Highlights October 2014 PDF

OCTOBER 2014
Thinking
beyond
EPC
Semen Indonesia
gains newest
OK mill
™
World’s first
Postgraduate Cement
Plant Engineering Degree
2 HIGHLIGHTS CEMENT – October 2014
LETTER FROM THE PRESIDENT SCAN TO VIEW PER

MEJNERT KRISTENSEN
INTRODUCE THIS EDITION
OF eHIGHLIGHTS
Strong partnerships
for a stronger future
Despite the cement market still being in a cyclical downturn, we
are on track at FLSmidth having the highest level of unannounced
orders for three years. We are seeing growth in opportunities in
countries including the Democratic Republic of Congo, Angola,
Nepal and Indonesia, which you can read about in this edition of
Highlights. Recently, we announced several important large orders,
including the supply of a complete equipment package for a
3,000 tpd greenfield plant in the Democratic Republic of the
Congo under the flagship of Lucky Cement Limited and the Rawji
Group (page 4). Another is the major modernisation project of
Holcim’s Ada plant in the US (page 5).
Product development and innovation are a hallmark of FLSmidth’s

contribution to the cement industry. Our most recent major release
is the new version of the OK Mill, which has been commissioned
at Semen Indonesia’s Tuban cement plant in Java, Indonesia. This
newest version of the OK Mill is a prime example of how FLSmidth
applies performance data and practical knowhow gained from
operations around the world. Close collaboration with cement
plants is an important element of FLSmidth research. Our research
partnership with Titan Cement (page 24) in conducting tests on
its OK Mill reflects our commitment to delivering solutions that
help meet our customers’ business challenges.
Contributing to local society is also central to the value we offer,

in particular training of local workforces. Our joint initiative with
the Helwan University in Egypt is an example of the long-term
efforts being made in overcoming the critical shortage of skills in
operating cement plants. Read about the FLSmidth sponsorship of
Helwan University’s new post-graduate cement plant engineering
degree on page 8.
360° certainty solution: Design, Build and Operate

For cement plant owners and investors in today’s demanding
business environment, we are continuing to see a greater need for
strong partnerships to add capacity and expand into new markets
– from design and engineering to operation and maintenance.
FLSmidth continues to strengthen its offerings in all these areas.
Read more about FLSmidth’s Design, Build and Operate solution
on page 26.
Welcome to Highlights Cement.
Per Mejnert Kristensen

President, Cement Division
HIGHLIGHTS CEMENT – October 2014 3
CONTENTS 8
cement.flsmidth.com
gives you more details and
additional articles
Editor-in-chief Letter from the President 2 FEATURES

Nadia Haagen Pedersen
Managing editor World’s first Postgraduate Cement
Charlotte Lærke Backmann NEW ORDERS Plant Engineering Degree 8
Content editor
New cement plant for the Democratic Right first time 14
Kit Franklin Momme
Associate editors Republic of Congo 4 Thinking beyond EPC 26
Brenda Kaplan,
FLSmidth to modernise
Bharathkumaar Soundararajan
Editorial board Holcim US Ada plant 5 SITE REPORTS
Mark Brugan, Palle Erik Grydgaard,
Clinkerisation project underway
Sten Stoltze, Martin Strouhal, Hari TR
Layout: Cross-Border Communications INNOVATION in Nepal 22
New graphite seal optimises kiln Gas-insulated switchyard in India 32
© 2014 FLSmidth. All rights reserved.
Reproduction permitted quoting performance 12 Great teamwork and reliable
‘Highlights’ as source. The new ECS/ControlCenter™ technology minimise plant disruption 36
All product names used herein are V8 process control system 18

trademarks of their respective owners. FLSmidth research delivers PRODUCTS & SOLUTIONS
silo-safe cement 24 Semen Indonesia gains newest
Editorial office:
FLSmidth Innovative fabric filter design 28 OK™ mill 6
Vigerslev Allé 77
FLSmidth STRIKE-BAR crusher
® ®
34 Delivering to customer needs 21
DK-2500 Valby, Copenhagen, Denmark
Tel: +45 36 18 10 00
Fax: +45 35 45 44 27
News in brief 38
Email: highlights@flsmidth.com
www.flsmidth.com/ehighlights
24 Upcoming events 40
SCAN HERE FOR

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THE HIGHLIGHTS
MAGAZINE 22
USE THESE QR CODES AS A QUICK WAY TO GET
MORE INFORMATION VIA YOUR SMARTPHONE
OR TABLET. DOWNLOAD THE SCANNER AT
GETSCANLIFE.COM
FRONT COVER: ILLUSTRATION OF FLSMIDTH’S

NEWEST OK™ MILL, RECENTLY COMMISSIONED
AT SEMEN INDONESIA’S TUBAN CEMENT PLANT
(SEE PAGE 6)
NEW ORDERS
CONTACT HUBERT SUINAT

HSU@FLSMIDTH.COM
Read more about new
orders on www.flsmidth.com/
announcements
New cement plant for

the Democratic
Republic of the Congo
DR Congo’s newest FROM L-R: MR. AHMED MASHKOOR,
MR. CARSTEN ZACHER GRAUGAARD,
Rawji Group of the Democratic Republic of
the Congo. Together, they have formed a
greenfield cement plant MR. MUHAMMAD ALI TABBA, MR.
JOHANNES ENGELSBY HANSEN, MR.
joint venture, and the new entity, Nyumba
in more than 40 years HUBERT SUINAT Ya Akiba sarl, will become one of the
country’s largest cement producers.
Lucky Cement is Pakistan’s largest producer

(7.75 million tpy) and a leading exporter of
high quality cement. Founded in 1993, the
company has developed to be the Pakistani
cement industry’s trendsetter in terms of
business excellence, innovation and envi-
ronmental performance. It is part of YBG,
which is among Pakistan’s leading business
houses with an unparalleled reputation for
professional management and strong
business ethics.
The Rawji Group includes companies involved

in commerce, industry and finance. Its history
goes back to 1910 when Mr Meraldi Rawji,
an Indian businessman, started trading
activities in the Congo. Today, the fourth
generation of the Rawji family is in charge
FLSmidth has been selected to supply a The equipment to be supplied includes of the group’s interests that range from
complete package of equipment and engi- FLSmidth crushers, pyroprocessing equip- import and distribution of products and
neering for a greenfield cement plant in ment and vertical mills for raw meal, coal equipment and manufacture of soaps,
the Democratic Republic of the Congo. and cement grinding – all well-proven edible oils and cosmetics to property and
The plant will be located in the province of machinery that is characterised by high banking services. With its extensive activities,
Bas-Congo, approximately 250 km west of productivity, flexibility and energy efficiency. the group has in-depth knowledge of the
the capital Kinshasa. Worth EUR 68 million, country’s social fabric and its economy.
the contract includes all the engineering, DR Congo’s largest cement producer
equipment and support for the construction The partners behind the project are Yunus Growth market
of the 3,000 tpd plant. Brothers Group (YBG) of Pakistan under “In addition to its enormous mineral re-
the flagship of Lucky Cement Limited and sources, the Democratic Republic of the
CONTACT SCOTT ZOLOTSKY

SCOTT.ZOLOTSKY@FLSMIDTH.COM
Congo is characterised by growing stability

and a rapidly increasing population. There FLSmidth selected as
supplier for Holcim (US)
is therefore an urgent need for cement for
the development of infrastructure and
housing. For the past 40 years, no new
cement plants have been constructed in
the Republic, therefore it is a very interest-
Ada Oklahoma Plant
ing market for FLSmidth,” says Per Mejnert
Kristensen, President of FLSmidth’s Cement modernisation
project
Division.
The project
Nyumba Ya Akiba and the project’s finan-
ciers highlight FLSmidth’s proven ability to
supply environmentally optimised and
energy-efficient equipment. They demanded
a solid technology provider with a proven
ability to deliver reliable products, particu-
larly because of the challenging conditions
under which the plant will be installed and
operated.
The site of the new plant, Kinsua village

in Songololo territory of the Bas-Congo
province was selected because of the good
quality raw materials in its vicinity. The new
plant will provide much-needed cement for
housing construction and road building in
a rapidly growing region. DR Congo is
Africa’s second-largest country and there is
a significant gap between its current pro-
duction capacity and demand for cement.
As the political climate is beginning to FLSmidth has been selected to supply the With the installation of two new FLSmidth
stabilise, investments in the economy are major equipment pieces needed as Holcim dust collectors, the project will significantly
likely to take place. The new plant will also looks to modernise its Ada Oklahoma improve the plant’s ability to reduce the
be well placed for exports to neighbouring plant. The modernisation of the pyro pro- particulate emissions.
countries. cess is expected to deliver lower emissions
of nearly all air pollutants while anticipating This contract further demonstrates
FLSmidth is proud to have been chosen by an increase in the plant’s capacity. FLSmidth’s ability to help US cement
two highly professional and experienced producers prepare for the upcoming
business partners to supply a state-of-the- The contract includes a dryer crusher, a NESHAP regulations.
art cement plant in a region with vast single-stage preheater with an ILC-calciner,
potential for growth. a dedusting cyclone, a ROTAX-2® kiln, a
kiln bypass system, a Duoflex® kiln burner
and Cross-Bar® cooler.
PRODUCTS & SOLUTIONS
Semen Indonesia CONTACT KLAUS BØGESKOV HANSEN

KBH@FLSMIDTH.COM
gains newest
OK mill ™
Amidst a buoyant cement FLSmidth’s newest version of the OK mill has been commissioned
at Semen Indonesia’s Tuban cement plant in east Java as part of its
industry in Indonesia, South plans to use advanced, high-quality technology that delivers the
East Asia’s largest cement lowest possible energy consumption and the minimum possible
supplier, Semen Indonesia, is environmental impact.
continuing to raise the bar on FLSmidth’s new OK mill, featuring an updated mechanical package
cement production capacity and structural design, will provide the required boost to Tuban’s
and efficiency. grinding capacity, helping to make the plant more effective and
energy-efficient.
Based on market data

This latest version has been developed using the performance
data from other FLSmidth OK mills as well as the practical know-
how and experience gained from working with them. Important
parameters included reducing maintenance requirements and
maintaining competitive pricing.
The update included reviewing and evaluating the complete me-

chanical package and structural design of the mill.
Of the many updates applied to the mill, the most significant

included optimising the grinding pressure needed for grinding
ordinary and high-Blaine cement. The grinding profile of the roller
and table enable a narrow wedge-shaped grinding area, without
compromising the peak pressure, which is the highest of any mill
in the market. The table profile ensures uniform bed thickness,
which eliminates the need for additional rollers or rolling scrapers
to remove material accumulated inside the dam ring.
The new OK mill includes the latest version of the ROKSH separa-
tor, which is an updated version of the standard OKS separator.
Requiring extremely low power, the ROKSH is a low-wear, highly
efficient separator and is one of the most durable ‘top seals’ in
the market.
FLSmidth’s OK mill
FLSmidth’s OK mill is a vertical roller mill designed for cement
and slag grinding. It combines drying, grinding and separation
processes into just one unit and can provide savings of approxi-
mately 40 percent in power consumption compared with tradi-
tional ball mills. This latest version has been commissioned at
cement plants in Brazil, Indonesia and India, joining the more
than hundred FLSmidth OK mills in operation around the world.
FLUID DYNAMICS WAS

APPLIED TO ACHIEVE THE
AIRFLOW CONDITIONS
NECESSARY TO OPTIMISE
PERFORMANCE AND
REDUCE WEAR
Optimal airflow
Fluid dynamics played a vital role in the development of the new
OK mill. The airflow through the nozzle ring and inside the mill
was carefully analysed to ensure the right amount of material was
lifted into the separator. To minimise wear, it was also important
to know the air velocity required in the mill to optimise the load
on the guide vanes and rotor.
Increasing demands for cement

Indonesia’s economic growth in recent years, resulting in continuing
investments in infrastructure development, has had a significant
influence on the country’s cement production demands. As Indo-
nesia’s leading cement supplier, PT Semen Indonesia has played a
major role in servicing the cement demands. The company’s Tuban
plant is located in East Java and has a total output of 33,600 tpd.
Tuban’s four lines have all been supplied by FLSmidth. Tuban required
extra grinding capacity at two of its lines. Even though the plant
operates with many ball mills, it needed more effective and energy-
efficient mills. This was a key reason for the choice of an OK mill.
The OK mill was put into service in 2013 as an Ordinary Portland

Cement (OPC) finish grinder. The mill was fitted to grind clinker
from the older but updated production lines Tuban 1 & 2. However,
Tuban also needed to use it for Portland Pozzolana Cement (PPC)
finish grinding for cement containing trass, a volcanic tuff that is
harder than the normal Pozzolane and has a higher level of moist
content. The upgrade project started in 2010, and the new OK
mill 42-4 with a capacity of 250-300 tph, began operations in
“WE OFTEN FACE
October 2013. CHALLENGES IN SPACE
Beating performance requirements
LIMITATIONS WHEN
Klaus Bøgeskov, Project Manager at FLSmidth, explains how some
of the installation and commissioning challenges were tackled:
INSTALLING NEW
“We often face challenges in space limitations when installing EQUIPMENT. IT WAS NO
new equipment. It was no different at Tuban Cement as the OK
mill had to be squeezed between two existing mills. We solved it
DIFFERENT AT TUBAN
by modifying the mill’s design to fit the plant’s layout.” CEMENT PLANT AS THE
Klaus Bøgeskov explains that the OK 42-4 mill was guaranteed OK MILL HAD TO BE
to 250 tph OPC according to ASTM C-150 Type 1 (Standard
Specification for Portland Cement). “But when the PGT certificate
SQUEEZED BETWEEN
was signed, the mill was running 253tph at a Blaine value of
3559cm2/g,” he says, adding, “The total power consumption
TWO EXISTING MILLS.”
goals for the main motor, separator and fan motor were 26.8 Klaus Bøgeskov,
kWh/t, and we achieved a figure of 24kWh/t.” Project Manager at FLSmidth
FEATURES
CONTACT CRISTINA HOLMARK

CRHO@FLSMIDTH.COM
World’s first
Postgraduate Cement Plant
Engineering Degree
FLSmidth and Helwan
University in Egypt
launch new education
programme, paving
the way for a cement
plant career
Operating and maintaining cement plants requires a high level of During the pilot project, FLSmidth Group engineers did the student
competence, and a critical shortage of skills in some local regions lectures, while the university’s professors observed and learned.
has made it difficult to operate plants at maximum efficiency. We feel this process has equipped the professors well, so they
would be able to teach the course material independently following
One of those regions was Egypt, where FLSmidth has had difficulty the pilot project.”
employing qualified engineers with the right experience and skillset.
This is a key reason behind FLSmidth’s drive for a postgraduate And the pilot project was quite a success. Of its 33 graduates,
cement engineering diploma degree programme in Egypt. Launched 11 have been employed at three different plants operated and
in February 2014, the degree has been put together in partnership maintained by FLSmidth and others have found employment in
with Helwan University. related industries.
Cristina Holmark, General Manager of Global FLSmidth Institute, A world-first for the cement industry
has led FLSmidth’s development of the degree. She explains, Meanwhile, during the pilot project, extensive preparation was taking
“The idea was to create a graduate level degree that could bridge place for the full implementation of the cement diploma degree.
the educational and qualification gap for engineers and prepare This involved obtaining approval from Egypt’s Higher Counsel of
them adequately for a potential career in the cement industry. Ministry of Education, a process that took one year. With the
We also saw it as a good opportunity to play a very positive role ministry’s blessing, the degree was sanctioned allowing 16 students
in the local community as well as nurture loyalty among FLSmidth to begin their new educational venture in February 2014. >>
Group employees.”
The degree is a combination of academic theory and practical

The Helwan Postgraduate Cement
experience, which is designed to equip cement plant engineers
Engineering Diploma Degree
with the knowledge and hands-on experience required for This is a diploma degree course offered by Egypt’s Helwan
cement plant operation and maintenance. It makes effective use University and created in partnership with FLSmidth.
of different learning styles to stimulate and motivate students.
The degree is taught by the University’s staff and provides
Cristina Holmark elaborates, “Students are exposed to lectures three semesters of academic teach and a practical project
with professors from Helwan University, group work and plant supplemented by short cement-specific courses.
visits. The plants involved are Ramliya and Wadi el Nile where
students will be exposed to our high safety standards and Sixteen students from different Egyptian cement companies
on-the-job challenges.” are enrolled in the programme for 2014 and 2015.
Successful knowledge transfer

The diploma degree is part of an extensive education programme
that started in late 2009 with the search for an academic partner.
Cristina Holmark says, “We looked into and spoke with several
universities in Egypt and the choice fell on Helwan University rela-
tively quickly. Apart from being located close to cement plants,
Helwan University showed the most interest and demonstrated
high commitment. The university is a large public university with
around 100,000 students and 21 faculties, so we are very pleased
to be partnering with Helwan.”
Less than a year after an agreement was reached, the first phase
of the programme was launched by the FLSmidth Helwan Cement
Institute. This involved a pilot project of two semesters that was an
essential part of developing a workable, sustainable educational
programme resulting in the diploma degree.
“We wanted to create this degree according to established

academic processes,” explains Cristina. “This involved extensive
train-the-trainer programmes, including formal training sessions
in Denmark and Egypt as well as peer-to-peer training.
WORLD’S FIRST STUDENTS AFTER A

POSTGRADUATE CEMENT PLANT DAY OF CLASS ROOM
ENGINEERING DEGREE LECTURES OUTSIDE OF
THE TRAINING CENTRE
Cristina Holmark emphasises that the programme is now owned

by Helwan University, following the success of the pilot project “WE’RE NOT JUST
and handover process: “FLSmidth’s role in the future is to help
with marketing and promotion as well as training the professors.
OPERATING A PLANT, WE
We will provide any necessary support, but it is the university’s
programme now.”
ARE SUPPORTING THE
COMMUNITY AND
“We are very happy that the goal we set out to achieve in 2009
has come to fruition. Helwan is now the first university in the
WORKING ACTIVELY
world to offer a degree like this, so we are proud to be behind it,”
she adds.
WITHIN IT. TRANSFERRING
KNOWLEDGE IS A
Professor Yasser Sakr, Helwan University President, sees many
benefits for the university, claiming, “This degree provides an
FUNDAMENTAL PART
attractive value proposition for the university. Our partnership with
FLSmidth has enabled us to prepare an innovative curriculum and
OF THIS.”
a commercially viable offering to the private sector, and it has meant Cristina Holmark,
we have developed state-of-the-art facilities for our students.” General Manager of Global FLSmidth Institute
PROMOTIONAL LAUNCH OF POSTGRADUATE

THE POSTGRADUATE CEMENT STUDENTS ON FIRST
ENGINEERING DIPLOMA SEMESTER
DEGREE, OFFERED BY HELWAN
UNIVERSITY, CAIRO, EGYPT IN
COOPERATION WITH
FLSMIDTH, COPENHAGEN,
DENMARK
Professor Sakr is also convinced that it provides significant benefits role in raising the education and skill levels of cement plant engi-
to students: “The degree will provide the students with marketable neers: “We want the partnership to make a long-term difference
skills and almost certainly a stepping stone to employment. The for the community. It is a sign of our commitment to the country
international environment offered through the collaboration with and the plants that we operate and maintain for our customers.”
FLSmidth is very valuable, in particular.”
Initiating and developing local programmes such as these is the
Bonding with the local community FLSmidth Institute’s core business. Other similar projects currently
The cooperation between Helwan University and FLSmidth is a underway internationally include an energy efficiency training
public-private partnerships in Egypt. It is expected to benefit the programme in Vietnam and a vocational programme for unem-
industry, the tertiary education system, local society in general, ployed youths in India.
and FLSmidth’s profile in Egypt. Indeed, Denmark’s Ministry of
Foreign Affairs has identified this as a role-model example of CSR, “For FLSmidth as a whole, it’s important to realise that we’re not
and the Danish governmental aid organisation, DANIDA, has just operating a plant, we are supporting the community and
supported the project under its ‘Innovative Partnership Develop- working actively within it. Transferring knowledge is a fundamental
ment’ (IPD) Programme. part of this,” asserts Cristina Holmark. “I believe we have 33 grad-
uates and 16 current students on the FLSmidth Helwan Cement
Cristina Holmark is convinced the programme has strengthened Institute programme who can attest to that.”
FLSmidth Group’s ties to the local community by playing an active
INNOVATION
CONTACT MORTEN HANSEN

MOH@FLSMIDTH.COM
CONTACT NAVEEN SEELAM

NKS-IN@FLSMIDTH.COM
New
Energy efficiency and low maintenance is essential to optimal
kiln performance. The new FLSmidth kiln graphite seal reduces
the need for maintenance and optimises the operation pressure
stability by preventing false air entering the system.
graphite seal FLSmidth provides a highly effective kiln seal that utilises carbon
graphite. The seal, which fits any kiln, uses a staggered
arrangement of overlapping graphite blocks [1] held in place
optimises kiln by a wire rope system to ensure an efficient seal against the
outer air casing [3]. The arrangement allows the graphite
performance
blocks to move independently with the radial movement of
the kiln without the graphite blocks getting stuck or damaged.
The locking plates [4] on the rear flange [2] is a key design
feature that prevents false air from entering the kiln system.
The inlet seal air casing is designed to handle back spillage,

Designed for fast installation directing it to the hopper for collecting in the bin.
on any kiln, FLSmidth’s new Trial assembly of the modular frames and thorough inspection
kiln graphite seal reduces ID of geometrical tolerances of the flanges in the workshop
fan power consumption ensures the highest product quality standards.
EACH MODULE IS SCAN TO VIEW

DESIGNED TO BE PRODUCT SITE ON
PRE-ASSEMBLED BEFORE FLSMIDTH.COM
INSTALLATION
Designed for predictable, low maintenance will hold the graphite blocks in place in the unlikely event of
A visual inspection can reveal whether maintenance is required. wire failure.
When it is necessary, the wire rope system and modular frame
enables quick replacement of the graphite blocks, while spe- Fast, cost-effective installation on all kilns
cially shaped distance spacers [5] prevent the need to dismount The new graphite seal can be fitted on any type and size of kiln
the flanges. – not just FLSmidth kilns. The graphite seal modular concept
is designed to fit to the existing casing and cooling mantle
The wire rope system is comprised of counterweights and without the need for modifications.
independent rope systems covering each row of graphite
blocks. The ropes grip the graphite blocks tightly in place while Installation of the graphite seal typically takes seven to ten
also allowing for movement caused by kiln runout, ovality and days. A large amount of pre-assembly can take place before
expansion. This design allows for radial movement of up to installation. This is made possible by the seal’s modular design.
+/-50mm and axial movement of approximately 300-400 mm.
FLSmidth’s inlet and outlet graphite seal has been retrofitted
The need for spare parts is limited, as the graphite blocks and on a non-FLSmidth kiln at NCC Egypt.
wire ropes are interchangeable between the inlet and outlet
seals. Furthermore, the graphite blocks’ self-lubricating prop- Inlet and outlet seals
erties significantly reduce the wear of the sealing components. Two types of kiln graphite seals are available. The kiln inlet seal
Typically, the expected wear on the graphite blocks is 5-8 mm is designed to provide the interface between the kiln and pre-
per year, resulting in a long lifetime. heater and the kiln outlet seal interfaces the kiln and the cooler.
The wire rope is designed to run for a full production campaign, Both seals are designed to help maintain optimal kiln operating
but as an added preventative measure, the seal’s locking system conditions and to minimise the loss of expensive energy.
“VISUAL INSPECTION OF THE SEALING DURING

OPERATION IS EASY. WE HAVE EASY ACCESS TO
GRAPHITE SEAL BLOCKS AND WE CAN CHANGE
THESE WITHOUT COOLING DOWN THE KILN
COMPLETELY IF NECESSARY. THAT IS A HUGE
ADVANTAGE. FURTHERMORE, ANY BACK
SPILLAGE FROM THE INLET IS EFFECTIVELY
HANDLED AND LEAD TO THE GROUND.”
Technical Project Manager, NCC Egypt
Right
FEATURES
first time
CONTACT SIMON LINDBERG

SLIN@FLSMIDTH.COM
Production underway The commissioning was all the more im-

pressive considering the plant’s unique
Knowledge transfer for
sustainable operations
at FCKS cement plant challenges. FCKS is located in a remote area FCKS has chosen to continue its close
in Angola near the town of Sumbe in the Kwanza Sul relationship with FLSmidth Group through
province, about 300 km south of Angola’s an operation and maintenance (O&M) con-
capital, Luanda. Even though Angola has tract over the next five years. The contract
vast mineral resources and a fast-growing sees NLSupervision – part of the FLSmidth
economy, its cement industry is underdevel- Group employing all the necessary plant
Paul Dreyer looks back at the commissioning oped and the country possesses very limited operators and maintenance personnel. It
of the new Angolan cement production specialist cement expertise. As one of also includes sourcing and inventory control
plant Fabrica de Cimento Do Kwanza-Sul S.A. Angola’s newest and most modern cement of spare parts and lubricants. The plant is run
(FCKS) with satisfaction. It was a difficult plants, FCKS represents a significant step in by the local recruitment and training divison
project with many obstacles, but despite the development of the country’s growing with local personnel under the supervision
the difficulties, we managed to commission cement industry. “That is why it was import- of key NLSupervision staff – backed by the
the cement plant in the best possible way,” ant to work with a reputable, experienced knowledge center of FLSmidth Group.
says the FCKS technical administrator. partner. This is how we saw FLSmidth,”
“From the crushers to the raw mill to the says Paul Dreyer. Paul Dreyer explains the reasons for outsourc-
kiln and packaging plant, we managed to ing O&M: “Since the level of expertise and
commission, start up and conduct successful To complete the plant FCKS entered into an resources in the cement industry in Angola is
performance tests the first try every time. EPC contract with ETA Star International still very limited, and because FCKS is relatively
Nothing failed; all key equipment behaved from Dubai. FLSmidth supplied all the design new to the cement industry, it makes sense
as it should. I have not experienced this and all mechanical, electrical and automa- to be assisted by people who are highly
before and it was beyond our expectations.” tion equipment for the cement plant. experienced in cement plant operations. >>
RIGHT
FIRST TIME
It brings us a lot of benefits for FLSmidth new plant and it has taken time for the agreement and a central reason for FCKS
Group to operate and maintain the plant, operations and maintenance team to find continuing to working with FLSmidth. In
not just because we have FLSmidth equip- its feet, but the issues are being ironed out collaboration with the Angolan educational
ment, but also because they can easily and we can see improvements daily. One key authorities, NLSupervision is setting up
source spare parts and provide the right issue was the need for a huge expatriate a training centre where courses will be
technical support.” workforce in the beginning. As a foreign offered in mechanical, electrical, process
company in Angola, it takes time and is and safety skills.
All equipment knowledge and many of the not easy to recruit the right workforce and
supervisors involved with the plant’s construc- then build and manage a cohesive team.” Paul Dreyer says, “FLSmidth’s training
tion and commissioning have now moved division is very strong and we want to
into the O&M team. Simon Lindberg, Project He adds: “My experience with FLSmidth is benefit from that as much as possible so we
Manager says, “This will bring valuable that they do not walk away from or try to can become sufficiently skilled in cement
experience and knowledge to the O&M hide a problem. In the event that an equip- plant operations. The ability to train our
team, which ensures the plant can continue ment problem arises, they take responsibility nationals is just as important as the pro-
full production during the transition period for rectifying it. This is a strong quality and duction goals.”
from commissioning to handover to O&M.” is obviously part of the FLSmidth culture.”
The training centre will be operated by NLS
But Paul Dreyer observes that even the most In addition to operating the plant, the transfer Supervision, Angola, and helps to qualify
experienced O&M teams can run into chal- of knowledge in efficient and cost-effective local workers not only for the cement plant
lenges, particularly in a developing nation production methods to the local workforce at Sumbe, but also more generally for the
such as Angola. “There are hiccups with any is an equally important part of the O&M industrial environment of any state-of-the-art,
modern plant. This involvement in the sion,” explains Paul Dreyer, emphasising
local community is a significant contribu- the specialist skills FLSmidth brought to the
tion to the development of the Angolan project. Simon Lindberg, Project Manager
nation and is an example of both FCKS’ discusses the challenges of working in a
and FLSmidth Group’s commitment to remote location: “The site is located about
Corporate Social Responsibility. 30km away from the nearest large town,
Sumbe, in an area with no existing facili-
Close teamwork ties. There were many different parties
When the agreement for the 4,200 tpa plant involved and everyone lived in a compound
was signed in 2008, FLSmidth’s project just beside the plant. It was essential that
scope was the engineering, and the design the different teams could function well
and supply of all mechanical, electrical and together and to help make this happen,
automation equipment. All the machinery, recreational facilities, an organised office
from crushers to kiln and mill to packers, and a camp area was established.”
including automated control systems, were
designed and supplied by FLSmidth to ETA It was a complex project lasting from 2009
Star International LLC of Dubai, who was to 2013. Completing the plant successfully
responsible for the plant’s construction. required a lot of hard work, dedication
and good communication by all parties.
“The reputation and quality of FLSmidth’s “We managed to overcome the challenges cooperation, and the expertise and experi-
equipment was a key factor in FCKS’ deci- through numerous design meetings, close ence of many solution-oriented people,
working together as a team. We felt like we
were one big family that had been through
a lot together”, says Simon Lindberg.
“IT BRINGS US A LOT OF
Paul Dreyer believes the contribution
BENEFITS FOR FLSMIDTH GROUP from the FLSmidth team was a key factor:
TO OPERATE AND MAINTAIN THE “The coorporation with FLSmidth and

ETA played a huge role in the success of
PLANT, NOT JUST BECAUSE WE the commissioning and start-up of the
plant, during which everything went to
HAVE FLSMIDTH EQUIPMENT, schedule.”
BUT ALSO BECAUSE THEY CAN A foothold for future growth

EASILY SOURCE SPARE PARTS FCKS aims to achieve 1.1 million tpa clin-
ker in the first year and then lift this to
AND PROVIDE THE RIGHT 1.3 million tpa during the second year,
TECHNICAL SUPPORT.” maintaining this production level over the

plant’s lifetime. Paul Dreyer concludes, “Of
Paul Dreyer, course, we are looking to expand business
Technical Administrator, FCKS in the long term and we have plans for a
second line, but for now our main focus is
to get the plant to full capacity and, with
the help of FLSmidth, truly make our mark
in the Angolan cement market.”
INNOVATION
The new
ECS/ControlCenter V8 process control system
FLSmidth recently released the Trend-setter for modern users
In line with current trends, the latest release of the ECS/Control-
brand new ECS/ControlCenter™ V8 Center software is developed with focus on usability and making
process control system for the things easy to do. This marks a departure from many years of tradi-
cement and minerals industries. tional engineering of the system through technical tools.
It is now even better than before The intention is to make everyday tasks easier to do – not only
– more intuitive and simpler to for operators, but also for the system maintenance engineers – by
use thanks to a new, modern and simplifying the most common tasks so that deep technical knowl-
edge is not required. This will allow the users to focus on solving
user-friendly design. their tasks, rather than figuring out how to work the system.
CONTACT JAN SCHILLING

JSCH@FLSMIDTH.COM
The perfect fit As always, the ECS/ControlCenter software delivers the reliability,
The ECS/ControlCenter solution is tailor-made for the cement and scalability and user-friendliness production plants need to be oper-
minerals industries. It offers the best combination of high-quality ated effectively.
standards combined with the necessary flexibility to adapt to
ever-changing conditions on the plant. Beauty is in the details
The previous version of the ECS/ControlCenter software was already
Based on FLSmidth’s more than 25 years of experience in automat- a very strong solution. So what makes the new version even better?
ing large production plants, all our control system solutions come
with “knowledge built-in”. Learning from previous projects, gather- By carefully inspecting every part of the system, FLSmidth has
ing experience and listening to feedback has enabled FLSmidth to identified missing features and identified opportunities for incre-
make a control system that fits perfectly to customers’ needs. mental improvements.
Through a unique combination of programming skills, experience

in developing control system software, engineering and commis-
sioning expertise and a very close relationship with customers,
FLSmidth has been able to develop a new modern version of the
control system launched more than 25 years ago.
The platform
Through five years of development – including two years of site
testing to ensure high quality utilising the latest technologies and
new effective programming paradigms, this is a product prepared
for the future.
The system is built for better integration between different products

on large installations, while at the same time avoiding annoying
constraints and version dependencies. Combined with a strong
server-client foundation, the new solutions will be perfect for
implementation in a virtual environment such as VMware.
Product details
For operators, the system will seem much more intuitive and com-
plete, with all functionality contained in one common “portal”,
rather than a selection of “tools”. The new system is much more
user-focused and provides a simplified operator environment with
easy login and a personalised user environment. >>
FLSMIDTH’S ECS/
CONTROLCENTER V8
SOFTWARE HAS JUST
BEEN RELEASED
THE NEW
ECS/CONTROLCENTER V8
PROCESS CONTROL SYSTEM
For example, each operator can choose a specific role such as The ECS/ControlCenter solution still comes with built-in high-
“mill operator”, which will present only information relevant to performance communication drivers for Siemens, Rockwell and
the mill areas. This will improve focus on what really matters, Schneider process controllers (PLCs) as well as OPC to allow for
without the confusion and potential information overload from flexible hardware selection, while retaining the same user interface.
areas handled by the other operators.
PLC programming is still required, but utilising the ECS/ACESYS
The system will also be available in a simplified version for touch function block library will encapsulate most of the complexity,
control, for example for machine control out on the plant floor. leaving mostly interlocking to the programmer. It also provides
This provides a uniform look and feel across the systems. Linking DCS-like functionality and advanced faceplates with direct access
these decentralised control systems with an overall process control to detailed diagnostics.
system requires minimum engineering and will provide easy access
to all parts of the system directly from the central control room. What’s next?
The development of FLSmidth’s products never stops. The next release
of the ECS/ControlCenter software and the supporting ECS/ACESYS
library is planned for spring 2015 and will include improved focus
on functional safety and full alarm management based on the ISA
18.2 standard. FLSmidth is continuously working on making its
“THE ECS/CONTROLCENTER SOFTWARE
OFFERS A MODERN, USER-FRIENDLY products even better – for the benefit of customers.
ENVIRONMENT FOR OPERATORS.”
PRODUCTS & SOLUTIONS
Delivering
to customer needs
My Home Industries (MHIL) is a joint
venture between My Home Group
and CRH plc, an Irish building materials
conglomerate with 3,500 locations
spread across 33 countries.
From three manufacturing units located in and technology upgrades to reduce power cyclone, calciner and kiln drive modification
Melacheruvu in the Nalgonda district of and fuel consumption. FLSmidth’s intention along with a new preheater fan.
Andhra Pradesh, MHIL produces 3.3 million is to provide effective, engineered systems
tons of cement per annum. Another unit, to meet customer requirements by using The Phase I modification has been in oper-
Sree Jayajothi Cement – SJCL, in the Kurnool the best quality products. ation since January 2014 and the customer
district of Andhra Pradesh produces 3.2 is satisfied with all the major benefits that
million tons per annum. To meet increasing MHIL already had an SF Cross-Bar™ cooler the upgrade has delivered:
demand for cement in domestic and inter- 2 X 4 in its Line I. MHIL had been very • Clinker production at 2550 TPD
national markets, MHIL has also set up satisfied with the SF Cross-Bar cooler’s • 10-12 Kcal/Kgcl savings in fuel
a cement grinding unit at Mulkapalli in performance over the last five years and consumption
Visakhapatnam district of Andhra Pradesh wanted to use the ‘best’ in cooling tech- • Cooler maintenance shutdowns de-
with a capacity of 2.0 million tons of nology at its Line II upgrade. FLSmidth creased drastically since the upgrade
cement per annum. engineered a system by modifying the • No major spare parts changed during
cyclones 1, 2 and 4 with new preheater this period
FLSmidth won an order for the modernisa- fans, new Cross-Bar 10X37 cooler and a • No HRB maintenance shutdown in last
tion of MHIL’s Line II pyroprocessing unit, new modular frame heavy-duty roller eight months
which consists of a six-stage ILC PH tower breaker (HRB). The system also included • Mechanical HRB motor power drawn is
and a CIS-CFG cooler. This plant was sup- the new RABH & RABH fan, modifications less compared to the conventional
plied, constructed and commissioned by to the bag house and kiln main drive. crusher.
FLSmidth in 2002. After analysing MHIL’s
requirements, FLSmidth provided a cost and The project was completed in three phases. Phase II is expected to be completed by
time-efficient solution to meet MHIL’s Phase I included a new Cross-Bar cooler December 2014 and Phase III before the
upgrade objectives. Major objectives of this with new HRB. Phase II includes a new middle of 2015. MHIL is satisfied with the
upgrade were increased clinker production RABH and RABH fan, and Phase III includes Phase I modification and placed two more
orders with FLSmidth in 2013 for the Jaya-
jothi unit (new Cross-Bar cooler with HRB
The conditions before and after modification and PH modification) and two orders in
Guaranteed values Achieved 2014 for Line I (coal mill and PH modifica-
Before after Phase III after Phase I tion).
Parameters modification modification modification
Clinker production,
MTPD 2472 2750 2550
Savings in specific fuel
consumption Δ, Kcal/Kgcl Nil 20 10-12
Clinker temperature at
kiln discharge, degrees 134 + Ambient 65 + Ambient 64 + Ambient CONTACT ANILKUMAR MUKUNDAN
CM.ANILKUMAR@FLSMIDTH.COM
SITE REPORT
Clinkerisation
project underway in Nepal
Project timeline
Signing of the contract 7 June 2012
Effective date of contract 15 October 2012
Completion of engineering 30 December 2013
Supply of major equipment 6 May 2014
Expected commissioning December 2014
In a move that reflects this demand, the • FRF silo (16 X 28m)
Saurabh Group has awarded the Sarbottam • Preheater: 5-stage single string ILC
Cement Plant’s clinkerisation project in • Rotary kiln (3.15 X 47m)
With the increasing Nepal to FLSmidth. This is the first full-scope • Clinker cooler: FLSmidth Cross-Bar®
need for dams, bridges, supply of equipment to be undertaken by Cooler 6 X 29 with clinker breaker
housing projects and FLSmidth in Nepal. The 1200 tpd cement
plant will be located about 50 km from
• Coal mill TIRAX® ball mill (TM30 X 4.5
+ 2.30) with air separator RTKM 17.5
other infrastructure Lumbini, the birthplace of Buddha. • Electrical, automation & instrumentation
generating more items (from 33 KW incomer to control
construction projects, FLSmidth scope of supply
The project supply includes everything from
system complete design and supply)
the demand for cement the crusher and mills to pyroprocessing, Progress at site
in Nepal is growing electrical systems and automation. Mechanical installations are in progress and
year on year. Cement FLSmidth’s scope of supply:
• Limestone crusher (Impact – 480 KW)
the major installations, including limestone
crusher, kiln, cooler, preheater and raw mill
manufacturers are • Limestone stacker (luffing) & bridge are nearing completion. This is closely
looking to build new reclaimer, material handling equipment followed by installation of the electrical
plants in order to • Raw mill grinding ATOX 30 & 32.5 RAR
air separator
and automation equipment.
expand cement • Raw mill & coal mill bag house & “Being the largest producer of cement in
production capacity. cooler ESP Nepal, we awarded our new project
Saurabh Group
CONTACT MANOJ MANDHANA
MANOJ.MANDHANA@FLSMIDTH.COM The Saurabh Group was established
in 1964 by well-known business man
Mr. Lila Ram Neupane initially as a
trading agency and a fleet of bus
services. After coming to Nepal from
Myanmar, the group diversified its
activities when the founder’s son,
Mr. Bishnu Prasad Neupane, joined
the group in 1986. The group is now
mainly involved in the production of
cement, steel, tea, spun yarn, PP
Woven fabrics, calcium carbonates
and other products.
‘Sarbottam Cement Pvt. Ltd.’ to FLSmidth. Several ‘firsts’ in Nepal

As our dream cement plant is being built In addition to the fact that Sarbottam
now, we could see that FLSmidth’s team is Cement is the first project for which equip-
fulfilling their commitment of lowest thermal ment is supplied by FLSmidth in Nepal,
and electrical energy consumption, and Sarbottam Cement plant provides the first
also honouring the trust that we placed in ATOX® mill (VRM) at a cement plant in
them through their meticulous planning, Nepal. In addition, it is the first ECS, IMCC
effort and cooperation,” says Mr. Bishnu and intelligent network system to be in-
Prasad Neupane, Managing Director of stalled in Nepal as well.
Sarbottam Cement.
Sarbottam Cement Plant has also ordered
Trial runs of equipment are expected to be a 70 tph OK 25-0 vertical roller mill for
performed in October 2014. cement grinding, and packing plants from
FLSmidth. The plant’s objective will be to
“This project was planned in such a way produce 1,500 tons of OPC & PPC cement
that there were no hurdles at site for want per day.
of drawing or materials, which relieved us
of stress and saved our time in follow-up
activities with the supplier,” adds Mr. Bimal
Kumar Sawarthia, Finance Director of KILN DURING
Sarbottam Cement. ERECTION
INNOVATION
CONTACT JESPER HAVN ERIKSEN

JEHE@FLSMIDTH.COM
FLSmidth
Lumps and blockages in cement silos have long been an issue at
some cement plants. In the 1970s, FLSmidth conducted research
on ball mills and cement storage that revealed the cause to be an
research
unfortunate combination of insufficient gypsum dehydration in
the mill, high silo storage temperature and lengthy storage time.
When stored at high temperatures, the gypsum continues to
dehydrate. The water released from the gypsum prehydrates the
delivers silo-safe
cement in the silo, and lumps begin to form.
In more recent developments, some plants have begun to report
cement
issues in silos storing cement produced in vertical mills. Similar to
the past, these issues are the result of a combination of factors
such as lower degree of gypsum dehydration or high rates of
water injection such that the moisture content of the cement
stored in silos is increased.
Real-world research
Close collaboration with cement plants is an important element of
FLSmidth research. It ensures that the complexities of industrial
operations are considered from the outset and that the research
can be applied in practice. Titan Cement is a valuable collaboration
A current project examines how to partner in this project. The FLSmidth Research and Process depart-
ments were therefore pleased to be invited to carry out tests at
avoid lumps and blockages in silos Titan Zlatna Panega in Bulgaria. The plant produces OPC cement
with vertical mill cement. with 4% limestone and max. 3.5% gypsum using an OK™ Mill 30-4.
The field tests were a critical part of a study that also included labo- WATER CONTENT FROM
ratory tests and special analyses. The results showed that the cement GYPSUM IN CEMENT AS
FUNCTION OF MILL OUTLET
storage stability can be controlled by adjusting the OK Mill tempe-
TEMPERATURE AND WATER
rature and water injection (if water is used). Optimum mill operation INJECTION
depends on specific plant conditions and constraints, including
clinker temperature, availability of hot gas, climatic conditions,
quality of the feed materials (clinker composition, amount of additive Effect of temperature and water
materials such as gypsum, limestone, slag and their water content), injection on gypsum dehydration
legislative requirements, and storage time in the cement silo.
HIGH WATER INJECTION
MEDIUM WATER INJECTION
The OK Mill field tests were performed over several weeks. Com- LOW WATER INJECTION
plete quality analyses were performed on cement product samples
0.7
taken with the mill in operation with different process conditions.
0.6
Water from gypsum %

The mill outlet temperature was varied from 75 to 120 degrees
Celsius and water injection was varied from zero to approximately 0.5
2.3 percent (mass) of the total production in the mill. 0.4
0.3
Mill temperature tests
Within the temperature range of the tests, the effects on gypsum 0.2
dehydration and prehydration were clear. 0.1
0
Low mill outlet temperature 60 70 80 90 100 110 120 130
• Cement produced at low mill temperatures (app. 75-80 degrees Mill outlet temperature (°C)
Celsius) had a relatively low level of gypsum dehydration com-
pared to typical mill cement. However, as the cement tempera-
ture is low, the gypsum in the silo does not dehydrate. Thus • If water injection rates are maintained within recommended safe
making the cement silo-safe. This supports the conventional ranges, silo-safe cement with good quality can be produced.
rule-of-thumb that cement temperatures below 70 degrees • High water injection can cause prehydration, especially at low
Celsius are silo-safe for longer periods of time (weeks). mill temperatures, resulting in lower cement strength and an
• At low mill temperature excessive water injection should be avoided. increase in the total water fed to the cement silo
• Vertical Roller Mill (VRM) cement produced with low mill outlet • Excessively high water injection rates may be problematic even
temperature should not be stored in a silo together with high at high temperatures and should be avoided.
temperature cement (>70 degree Celsius). • OK mill operation with no or minimal water injection is best for
producing silo-safe cement
High mill outlet temperature
• Cement produced at high outlet temperatures (>110 degrees Conclusion
Celsius) had significantly dehydrated gypsum. As a result, high Overall, the study confirms that it is possible for an OK Mill to
temperatures in the silo do not cause problems. produce cement of similar quality to a ball mill and to match the
• High mill temperature can produce cement with gypsum dehy- gypsum dehydration and behaviour in the cement silo. This can be
dration similar to ball mill cement, but water injection must be achieved by ensuring that the proper operating parameters are
low to medium. used. The plant tests also show that it is possible to produce si-
lo-safe cement over a range of operating parameters that can be
The graph illustrating the water content from gypsum in cement varied according to specific site conditions.
shows the impact of different VRM operating conditions evaluated
in the study on gypsum dehydration. Ongoing research
The results of this study demonstrate the versatility of the OK mill.
Water injection tests Further research is also being conducted to study the effects of
The impact of water injection is explained below. temperature and water injection on power consumption, cement
quality and storage stability. Activities include accelerated storage
In general water injected on the mill table acts as a grinding aid to testing of cements at the FLSmidth laboratories as well as addi-
increase production and lower power consumption. Water also helps tional field studies to investigate especially sensitive cements with
reduce mill vibrations, especially with dusty clinker. Ideally, in this high contents of aluminate, gypsum and alkalis, as well as blend-
case it is better to study and improve the factors impacting clinker ed cements with very wet additives. If your plant is interested in
granulometry rather than use increased water injection rates. participating in additional studies, please contact us.
FEATURES
Thinking beyond
EPC
How a full-service partner can
help safeguard investments in
cement plants.
For cement plant owners and investors in today’s demanding

business environment, strong partners are a necessity to provide
the elements and conditions for efficiently designing and building
cement plants - adding capacity and expanding to new markets.
Entering into an EPC contract is one way to minimise risk and
streamline the process by providing a single source for the delivery
of the plant.
But an EPC contract alone may not be enough to ensure that the
plant’s long-term business goals are met. Owners and investors
also need assurances that the ongoing operations and mainte-
nance (O&M) of the plant will support the market potential: What
happens after production is underway? How will it be staffed and
run? How will the plant’s performance goals be monitorised and
optimised?
FLSmidth’s Design, Build, Design, build and then operate

Operate Solution The return on investments in a cement plant are achieved through
maximising future cement sales. It is therefore vital that investors
FLSmidth provides a unique 360° certainty solution for the
know how the cement plant will operate over the full extent of its
cement plant lifecycle, covering everything from initial raw
lifetime and have certainty that it can deliver to its full potential.
material investigation and Engineering, Procurement and
Planning for the long-term operating potential at the same time
Construction (EPC) through to ongoing operation and main-
as preparing the EPC contract will reduce the investment risk,
tenance services.
shorten payback time and maximise the return on investment.
Our combined EPC and O&M solution is a unique offering

The key is to bring an O&M strategy into the EPC planning from
managed by some of the most experienced engineers in the
the outset. This will deliver assurances from the very beginning
business alongside locally recruited staff who are trained and
that the plant will run smoothly and deliver the expected return
integrated into our expert teams.
over the full lifetime of the plant.
With 130 years of specialist know-how, FLSmidth can guarantee

A strategic approach to O&M requires extensive operational expertise
a fully sustainable and efficient model that will grow the plant
and planning, but contributes significantly to a plant’s bottom
– and profits – long after operations begin.
line. An effective O&M strategy includes several elements, such as:
CONTACT SAMIR IDRIS Risk sharing, in particular, should be carefully planned. Typically, the
SAI@FLSMIDTH.COM plant owner is responsible for fundamental supply issues, such as
power, water, fuel and raw materials as well as capital investments in
CONTACT ANDERS BECH
AB@FLSMIDTH.COM machinery and property. The full-service provider helps define specifi-
cations and make recommendations where and when necessary.
The key is for the owner to be able to transfer the risk and com-
plexities of the operations to a single partner who is responsible
for engineering, procurement, construction, and operating and
maintaining the facility according to best-in-class standards. This
leaves the plant owner to focus on building the business and the
marketing and selling of the cement.
Opening doors to financing

FLSmidth Financing for a cement plant is challenging, and a complete design,
build and operations strategy can make a significant difference to the
Design, build financing terms. Early on, banks require risk assessments and certainty
& operate
that production goals and cash flow targets will be met. However, this
can only be predicted with reasonable accuracy if the daily operations
have been planned in detail from the outset. Thorough strategic plan-
ning demonstrates to financial institutions how long-term revenues
will be generated and tailor-made solutions guide the investor through
the entire process covering all financial institutions requirements to
facilitate the credit needed with the right repayment strategy in place.
In addition, having the right partner gives the financial institution the
best guarantee that the plant will be a successful investment.
Sustainable, profitable operations

With an end-to-end solution covering design, build and operations,
cement plant owners can put their business goals into action, guar-
anteeing the most efficient and sustainable model to develop the
business and achieve the bottom-line results demanded over the
• Implementing and ensuring health, safety and environmental lifetime of the investment. By guaranteeing the plant is operated
practices in accordance with international standards and maintained according to the highest standards, the plant deliv-
• Having clear performance goals associated with the perfor- ers a lower total cost of ownership and ensures that the asset main-
mance of the plant staff tains the highest possible value throughout the plant lifetime.
• Ensuring sufficient technical expertise is available to run and
maintain the plant
• Ensuring strong organisational and technical training capabilities
• Securing that the supply chain and organisation is in place to
PLANNING FOR THE
deliver original spare parts LONG-TERM OPERATING
• Implementing IT systems for optimising plant management
and maintenance POTENTIAL AT THE SAME
One-source partner
TIME AS PREPARING THE
Forming a full plant lifecycle strategy may seem a complex task before EPC CONTRACT WILL
construction begins. That is why it is important to work with a partner
who can assist you to plan for the future and navigate every step of REDUCE THE INVESTMENT
the process. A single-source supplier should have the capabilities to
provide full life-cycle support, from initial raw material investigation
RISK, SHORTEN PAYBACK
through construction and commissioning to ongoing day-to-day TIME AND MAXIMISE THE
performance. They need to know how to put together a complex
industrial project, manage suppliers and contractors, build new organ- RETURN ON INVESTMENT.
isation and ensure the operational organisation runs efficiently.
INNOVATION
FLSmidth introduces two

new DuoClean™ filters
FLSmidth has recently introduced two new,
revolutionary DuoClean™ filter types – the
DuoClean™ DC2 and the DuoClean™
DC8. Continuing FLSmidth’s objective of
providing cost-efficient and effective filter
solutions, the new DuoClean filters meet
the strictest emission requirements, while
reducing upfront costs. They feature an
innovative octagonal shape and a compact,
modular design.
Lars Gamborg, FLSmidth’s Global Product

Manager for Fabric Filters, explains that
FLSmidth set out to design a fabric filter
that performed exceptionally, but at a
lower cost of investment. “Based on this
vision, we developed a compact filter that
is simple to manufacture, transport and
assemble, while also delivering low opera-
tional costs, high performance and low
emission. With the new, compact DuoClean
filters, which are based on modules, we
focused on manufacturability and con-
structability, and this enabled us to create
filters that minimise environmental footprint
to an even greater degree.”
Further development of
proven technology
Already installed at more than 50 plants
worldwide, the DuoClean filter has a proven
design and technology concept. In creating
the two new filters, FLSmidth has further
developed the most important DuoClean
features, including the cleaning system,
gas distribution capabilities and the long-bag
technology. A close look at supply chain
and customer requirements revealed the
need to reduce engineering, manufacturing
and installation costs. To meet these needs,
CONTACT LARS GAMBORG the new filters feature a standardised,
LARS.GAMBORG@FLSMIDTH.COM
modular design.
Innovative
Advanced gas and dust
distribution screen
DuoClean’s technology is characterised by
a dual-flow gas approach. Gas flows from
fabric filter design reduces

the bottom and side of the bags ensuring
low, uniform velocity over the entire bag
filtration area. This allows the use of longer
costs and cuts emissions bags, which reduces the filter footprint.
To ensure gas is distributed evenly to the capital expenditures (CAPEX) requirements, THESE 8 STEPS ILLUSTRATE A
hoppers and on the bags, individually as lighter filters are easier and more cost- DUOCLEAN DC2 FILTER TAKING SHAPE.
CONSTRUCTION AND INSTALLATION
designed gas distribution screens are used effective to fabricate, transport and assemble.
CAN BE AS QUICK AS JUST FOUR WEEKS.
for each filter application. THE COMPONENTS ARRIVE ON-SITE IN
Easy transportation and installation CONTAINERS. YOU ONLY NEED A
Lighter filters reduce investment costs The octagonal shape also plays an important CRANE FOR THE FINAL MOVING OF
The DuoClean DC2 and DC8’s modular role in simplifying transportation and instal- THE PRE-INSTALLED COMPONENTS TO
THE FINAL FILTER LOCATION; OTHERWISE
design features eight identical panels as- lation. The filter’s steel components, trans-
ALL CONSTRUCTION IS DONE AT
sembled in an octagon. The filter uses simple ported in standardised containers, are GROUND LEVEL.
reinforcement profiles and requires fewer designed so the casing, the eight side-panels
components. Its near-round shape has a and the hole-plate elements are a perfect
self-reinforcing, strengthening effect, which, fit to the container. The container is packed
together with the optimised casing and efficiently utilising the entire space, so fewer
hoppers, means it is significantly lighter than containers are required. This helps to mini-
comparable fabric filters. This leads to lower mise transportation costs. >>
1. PENDULAR SUPPORT
AND SUPPORT BEAMS 2. BOTTOM HOPPERS 3. INTERNAL BRACING 4. GAS DISTRIBUTION SCREENS
7. C
LEANING SYSTEM
5. CASING AND DUCT 6. TUBE SHEETS AND ACCESS LIDS 8. WEATHER ENCLOSURE
TOP WALK-IN WEATHER

ACCESS PLENUM ENCLOSURE
The filter components are then typically

assembled at a dedicated area close to the
plant, and construction is completed on-
site. This process reduces the demand for
scaffolding and crane capacity and means
construction takes place quickly, safely and
cost-effectively. The use of standardised, “AS A TECHNOLOGY LEADER,
prefabricated parts reduces the risk of
errors and optimises quality assurance.
FLSMIDTH IS COMMITTED TO
DELIVERING EXCELLENT
Cleaning system increases bag lifetime
FLSmidth’s DuoClean filters ensure out- SOLUTIONS FOR REDUCING
standing performance at a low operational
cost. Thanks to the unique gas distribution
EMISSION LEVELS NOW AND
and pre-separation of dust, the pulse jet IN THE FUTURE. IT IS
cleaning system operates with a minimal
number of cleaning cycles, resulting in low DEFINITELY OUR OBJECTIVE TO
compressed air consumption, less wear of
the bags and an increased bag lifetime.
PROVIDE OUR CUSTOMERS
The low pressure cleaning system (cleaning WITH A FUTURE-SAFE
pressure ≤ 2.0 bar), developed with exten-
sive R&D, is also available to ensure efficient INVESTMENT.”
cleaning and reduced stress of the long
Lars Gamborg
bags. This means that the traditional
Global Product Manager, Fabric filters
high-pressure compressor (6-7 bar) can
be replaced with a root blower, saving
investment and operational costs.
Smaller filters for smaller applications

FLSmidth’s DuoClean DC8 filter has been
designed to meet the needs of smaller
SCAN HERE TO
LEARN ABOUT MORE
SUCCESSFUL CASES
cement mill applications. Also featuring an Lars Gamborg elaborates on FLSmidth’s

octagonal-shaped casing, The DuoClean DC8 R&D efforts: “We have invested extensively
BMIC,
is a compact, one-compartment filter for use in R&D to ensure that a well-proven tech-
Egypt
at a gas flow range of 45,000 to 150,000 nology is transformed into innovative filter At the BMIC cement plant in Egypt, all
Am3/h. With a small footprint and typical solutions responding to the needs of to- emission targets have been met suc-
bag length of six to eight metres, it is up to day’s plants and industry trends. The test- cessfully with the DuoClean DC8 filter.
40 percent lighter than conventional filters. ing was carried out at our R&D Centre With a bag length of six metres, the
Dania, which is now the biggest in the filter operates at a gas flow of 72,000
Significant R&D investments industry. Besides testing many prototypes, Am3/h and temperature of 140 °C.
The new filter types are the result of sub- the full-scale pilot filter allowed us to test
stantial R&D efforts by FLSmidth, in particular the 10m long bags in different operating Askale Cement,
using computational fluid dynamics (CFD) conditions.” Gumushane, Turkey
to achieve optimal control of gas distribution The Askale Gusmushane plant in Turkey
and the ideal dualflow split. The CFD results “As a technology leader, FLSmidth is com- selected the DuoClean DC2 filter for
demonstrated a well-distributed gas flow mitted to delivering excellent solutions for the plant’s cement mill due to the filter’s
with a significant amount of dust being reducing emission levels now and in the compact design and ability to handle
preseparated to the hopper. This delivers future. It is definitely our objective to pro- large gas flows. With an emission guar-
uniform gas speed to the bags, reduces vide our customers with a future-safe antee of 10 mg/Nm3, the filter has a
compressed air usage and increases the investment,” concludes Lars Gamborg. 10-metre bag and operates at a gas
lifetime of the bags, all factors that help flow of 850,000 Am3/h and tempera-
reduce operating costs. ture of 95 °C.
CEMEX, APO,
Philippines
At CEMEX APO in the Philippines, the
DuoClean DC2 filter is installed on the
plant’s cement mill. The eight-metre
bag provides an emission guarantee of
15 mg/Nm3 at a gas flow of 780,000
Am3/h and temperature of 100 °C.
Lafarge Cement,
Rezina, Moldova
A nine-metre bag provides an emission
guarantee of 10 mg/Nm3 on the kiln/
raw mill at Lafarge, Rezina plant in
Moldova. The filter operates at a gas
flow of 630.000 Am3/h and tempera-
ture range of 100-250 °C.
Performance test results show

an actual emission at
1.24 mg/Nm3
SITE REPORT
Indian cement
LONG VIEW
OF GIS
industry’s first
gas-insulated switchyard
India’s Reliance Cement chose a complete electrical and automa-

tion package from FLSmidth for its 10,000 tonnes–per-day plant
When there is a need for high at Maihar, Madhya Pradesh. Signed on an EPC basis, the contract
reliability and flexibility, low entailed complete engineering, procurement and commissioning
of the first GIS system to be installed at an Indian cement plant.
lifecycle costs and maximum
environmental sustainability, From the time of the equipment’s arrival at the site, it took only 17
gas-insulated switchgear (GIS) is days to install, test, assemble and charge up the switchgear. Manag-
ing risk was a key factor during the delivery and commissioning of
the best choice over conventional the GIS system in terms of equipment selection, engineering,
air-insulated switchgear (AIS). project execution and installation.
JOINTLY CONTRIBUTED BY GIS – CLOSE-UP

SUJITH VARGHESE GEORGE & VIEW
SUDEEP SAR
CONTACT SUDEEP SAR

SUDEEP.SAR@FLSMIDTH.COM
Competitive sourcing
FLSmidth applied its in-depth understanding of the cement-making
process to select the equipment and components that would
ensure optimum performance. Extensive global knowledge of the
established electrical and automation OEM suppliers enabled the
cost-effective sourcing of equipment.
Dynamic engineering
The performance of any equipment supplied in a project depends
on how well it is engineered to match site requirements. FLSmidth
successfully met the challenges of bridging national, cultural and
linguistic gaps between supplier and end-user, whilst fulfilling the
customer’s expectations in terms of safety, acceptance, performance
and service.
The engineering started with concept drawing followed by 3D

modelling to mitigate any civil work issues. Complete testing of
the equipment took place at the suppliers’ workshops to prevent
unnecessary surprises at the site and save time in the execution
phase, where only resonance frequency testing was necessary.
Seamless execution
A well-structured organisation with dedicated managers for engi-
neering, sourcing and logistics helped ensure efficient project
execution. The process involved obtaining all the necessary approvals
from customer consultants and electricity boards, securing the supply
of special or ‘first-time’ equipment, and ensuring timely ordering,
inspection and delivery. All logistics were well-planned and deliveries
were tracked to ensure compliance with the agreed timelines.
Installation
The FLSmidth site engineers, the customer’s engineers and the well as bushings and cable holders. GIS is compact, environmen-
OEM engineers worked seamlessly together in identifying, installing tally adaptable, safe and easy to operate and handle. It is reliable,
and commissioning the various equipment parts. Civil engineering flexible and requires minimal maintenance. GIS rated voltages
levels were verified against the approved drawings. After being range from 72.5 kV to 800 kV and rated short-circuit breaking
installed, the equipment was tested as recommended by the current ranges up to 63 kA.
OEM supplier.
Indian cement industry’s second GIS solution
About gas-insulated switchgear The best reward any company can expect for exceeding a
The gas-insulated switchgear (GIS) in a substation is contained customer’s expectations is to receive another order from the same
in an earthed metal (aluminium) enclosure, which is filled with customer. Reliance Cement awarded FLSmidth a second electrical
high-insulation pressurised sulphur hexafluoride (SF6) gas as the and automation EPC contract for the grinding unit in Kundanganj,
insulating and arc-extinguishing medium. The switchgear equip- Uttar Pradesh, India. Following the same successful engineering,
ment includes a circuit breaker, disconnecting switch, voltage procurement and commissioning model developed for the Maihar
transformer, current transformer, and surge/lightning arrester as Plant, the GIS for this new site is already in use.
INNOVATION
FLSmidth®
STRIKE-BAR crusher ®
The EV hammer crusher has been The new crusher family member
The FLSmidth STRIKE-BAR crusher is the
the preferred choice for raw material newest member of the FLSmidth crusher
crushing at cement plants for many years. family and a perfect match to the EV™
A billion tonnes of limestone has been crusher. The STRIKE-BAR is a horizontal

impact crusher for raw material crushing
crushed by this grand old machine. and, at first glance, it looks sturdy and
And now it is joined by a little brother. heavy duty – and a bit similar to the EV.
The two machines certainly share some

familiar features, but the skin deceives and a
peek under the hood reveals the differences.
Crushing raw materials for cement presents

a number of challenges, and it is important
to select the right crusher for the job. Lime-
stone comes in many forms and can exhibit
different physical properties that causes
varying degrees of wear of the machinery.
Other factors to consider include the required
reduction ratio and the size requirements
of the end product. This is where a broad
panel of crushers makes sense. At FLSmidth’s
in-house test facilities, the correct material
properties can be determined and the
appropriate crusher selected.
FLSMIDTH EV HAMMER
IMPACT CRUSHER
CONTACT HENRIK SØRENSEN

HENS@FLSMIDTH.COM
IN MACHINERY OPERATING
The working principle
AT SUCH HIGH SPEEDS AND
The main area of difference between the IMPACT FORCES, FLEXIBILITY
STRIKE-BAR crusher and the EV is the
impact zone. IN THE SYSTEM IS A MUST
On traditional hammer crushers, the main
AND IT IS OF COURSE AN
impact occurs between a pivoting hammer, INTEGRATED PART OF BOTH
rock and a fixed breaker plate. The final
crushing occurs between hammer and THE STRIKE-BAR CRUSHER
grate. The STRIKE-BAR crusher utilises the
similar high-speed impact, but the main
AND THE EV.
impact occurs between a fixed bar, rock
and ‘flexible’ breaker plates.
In machinery operating at such high speeds

and impact forces, flexibility in the system is Maintenance inspection and to enable free access above
a must and it is of course an integrated part The main crusher at a cement plant is the the rotor and breaker plates when major
of both the STRIKE-BAR crusher and the EV. first machine in the process. This crusher overhauls are needed. This is just one of the
processes heavy quarry boulders weighing features that makes maintenance simpler
The EV utilises the fixed grate for fine up to five tonnes each and reduces them to and more cost-effective. Others include
crushing or grinding, making it suitable for mill-feed size. This kind of operation de- bolted-on wear segments, adjustable breaker
high reduction ratios and small output (such mands an extremely durable crusher. But no plates, minimal use of different spare parts
as for a ball mill feed). The STRIKE-BAR machine can perform endlessly under such and chrome/manganese wear parts.
crusher utilises several flexible breaker circumstances; hence the crusher must be
plates for crushing making it the right flexible from the perspective of wear com- All of these challenges have been solved
choice for medium course output (for pensation, maintenance and replacement of in the design of the STRIKE-BAR crusher,
example on vertical roller mills), easy wear wear parts. It is important that crushers have which is based on many years’ operational
adjustment and more flexible output size. several inspection hatches for easy regular experience gained from the EV crusher.
FLSMIDTH STRIKE-BAR
CRUSHER
SITE REPORT
CONTACT PETER BROCKMANN UNCOVERED BREAK OF

PEB-CH@FLSMIDTH.COM AUXILIARY DRIVE TO
SHOW DESIGN - PRIOR
TO INSTALLATION OF
BREAK GUARD
Great teamwork
and reliable technology
minimise plant disruption
When plant equipment fails, replacement technology is not Meanwhile on another of Tahama’s mills, an FLSmidth MAAG®
the only answer. Teamwork plays a vital role in ensuring gearbox had consistently been performing to expectations. So
operations get quickly back to normal. when the decision had to be made for a replacement gearbox,
the choice fell on FLSmidth MAAG.
Something was amiss at the Tahama Cement Plant in Saudi Arabia.
The gearbox installed on one of its mills had not been meeting The Tahama Cement Plant is owned by Southern Province Cement
performance requirements, and when the gearbox failed, a quick Company (SPCC), one of Saudi Arabia’s leading cement producers.
solution was needed to get the mill back into operation. SPCC operates three cement plants with a total cement production
“THE FOUNDATION OF THE PREVIOUS

GEARBOX WAS QUITE COMPLEX AND
NOT COMPATIBLE WITH THE FLSMIDTH
MAAG CPU. SO THE FIRST PART OF THE
PROJECT INVOLVED COMPLETELY
OVERHAULING AND RENEWING THE
FOUNDATION.”
Peter Brockmann,
Field Service Engineer at FLSmidth MAAG
capacity of over 8.4 million tpy. The Tahama plant produces more similar projects before. The key, especially when you have to work
than 3.63 million tons of clinker a year. As of March 2015 the pro- at speed, is teamwork, which involves communicating and everyone
duction will be even further increased to 5.45 million tons a year. taking responsibility for specific tasks.”
Peter Brockmann, Field Service Engineer at FLSmidth MAAG, Preparing the foundation
arrived at the Tahama plant soon after the gearbox failure. The old The replacement of the foundation started with positioning and
gearbox had already been removed and Peter and his colleagues roughly aligning the gear unit to the mill. This included the precise
could quickly get to work. The project consisted overall of two control of the mill input flange and mounting the coupling connect-
parts. First, the foundation needed to be prepared. Then the gear- ing the mill to the gearbox.
box could be installed, aligned and tested.
With the gearbox fixed and grounded, the oil system and piping
Peter Brockmann explains the challenge of preparing the foundation: could be installed. This was followed by testing the oil system
“The foundation of the previous gearbox was quite complex and before the equipment was flushed. Then, as the last steps before
not compatible with the FLSmidth MAAG CPU. So the first part of the final spin test and hot commissioning of the mill, the protection
the project involved completely overhauling and renewing the interlocks were tested and the motor and gear unit were aligned.
foundation.”
Today, the mill is once again fully operational thanks to the FLSmidth
SPCC was aware of this challenge, and it was one of the main MAAG CPU and the quick response and professionalism of the
reasons FLSmidth MAAG had been chosen. Yet SPCC wanted SPCC and FLSmidth MAAG teams.
assurances that the new gearbox would meet its performance
requirements, as any potential malfunctions and resulting downtime
would be costly. This is where FLSmidth MAAG’s professionalism
and expert knowledge of the particular demands of a cement mill
came to the fore. The installation engineers brought a professional
attitude and they knew it was important to work as a team with
the site’s staff, especially as time was of the essence.
Peter Brockmann says, “Our client wanted to know that we could

make everything work despite the challenges of the project. It was
important that the foundation was prepared properly so that the
gearbox would have optimal conditions. We were confident we
could deliver to SPCC’s expectations as we brought many years’
practical experience to the challenge and had completed many
NEWS IN BRIEF
Plant Service
CONTACT JENS PETER KOCH
JPKO@FLSMIDTH.COM
Agreements
CONTACT JACOB JØRGENSEN
JACJ@FLSMIDTH.COM
Optimising cement plant operations

FLSmidth launches Service Agreement a flexible service agreement concept that Jørgensen. “It applies to everything from
Concept for on-site plant inspections, gives plant managers everything they need crushers, stackers and all types of mills
remote support, assistance and training to effectively plan their maintenance.” through to gear units, kilns and coolers.
It also covers a plant’s automation systems.
Improvements in technology are increasing Regular inspections for peace of mind The agreement can mean extended war-
the lifecycles of cement plant equipment. But Central to the service concept are regular rantees to the equipment.”
even the most reliable, advanced equipment onsite inspections, which aim to monitor
requires maintenance to optimise its perfor- the equipment and reveal potential issues Jacob Jørgensen emphasises the importance
mance. With a ‘preventive maintenance’ before they arise. After each inspection, a of training as part of the service agreement:
approach, cement plant owners can combat comprehensive report is produced, which “In addition to providing on-site assistance,
the uncertainty of maintenance and avoid provides valuable insight into the plant’s we offer training in the use of cement
unplanned stoppages. FLSmidth has launched day-to-day operations. These reports are plant equipment. This is valuable for plant
a flexible service concept based on the particularly useful in the event of an unex- managers to ensure their personnel have
principles of preventive maintenance that pected failure between inspections. In such the right skills to operate the equipment.”
aims to ensure maximum availability of the cases, the service agreement will facilitate
plant while reducing the cost of maintenance. that FLSmidth can provide instant technical Reduce the cost of maintenance
support in between inspections solving Maple Leaf Cement in Pakistan is one
Jacob Jørgensen, Head of FLSmidth’s Service issues based on the intimate knowledge plant that recognises the opportunity to
Department in Denmark, says, “Cement of the plant. reduce the cost of maintenance through
plant owners are looking for high availability a long-term approach to service. Mr. Amir
in their operations. Stoppages are unavoid- “FLSmidth has published a comprehensive Feroze, Maple Leaf Cement’s General
able to a certain point, but their effect on service catalogue, and everything contained Manager says, “The FLSmidth Service
production time can be minimised if they within the catalogue can be included within Agreement Concept is a good match to
are planned. This is why we have developed the service agreement,” explains Jacob our own reliability-centred maintenance
strategy and it creates increased continuity
“THE FLSMIDTH SERVICE in the services delivered and lowers the

cost of the maintenance.”
AGREEMENT CONCEPT IS A GOOD
FLSmidth’s service agreement covers every-
MATCH TO OUR OWN thing from a one-time equipment inspection
RELIABILITY-CENTRED to full flow sheet service agreements,

including continuous inspections and tech-
MAINTENANCE STRATEGY AND IT nical support. It provides several benefits.
As it is based on a fixed-price agreement,
CREATES INCREASED CONTINUITY costs are predictable for the duration of
IN THE SERVICES DELIVERED AND the agreement. At the same time, mainte-
nance budgets are reduced by eliminating
LOWERS THE COST OF THE non-value-adding costs resulting in more
favorable pricing of the individual inspec-
MAINTENANCE.” tion. “We estimate that plants can save
between 10 and 20 percent on mainte-
Mr. Amir Feroze,
nance by pre-scheduling inspections,” says
General Manager, Maple Leaf Cement’s
Jacob Jørgensen, adding, “There is also
less need for inventory as the inspections
lead to better spare part planning.”
Successful
CONTACT MARK BLOWER
MARK.BLOWER@FLSMIDTH.COM
cooler upgrade
ABC™ INLET DURING
CONSTRUCTION
In May 2011, Holcim and FLSmidth

partnered to upgrade the existing
clinker cooler at Holcim’s Nobsa
plant in Colombia.
The existing air beam grate cooler was suffering from high mainte- The equipment for the project was delivered in late 2011, but
nance costs and poor cooler efficiency. Several options were reviewed a strong Colombian market postponed the plant’s planned shut-
for the upgrade of the cooler. After detailed review and analysis down for cooler upgrade and installation until October of 2012
Holcim chose a selective solution, upgrading the following key com- when the cooler upgrade was installed during a scheduled main-
ponents of the cooler, while minimising capital costs for the upgrade: tenance stoppage. The shutdown, from flame-off to flame-on,
• New ABC™ (air blast controlled) fixed inlet with two new lasted 20 days.
undergrate fans
• Compartmentalisation of the existing cooler, adding new FLSmidth has visited the plant twice since the installation, and the
compartments, floor plates, and inter-compartment seals cooler continues to perform well, with high reliability, limited
• New tube conveyor to transport the spillage material, replacing maintenance and good fuel consumption.
the existing open-style drag chain
• New pocket type grate plates for the entire cooler
Holcim and FLSmidth worked together closely on the upgrade, Performance testing
incorporating Holcim design parameters into the final equipment
Guarantee description Guarantee Obtained
arrangement. Additionally, while both parties realised that all new
Capacity 3,300 tpd 3,449 tpd
fans for the cooler would further improve results, only the fans for
Fuel consumption savings -20 kcal/kg -50 kcal/kg
the inlet were replaced, and the rest of the existing fans were
Clinker temperature 165˚C 164 ˚C
rearranged and re-used.
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FLSmidth Reliability-focused
performance
APRIL 2013
How will the

OCTOBER 2013
APRIL 2014
industry move ahead

in cooperation with the Avoid expensive
unforeseen shutdowns
A source for good equipment
Stay in touch through

service suppliers? Loan bundling
saves money
Cement
evolution of SCM O&M Cement
Highlights in print and online,

reaches new heights
Automation
technologies enabling
ICE
in person at events and

conferences, and across a
range of social media channels
Meet with us
The online edition – eHighlights Cement - is enriched with videos, As a global player, FLSmidth regularly attends events and confer-
animations, images and links to related material. The eHighlights ences all over the world. At these events, we present the full range
online platform is constantly updated with new content. of our products and services and we offer the opportunity for a
no-obligation discussion about your cement plant requirements.
Highlights Cement also comes in an interactive tablet-friendly
version available for iPad. Download the app free in iTunes. Here are some of the events where you can meet us in the com-
ing year. Be sure to stop by and see us!
Upcoming events

DATE EVENT LOCATION
October 29-30, 2014 FLSmidth seminar Tehran, Iran
November 11-13, 2014 AUCBM Marrakech, Morocco
November 12-13, 2014 CBI New Delhi, India
April 21-25, 2015 AFCM Hanoi, Vietnam
April 26-30, 2015 IEEE-IAS/PCA Toronto, Canada
Stay updated on eHighlights where you will find information

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and papers.
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OCTOBER 2014

LETTER FROM THE PRESIDENT SCAN TO VIEW PER

Product development and innovation are a hallmark of FLSmidth’s

Contributing to local society is also central to the value we offer,

360° certainty solution: Design, Build and Operate

Welcome to Highlights Cement.

Per Mejnert Kristensen

Editor-in-chief Letter from the President 2 FEATURES

All product names used herein are V8 process control system 18

SCAN HERE FOR

FRONT COVER: ILLUSTRATION OF FLSMIDTH’S

CONTACT HUBERT SUINAT

New cement plant for

Lucky Cement is Pakistan’s largest producer

The Rawji Group includes companies involved

CONTACT SCOTT ZOLOTSKY

Congo is characterised by growing stability

The site of the new plant, Kinsua village

PRODUCTS & SOLUTIONS

Semen Indonesia CONTACT KLAUS BØGESKOV HANSEN

supplier, Semen Indonesia, is environmental impact.

Based on market data

The update included reviewing and evaluating the complete me-

Of the many updates applied to the mill, the most significant

FLUID DYNAMICS WAS

Increasing demands for cement

The OK mill was put into service in 2013 as an Ordinary Portland

CONTACT CRISTINA HOLMARK

The degree is a combination of academic theory and practical

Successful knowledge transfer

“We wanted to create this degree according to established

WORLD’S FIRST STUDENTS AFTER A

Cristina Holmark emphasises that the programme is now owned

PROMOTIONAL LAUNCH OF POSTGRADUATE

CONTACT MORTEN HANSEN

CONTACT NAVEEN SEELAM

The inlet seal air casing is designed to handle back spillage,

EACH MODULE IS SCAN TO VIEW

“VISUAL INSPECTION OF THE SEALING DURING

CONTACT SIMON LINDBERG

Production underway The commissioning was all the more im-

TO OPERATE AND MAINTAIN THE “The coorporation with FLSmidth and

BUT ALSO BECAUSE THEY CAN A foothold for future growth

TECHNICAL SUPPORT.” maintaining this production level over the

CONTACT JAN SCHILLING

Through a unique combination of programming skills, experience

The system is built for better integration between different products

PRODUCTS & SOLUTIONS

‘Sarbottam Cement Pvt. Ltd.’ to FLSmidth. Several ‘firsts’ in Nepal

CONTACT JESPER HAVN ERIKSEN

In more recent developments, some plants have begun to report

Water from gypsum %

dehydration and prehydration were clear. 0.1

For cement plant owners and investors in today’s demanding

FLSmidth’s Design, Build, Design, build and then operate

Our combined EPC and O&M solution is a unique offering

With 130 years of specialist know-how, FLSmidth can guarantee

Opening doors to financing

Sustainable, profitable operations

FLSmidth introduces two

Lars Gamborg, FLSmidth’s Global Product

fabric filter design reduces

TOP WALK-IN WEATHER