
role. New plants there have the
most modern equipment and
a number of special design fea-
tures and operational require-
ments.
Since 2005 about 22 million metric
tonnes per year of new capacity has
been sold in North America, and a simi-
lar amount is identified in future proj-
ects. FLSmidth was well prepared for this
wave of activity and is proud to have
captured the majority of the new pro-
duction market in the Americas. This lat-
est generation of contracted projects will
be built and commissioned over the next
couple of years.
Of particular interest is Holcims massive
greenfield plant being built alongside the
Mississippi River in Ste. Genevieve Coun-
ty, Missouri, USA. This facility will feature
the largest single clinker production line
anywhere in the world with an annual
cement capacity of four million metric
tonnes. Similarly, the new CEMEX S.A.B.
DE C.V. (CEMEX) Tepeaca plant will, at
2,300 metres above sea level, be the
largest single clinker production line ever
built in Mexico and Latin America.
So, what state-of-the-art solutions in
the pyroprocess and milling areas is
FLSmidth supplying?
The pyroprocess solution
Two- or three-support kiln
At the heart of the clinker production
line is the kiln, and all of the projects
with the exception of the large Holcim
and CEMEX plants will incorporate the
ROTAX-2 kiln, Figure 1. This two-support
design uses the standard features of tan-
gential suspension, electro-mechanical
friction drive through the supporting
rollers, and fully self-aligning roller sup-
ports.
Due to the sheer size of the kilns re-
quired at Ste. Genevieve and Tepeaca
which are 6.6 metres (21.7 feet) in diam-

A wide spread of projects

The recent projects using FLSmidth
equipment in the Americas (see Table 1)
have a broad spread of production line
capacity, ranging from 2,540 to 12,000
metric tonnes per day. But in general,
the type of core equipment is similar at
all plants.

Figure 1: Modern two-support kiln

Table 1: New FLSmidth projects in the Americas for 2005-2006*

Company Plant Clinker production (tpd)
Holcim (US) Inc. Ste. Genevieve, Missouri, USA 12,000
CEMEX S.A.B. DE C.V. Tepeaca, Mexico 10,000
Essroc Cement Corp. Martinsburg, West Virginia, USA 5,000
Keystone Cement Bath, Pennsylvania, USA 3,000
Caribbean Cement Co. Rockfort, Jamaica 2,800
GCC Rio Grande Inc. Pueblo, Colorado, USA 2,630
Rinker Materials Brooksville, Florida, USA 2,540
* Not including two undisclosed projects totaling 8,570 tpd

12 Highlights April 2007

 Figure 2: Recently installed MMC cooler in the United States.
eter and 93 metres (305 ft) in length
three supports will be used. But the de-
sign will still take advantage of semi-
rigid roller supports and tangential sus-
pension-type attachment.

ILC or SLC-D Preheater System

In general, the low-NOx ILC (In-Line Cal-
ciner) preheater system from FLSmidth
has become the standard solution for
cement plants today. It is proven to have
the lowest NOx and CO emissions in the
industry and is suitable for burning both
traditional fossil fuels and many alterna-
tive fuels. All but two of the projects will
have this type of preheater system. Sev-
eral of the low-NOx ILC preheaters will
also incorporate a high-temperature oxi-
dation zone to make them even better
for burning petcoke and other alterna-
tive fuels. The preheater designs for the
large production systems at Ste.
Genevieve and Tepeaca are spectacular
in their own right and will incorporate
twin-string versions of the ILC system.
FLSmidth also offers the low-NOx
Separate-Line Calciner with Downdraft
pre-combustion chamber (SLC-D). This
type of preheater system will be supplied
to Keystone Bath, as well as an undis-
closed plant, due to especially
largeamounts of liquid waste firing. The
SLC-D system can meet stringent resi- Clinker cooler Customers particularly like the fact that
dence time requirements for particular The latest generation Cross-Bar cooler, the MMC has fewer wear parts, longer
waste fuels to achieve acceptable de- Figure 2, known as the Multi-Movable wear life, and horizontal construction.
struction and removal efficiencies. Cross-Bar cooler (MMC), is being sup- Two retrofit coolers with MMC cassettes
plied to all the projects except Caribbean are already in operation, and the GCC
Cement and Essroc Martinsburg. Due to Rio Grande Pueblo plant will become the
timing or prior arrangements, these first full new MMC cooler to come on
plants will use the Cross-Bar technology line in the Americas.
in the original SFC design.
The success of the Cross-Bar cooler,
which has been on the market for 10
years, continues with the MMC design.
Highlights April 2007 13
The Americas next generation of plants

Figure 3: DUOFLEX burner in operation.

DUOFLEX burner
The very successful DUOFLEX burner,
Figure 3, will be supplied to all but one
of the projects. It is a modern, multi-
channel design that allows the firing of
multiple traditional and alternative fuels
while minimising NOx formation. The
DUOFLEX will not only be employed
as the main kiln burner, but also as
the calciner burner in the combustion
chambers of the SLC-D systems.

Secondary emission reduction

No other trend is more evident in todays
projects than that of increasingly strict
emission requirements. Permit levels of
NOx, SO2, CO, and VOCs are some of
the lowest ever seen, and, in some cas-
es, beyond the levels currently achiev-
able by primary equipment and process
design. For example, NOx emission levels

as low as 380 mg/Nm3 at 10% O 2 (1.6

lb/STcl) during the summer ozone season
will be required for Holcim Ste. Gene-
vieve. Fortunately, effective and simple
methods exist for controlling the emis-
sions but at a significant price of opera-
tional changes or handling and using
costly reagents.
SNCR (Selective Non-Catalytic Re-
duction) with the use of aqueous ammo-
nia has become a popular and effective
technique for secondary NOx reduction
and will be installed from the outset in
many of the projects. Provisions for hy-
drated lime injection for SO2 reduction
are also included in many cases. To con-
trol CO or VOC emissions, two of the
plants will feature a material split to di-
vert a portion of the incoming kiln feed
to a lower position in the preheater, or
even direct it to the calciner.
The milling solution
Raw grinding
Vertical roller mills for raw grinding have
been the industry standard for many
years, and FLSmidth recommends either
the FRM or ATOX design depending on
the application and specific require-
ments. Most of the projects will feature
the FRM mill, Figure 4, and the ATOX
raw mills being supplied at Holcim Ste.
Genevieve will be the first of their kind
in the US.
Rinker Brooksville is the sole excep-
tion to the vertical roller mill standard. It
will use a ball mill for raw grinding be-
cause the extreme characteristics of the
raw materials are not suitable for
smooth and reliable operation with a
vertical roller mill. In this unusual case, a
trade-off of using a less energy-efficient
technology is more practical.
Coal grinding
All plants with FLSmidth-supplied coal
mills will be vertical roller mills of the
ATOX design, Figure 5. Popular for many
years in other parts of the world, includ-
ing Latin America, the ATOX coal mill
has finally entered the US market. Con-
tinuous improvement of the ATOX coal
mill has resulted in todays compact con-
struction together with high efficiency
and reliability.
Cement grinding
FLSmidth will use the OK vertical roller
mill, Figure 6, for all finish cement grind-
ing. This type of mill has become the
market standard, and a total of 22 OK
mills will be in operation in the Americas
by the time this new group of projects is
commissioned.
The OK mill has better grinding effi-
ciency than any other vertical roller mill
on the market. Many of the new plants
will incorporate a compact layout, using
cyclones and hot gas recycling to min-
imise the vented volume and emissions
to atmosphere.
.
14 Highlights April 2007
Figure 4: FRM vertical roller mill for raw grinding.

Figure 5: ATOX vertical roller mill for coal grinding. Figure 6: OK vertical roller mill for cement grinding.

Highlights April 2007 15

 The preferred supplier for 125 years

Ever since its creation 125 years

ago, FLSmidth has been charac-
terised by innovative thinking and
a desire to find the best possible
technological solutions. Today,
more than 650 of the 6,500 peo-
ple who make up the companys
workforce are directly involved in
developing the technology of the
future.
Frederik Lsse Smidth, an Poul Larsen, a mechanical engineer Alexander Foss, a civil engineer of
innovative and practically-minded and a gifted organiser with strong great vision and political commit-
machine designer, opened his Tech- business acumen, joined the firm in ment, entered the firm in October
nical Bureau on 2 January 1882. July 1884. 1885.

1890 1893 1898

The Shofer continuous working
shaft kiln manufactured Portland
and other cements and lime.
The fuel consumed in a Shofer kiln
was only a third of that used in an
ordinary kiln.
Far better at crushing hard clinker than the previous technology, FLSmidths In the USA, the oil-fired rotary kiln for
tube mill signalled the start of a whole new era in cement production. burning cement had been developed to
save labour costs. In Europe, FLSmidth
introduced the coal-fired rotary kiln,
constructing two 18 m long kilns at
the Aalborg Portland cement plant.

1960 1964 1980 1992

solution compared to the Cement Co. plant is home to the
Preheating of particles suspended in The United States holds
long and energy-intensive worlds largest rotary kiln measuring 7.6
hot kiln gases was invented by great historical signifi- cance
wet kilns. x 6.4 x 6.9 x 232 m.
FLSmidth back in 1933 but did not for FLSmidth as the source
come into general use before 1960 of the rotary kiln technology
when it proved a better and cheaper that was a cornerstone of
the companys international
success. The Dundee
16 Highlights April 2007
The ATOX vertical mill com- bines the grinding, separa-
tion and drying processes into a single unit.
16 Highlights April 2007
FLSmidth contracts to build the worlds
first 10,000 tpd kiln at Siam City Cement
Company in Thailand. The same year
Siam Cement Co. orders a similar kiln for
their Khao Wong plant also in Thailand.

1900
The Kominor mill was specially developed for heavy
grinding. It was later ousted by the tube mill.
1998
The first SF Cross-Bar cooler based on
the concept of fixed grates, separates
clinker conveying through cross-bars
and air flow control through mechanical
flow regulators.
From the start, FLSmidth focused on the technical and
scientific aspects of cement production.
1922 1925
The UNAX satellite cooler, The famous Symetro gear together with
which reduced dust problems, the Unidan tube mill became the preferred
was constructed as an integral installation for cement grinding.
part of the kiln.
2001 2007
The HOTDISC is used to burn The cement plant at Ste. Genevieve, Missouri, will hold
large items of waste and the hot the worlds single biggest production line with a capacity
combustion gases are utilised in of four million tpy, corresponding to 12,000 tpd.
the calcining process.
Highlights April 2007 17
 D.G. Khan upgrades cooler
The Pakistani cement producer,
D.G. Khan Cement Co. Ltd. and
FLSmidth have worked closely
for more than twenty years. The
upgrade project for the cooler
serving kiln no. 2 at the D.G.
Khan plant is the latest example
of their long-standing relation-
ship. With the contract signed in
January, commissioning of the
upgraded cooler is expected to
take place in the spring of 2008.
After lengthy discussions about extra
cooling capacity, the final contract was
signed. The talks were based on current
operational data, notably the clinker
temperature, and D.G. Khan eventually
opted for a major cooler expansion solu-
tion including two Multi-Movable Cross-
Bar cooler (MMC) cassettes. Instead of a
traditional clinker crusher, D.G. Khan
chose a Heavy-duty Roll Breaker (HRB),
consisting of two crushing rolls and sev-
eral transport rolls.
18 Highlights April 2007
A second upgrade for the cooler The first of many?
Some years ago, FLSmidth upgraded D.G. Khan is the first plant in Pakistan to
D.G. Khans kiln no. 2 from 3,300 tpd to be upgraded with MMC cassettes and
4,000 tpd, carrying out a minor modifi- an HRB. FLSmidths Customer Services
cation of the existing Coolax cooler. This Projects department hopes to upgrade
time the cooler is being upgraded with several similar production lines using
MMC cassettes, which are similar to the the same concept in Pakistan in the near
modules of an SF Cross-Bar cooler, but future.
without the supporting frame.
The major difference is the way the
drive mechanism is constructed and
works in the MMC cooler. Each cassette
has two built-in drives and cross-bars
above the grate line, but not all cassettes
have a hydraulic cylinder. And all the
cross-bars are moveable and reciprocate,
which improves conveying efficiency.
The MMC cooler can be installed hori-
zontally and the drives can have individ-
ual stroke lengths and speeds to match
the operation of the clinker belt conveyor.
D.G.Khan Cement Co. has recently ordered a cooler upgrade
including the new Multi-Movable Cross-Bar (MMC) cooler
cassettes and the Heavy-duty Roll Breaker (HRB). This type of
upgrade is the first in Pakistan.
Delivering worlds largest-capacity
DOCKSIDER
FLSmidths Pneumatic Transport Depart-
ment (FLS-PT) has been awarded a con-
tract with Eastern Portland Cement
Company to supply a new ship unloader
for their Florida terminal, Port Manatee.
The ship unloader is a gantry-mount-
ed DOCKSIDER type. Since the cus-
tomers berth is shared by other port
tenants, the gantry is supplied with
steerable rubber-tyre wheelsets for
movement to a parking position away
from the dock.
With a design capacity of 700 metric
tonnes per hour, this ship unloader will
be the largest-capacity DOCKSIDER in The Eastern Portland ship unloader will be similar to the Hawaiian Cement
the world. The vacuum system includes unloader shown here
our newest design vacuum arm capable
of unloading 45,000 DWT bulk vessels.
The pressure system includes three
FLSmidth SAHARA dry screw compres-
sors and conveys cement through a 22-
inch diameter pipeline nearly 1,500 feet
to storage.
In addition, FLS-PT has entered into
an agreement with Borton LC of
Hutchinson, Kansas to supply the distri-
bution, reclaim and loadout equipment
for the two new storage silos. FLS-PT will
also supply equipment to the customers
general contractor for modifications and
improvements to the four existing silos.
The Eastern Portland Port Manatee Terminal

Correction
In our November 2006 edition of Highlights the picture of the
Faraz Firouzkuh Cement Company (FFCC) plant on page 21 was
mistakenly referred to as being the Fars Firuzkuh cement plant.
The editors regret this mistake as we know the justifiable pride
that Faraz Firouzkuh Cement Company takes in the successful
commissioning of their new line.

Highlights April 2007 19

 KOCH strengthens FLSmidth Group
FFE Minerals, the minerals
processing arm of FLSmidth, re-
cently acquired the German and
Austrian divisions of KOCH Trans-
porttechnik. An exciting addition
to the FLSmidth Group, KOCH
is a dominant global force in
materials handling systems and
the clear market leader in pipe
conveyors.
KOCH designs, manufactures and servic-
es a broad range of mechanical trans-
port systems and equipment used in
minerals processing and cement produc-
tion around the globe. KOCH Austria
currently supplies pipe conveyors for the
world's largest cement production line in
St. Genevieve, USA which was designed
and is currently being constructed by
FLSmidth.
Global reputation combined with
local presence
Uniting KOCH's expertise in conveying
equipment application, design and engi-
neering with FFE Minerals' direct pres-
ence in 11 countries will help establish a
powerful market position for the com-
pany. FFE Minerals is also creating a new
Materials Handling Technology Centre to
be headed by Heinz Knel. Currently the
General Manager of FLSmidth-owned
MVT, he also has 18 years previous ex-
perience in working with KOCH.
World's longest pipe conveyor
One of KOCH Germanys biggest proj-
ects is the construction of the world's
longest pipe conveyor for Cementos
Lima in Peru. With a total length of
8.2 km, the finished pipe conveyor will
be able to handle up to 690 t/h of
cement (upper strand) and 515 t/h of
coal (lower strand).
The Cementos Lima pipe conveyor
will transport materials between the
20 Highlights April 2007
cement plant in Atoconga and the port
in Conchn, without transfer stations.
The upper strand of the conveyor will
carry cement and clinker from the plant
to the ship loading facility, while the
lower strand will convey coal and lime-
stone, as well as other materials such as
iron ore, iron pellets and gypsum. To
avoid material spillage from the lower
strand, the belt will be turned at either
end, allowing the same side of the belt
to carry material in both directions.
Superior to the belt conveyor
Between the plant and the ship loading
pier, the conveying line passes through a
twisting 6.5 km tunnel, taking it under a
network of busy roads. The pipe convey-
or is ideal for this. Far superior to con-
ventional belt conveyor technology, it
can follow horizontal and vertical curves
with a minimal radius which allows opti-
mum integration into the tunnel. The
pipe conveyor also eliminates dust emis-
sions and material spillage, improving
ventilation and minimising the need for
tunnel maintenance.
In addition to the transport system,
KOCH is also supplying various storage
facilities for clinker and cement. The sys-
tem is due to start in 2007.
Recently acquired KOCH Transporttechnik is
supplying the worlds longest pipe conveyor in
Peru to carry bulk materials between the cement
plant and the port.
A large section of Cementos Limas pipe
conveyor runs underground. The enclosed
transport system is easy to service even in
the tunnel.
The 8.2 km long pipe conveyor is a dust-free and efficient transport system and is easily configured to follow sharp vertical and horizontal curves.

FLSmidth opens new workshop in China

On 9 January 2007, FLSmidth inaugurat-
ed its brand new manufacturing plant in
the port of Qingdao in Chinas Shandong
province. The workshop covers an area of
12,000 square metres and replaces the
old facilities which had become too small.
The workshop is already busy producing
various types of FLSmidth machinery and
machine components, notably for
Duoflex burners, SF Cross-Bar and MMC
coolers, pneumatic transport equipment
and Pfister weighfeeders.
The workshop was designed, built
and installed in accordance with sched-
ule. It took only thirteen months from the
project was approved by FLSmidth and
the local government officials to the man-
ufacturing plant was officially opened
and production was up and running.

Highlights April 2007 21

 Airtech fabric filter technology
the optimal choice for todays
cement industry
The requirements for process
filtration equipment are chang-
ing in the cement industry. With
kiln and mill capacity increasing
and emissions decreasing
environmental equipment must
become larger in size. Conse-
quently, fabric filter technology,
in particular large fabric filters,
is gaining in popularity.
Giving customers a crucial
advantage
Already a leading supplier of bag filters
to the cement industry, FLSmidth Airtech
is continuously developing products
which offer customers a technological
edge and reduce operating costs.
Our fabric filters are designed to deliver:
Low emissions
Low differential pressure
Low compressed air consumption
rates
Long filter bag lifetime
To meet these goals, the filter products
are fitted with special gas distribution
features that ensure a low pressure drop
across the filter media and a long life.
The technology also utilises low cleaning
pressure techniques to optimise the
cleaning process.
In the DuoClean filter the gas is exposed to the filter bags
from the bottom of the bags - like the UniClean - and as
a new feature also to the side of the filter bags. This new
approach of distributing the gas and dust makes it possible
to use long bags (6 8 m).
22 Highlights April 2007
Our pulse jet products:
Application
Kiln/Cooler/Bypass
Cement/Coal Mill
Nuisance application
The product range above, first launched
ten years ago, has been applied in more
than 150 process filters across an array
of applications. And thanks to ongoing
improvement efforts, FabriClean, Pulse-
Clean and UniClean are now established
as market leaders. Customers have been
particularly impressed with the gas and
dust distribution and low pressure clean-
ing features which have delivered re-
markable results.
As well as new filters, FLSmidth
Airtech also offers an electrostatic pre-
cipitator (ESP) conversion, with the
proven fabric filter technology built into
the ESP. Such a conversion can ensure
lower future emissions if capacity in-
creases or emission levels change. Our
reference list currently includes more
than 30 conversions and hybrid filters (a
combined ESP and fabric filter, usually in
the same casing).
The main benefit of hybrid filters is
the synergy between the filter technolo-
gies (pre-separation and charging of the
dust), which enables either a higher A/C
ratio or smaller pressure drops. Docu-
mented results of this synergy have
shown reductions in the cleaning cycle
by a factor of 30-50. Our work with hy-
brid filters in kiln and cement applica-
tions has delivered some impressive re-
sults. For instance, we have seen cement
mill filters operating at a pressure drop
of 50 mm Wg, and an emission rate of
Products available
FabriClean or PulseClean
DuoClean or UniClean
CE filter
1.5 mg/Nm3. Whats more, the bags
lifetime is more than four years.
Working to increase bag
lifetimes
Bags for FLSmidth Airtech fabric filters
are supplied by Advanced Filtration Tech-
nology (AFT) a US-based bag produc-
tion company fully owned by FLSmidth.
The main factors for long filter bag life-
time, besides gas and dust distribution,
are bag material selection, bag and cage
design, and compliance with standard
operating and maintenance philosophy.
The very close working relationship
between FLSmidth and AFT has also
helped generate additional knowledge
about how to achieve longer lifetimes
for the filter bags. Specifically, this col-
laboration has resulted in improved me-
chanical design and cleaning cycle pa-
rameters. Achieving longer and longer
bag lifetimes is a continuous process,
and, together with AFT, we are commit-
ted to making further progress in the
years ahead.
The optimum choice
Our products are ideal for medium to
large filter applications in the cement
industry. The standard design has a filter
capacity exceeding 1,500,000 m3/hr
in one filter casing. We have delivered
solutions that include several filters,
reach with capacities in the range of
1-1,500,000 m3/hr, all of which are
operating successfully.
Highlights April 2007 22
 This filter is designed for venting of large cement kilns.
Always at the forefront of technological
advances, FLSmidth was the first compa-
ny to apply long bag filter tech-nology
for kiln venting. And recently, FLSmidth
Airtech was selected to supply long bag
filter technology to the worlds largest
cement production line Ste. Genevieve
in the USA (12,000 tpd).
New product hits the market FLS
Airtech recently launched a new filter
type DuoClean targeted at cement
mill applications. Increases in cement
mill capacity have pushed the UniClean
filter into a very long and slim filter,
which is not the most economical
23 Highlights April 2007
shape for a large fabric filter. A more
economical filter with long filter bags
(up to 8 m) is being launched as the op-
timal solution for very large cement mill
circuits. The DuoClean filter is also
equipped with a state-of-the-art gas and
dust distribution system which secures a
very long bag life. The main benefits of
this filter are its significantly lower capi- Filter bags (P84) after 8 years in operation. There is no me-
chanical damage on the surface such as rips, cracks or holes.
tal cost and greatly reduced footprint.
Well agglomerating dust layer.
Highlights April 2007 23
 Sanghi Cement production
at historic 10,500 tpd
During November 2006, Sanghi
Cement Plants C2 string was
commissioned, and within a
week of its operation it touched
a historic high of 10,500 tpd, be-
yond the guaranteed production
level of 9,000 tpd.
The plant is located in the Kutch district
in the State of Gujarat, on the northwest
border of India. The State of Gujarat has
the longest coastline among all states in
India and has a long tradition of mar-
itime trade.
The original Sanghi cement plant
was conceptualised in 1994-95 for a ca-
pacity of 7,500 tpd with two preheater
towers. However, after combating with
innumerable bottlenecks, including envi-
ronmental clearances, the work on this
project commenced much later. At this
stage, the plant was redesigned to pro-
duce 9,000 tpd with three preheater
strings. However, when commissioned in
the month of March 2002 the plant was
rated for an output of 7,500 tpd with
only two preheater towers.
The clinker grinding plant is located
approximately 12 km away from the
clinkerisation plant, on the shores of the
Arabian Sea. This plant is self-sufficient
with electricity and water, having its own
power generating sets and desalination
facility to cover its service water require-
ments.
Third preheater string
now on stream
Now with the commissioning of the
third preheater tower the plant has been
optimised at an output level of 10,000
tpd against the guaranteed 9,000 tpd.
It is Indias largest capacity plant with a
single kiln and one of its most modern
100% lignite fired plants.
It has been a rich experience for
FLSmidths specialist team to commission
a single kiln with a three-string six-stage
preheater and calciner (one ILC and two
SLC strings). Additionally, arriving at a
capacity of more than 10,000 tpd once
again testifies to FLSmidths world-lead-
ing technology and project capability
when it comes to very large kiln systems.

Major equipment includes:

FRM-59.480 vertical mill for limestone grinding,
capacity 670 tph, baghouse for dedusting
Two FRM-26.30D vertical mills for lignite grinding
Three-support kiln dia. 5.6 m x length 84 m with
CIS MFR cooler built by Fuller in 1995
Six stage preheater with precalciner
Alkali bypass

With Sanghi Cement Plants third preheater string (the tower to the right)
now on stream, the plant is producing 10,500 tonnes per day.

24 Highlights April 2007 Highlights April 2007 24

 A cost-effective shortcut
to dry conversion
The rising price of fuel is a grow-
ing burden on wet or semi-wet
plants because of the heat it
takes to dry the raw slurry. As a
result, cement producers are
looking at ways to reduce heat
consumption. A hammer mill dri-
er downstream of the converted
cyclone preheater kiln could be
the answer.
Several cement plants still use a wet or
semi-wet process. One way to reduce
heat consumption is to convert the en-
tire production line to the more fuel-effi-
cient dry process. But, this is often a ma-
jor project involving many elements, in-
cluding raw material preparation, raw
grinding, shortening the kiln and chang-
ing the cooler.
Partial conversion of
the wet plant
Converting the plant to the semi-dry
process is a much simpler and more
25 Highlights April 2007
cost-effective alternative, particularly if Reliable and low cost operation
the raw materials have a high natural The fineness of the feed must always
moisture content. The wet preparation match the requirements of the burning
of the slurry is retained, and the wet- process. The hammer mill drier merely
process kiln converted into a cyclone serves to disagglomerate the wet sticky
preheater kiln system. This solution is materials and only to some extent
cheaper than an all-out dry conversion, grinds the materials.
and entails drying the moist raw materi- An extremely reliable machine, the
als in a separate hammer mill drier be- hammer mill drier has low maintenance
fore they enter the kiln system. costs. Because the machine is an integral
part of the kiln system, operational relia-
The hammer mill drier bility is very important. So far, FLSmidth
is the core has designed hammer mill driers that
The principal machine involved in the meet the requirements of kilns produc-
semi-wet concept is the hammer mill dri- ing up to 4,000 tonnes per day. If the kiln
er. This machine is specially designed to system consists of two preheater strings,
disagglomerate and dry in one opera- two driers may operate in parallel.
tion sticky, non-abrasive raw materials
such as chalk, clay, slurry filter cake or
simply slurry. The drier easily copes with
a moisture content in excess of 30 per-
cent.
An apron feeder, a self-cleaning ro-
tary sluice or slurry spray nozzles feed
the materials into the hammer mill drier.
Hot preheater exit gases with an inlet
temperature of up to 750oC continuous-
ly sweep the hammer mill drier. After
passing the hammers, most of the ma-
terial is disagglomerated to a suitable
fineness, and is then swept away by
the air. Final drying takes place in the
riser duct, and the raw meal is then
separated in a cyclone.
The hammer and the rotor are de-
signed to effectively disagglomerate the
feed and ensure heat is transferred from
the gases to the material. To improve
drying efficiency, a static or dynamic sep-
arator may be installed in the riser duct.
The purpose of the separator is to return
the large lumps or coarse grains to the
hammers for further pulverisation, en-
abling more moisture to evaporate.
The hammer mill dryer disagglomerates and dries
sticky, non-abrasive materials in one operation.
Highlights April 2007 25
 Contestants give kiln simulator
the thumbs-up
Last year, FLSmidth launched
Beat the Autopilot, a kiln simula-
tion competition designed to
demonstrate the complexity in
process control and optimisa-
tion. More than just competitive
fun, the simulator is a great
learning tool to help operators
improve their knowledge and
reaction times.
The completion was a web-based simu-
lation of an ILC kiln process where the
number of measurements and con-
trol handles was reduced signifi-
cantly for the sake of simplicity.
Also, in order to reflect the process
interaction in the shortest avail-
able time, the speed of the
simulation was acceler-
ated by a factor of
20. In this way
the players were
able to interact
with the simula-
tor and observe
the process re-
sponse to their own ac-
tions over 100 minutes in just
five minutes.
26 Highlights April 2007
Highly responsive
Within days of its launch, dozens of
competitors from around the world had
signed up for Beat the Autopilot, pitting
their wits against each other in a bid to
get closest to the optimum process per-
formance target. Feedback has been ex-
tremely positive, with participants full of
praise for its realism and attention to de-
tail. One of the early front-runners was
Adrian Oarga, a Plant Operator at Hol-
cim Romania. He says: The simulator
does an excellent job of reproduc-
ing a real kiln, and it responded
to every change I made. For ex-
ample, when I reduce the fuel
in the burning zone, oxygen
levels at the back end increase
and the NOx decreases
which is what hap-
pens in a real
kiln.
Close to reality
Randy Walters also enjoyed Beat the
Autopilots realism. And as a Control
Supervisor operating a four-year-old
3,500 tonne per day 5-stage FLSmidth
preheater low NOx kiln, a 400 tonne per
hour vertical raw mill, a vertical coal mill
and a 150 tonne per hour OK mill for Salt
River Materials Group, he should know.
He said: Its pretty close to the real thing.
I like that it shows that making too many
moves will put the kiln in a cycle that can
result in out of spec. clinker or emissions
that arent within range.
Asked what functions would have
enhanced the simulators accuracy,
Randy Walters opted for kiln speed and
secondary air temperature. But overall,
he felt the simulator was a very good
learning tool. It can really increase the
knowledge and improve the reaction
times that are needed to operate newer
kilns, he concluded.
Our idea with this web competition
was to demonstrate the process control
complexity, says Hassan Yazdi, FLSmidth
Automation Product Manager. Chang-
ing one parameter for process control,
main fuel for example, influences several
Highlights April 2007 26
 process parameters. Some of these are
desired changes, some are not. This is
due to interactions inside the process.
That is why a tight control of the process
for best utilisation of power and fuel re-
quires a computer-based expert system,
an autopilot in other words.
As the players could play as many
times as they liked, their performances
have steadily improved. This shows that
a safe environment, where operators
can conduct trial and error exercises
will certainly prevent unnecessary waste
production, process shut downs and
overhead production costs.
This web-based process simulation
has also proven the potential for remote
operator training in the cement indus-
try, concludes Hassan Yazdi.

New literature
FLSmidths 125th anniversary book To
Since the last issue of Highlights, FLSmidth has issued
order copies of FLSmidths 125th
the following new brochures. Order your own copy anniversary book, please contact Marketing
from FLSmidths Marketing Department at info@flsmidth.com
info@flsmidth.com or download a PDF file from our
website, www.flsmidth.com

Air Blast Controlled inlet FLSmidth O & M the
ABC inlet total service concept
Describes the new cooler FLSmidth is widening its scope of
inlet which makes snowmen service to cement producers by
a thing of the past. introducing complete Operating
and Maintenance contracts.
FLSmidth terminal
solutions
A complete range of ship
unloading and loading facili-
ties is offered by FLSmidth.
Our capabilities
All the materials handling
systems and equipment
compiled in one brochure.
Addresses worldwide
An up-to-date list of
FLSmidth Group
companies and offices
around the globe.

27 Highlights April 2007 Highlights April 2007 27

 Take the e-highway to
FLSmidth spare parts
Every time we build a cement
plant or deliver machinery and
equipment, we make a commit-
ment to provide any additional
parts our customers might need
to operate and maintain their
plant or equipment. This has
been our promise for the last
125 years and one we will up-
hold well into the future.
specifications every time, so we accu-
rately identify the correct parts when
handling orders for replacements. It is
equally important that we receive the
right information to process orders
swiftly and efficiently.
The key to correctly identifying spare
parts is maintaining a detailed and up-
to-date record of the machinery sup-
plied, including each of its components.
Which is why every contract for
FLSmidth machinery includes a compre-
hensive catalogue of spare parts for the
plant or installation in question. Tradi-
tionally, these catalogues have been
presented as paper copies. However,
we are introducing an additional e-
Catalogue to new contracts which can
be accessed via the FLSmidth Customer
Services website.

A standard cement plant contains more

than a million different parts - the major-
ity of which are non-standard - and
FLSmidth can offer replacements for all
of them. For the machines we sell, we
can supply everything from the smallest
screw to the largest rotating gear com-
ponent. Its essential that the customer
receives the right parts with the correct

28 Highlights April 2007 Highlights April 2007 28


e-Catalogue saves time and effort
The e-Catalogue is a dynamic and user-
friendly tool for searching for spare parts
information. An online resource, the e-
Catalogue for the particular plant is up-
dated when FLSmidth Customer Services
is informed about subsequent changes
or adjustments at the customers plant
and also when FLSmidth and the cus-
tomer agree on technological improve-
ments to equipment or components.
This means that customers no longer
need to update their own spares docu-
mentation. And to eliminate errors, both
the customer and supplier use the same
information.
An improvement on its hard copy
counterpart, the e-Catalogue is simple
to work with and precisely identifies
spare parts by part number. Customer
inquiries sent via e-Catalogue will auto-
matically track all the information need-
ed to identify the individual parts. This
information is sent to the customer and
forwarded to FLSmidth Customer Ser-
vices for swift processing, saving time
and effort for both parties involved.
e-Catalogues available for
all recent and new contracts
The e-Catalogue will be provided with
new contracts as a supplement to the
traditional hardcopy catalogues. e-Cata-
logues are also available for all equip-
ment contracts dated from 2000 and we
are working to introduce e-catalogues
for all equipment contracts entered into
between 1995 and 2000.
We believe that electronic documen-
tation is the way forward and we
expect to further develop and expand
our e-Catalogue platform to continue to
make it even easier to do business with
FLSmidth.
Vasavadatta Cement
chooses FLSmidth pyroprocessing
technology
In December 2006, FLSmidth
commissioned a 3,800 tonnes
per day pyroprocessing system
for Vasavadatta Cement, a
member of B.K. Birla Groups
Kesoram Industries Ltd. A
leading cement manufacturer,
B.K. Birla operates two clinker-
isation lines in the southern
Indian state of Karnataka.
In June 2004, FLSmidth India was invited
to bid for a third line at the existing site
at Sedam. While the proposal was being
evaluated, key representatives from
Vasavadatta Cement visited FLSmidth-
supplied cement plants in India, China
and Europe.
The Vasavadatta representatives
were impressed by the efficiency of the
FLSmidth plants they visited. This, and
FLSmidths prompt response to the bid,
meant Vasavadatta Cement selected
FLSmidths most advanced pyroprocess-
ing technology.
First Rotax in India
Vasavadatta Cement is using the first
Rotax kiln in India, a 6-stage ILC pre-
heater (with provision for future incor-
poration of a HOTDISC) and an SF Cross-
Bar cooler. The plant also includes a bag-
house designed for 800,000 m3/hr at
2400 C. The baghouse complies with
stringent emission standards and comes
with an on-line maintenance facility. The
baghouse uses specially treated fibre-
glass bags, and has an overhead outlet
manifold that was designed specifically
to customer layout requirements.
The kiln firing and kiln feed systems
are provided with Pfister rotor scales
(sourced from Pfister Germany/Pfisters
licensee in India).
With plant operation stabilised,
clinker production now stands at 4,200
tonnes per day with free lime well below
1.5 percent as guaranteed.
Vasavadatta Cements new line 3 contains the
best of FLSmidth pyroprocessing technology,
including the first Rotax kiln in India.
Highlights April 2007 29
 Sebryakovcement sets the ball
rolling in Russia
On a cold winters day in January 2005,
the contract for a ball mill installation at
JSC Sebryakovcement in Russia became
effective. In addition to the 120 tph
UMS 46x14 mill, the contract included a
SEPAX separator, a MAAG CPU gear unit
and FLSmidth Automation control
equipment. The contract was preceded
by several rounds of tendering and
negotiations.
What made the order particularly in-
teresting was the fact that it came from
Russia, and so was a sign of growing
activity in this potentially huge market.
JSC Sebryakovcement was among the
very first to team up with FLSmidth in
the expansion and modernisation of the
Russian cement industry.
Now, two years later, cement con-
sumption in Russia has rocketed above
the magic 50 million tpy mark, and the
Sebryakovcement ball mill is working all
out. The plant has achieved, and at
30 Highlights April 2007
times exceeded, the guaranteed
throughput of 120 tph of standard OPC
ground to a fineness of 3,200 blaine,
which makes this mill the largest in-
stalled in Russia. By January 2007, the
parties involved in the project were able
to celebrate a job well done with the fi-
nal handing over of the grinding plant.
Getting the job done
JSC Sebryakovcement is about three
hours drive northeast of Volgograd,
which is a fairly remote place even by
Russian standards. As a result, the proj-
ect had to be planned and organised in
minute detail and the customer was
keen to ensure good working conditions
at the site. FLSmidths staff were accom-
modated at a nearby hotel owned by
JSC Sebryakovcement and participated
in all stages of the project, from open-
box inspection, supervision of mechani-
cal and electrical installation to final
commissioning. FLSmidth Automation
and MAAG Gear specialists also took
part in the process.
FLSmidth used its global organisa-
tion to design the plant and have the
machinery manufactured. It is hoped
that the Sebryakovcement mill will serve
as a reference project that both the cus-
tomer and FLSmidth can be proud of
and inspire other cement producers in
Russia.
12 December 2006 saw the achieve-
ment of the guaranteed production lev-
el: the mill ran for 68 hours at 90 per-
cent charge with only two stoppages
lasting a total of one hour. Since then
the ball mill has just kept on rolling.
Sebryakovcements new UMS cement mill is produc-
ing 120 tph of standard OPC. The successful com-
missioning and final handing over was celebrated in
January this year.
The UMS mill was delivered by barge and then by truck to the Sebryakovcement plant, 300 km northwest of Volgograd.

Can you travel next Wednesday? Continued from back page > > >
According to Niels, FLSmidths perform- As Niels sees it, training is the alpha and combining human understanding, proj-
ance in implementing these projects was omega. Both FLSmidth and its customers ect management and technology so that
recognised at ministerial level, and this should be willing to spend time and re- they are able to install, commission, opti-
fact contributed to the company and its sources on training selected candidates. mise and maintain a production line.
partner Orascom subsequently winning He himself has had the pleasure of guid- Once youve learnt how to combine
three major projects in Algeria: MSila, ing several young FLSmidth engineers these aspects, theres no limit to how far
CIBA White and CIBA Grey. and a large number of customer you can get, Niels concludes.
trainees. He has taught them the art of
Human understanding, project
management and technology
must interact
Almost 50 years after his first assign-
ment abroad, Niels is still on the go, ci-
gar in mouth. His favourite destination is
Titan in Greece, back where it all started.
Twelve kilns have been bought by Titan
from FLSmidth, and Niels has many old
friends in high-ranking positions among
Titans staff who continue to draw on his
and FLSmidths expertise. This is how it
should be in an industry based on long- Niels Munk Jensen (front row, left) as
term relationships. It takes time to learn a machinists apprentice in 1958.
how to install and maintain a cement
plant. Niels Munk Jensen at the same
spot in 2007.

Highlights April 2007 31

 Can you travel next Wednesday?
The year is 1970 and Niels Munk
Jensen is busy painting his flat in
Denmark when the phone rings.
On the other end of the line is
Mr P.A. Knudsen, FLSmidths
renowned Vice President of
Sales. An important kiln installa-
tion job is underway in Greece
and there is a vacancy for a bright
young engineer.
On the job:
Niels did not hesitate. He had been wait-
ing for such a call for a year while work-
ing in the Layout Department. Since his
youth, Niels had heard his father tell
stories about the exciting adventures of
an FLSmidth engineer working overseas.
So after leaving school at the age of
17, Niels was determined to work
abroad. In 1958 he embarked on
the classic career path
of an engi-
neer:
32 Highlights April 2007
a machinists apprenticeship at the
FLSmidth machinery works, followed by
a BSc in mechanical engineering and
then military service and officers training
in the Air Force. He had acquired crafts-
manship, engineering expertise and
leadership training, in that order.
Niels left for Greece the following
Wednesday and has been travelling ever
since, with the occasional assignment
back at headquarters in Denmark, en-
abling the children to stay in touch with
their Danish heritage.
Nihil sine labore
nothing without work
Thirty years of travel have taken Niels
and his family to
many countries:
Greece, Alge-
ria, Poland,
Chile, Holland,
Belgium, Mex-
ico, Turkey,
Egypt, Portugal and France. Major proj-
ects tend to last between one and three
years and Niels lists the Mediterranean
countries of Greece, Turkey and Algeria
as his favourite stop-offs.
Niels lets his work and spare time
blend to such an extent that he builds
replica antique monuments at all major
sites where he works. On these Greek-
inspired statues he inscribes his motto
Nothing without work in Latin, Arabic
and runes, serving as an inspiration for
visitors and a lasting testament to a job
well done.
His passion for international relations
is as strong as ever. As he says, If you
can build strong human relations at a
construction site, the technical side is a
piece of cake.
Niels left his mark on the camp facili-
ties of major turnkey projects in the
somewhat turbulent Algeria during the
1980s (Ain Touta) and 90s (Tebessa). De-
spite the political uncertainty, everyday
life had to go on. At Tebessa, the situa-
tion became so insecure that most for-
eigners left the country, though FLSmidth
remained at the construction site. How-
ever, it soon became necessary to aban-
don the beautiful camp, including the
large swimming pool designed by Niels.
While in involuntary exile in Spain, Niels
designed a new high-security camp
which the customer then built at the
plant site in just two months. A self-con-
tained community complete with restau-
rant, bar, lounge, chicken yard, park and
green houses, the camp and a host of
communal activities helped to keep spir-
its high in a tough environment.
The cement project was completed
to the customers full satisfaction and
the Final Acceptance Certificate was ob-
tained on time and without lengthy dis-
cussions, despite bureaucratic hurdles.
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