2007

Highlights

April
Highlights
Highlights Equipped for
Editor: Anders Klinkby Godiksen
(responsible under Danish law)
the future
Brenda Kaplan
V. Ragini Shah
Henrik Vinther Tuesday 2 January 2007 was a historical day for FLSmidth as it
Production: Gunnar Andreasen
celebrated the 125 years that have passed since the company
Translations: Martin Bojesen
was established. The day also marked the beginning of another
Editorial office:
exciting year for the global cement industry. Highlights asked
FLSmidth A/S
Vigerslev All 77, CEO Jrgen Huno Rasmussen to comment on the companys
DK-2500 Valby, Copenhagen, Denmark anniversary.
Tel: +45 36 18 10 00

Fax: +45 36 45 44 27 Is FLSmidth equipped Youve also been favoured

Email: info@flsmidth.com
for the future? by fortune?
Internet: www.flsmidth.com
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
All rights reserved
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
Contents not become overwhelmed by our cement industry has its ups and
good fortune. The demand for ce- downs, a fact to which the FLSmidth
Equipped for the future 2
ment machinery is at an all-time high, organisation can certainly testify. The
Breaking records in Mexico 4
which is challenging our organisation. companys present success derives not
Another major project for Kazakhstan 4 We are well equipped because we only from the size of the market, but
Green cement plant for the Emerald Isle 6 have chosen a precise strategy and also from our own history and flexibili-
One of largest white cement plants 7 returned to our roots within cement ty. The FLSmidth flag is planted across
Largest-scale ATOX mills on stream 8 and minerals. This focused strategy is the globe and is testament to the ac-
Chinas leading cement producer 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
Americas next generation of plants 12
of expertise as a global and forward- and paved the way for future success-
The preferred supplier for 125 years 16
thinking engineering company. All in es. We still see old, well-maintained
D.G.Khan upgrades cooler 18 all, we are well prepared to supply plants running seamlessly. By continu-
New ship unloader for Eastern Portland 19 the plant and service solutions of the ing the same actions today and mak-
KOCH strengthens FLSmidth 20 future. ing the appropriate decisions, we are
New workshop in China 21
Airtech fabric filter technology 22
Sanghi Cement at historic 10,500 tpd 24
Cost-effective shortcut to dry conversion 25
Thumbs-up to kiln simulator 26
New FLSmidth literature 27
Vasavadatta Cement commissioned 28
Take the e-highway to spare parts 28
Sebryakovcement sets ball rolling 30
On the job 32

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

2 Highlights April 2007
also paving the way for future genera- show it in practice. And you can read ner for at least another hundred years.
tions. about it in this magazine. Our values can But the anniversary celebrations will
be expressed in different ways, but I ven- include customers. In May, well embark
New ways? ture to say that everyone in FLSmidth is on a road show with seminars in Den-
FLSmidth will grow considerably over the proud of the companys reputation as mark, Egypt, India, Indonesia and the
coming years. In Cement, our aftermar- the industrys preferred partner. If you USA. These will be high-profile events
ket activities and the design of new see an FLSmidth logo on a machine, shared with management executives
technological solutions are making good there is no doubt that this is top-quality from our customers. There is every rea-
progress. In Minerals, we have recently equipment backed by a global organisa- son to celebrate.
taken a positive step forward by acquir- tion willing to provide top-level service I wish you pleasant reading of this
ing KOCH Transporttechnik, the German when needed. new issue of Highlights, which as usual
materials handling group. Their exten- also comes in an electronic version,
sive know-how will prove highly useful Will the anniversary year see eHighlights on www.flsmidth.com
to FFE Minerals, which we plan to grow any special events?
to a size comparable to Cement. Were already busy with one of the com- J. Huno Rasmussen
panys most important years in recent CEO, FLSmidth
How about specific FLSmidth times. Of course, our anniversary has
values? been highlighted in the press. Mean-
We dont blow our own trumpet with while were sticking to our normal prin-
trendy slogans. Our customers know ciple: business as usual. Thats because
perfectly well what we stand for. We we intend to remain the preferred part-

Highlights April 2007 3

 Breaking records Another major
in Mexico project for
Kazakhstan
CEMEX S.A.B. DE C.V. (CEMEX), a global building The last issue of Highlights reported on
solutions company that provides high quality FLSmidths first major order in Kazakhstan, a
products and reliable service to customers and 3,500 tpd modernisation project. More recently,
communities in more than 50 countries, has East Energy Company (EEC), part owner of
awarded FLSmidth a contract to build the largest Kokshe Cement, has placed a EUR 90 million
kiln system in South America. contract for a complete new greenfield plant,
confirming Kazakhstan as a major new market.
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- Kazakhstan, a country rich in oil, gas and minerals, is see-
tem is part of a 4.4 million tonnes per year expansion project ing double-digit growth in construction activity. The coun-
to mark CEMEXs 100-year anniversary. Additional equipment trys 15 million people, who inhabit an area comparable to
packages will be tendered later on. Western Europe, need increasing volumes of cement for
roads, homes and industrial development. Several new
Meeting strict environmental standards cement plant projects are being considered, but the first
The USD 35.9m project demonstrates FLSmidth's leadership one to begin operation will be Kokshe Cements two
and capability in designing large clinker production systems. million tpy plant.
The contract includes the latest generation Multi-Movable
Cross-Bar Cooler. In addition, the ILC 5-stage preheater with Mutual trust
low NOx and CO calciner will ensure that the strict environ- Most of 2006 saw a very constructive dialogue between
mental and efficiency demands are met. the customer, its German advisor and project developer
With a strong local presence in North America, FLSmidth Evagor GmbH and FLSmidth, which was chosen to design
was able to differentiate itself from possible competitors. and supply the plant. The talks, which took place in an
FLSmidth's US project centre based in Bethlehem, Pennsylva- open atmosphere of mutual trust, culminated in the sign-
nia, which is responsible for the project, attributes the success ing of a contract in late 2006.
of the contract to its ability to act as a complete partner for The new greenfield plant will be situated 270 km
the supply of engineering services, project management, and northwest of Astana, the Kazakhstani capital. The regions
commissioning as well as all major machines for the clinker surrounding Astana, in the centre of the country, and
production line. 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.
Seated (l to r):Peter Westring and Hugo Bolio.
EEC also has a construction business which will handle some
Standing (l to r):Richardt Fangel, Enrique Mendez, Elias Garza,
Edmo Gutierrez, Hector Trevino, Hector Mendez, Emiliano Quiroga. 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.

4 Highlights April 2007

The plant site is strategically located ment will be to provide the bulk of tech-
with plenty of limestone and clay re- nical documentation in both English and
serves nearby. A special railway line will Russian.
be built to the plant for deliveries of
equipment and, subsequently, additives First modern cement plant
and other materials needed in cement This contract confirms our expectations
production. Distribution of cement, of growing cement industry activity in
mainly in bulk, will also primarily take the former Soviet Union countries, and
place by rail. FLSmidth is actively pursuing the vast
opportunities in this fast growing re-
State-of-the art project gion, FLSmidth Group CEO Jrgen
With temperatures dropping to -40o C in Huno Rasmussen says.
the winter, building the plant and de- Leif Kirk, Vice President, Sales, FLSmidth and Kapanov
Sailaubek, Director Kokshe Cement, sign the contract.
signing equipment that can withstand
the cold will be a major challenge. Civil Scope of equipment supplies
works, plant installation and commis- EV 200x200 limestone crusher
sioning are planned to take place during Side Scraper store for limestone and clay
the frost-free months of 2007, 2008 and ATOX 47.5 raw mill
2009, respectively. CF silo dia. 20x56 m (21,500 tonnes)
The plant will feature state-of-the-art ATOX 22.5 coal mill

production equipment and control sys- 5-stage ILC preheater with ammonia injection to reduce NOx
tems, all designed to achieve maximum Two-support kiln 5.25x62 m (5,500 tonnes per day)
production efficiency and best practice SF Cross-Bar cooler 4x6
environmental performance. The con- Clinker store dia. 60x46 m (100,000 t)
tract includes not only equipment sup- Two OK 33-4 cement mills
plies, but also engineering, training and Four CFS cement silos dia. 20x40 m
spare parts. FLSmidth is responsible for MAAG Gear units
transporting the equipment to the site, a Two Ventomatic packing lines
major operation involving deliveries from Pfister feeders
selected manufacturing plants by rail, FLSmidth Automation control system, including RoboLab
ship and truck. Another major assign- FLSmidth Airtech bag filters and electrostatic precipitators
Highlights April 2007 5
 Green cement plant for
the Emerald Isle
FLSmidth has been entrusted line, meeting best practice environmen- Pfister coal feeders
with a 4,000 tpd project for Irish tal standards. The new line will both ILC preheater and ROTAX two-
Cement Ltd.s Platin Works north increase the overall plant capacity from support kiln dia. 5 x 60 m
of Dublin. The state-of-the-art 2 to 2.8 million tpy and lower carbon MMC 11x97 cooler
plant will be designed to comply dioxide emissions. Once line 3 is in oper- OK 36-4 cement mill
with the most stringent environ- ation by late 2008, it is expected that MAAG gear units
mental requirements. the existing line 1 dating back to 1972
will be closed down. Platin Cement Works is located near
The signing of a contract with Irish Ce- FLSmidths role in the new project Drogheda in eastern Ireland, some
ment Ltd. (ICL) for a new 4,000 tpd consists of supplying a total package of 50 km north of Dublin. The new produc-
clinker production line practically coin- machinery and equipment plus engi- tion line will be the biggest investment
cided with FLSmidths 125th anniversary neering services. The main equipment ever in Ireland by Cement Roadstone
around New Year 2007. This is not the items are: Holding (CRH), the leading international
first time ICL and FLSmidth have cele- MVT raw material store, 95 metres in materials group which owns ICL. Platins
brated an anniversary by signing a con- diameter expansion project will ensure adequate
tract. On 5 December 1996, the two ATOX 47.5 raw mill supplies for Irelands thriving economy
parties marked the 60th anniversary of ATOX 25 coal mill and growing construction sector.
their mutual relationship by signing a
contract for the rehabilitation of Kiln 2

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 range of ATOX mills now spans from 1,200 tpd line commissioned in 2003;
continue to grow in size, there 665 to 5,931 kW installed power. and a 6,000 tpd line commissioned in
is a corresponding demand for 2005. The latter is equipped with an
larger mills. In the previous issue Chinese cement company ATOX 52.5 raw mill, the first of the
of Highlights, we discussed the has success with mega-sized mega-sized vertical grinding units to
increasing size of OK vertical ATOX mills enter into operation. The mill has a main
mills used for finish grinding In 2003, FLSmidth sold the first of its drive of 4,266 kW, a MAAG gear and an
of cement and slag. This article new larger-sized mills to the Chinese RAR-LVT 52.5 separator. Following its
focuses on the ATOX vertical mill state-owned organisation Anhui Wan- successful commissioning, the mill com-
used for raw material and coal wei Update High-Tech Material Industry fortably achieved its performance expec-
grinding. Co. Ltd (known as Wanwei). Located in tations.
Chaohu City in the Chinese province of
More than 300 ATOX mills have been Anhui, Wanwei is active in chemicals, Accepted by the industry
sold since the first mills were commis- fabrics and cement. Since 2004, FLSmidth has sold nine
sioned during the early to mid-1980s. Founded in the 1970s, Wanwei orig- more mills like the one used by Wanwei,
The ATOX range originally comprised of inally manufactured fabric. But growth and even some larger ATOX mills. These
11 sizes, the largest being an ATOX 50 in chemical and fabric production result- will be featured in the next issue of
a mill with a grinding table measuring ed in an increasing amount of calcium Highlights.
five metres in diameter. carbide residue which led to the Today vertical mills are widely accept-
At the beginning of this century, development of cement production at ed as the most efficient means of prepar-
FLSmidth expanded its range to meet Wanwei. ing kiln feed for the production of ce-
the industrys need for higher capacity. Wanwei now has three cement pro- ment clinker. The mills can finely grind a
Four new mill sizes were introduced: duction lines: a 1,000 tonnes per day wide range of feed materials using a
ATOX 52.5, 55, 57.5 and 60. The total (tpd) line commissioned in 2000; a highly energy-efficient process. Raw

8 Highlights April 2007

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. World leader in huge cement This experience confirms FLSmidths
Tongling is one of the worlds plants position as the leading supplier of very
largest cement plants. FLSmidth The two most recent lines, which are large kiln systems to the global cement
has provided vital parts of the also the largest, are very impressive with industry.
technology including the recent- their twin preheater towers rising 146
ly commissioned twin 10,000 tpd metres up in the horizon. By contrast, A successful start
pyroprocessing lines. the relative peace and quiet of this mas- At 20:38 on 26 May 2004, Tongling
sive installation is quite remarkable, as Conch ignited the first of its 10,000 tpd
Large kilns have always exerted a strong there are no clinker grinding facilities at kilns which on 5 June produced the first
attraction on cement people, both be- the site. actual clinker. A grand opening ceremo-
cause of their sheer size and because of The two 10,000 tpd clinker produc- ny attended by cement industry execu-
their huge production capacity. tion lines were the first of their kind in tives and provincial government officials
To gain a good impression of a gi- China. At the time, the worlds only oth- celebrated both the first and the next
gantic cement facility, there is no better er lines of that capacity were the three 10,000 tpd pyro systems plus the four
place to go than Tongling, China, the which FLSmidth had previously supplied new ATOX raw mills at Tongling.
Anhui Conch Groups largest production to cement producers in Thailand. After a brief commissioning period,
complex. The plant is able to produce 10 the first line was steadily producing
million tonnes clinker per year and con- more than 11,000 tpd. Construction of
sists of four lines located at two inter- the first of the two new clinker lines
connected sites a few kilometres from took only 18 months from erection to
the Yangtze River in the Anhui province production an impressive achievement
of eastern China. The cement plant is considering the scale of the project.
close to plentiful reserves of high-grade The second line entered production
limestone. 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.

10 Highlights April 2007

Scope of contract Distribution and boosting of exports from the pres-
FLSmidth has a long standing and strong The new Tongling site does not grind ent level of nearly five million tonnes per
relationship with Conch dating back to finished cement. Instead the clinker is year. The new Tongling site has there-
the early 1990s when it signed the con- transported to grinding plants located fore been designed to accommodate a
tract for Tonglings first line (4,000 tpd). on Chinas east coast or at major cities third line, but the final decision to ex-
The successful implementation of that along the Yangtze river where cement pand the plant has yet to be made.
project led to a number of orders from consumption is high. Within the next five years, Conch
Conch over the following years. FLSmidth A covered belt conveyor carries the hopes to boost its annual clinker produc-
has been a supplier of cement-making clinker from the plant to the distribution tion capacity from approximately 50
machinery to China since 1906. terminal on the Yangtze river, a distance million tonnes to 100 million tonnes. If
In 2002 Anhui Conch Cement Co. of 7 km. On its way back the belt carries this growth materialises, Conch will join
awarded FLSmidth the contract for key coal. The pier at the busy terminal re- the worlds top ten league of cement
technology and equipment for the two ceives vessels up to 5,000 dwt. It has producers.
new lines at Tongling. The scope of sup- three loading stations each with a ca-
ply was pacity of 1,200 tph of clinker or 800 tpd
of cement from the old Tongling site.
Two 2-string, 5-stage ILC preheaters
Two 10,000 tpd rotary kilns Ambitious plans for the future
Two Duoflex kiln burners for coal The Conch Group is already Chinas
Four ATOX 50 raw mills largest cement producer, accounting for
Four 3,800 kW planetary gears sup- 4-5 percent of the nations current con-
plied by MAAG Gear sumption. Conchs plans for the future
Pfister coal feeders. 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- Of particular interest is Holcims massive The pyroprocess solution
dented rise in new plant capacity greenfield plant being built alongside the Two- or three-support kiln
in the past couple of years with Mississippi River in Ste. Genevieve Coun- At the heart of the clinker production
North America playing a leading ty, Missouri, USA. This facility will feature line is the kiln, and all of the projects
role. New plants there have the the largest single clinker production line with the exception of the large Holcim
most modern equipment and anywhere in the world with an annual and CEMEX plants will incorporate the
a number of special design fea- cement capacity of four million metric ROTAX-2 kiln, Figure 1. This two-support
tures and operational require- tonnes. Similarly, the new CEMEX S.A.B. design uses the standard features of tan-
ments. DE C.V. (CEMEX) Tepeaca plant will, at gential suspension, electro-mechanical
2,300 metres above sea level, be the friction drive through the supporting
Since 2005 about 22 million metric largest single clinker production line ever rollers, and fully self-aligning roller sup-
tonnes per year of new capacity has built in Mexico and Latin America. ports.
been sold in North America, and a simi- So, what state-of-the-art solutions in Due to the sheer size of the kilns re-
lar amount is identified in future proj- the pyroprocess and milling areas is quired at Ste. Genevieve and Tepeaca
ects. FLSmidth was well prepared for this FLSmidth supplying? which are 6.6 metres (21.7 feet) in diam-
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.

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 The milling solution ATOX design, Figure 5. Popular for many
will be required for Holcim Ste. Gene- Raw grinding years in other parts of the world, includ-
vieve. Fortunately, effective and simple Vertical roller mills for raw grinding have ing Latin America, the ATOX coal mill
methods exist for controlling the emis- been the industry standard for many has finally entered the US market. Con-
sions but at a significant price of opera- years, and FLSmidth recommends either tinuous improvement of the ATOX coal
tional changes or handling and using the FRM or ATOX design depending on mill has resulted in todays compact con-
costly reagents. the application and specific require- struction together with high efficiency
SNCR (Selective Non-Catalytic Re- ments. Most of the projects will feature and reliability.
duction) with the use of aqueous ammo- the FRM mill, Figure 4, and the ATOX
nia has become a popular and effective raw mills being supplied at Holcim Ste. Cement grinding
technique for secondary NOx reduction Genevieve will be the first of their kind FLSmidth will use the OK vertical roller
and will be installed from the outset in in the US. mill, Figure 6, for all finish cement grind-
many of the projects. Provisions for hy- Rinker Brooksville is the sole excep- ing. This type of mill has become the
drated lime injection for SO2 reduction tion to the vertical roller mill standard. It market standard, and a total of 22 OK
are also included in many cases. To con- will use a ball mill for raw grinding be- mills will be in operation in the Americas
trol CO or VOC emissions, two of the cause the extreme characteristics of the by the time this new group of projects is
plants will feature a material split to di- raw materials are not suitable for commissioned.
vert a portion of the incoming kiln feed smooth and reliable operation with a The OK mill has better grinding effi-
to a lower position in the preheater, or vertical roller mill. In this unusual case, a ciency than any other vertical roller mill
even direct it to the calciner. trade-off of using a less energy-efficient on the market. Many of the new plants
technology is more practical. will incorporate a compact layout, using
cyclones and hot gas recycling to min-
Coal grinding imise the vented volume and emissions
All plants with FLSmidth-supplied coal to atmosphere.
mills will be vertical roller mills of the
.
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 Far better at crushing hard clinker than the previous technology, FLSmidths In the USA, the oil-fired rotary kiln for
shaft kiln manufactured Portland tube mill signalled the start of a whole new era in cement production. burning cement had been developed to
and other cements and lime. save labour costs. In Europe, FLSmidth
The fuel consumed in a Shofer kiln introduced the coal-fired rotary kiln,
was only a third of that used in an constructing two 18 m long kilns at
ordinary kiln. 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- FLSmidth contracts to build the worlds
tion and drying processes into a single unit. 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.

16 Highlights April 2007

 From the start, FLSmidth focused on the technical and
scientific aspects of cement production.

1900 1922 1925

The Kominor mill was specially developed for heavy The UNAX satellite cooler, The famous Symetro gear together with
grinding. It was later ousted by the tube mill. which reduced dust problems, the Unidan tube mill became the preferred
was constructed as an integral installation for cement grinding.
part of the kiln.

1998 2001 2007

The first SF Cross-Bar cooler based on The HOTDISC is used to burn The cement plant at Ste. Genevieve, Missouri, will hold
the concept of fixed grates, separates large items of waste and the hot the worlds single biggest production line with a capacity
clinker conveying through cross-bars combustion gases are utilised in of four million tpy, corresponding to 12,000 tpd.
and air flow control through mechanical the calcining process.
flow regulators.
Highlights April 2007 17
 D.G. Khan upgrades cooler

The Pakistani cement producer, A second upgrade for the cooler The first of many?
D.G. Khan Cement Co. Ltd. and Some years ago, FLSmidth upgraded D.G. Khan is the first plant in Pakistan to
FLSmidth have worked closely D.G. Khans kiln no. 2 from 3,300 tpd to be upgraded with MMC cassettes and
for more than twenty years. The 4,000 tpd, carrying out a minor modifi- an HRB. FLSmidths Customer Services
upgrade project for the cooler cation of the existing Coolax cooler. This Projects department hopes to upgrade
serving kiln no. 2 at the D.G. time the cooler is being upgraded with several similar production lines using
Khan plant is the latest example MMC cassettes, which are similar to the the same concept in Pakistan in the near
of their long-standing relation- modules of an SF Cross-Bar cooler, but future.
ship. With the contract signed in without the supporting frame.
January, commissioning of the The major difference is the way the
upgraded cooler is expected to drive mechanism is constructed and
take place in the spring of 2008. works in the MMC cooler. Each cassette
has two built-in drives and cross-bars
After lengthy discussions about extra above the grate line, but not all cassettes
cooling capacity, the final contract was have a hydraulic cylinder. And all the
signed. The talks were based on current cross-bars are moveable and reciprocate,
operational data, notably the clinker which improves conveying efficiency.
temperature, and D.G. Khan eventually The MMC cooler can be installed hori-
opted for a major cooler expansion solu- zontally and the drives can have individ-
tion including two Multi-Movable Cross- ual stroke lengths and speeds to match
Bar cooler (MMC) cassettes. Instead of a the operation of the clinker belt conveyor.
traditional clinker crusher, D.G. Khan
chose a Heavy-duty Roll Breaker (HRB),
consisting of two crushing rolls and sev-
eral transport rolls.

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.

18 Highlights April 2007

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 cement plant in Atoconga and the port
processing arm of FLSmidth, re- in Conchn, without transfer stations.
cently acquired the German and The upper strand of the conveyor will
Austrian divisions of KOCH Trans- carry cement and clinker from the plant
porttechnik. An exciting addition to the ship loading facility, while the
to the FLSmidth Group, KOCH lower strand will convey coal and lime-
is a dominant global force in stone, as well as other materials such as
materials handling systems and iron ore, iron pellets and gypsum. To
the clear market leader in pipe avoid material spillage from the lower
conveyors. strand, the belt will be turned at either
end, allowing the same side of the belt
KOCH designs, manufactures and servic- to carry material in both directions.
es a broad range of mechanical trans-
port systems and equipment used in Superior to the belt conveyor
minerals processing and cement produc- Between the plant and the ship loading
tion around the globe. KOCH Austria pier, the conveying line passes through a
currently supplies pipe conveyors for the twisting 6.5 km tunnel, taking it under a
world's largest cement production line in network of busy roads. The pipe convey-
St. Genevieve, USA which was designed or is ideal for this. Far superior to con-
and is currently being constructed by ventional belt conveyor technology, it
FLSmidth. can follow horizontal and vertical curves
with a minimal radius which allows opti-
Global reputation combined with mum integration into the tunnel. The
local presence pipe conveyor also eliminates dust emis-
Uniting KOCH's expertise in conveying sions and material spillage, improving
equipment application, design and engi- ventilation and minimising the need for
neering with FFE Minerals' direct pres- tunnel maintenance.
ence in 11 countries will help establish a In addition to the transport system,
powerful market position for the com- KOCH is also supplying various storage
pany. FFE Minerals is also creating a new facilities for clinker and cement. The sys-
Materials Handling Technology Centre to tem is due to start in 2007.
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.
Recently acquired KOCH Transporttechnik is
supplying the worlds longest pipe conveyor in
World's longest pipe conveyor Peru to carry bulk materials between the cement
One of KOCH Germanys biggest proj- plant and the port.
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
A large section of Cementos Limas pipe
coal (lower strand).
conveyor runs underground. The enclosed
The Cementos Lima pipe conveyor transport system is easy to service even in
will transport materials between the the tunnel.

20 Highlights April 2007

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 Our pulse jet products:
filtration equipment are chang- Application Products available
ing in the cement industry. With Kiln/Cooler/Bypass FabriClean or PulseClean
kiln and mill capacity increasing Cement/Coal Mill DuoClean or UniClean
and emissions decreasing Nuisance application CE filter
environmental equipment must
become larger in size. Conse-

quently, fabric filter technology, The product range above, first launched 1.5 mg/Nm3. Whats more, the bags
in particular large fabric filters, ten years ago, has been applied in more lifetime is more than four years.
is gaining in popularity. than 150 process filters across an array
of applications. And thanks to ongoing Working to increase bag
Giving customers a crucial improvement efforts, FabriClean, Pulse- lifetimes
advantage Clean and UniClean are now established Bags for FLSmidth Airtech fabric filters
Already a leading supplier of bag filters as market leaders. Customers have been are supplied by Advanced Filtration Tech-
to the cement industry, FLSmidth Airtech particularly impressed with the gas and nology (AFT) a US-based bag produc-
is continuously developing products dust distribution and low pressure clean- tion company fully owned by FLSmidth.
which offer customers a technological ing features which have delivered re- The main factors for long filter bag life-
edge and reduce operating costs. markable results. time, besides gas and dust distribution,
As well as new filters, FLSmidth are bag material selection, bag and cage
Our fabric filters are designed to deliver: Airtech also offers an electrostatic pre- design, and compliance with standard
Low emissions cipitator (ESP) conversion, with the operating and maintenance philosophy.
Low differential pressure proven fabric filter technology built into The very close working relationship
Low compressed air consumption the ESP. Such a conversion can ensure between FLSmidth and AFT has also
rates lower future emissions if capacity in- helped generate additional knowledge
Long filter bag lifetime creases or emission levels change. Our about how to achieve longer lifetimes
reference list currently includes more for the filter bags. Specifically, this col-
To meet these goals, the filter products than 30 conversions and hybrid filters (a laboration has resulted in improved me-
are fitted with special gas distribution combined ESP and fabric filter, usually in chanical design and cleaning cycle pa-
features that ensure a low pressure drop the same casing). rameters. Achieving longer and longer
across the filter media and a long life. The main benefit of hybrid filters is bag lifetimes is a continuous process,
The technology also utilises low cleaning the synergy between the filter technolo- and, together with AFT, we are commit-
pressure techniques to optimise the gies (pre-separation and charging of the ted to making further progress in the
cleaning process. dust), which enables either a higher A/C years ahead.
ratio or smaller pressure drops. Docu-
mented results of this synergy have The optimum choice
shown reductions in the cleaning cycle Our products are ideal for medium to
by a factor of 30-50. Our work with hy- large filter applications in the cement
brid filters in kiln and cement applica- industry. The standard design has a filter
tions has delivered some impressive re- capacity exceeding 1,500,000 m3/hr
sults. For instance, we have seen cement in one filter casing. We have delivered
mill filters operating at a pressure drop solutions that include several filters,
of 50 mm Wg, and an emission rate of reach with capacities in the range of
1-1,500,000 m3/hr, all of which are
In the DuoClean filter the gas is exposed to the filter bags operating successfully.
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 Highlights April 2007 22

 This filter is designed for venting of large cement kilns.
Always at the forefront of technological shape for a large fabric filter. A more
advances, FLSmidth was the first compa- economical filter with long filter bags
ny to apply long bag filter tech-nology (up to 8 m) is being launched as the op-
for kiln venting. And recently, FLSmidth timal solution for very large cement mill
Airtech was selected to supply long bag circuits. The DuoClean filter is also
filter technology to the worlds largest equipped with a state-of-the-art gas and
cement production line Ste. Genevieve dust distribution system which secures a
in the USA (12,000 tpd). 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.
New product hits the market FLS tal cost and greatly reduced footprint.
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

Well agglomerating dust layer.

23 Highlights April 2007 Highlights April 2007 23

 Sanghi Cement production
at historic 10,500 tpd
During November 2006, Sanghi innumerable bottlenecks, including envi- Third preheater string
Cement Plants C2 string was ronmental clearances, the work on this now on stream
commissioned, and within a project commenced much later. At this Now with the commissioning of the
week of its operation it touched stage, the plant was redesigned to pro- third preheater tower the plant has been
a historic high of 10,500 tpd, be- duce 9,000 tpd with three preheater optimised at an output level of 10,000
yond the guaranteed production strings. However, when commissioned in tpd against the guaranteed 9,000 tpd.
level of 9,000 tpd. the month of March 2002 the plant was It is Indias largest capacity plant with a
rated for an output of 7,500 tpd with single kiln and one of its most modern
The plant is located in the Kutch district only two preheater towers. 100% lignite fired plants.
in the State of Gujarat, on the northwest The clinker grinding plant is located It has been a rich experience for
border of India. The State of Gujarat has approximately 12 km away from the FLSmidths specialist team to commission
the longest coastline among all states in clinkerisation plant, on the shores of the a single kiln with a three-string six-stage
India and has a long tradition of mar- Arabian Sea. This plant is self-sufficient preheater and calciner (one ILC and two
itime trade. with electricity and water, having its own SLC strings). Additionally, arriving at a
The original Sanghi cement plant power generating sets and desalination capacity of more than 10,000 tpd once
was conceptualised in 1994-95 for a ca- facility to cover its service water require- again testifies to FLSmidths world-lead-
pacity of 7,500 tpd with two preheater ments. ing technology and project capability
towers. However, after combating with 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- cost-effective alternative, particularly if Reliable and low cost operation
ing burden on wet or semi-wet the raw materials have a high natural The fineness of the feed must always
plants because of the heat it moisture content. The wet preparation match the requirements of the burning
takes to dry the raw slurry. As a of the slurry is retained, and the wet- process. The hammer mill drier merely
result, cement producers are process kiln converted into a cyclone serves to disagglomerate the wet sticky
looking at ways to reduce heat preheater kiln system. This solution is materials and only to some extent
consumption. A hammer mill dri- cheaper than an all-out dry conversion, grinds the materials.
er downstream of the converted and entails drying the moist raw materi- An extremely reliable machine, the
cyclone preheater kiln could be als in a separate hammer mill drier be- hammer mill drier has low maintenance
the answer. 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
Several cement plants still use a wet or fineness, and is then swept away by
semi-wet process. One way to reduce the air. Final drying takes place in the
heat consumption is to convert the en- riser duct, and the raw meal is then
tire production line to the more fuel-effi- separated in a cyclone.
cient dry process. But, this is often a ma- The hammer and the rotor are de-
jor project involving many elements, in- signed to effectively disagglomerate the
cluding raw material preparation, raw feed and ensure heat is transferred from
grinding, shortening the kiln and chang- the gases to the material. To improve
ing the cooler. drying efficiency, a static or dynamic sep-
arator may be installed in the riser duct.
Partial conversion of The purpose of the separator is to return
the wet plant the large lumps or coarse grains to the
Converting the plant to the semi-dry hammers for further pulverisation, en-
process is a much simpler and more abling more moisture to evaporate.

The hammer mill dryer disagglomerates and dries

sticky, non-abrasive materials in one operation.

25 Highlights April 2007 Highlights April 2007 25

 Contestants give kiln simulator
the thumbs-up
Last year, FLSmidth launched Highly responsive Close to reality
Beat the Autopilot, a kiln simula- Within days of its launch, dozens of Randy Walters also enjoyed Beat the
tion competition designed to competitors from around the world had Autopilots realism. And as a Control
demonstrate the complexity in signed up for Beat the Autopilot, pitting Supervisor operating a four-year-old
process control and optimisa- their wits against each other in a bid to 3,500 tonne per day 5-stage FLSmidth
tion. More than just competitive get closest to the optimum process per- preheater low NOx kiln, a 400 tonne per
fun, the simulator is a great formance target. Feedback has been ex- hour vertical raw mill, a vertical coal mill
learning tool to help operators tremely positive, with participants full of and a 150 tonne per hour OK mill for Salt
improve their knowledge and praise for its realism and attention to de- River Materials Group, he should know.
reaction times. tail. One of the early front-runners was He said: Its pretty close to the real thing.
Adrian Oarga, a Plant Operator at Hol- I like that it shows that making too many
The completion was a web-based simu- cim Romania. He says: The simulator moves will put the kiln in a cycle that can
lation of an ILC kiln process where the does an excellent job of reproduc- result in out of spec. clinker or emissions
number of measurements and con- ing a real kiln, and it responded that arent within range.
trol handles was reduced signifi- to every change I made. For ex- Asked what functions would have
cantly for the sake of simplicity. ample, when I reduce the fuel enhanced the simulators accuracy,
Also, in order to reflect the process in the burning zone, oxygen Randy Walters opted for kiln speed and
interaction in the shortest avail- levels at the back end increase secondary air temperature. But overall,
able time, the speed of the and the NOx decreases he felt the simulator was a very good
simulation was acceler- which is what hap- learning tool. It can really increase the
ated by a factor of pens in a real knowledge and improve the reaction
20. In this way kiln. times that are needed to operate newer
the players were kilns, he concluded.
able to interact Our idea with this web competition
with the simula- was to demonstrate the process control
tor and observe complexity, says Hassan Yazdi, FLSmidth
the process re- Automation Product Manager. Chang-
sponse to their own ac- ing one parameter for process control,
tions over 100 minutes in just main fuel for example, influences several
five minutes.

26 Highlights April 2007 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 FLSmidth terminal Our capabilities Addresses worldwide
ABC inlet total service concept solutions All the materials handling An up-to-date list of
Describes the new cooler FLSmidth is widening its scope of A complete range of ship systems and equipment FLSmidth Group
inlet which makes snowmen service to cement producers by unloading and loading facili- compiled in one brochure. companies and offices
a thing of the past. introducing complete Operating ties is offered by FLSmidth. around the globe.
and Maintenance contracts.

27 Highlights April 2007 Highlights April 2007 27

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

 Vasavadatta Cement
chooses FLSmidth pyroprocessing
technology
e-Catalogue saves time and effort In December 2006, FLSmidth First Rotax in India
The e-Catalogue is a dynamic and user- commissioned a 3,800 tonnes Vasavadatta Cement is using the first
friendly tool for searching for spare parts per day pyroprocessing system Rotax kiln in India, a 6-stage ILC pre-
information. An online resource, the e- for Vasavadatta Cement, a heater (with provision for future incor-
Catalogue for the particular plant is up- member of B.K. Birla Groups poration of a HOTDISC) and an SF Cross-
dated when FLSmidth Customer Services Kesoram Industries Ltd. A Bar cooler. The plant also includes a bag-
is informed about subsequent changes leading cement manufacturer, house designed for 800,000 m3/hr at
or adjustments at the customers plant B.K. Birla operates two clinker- 2400 C. The baghouse complies with
and also when FLSmidth and the cus- isation lines in the southern stringent emission standards and comes
tomer agree on technological improve- Indian state of Karnataka. with an on-line maintenance facility. The
ments to equipment or components. baghouse uses specially treated fibre-
This means that customers no longer In June 2004, FLSmidth India was invited glass bags, and has an overhead outlet
need to update their own spares docu- to bid for a third line at the existing site manifold that was designed specifically
mentation. And to eliminate errors, both at Sedam. While the proposal was being to customer layout requirements.
the customer and supplier use the same evaluated, key representatives from The kiln firing and kiln feed systems
information. Vasavadatta Cement visited FLSmidth- are provided with Pfister rotor scales
An improvement on its hard copy supplied cement plants in India, China (sourced from Pfister Germany/Pfisters
counterpart, the e-Catalogue is simple and Europe. licensee in India).
to work with and precisely identifies The Vasavadatta representatives With plant operation stabilised,
spare parts by part number. Customer were impressed by the efficiency of the clinker production now stands at 4,200
inquiries sent via e-Catalogue will auto- FLSmidth plants they visited. This, and tonnes per day with free lime well below
matically track all the information need- FLSmidths prompt response to the bid, 1.5 percent as guaranteed.
ed to identify the individual parts. This meant Vasavadatta Cement selected
information is sent to the customer and FLSmidths most advanced pyroprocess-
forwarded to FLSmidth Customer Ser- ing technology. Vasavadatta Cements new line 3 contains the
vices for swift processing, saving time best of FLSmidth pyroprocessing technology,
and effort for both parties involved. including the first Rotax kiln in India.

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.

Highlights April 2007 29

 Sebryakovcement sets the ball
rolling in Russia
On a cold winters day in January 2005, times exceeded, the guaranteed commissioning. FLSmidth Automation
the contract for a ball mill installation at throughput of 120 tph of standard OPC and MAAG Gear specialists also took
JSC Sebryakovcement in Russia became ground to a fineness of 3,200 blaine, part in the process.
effective. In addition to the 120 tph which makes this mill the largest in- FLSmidth used its global organisa-
UMS 46x14 mill, the contract included a stalled in Russia. By January 2007, the tion to design the plant and have the
SEPAX separator, a MAAG CPU gear unit parties involved in the project were able machinery manufactured. It is hoped
and FLSmidth Automation control to celebrate a job well done with the fi- that the Sebryakovcement mill will serve
equipment. The contract was preceded nal handing over of the grinding plant. as a reference project that both the cus-
by several rounds of tendering and tomer and FLSmidth can be proud of
negotiations. Getting the job done and inspire other cement producers in
What made the order particularly in- JSC Sebryakovcement is about three Russia.
teresting was the fact that it came from hours drive northeast of Volgograd, 12 December 2006 saw the achieve-
Russia, and so was a sign of growing which is a fairly remote place even by ment of the guaranteed production lev-
activity in this potentially huge market. Russian standards. As a result, the proj- el: the mill ran for 68 hours at 90 per-
JSC Sebryakovcement was among the ect had to be planned and organised in cent charge with only two stoppages
very first to team up with FLSmidth in minute detail and the customer was lasting a total of one hour. Since then
the expansion and modernisation of the keen to ensure good working conditions the ball mill has just kept on rolling.
Russian cement industry. at the site. FLSmidths staff were accom-
Now, two years later, cement con- modated at a nearby hotel owned by
sumption in Russia has rocketed above JSC Sebryakovcement and participated
the magic 50 million tpy mark, and the in all stages of the project, from open-
Sebryakovcement ball mill is working all box inspection, supervision of mechani-
Sebryakovcements new UMS cement mill is produc-
out. The plant has achieved, and at cal and electrical installation to final ing 120 tph of standard OPC. The successful com-
missioning and final handing over was celebrated in
January this year.

30 Highlights April 2007

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 a machinists apprenticeship at the Egypt, Portugal and France. Major proj-
Jensen is busy painting his flat in FLSmidth machinery works, followed by ects tend to last between one and three
Denmark when the phone rings. a BSc in mechanical engineering and years and Niels lists the Mediterranean
On the other end of the line is then military service and officers training countries of Greece, Turkey and Algeria
Mr P.A. Knudsen, FLSmidths in the Air Force. He had acquired crafts- as his favourite stop-offs.
renowned Vice President of manship, engineering expertise and Niels lets his work and spare time
Sales. An important kiln installa- leadership training, in that order. blend to such an extent that he builds
tion job is underway in Greece Niels left for Greece the following replica antique monuments at all major
and there is a vacancy for a bright Wednesday and has been travelling ever sites where he works. On these Greek-
young engineer. since, with the occasional assignment inspired statues he inscribes his motto
back at headquarters in Denmark, en- Nothing without work in Latin, Arabic
On the job: abling the children to stay in touch with and runes, serving as an inspiration for
their Danish heritage. visitors and a lasting testament to a job
Niels did not hesitate. He had been wait- well done.
ing for such a call for a year while work- Nihil sine labore His passion for international relations
ing in the Layout Department. Since his nothing without work is as strong as ever. As he says, If you
youth, Niels had heard his father tell Thirty years of travel have taken Niels can build strong human relations at a
stories about the exciting adventures of and his family to construction site, the technical side is a
an FLSmidth engineer working overseas. many countries: piece of cake.
So after leaving school at the age of Greece, Alge- Niels left his mark on the camp facili-
17, Niels was determined to work ria, Poland, ties of major turnkey projects in the
abroad. In 1958 he embarked on Chile, Holland, somewhat turbulent Algeria during the
the classic career path Belgium, Mex- 1980s (Ain Touta) and 90s (Tebessa). De-
of an engi- ico, Turkey, spite the political uncertainty, everyday
neer: 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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32 Highlights April 2007