Flsmidth Discover Cement

Grey/white Emissions reporting: Breakthrough in Unique
production: an reducing carbon cyclone financing

achievable ambition footprint technology partnership
P. 46 P. 38 P. 8 P. 44
Cement
DISCOVER
TECHNOLOGY
IN CYCLONE
BREAKTHROUGH
March 2018
WE DISCOVER POTENTIAL
Contents
SUBSCRIBE AT WEBSITE cement.flsmidth.com © 2018 FLSmidth. All rights reserved.
WWW.FLSMIDTH.COM LINKEDIN FLSmidth Cement Reproduction permitted quoting
/DISCOVER EDITOR Hanne Flyger “Discover Cement” as source.
Editorial Innovation New orders Products and solutions

08 51
04 05 08 11 34
LET’S LIFT THE LID ON LARGER GEAR DRIVES BREAKTHROUGH IN WORLD MAP OF NEW ORDERS CATALYTIC FILTER SOLUTIONS
PRODUCTIVITY TOGETHER FOR LARGER VERTICAL CYCLONE TECHNOLOGY Get an overview of selected major COME OF AGE
Senior Vice President Sofie Karen ROLLER MILLS “The new cyclone at our plant is orders placed since April 2017. Catalytic filtration solutions have proven
Lindberg comments on how the The trend towards single-mill cement a considerable breakthrough in to be effective in reducing emissions
cement industry can increase plants requires powerful, large-scale the cement industry,” says Mykola efficiently and cost-effectively.
productivity. drive gear systems. Makoviichuk, Production Director at
38 38
Ivano-Frankivskcement.
EMISSIONS REPORTING:
REDUCING CARBON FOOTPRINT
18
THEME Quinn Cement in Ireland has implemented a
Urbanisation drives the system for measuring carbon dioxide emissions.
Indian cement market

New government infrastructure initiatives and a fast-growing
07 40
POWER CEMENT ACCELERATES
population make the future bright for Indian cement producers. CEMENT PRODUCTION
Also in Nepal and Bangladesh, new growth opportunities are “The choice facing cement producers is
We're seeing an Our program is the
emerging. either to stay in the market by expanding - or
increasing number leave it to other producers. We chose to stay,” 'father' of over 1000
of producers
16
says Tahir Iqbal, CFO of Power Cement.
kilns throughout
INDIAN MARKET PUSHES FORWARD focussing on the world”
Country Head and CEO of FLSmidth India, Carsten Lund improving their 42
comments on the cement market in India, Bangladesh and Nepal.
efficiency and UNIQUE FINANCING PARTNERSHIP KELD HJORTSHØJ
FLSmidth, IFU and two Danish pension DEPARTMENT MANAGER
mitigating against
20
IN FLSMIDTH
funds have partnered up to invest in
equipment failure.” Power Cement’s expansion project.
MAKING GAINS WITH THE OK™ MILL
Cement producers in India, Nepal and Bangladesh CARSTEN
demonstrate the success of using VRMs. RIISBERG LUND
Site reports Features

COUNTRY HEAD AND CEO
24 OF FLSMIDTH INDIA
STRONG EPC PARTNERSHIP DRIVES

INDIAN BROWNFIELD PROJECT
FLSmidth and Larsen & Toubro teamed up to expand 46 48 50
TANCEM Cement’s operations in record time. GREY/WHITE PRODUCTION: CEMENTING CUSTOMER FLSMIDTH’S KILN CALCULATION
AN ACHIEVABLE AMBITION CONNECTIONS PROGRAM CELEBRATES 50 YEARS
26 28
Instead of building a new line, Riyadh Cement Global Product Line Manager for HRP The kiln calculation program revolutionised
converted an existing grey line to a dual systems, Avanish Karrahe shares the mechanical calculation of FLSmidth’s
CLINKER COOLER REPLACEMENT HYDRAULIC ROLLER PRESSES production line. how working with FLSmidth’s cus- kilns when it was first created in 1967.
DELIVERS IMPROVED PRODUCTIVITY BOOST PRODUCTIVITY AT tomers drives and motivates him. Today, it is still a valuable tool.
AT RAIN CEMENT ORIENT CEMENT
Impressive performance results were achived when Orient Cement increases performance by
the existing cooler was replaced by an FLSmidth® installing two hydraulic roller press systems
Cross-Bar® cooler. at its Karnataka plant.
Contents
SUBSCRIBE AT WEBSITE cement.flsmidth.com © 2018 FLSmidth. All rights reserved.
WWW.FLSMIDTH.COM LINKEDIN FLSmidth Cement Reproduction permitted quoting
/DISCOVER EDITOR Hanne Flyger “Discover Cement” as source.
Editorial Innovation New orders Products and solutions

08 51
04 05 08 11 34
LET’S LIFT THE LID ON LARGER GEAR DRIVES BREAKTHROUGH IN WORLD MAP OF NEW ORDERS CATALYTIC FILTER SOLUTIONS
PRODUCTIVITY TOGETHER FOR LARGER VERTICAL CYCLONE TECHNOLOGY Get an overview of selected major COME OF AGE
Senior Vice President Sofie Karen ROLLER MILLS “The new cyclone at our plant is orders placed since April 2017. Catalytic filtration solutions have proven
Lindberg comments on how the The trend towards single-mill cement a considerable breakthrough in to be effective in reducing emissions
cement industry can increase plants requires powerful, large-scale the cement industry,” says Mykola efficiently and cost-effectively.
productivity. drive gear systems. Makoviichuk, Production Director at
38 38
Ivano-Frankivskcement.
EMISSIONS REPORTING:
REDUCING CARBON FOOTPRINT
18
THEME Quinn Cement in Ireland has implemented a
Urbanisation drives the system for measuring carbon dioxide emissions.
Indian cement market

New government infrastructure initiatives and a fast-growing
07 40
POWER CEMENT ACCELERATES
population make the future bright for Indian cement producers. CEMENT PRODUCTION
Also in Nepal and Bangladesh, new growth opportunities are “The choice facing cement producers is
We're seeing an Our program is the
emerging. either to stay in the market by expanding - or
increasing number leave it to other producers. We chose to stay,” 'father' of over 1000
of producers
16
says Tahir Iqbal, CFO of Power Cement.
kilns throughout
INDIAN MARKET PUSHES FORWARD focussing on the world”
Country Head and CEO of FLSmidth India, Carsten Lund improving their 42
comments on the cement market in India, Bangladesh and Nepal.
efficiency and UNIQUE FINANCING PARTNERSHIP KELD HJORTSHØJ
FLSmidth, IFU and two Danish pension DEPARTMENT MANAGER
mitigating against
20
IN FLSMIDTH
funds have partnered up to invest in
equipment failure.” Power Cement’s expansion project.
MAKING GAINS WITH THE OK™ MILL
Cement producers in India, Nepal and Bangladesh CARSTEN
demonstrate the success of using VRMs. RIISBERG LUND
Site reports Features

COUNTRY HEAD AND CEO
24 OF FLSMIDTH INDIA
STRONG EPC PARTNERSHIP DRIVES

INDIAN BROWNFIELD PROJECT
FLSmidth and Larsen & Toubro teamed up to expand 46 48 50
TANCEM Cement’s operations in record time. GREY/WHITE PRODUCTION: CEMENTING CUSTOMER FLSMIDTH’S KILN CALCULATION
AN ACHIEVABLE AMBITION CONNECTIONS PROGRAM CELEBRATES 50 YEARS
26 28
Instead of building a new line, Riyadh Cement Global Product Line Manager for HRP The kiln calculation program revolutionised
converted an existing grey line to a dual systems, Avanish Karrahe shares the mechanical calculation of FLSmidth’s
CLINKER COOLER REPLACEMENT HYDRAULIC ROLLER PRESSES production line. how working with FLSmidth’s cus- kilns when it was first created in 1967.
DELIVERS IMPROVED PRODUCTIVITY BOOST PRODUCTIVITY AT tomers drives and motivates him. Today, it is still a valuable tool.
AT RAIN CEMENT ORIENT CEMENT
Impressive performance results were achived when Orient Cement increases performance by
the existing cooler was replaced by an FLSmidth® installing two hydraulic roller press systems
Cross-Bar® cooler. at its Karnataka plant.
FLSmidth Discover Cement 5
EDITORIAL
Regular readers will see that our magazine has a break free of conventional thinking and decades
new name and look, and even a new approach to of traditions to build new productive structures.
this editorial section. Rather than the traditional And to share knowledge and work together in
introduction by our President of the Cement Divi- By working transparent environments.
sion, Per Mejnert Kristensen, I have the opportu- This is what we focus on when we work
together
Larger gear
nity to use this space to welcome you to the first together with customers to help them build their
edition of Discover Cement. The stories herein towards a business of the future – and when we work s operators look to increase equipment
reflect our core promise: to help our customers
common goal, together with our own suppliers and business A capacity, the key is to ensure long-term
discover their potential. partners. This empowers us to offer our custom- reliability that guarantees continuous
drives for
Whether it’s a vested interest in a major rebuild, we can make ers a wider range of options and more value for kiln operation. There are several challenges.
such as the Power Cement extension in Pakistan, quantum money, while at the same time increasing industry Whereas machine design is often the limiting fac-
or providing dedicated solutions within emissions profitability and sustainability. tor for large ball mills and roller presses, it is the
reporting, catalytic filtration or cyclone design,
leaps towards The opportunities of quantum-leap productiv- drive systems that require focus in vertical roller
larger vertical
the stories in this edition show our multi-faceted productivity ity improvements are not necessarily right in front mills (VRMs). Placing silos before and after the kiln
approach to helping cement producers solve improvement” of us, and major opportunities are fewer and far can reduce short interruptions in the milling pro-
their unique challenges. between. But productivity also comes in smaller cesses, but long standstills caused by unexpected
roller mills
In many industries, traditional value chains scales by making smart investment choices that mechanical failures are difficult to avoid.
are being challenged. Products and job functions SOFIE KAREN bring about consistent gains – for example in the Reliability of VRMs depends on the drive
have disappeared entirely and business models LINDBERG case of Riyadh Cement, who instead of a major system, the grinding system and the operational
SENIOR VICE PRESIDENT
have failed because they did not adapt to the new investment in a new line, applied FLSmidth’s behaviour of the mill. To help lower initial cost
reality. Our industry is facing similar challenges know-how to convert an existing line into a dual investments aimed at preventing downtime,
and opportunities. grey and white line. particular attention must be devoted to the drive
While technology and data are often pivot In this issue, we also take a close look at the system and critical grinding components, such as
points, change is not brought about by them region of India, Bangladesh and Nepal. In addition roller and table.
alone. It requires special skills and expertise to to a commentary of the unique challenges and The global trend towards single-mill cement The rollers and the grinding table are exposed
apply data effectively to daily production pro- opportunities facing the region, you can read to high abrasive wear depending on the feed
cesses. An example of this is Quinn Cement’s about the steps Orient Cement, TANCEM Cement
plants is unquestionable. With civil construction material properties, the product fineness, and
use of a web-based reporting system to measure and Rain Cement are taking to boost productivity. cost savings, higher throughput and lowered the combination of rollers and table materials. At
emissions. We are on this journey together. If you have regular intervals, therefore, the table and roller
a story to share, or you simply want to talk to us
maintenance costs, the use of single large wear liners must be exchanged or repaired by
Sofie Karen Lindberg Partnering up to find new solutions about your challenges, you are always welcome VRMs for cement and raw grinding is the surface-layer welding.
Senior Vice President, By working together towards a common goal, we to contact us. If you start with me, I will connect Without the natural redundancy of an ap-
Group Communications can make quantum leaps towards productivity you with the right person who will help your
optimal choice. The sheer size requires proach with two mills in parallel, flexibility is key.
skl@flsmidth.com improvement. Everyone needs to be involved to cement business discover its potential. ■ powerful, large-scale drive gear systems. The OK™ mill has individual roller arrangements
FLSmidth Discover Cement 5
EDITORIAL
Regular readers will see that our magazine has a break free of conventional thinking and decades
new name and look, and even a new approach to of traditions to build new productive structures.
this editorial section. Rather than the traditional And to share knowledge and work together in
introduction by our President of the Cement Divi- By working transparent environments.
sion, Per Mejnert Kristensen, I have the opportu- This is what we focus on when we work
together
Larger gear
nity to use this space to welcome you to the first together with customers to help them build their
edition of Discover Cement. The stories herein towards a business of the future – and when we work s operators look to increase equipment
reflect our core promise: to help our customers
common goal, together with our own suppliers and business A capacity, the key is to ensure long-term
discover their potential. partners. This empowers us to offer our custom- reliability that guarantees continuous
drives for
Whether it’s a vested interest in a major rebuild, we can make ers a wider range of options and more value for kiln operation. There are several challenges.
such as the Power Cement extension in Pakistan, quantum money, while at the same time increasing industry Whereas machine design is often the limiting fac-
or providing dedicated solutions within emissions profitability and sustainability. tor for large ball mills and roller presses, it is the
reporting, catalytic filtration or cyclone design,
leaps towards The opportunities of quantum-leap productiv- drive systems that require focus in vertical roller
larger vertical
the stories in this edition show our multi-faceted productivity ity improvements are not necessarily right in front mills (VRMs). Placing silos before and after the kiln
approach to helping cement producers solve improvement” of us, and major opportunities are fewer and far can reduce short interruptions in the milling pro-
their unique challenges. between. But productivity also comes in smaller cesses, but long standstills caused by unexpected
roller mills
In many industries, traditional value chains scales by making smart investment choices that mechanical failures are difficult to avoid.
are being challenged. Products and job functions SOFIE KAREN bring about consistent gains – for example in the Reliability of VRMs depends on the drive
have disappeared entirely and business models LINDBERG case of Riyadh Cement, who instead of a major system, the grinding system and the operational
SENIOR VICE PRESIDENT
have failed because they did not adapt to the new investment in a new line, applied FLSmidth’s behaviour of the mill. To help lower initial cost
reality. Our industry is facing similar challenges know-how to convert an existing line into a dual investments aimed at preventing downtime,
and opportunities. grey and white line. particular attention must be devoted to the drive
While technology and data are often pivot In this issue, we also take a close look at the system and critical grinding components, such as
points, change is not brought about by them region of India, Bangladesh and Nepal. In addition roller and table.
alone. It requires special skills and expertise to to a commentary of the unique challenges and The global trend towards single-mill cement The rollers and the grinding table are exposed
apply data effectively to daily production pro- opportunities facing the region, you can read to high abrasive wear depending on the feed
cesses. An example of this is Quinn Cement’s about the steps Orient Cement, TANCEM Cement
plants is unquestionable. With civil construction material properties, the product fineness, and
use of a web-based reporting system to measure and Rain Cement are taking to boost productivity. cost savings, higher throughput and lowered the combination of rollers and table materials. At
emissions. We are on this journey together. If you have regular intervals, therefore, the table and roller
a story to share, or you simply want to talk to us
maintenance costs, the use of single large wear liners must be exchanged or repaired by
Sofie Karen Lindberg Partnering up to find new solutions about your challenges, you are always welcome VRMs for cement and raw grinding is the surface-layer welding.
Senior Vice President, By working together towards a common goal, we to contact us. If you start with me, I will connect Without the natural redundancy of an ap-
Group Communications can make quantum leaps towards productivity you with the right person who will help your
optimal choice. The sheer size requires proach with two mills in parallel, flexibility is key.
skl@flsmidth.com improvement. Everyone needs to be involved to cement business discover its potential. ■ powerful, large-scale drive gear systems. The OK™ mill has individual roller arrangements
6 FLSmidth Discover Cement Innovation FLSmidth Discover Cement 7
The design power of

such large VRMs depends on
the grindability of material.
Raw mill applications
require up to approximately
9,000kW, with slag and
cement grinding needing up
to 14,000kW. Regardless of
the type these VRMs’ drive
systems need to deliver
reliable torque transmission”
MARTIN BAECHLER
PRODUCT MANAGER
AT FLSMIDTH MAAG GEAR
The challenge with the

integrated drive system in the
VRM is developing an electrical
motor with the highest
possible power density.” With design power of 11,600kW,
MAX Drive™ drives the cement mill
via a common girth gear and two
MARTIN BAECHLER drive units.
with swing-out mechanisms to facilitate mainte- ing device and a highly flexible coupling connects couplings and gearboxes or as small vertical PRODUCT MANAGER
nance or replacement of the rollers. In the case the motor and gearbox. motors, integrated partially into the gear casing AT FLSMIDTH MAAG GEAR
of mechanical failure, the mill can easily operate Yet there are limits to such a system. The bev- and connected to a central toothed wheel inside
with fewer rollers. The only requirement is that the el stage in the gearbox, primarily used to redirect the gearbox.
remaining rollers are uniformly distributed around the rotating movement from the horizontal motor As a result, power distribution bevel stages
the table circumference and that they are all the shaft into vertical direction of the grinding table, are considerably smaller or, in vertical motors,
same size. Production can then continue, albeit at limits power capability. For design power of up to completely eliminated. The drive systems are built
a reduced rate, to minimise operational disruption. approximately 9,000kW, this can be overcome by so that they can operate with fewer motors in the
Impressively, the OK mill can achieve 60 to 70 increasing the gear ratio in the following planetary case of malfunction or maintenance. This means
percent of nominal output with half of its rollers stage, which keeps the bevel stage size within that operation at a reduced production rate can Elimination of weakest element stator. To operate such type motors, variable parts is kept to a minimum. The variable frequen-
out of service. feasible dimensions. However, this does not fulfil still occur, minimising production losses during The integrated drive system in the VRM replaces frequency converters are necessary. Integration cy converter allows the operator to adjust the mill
mill requirements and a further increase in drive scheduled maintenance. This has the effect, the bevel stage with one vertical motor built into also makes special cooling necessary, because table speed without time delay and to influence
Drive systems power requires larger dimensions, especially the however, of increasing complexity of the power the gear casing. While this does not affect the air-cooled motors do not reach the required the grinding process individually when grinding
“The design power of such large VRMs depends diameter of the bevel wheels. This decreases the distribution between the main switch gear and the power distribution, compared with the conven- power density. different product in the same mill or as feed
on the grindability of material. Raw mill appli- overall reliability of the drive system. Conventional motors and also increasing maintenance effort. tional system, the overall dimensions of the motor For example the motor in FLSmidth MAAG® quality changes over time.
cations require up to approximately 9,000kW, gear units cannot operate VRMs with higher In addition to the main switch gear, each must be adapted to the available space for a Gear’s CEM Drive includes special cooling tubes Large VRMs can help to meet the demands
with slag and cement grinding needing up to design power. The drive system for these applica- motor needs a separate circuit breaker and a bevel stage in a conventional gearbox. Otherwise, in the stator arrangement. This provides optimal of a single-mill cement line by addressing the
14,000kW. Regardless of the type, these VRMs’ tions is based on two main principles: partition of motor control cabinet to allow operation with a costly design changes of the mill support and flow of the cooling media and enables the use of typical challenges of grinding systems. In doing
drive systems need to deliver reliable torque power to several drive units and elimination of the reduced number of motors. In order to provide foundation are required. gear lubrication oil in the motor cooling circuit. so, FLSmidth’s OK mill can provide a solution for
transmission,” says Martin Baechler, Product weakest element in the drive train. uniform torque to the common central wheels, the According to Martin Baechler, the challenge most single-mill cement lines wanting to increase
Manager at FLSmidth MAAG gear. load and speed of each motor is synchronised by with the integrated system is developing an Smart design their throughput. ■
Conventional drive systems typically consist Partitioning drive power either a variable frequency converter or a highly electrical motor with the highest possible power Despite the challenges associated with large
of a switch-gear to connect the drive motor to the By separating the drive power, large VRMs can flexible or fluid coupling. During start-up, when density. A design study comparing different motor VRMs, there are important benefits to having an
electrical grid. The transformer converts the grid provide the required torque with multiple motors. the mill is running at full speed with fewer motors, types showed that meeting space requirements integrated drive system embedded in the design.
voltage to the motor design voltage and protects The motors are designed either as individual the timing of the connecting additional motors is are only possible with a synchronous motor with Power distribution, such as that in a partial-load MARTIN BAEHCLER
the equipment from voltage peaks. A rotor start- drive assemblies containing their own motors, essential to prevent torque peaks. permanent magnet excitation and a single coil system, is not required and the number of rotating Martin.Baechler@FLSmidth.com
The design power of

such large VRMs depends on
the grindability of material.
Raw mill applications
require up to approximately
9,000kW, with slag and
cement grinding needing up
to 14,000kW. Regardless of
the type these VRMs’ drive
systems need to deliver
reliable torque transmission”
MARTIN BAECHLER
PRODUCT MANAGER
AT FLSMIDTH MAAG GEAR
The challenge with the

integrated drive system in the
VRM is developing an electrical
motor with the highest
possible power density.” With design power of 11,600kW,
MAX Drive™ drives the cement mill
via a common girth gear and two
MARTIN BAECHLER drive units.
with swing-out mechanisms to facilitate mainte- ing device and a highly flexible coupling connects couplings and gearboxes or as small vertical PRODUCT MANAGER
nance or replacement of the rollers. In the case the motor and gearbox. motors, integrated partially into the gear casing AT FLSMIDTH MAAG GEAR
of mechanical failure, the mill can easily operate Yet there are limits to such a system. The bev- and connected to a central toothed wheel inside
with fewer rollers. The only requirement is that the el stage in the gearbox, primarily used to redirect the gearbox.
remaining rollers are uniformly distributed around the rotating movement from the horizontal motor As a result, power distribution bevel stages
the table circumference and that they are all the shaft into vertical direction of the grinding table, are considerably smaller or, in vertical motors,
same size. Production can then continue, albeit at limits power capability. For design power of up to completely eliminated. The drive systems are built
a reduced rate, to minimise operational disruption. approximately 9,000kW, this can be overcome by so that they can operate with fewer motors in the
Impressively, the OK mill can achieve 60 to 70 increasing the gear ratio in the following planetary case of malfunction or maintenance. This means
percent of nominal output with half of its rollers stage, which keeps the bevel stage size within that operation at a reduced production rate can Elimination of weakest element stator. To operate such type motors, variable parts is kept to a minimum. The variable frequen-
out of service. feasible dimensions. However, this does not fulfil still occur, minimising production losses during The integrated drive system in the VRM replaces frequency converters are necessary. Integration cy converter allows the operator to adjust the mill
mill requirements and a further increase in drive scheduled maintenance. This has the effect, the bevel stage with one vertical motor built into also makes special cooling necessary, because table speed without time delay and to influence
Drive systems power requires larger dimensions, especially the however, of increasing complexity of the power the gear casing. While this does not affect the air-cooled motors do not reach the required the grinding process individually when grinding
“The design power of such large VRMs depends diameter of the bevel wheels. This decreases the distribution between the main switch gear and the power distribution, compared with the conven- power density. different product in the same mill or as feed
on the grindability of material. Raw mill appli- overall reliability of the drive system. Conventional motors and also increasing maintenance effort. tional system, the overall dimensions of the motor For example the motor in FLSmidth MAAG® quality changes over time.
cations require up to approximately 9,000kW, gear units cannot operate VRMs with higher In addition to the main switch gear, each must be adapted to the available space for a Gear’s CEM Drive includes special cooling tubes Large VRMs can help to meet the demands
with slag and cement grinding needing up to design power. The drive system for these applica- motor needs a separate circuit breaker and a bevel stage in a conventional gearbox. Otherwise, in the stator arrangement. This provides optimal of a single-mill cement line by addressing the
14,000kW. Regardless of the type, these VRMs’ tions is based on two main principles: partition of motor control cabinet to allow operation with a costly design changes of the mill support and flow of the cooling media and enables the use of typical challenges of grinding systems. In doing
drive systems need to deliver reliable torque power to several drive units and elimination of the reduced number of motors. In order to provide foundation are required. gear lubrication oil in the motor cooling circuit. so, FLSmidth’s OK mill can provide a solution for
transmission,” says Martin Baechler, Product weakest element in the drive train. uniform torque to the common central wheels, the According to Martin Baechler, the challenge most single-mill cement lines wanting to increase
Manager at FLSmidth MAAG gear. load and speed of each motor is synchronised by with the integrated system is developing an Smart design their throughput. ■
Conventional drive systems typically consist Partitioning drive power either a variable frequency converter or a highly electrical motor with the highest possible power Despite the challenges associated with large
of a switch-gear to connect the drive motor to the By separating the drive power, large VRMs can flexible or fluid coupling. During start-up, when density. A design study comparing different motor VRMs, there are important benefits to having an
electrical grid. The transformer converts the grid provide the required torque with multiple motors. the mill is running at full speed with fewer motors, types showed that meeting space requirements integrated drive system embedded in the design.
voltage to the motor design voltage and protects The motors are designed either as individual the timing of the connecting additional motors is are only possible with a synchronous motor with Power distribution, such as that in a partial-load MARTIN BAEHCLER
the equipment from voltage peaks. A rotor start- drive assemblies containing their own motors, essential to prevent torque peaks. permanent magnet excitation and a single coil system, is not required and the number of rotating Martin.Baechler@FLSmidth.com
BREAKTHROUGH
KEY BENEFITS OF THE COUNTER CURRENT CYCLONE
IN CYCLONE $
TECHNOLOGY
Lower operating Fast, simple Lower civil and structural
costs installation costs for new preheaters
Leading the way as the next generation of top-stage

cyclone technology, FLSmidth's Counter Current
Cyclone (CCX) successfully demonstrates its ability
Lightweight Suitable for retrofits
to make the preheating process more economical construction and upgrades.
and productive at Ivano-Frankivskcement.
ith cement production in Ukraine 1.8. Mykola Makoviichuk, Production Director at

W rising steadily, Ivano-Frankivskcement, Ivano-Frankivskcement comments:
based in Yamnytsia, Ukraine is reaping “The new cyclone at our plant is a considerable
production benefits by being the first plant to This cyclone has the breakthrough in the cement industry, and we are
commission the new Counter Current Cyclone equivalent effect of 1.8 proud to be the first to install one. When we saw
(CCX) preheater system on one of its production reduced pressure losses of 40-50 percent, we
lines. standard cyclones, which were pleasantly shocked!
meant we could reduce one “This cyclone has the equivalent effect of 1.8
Impressive results standard cyclones, which meant we could reduce
The relationship between the Ukraine-based plant
section of the preheater, one section of the preheater, ultimately reducing
and FLSmidth has spanned almost twenty years, ultimately reducing construction costs.”
including two production lines at the plant com- construction costs.”
missioned by FLSmidth in 2008 and 2014. The The CCX top cyclone explained
plant had already installed the precursor Down MYKOLA MAKOVIICHUK Conventional cyclones separate dust from gas,
Draft Cyclone (DDX) in a successful upgrade pro- PRODUCTION DIRECTOR
but unlike the conventional types, the CCX
ject in 2015, and was therefore keen on commis- AT IVANO-FRANKIVSKCEMENT combines heat exchange and separation into
sioning the CCX on one of its production lines. one process. As a result, not only is heat transfer
The new CCX at Ivano-Frankivskcement improved, but meal exits the cyclone at a higher
has currently been in operation for almost temperature than the exit gas. This guarantees
23 months and delivered impressive results. reduced net heat consumption of 8-10 kcal/kg
Industrial tests show that production has been clinker along with a 50 percent pressure drop
increased by approximately 6-8 percent and the compared with a conventional cyclone of the
heat exchange has been improved by a factor of same size.
BREAKTHROUGH
KEY BENEFITS OF THE COUNTER CURRENT CYCLONE
IN CYCLONE $
TECHNOLOGY
Lower operating Fast, simple Lower civil and structural
costs installation costs for new preheaters
Leading the way as the next generation of top-stage

cyclone technology, FLSmidth's Counter Current
Cyclone (CCX) successfully demonstrates its ability
Lightweight Suitable for retrofits
to make the preheating process more economical construction and upgrades.
and productive at Ivano-Frankivskcement.
ith cement production in Ukraine 1.8. Mykola Makoviichuk, Production Director at

W rising steadily, Ivano-Frankivskcement, Ivano-Frankivskcement comments:
based in Yamnytsia, Ukraine is reaping “The new cyclone at our plant is a considerable
production benefits by being the first plant to This cyclone has the breakthrough in the cement industry, and we are
commission the new Counter Current Cyclone equivalent effect of 1.8 proud to be the first to install one. When we saw
(CCX) preheater system on one of its production reduced pressure losses of 40-50 percent, we
lines. standard cyclones, which were pleasantly shocked!
meant we could reduce one “This cyclone has the equivalent effect of 1.8
Impressive results standard cyclones, which meant we could reduce
The relationship between the Ukraine-based plant
section of the preheater, one section of the preheater, ultimately reducing
and FLSmidth has spanned almost twenty years, ultimately reducing construction costs.”
including two production lines at the plant com- construction costs.”
missioned by FLSmidth in 2008 and 2014. The The CCX top cyclone explained
plant had already installed the precursor Down MYKOLA MAKOVIICHUK Conventional cyclones separate dust from gas,
Draft Cyclone (DDX) in a successful upgrade pro- PRODUCTION DIRECTOR
but unlike the conventional types, the CCX
ject in 2015, and was therefore keen on commis- AT IVANO-FRANKIVSKCEMENT combines heat exchange and separation into
sioning the CCX on one of its production lines. one process. As a result, not only is heat transfer
The new CCX at Ivano-Frankivskcement improved, but meal exits the cyclone at a higher
has currently been in operation for almost temperature than the exit gas. This guarantees
23 months and delivered impressive results. reduced net heat consumption of 8-10 kcal/kg
Industrial tests show that production has been clinker along with a 50 percent pressure drop
increased by approximately 6-8 percent and the compared with a conventional cyclone of the
heat exchange has been improved by a factor of same size.
NEW ORDERS
FLSmidth supplies engineering, equipment
and service solutions to a host of cement
producers globally. Take a look at selected
top orders placed since April 2017.
Due to the CCX's improved heat transfer efficiency, it is often possible to reduce
the number of cyclones, resulting in lower structural and installation expenses.
The CCX’s improved heat transfer efficiency For plant owners, this means the ability to boost
means it is often possible to reduce the number preheater operation at a lower cost.
of cyclone stages. For example, a four-stage Following the success of the first installation
preheater will often be possible instead of a five-
I want to thank FLSmidth of the CCX, Ivano-Frankivskcement contracted
stage preheater, resulting in lower structural and for their collaboration on FLSmidth to supply a new production line and re-
installation expenses. this upgrade project. quested the CCX top-stage cyclone based on the
A special feature is the gas outlet duct excellent experience with the first one installed. It
installed at the bottom of the CCX cone. This pre- Their new CCX is far ahead went into production in December 2017. ■
vents the cyclone from being filled with dust from of anything else on the market
a blocked meal outlet pipe. This allows a much
larger cyclone to be installed, resulting in a lower
and enables us to increase
pressure drop across the cyclone. our outputs. We are very
happy with the results.”
Low-cost, fast installation
For new preheater projects, the CCX will de-
crease the initial cost of the preheater structure MYKOLA MAKOVIICHUK
and installation time. In existing preheater towers, PRODUCTION DIRECTOR
the acting loads on the structure usually limit AT IVANO-FRANKIVSKCEMENT
ALEXANDER TOKMAN
installation of larger top-stage cyclones than alexanderf.tokman@flsmidth.com
originally installed. However, due to its lightweight CARSTEN DAMSLUND JENSEN
design, the CCX is well suited for such upgrades. cdj@flsmidth.com
NEW ORDERS
FLSmidth supplies engineering, equipment
and service solutions to a host of cement
producers globally. Take a look at selected
top orders placed since April 2017.
Due to the CCX's improved heat transfer efficiency, it is often possible to reduce
the number of cyclones, resulting in lower structural and installation expenses.
The CCX’s improved heat transfer efficiency For plant owners, this means the ability to boost
means it is often possible to reduce the number preheater operation at a lower cost.
of cyclone stages. For example, a four-stage Following the success of the first installation
preheater will often be possible instead of a five-
I want to thank FLSmidth of the CCX, Ivano-Frankivskcement contracted
stage preheater, resulting in lower structural and for their collaboration on FLSmidth to supply a new production line and re-
installation expenses. this upgrade project. quested the CCX top-stage cyclone based on the
A special feature is the gas outlet duct excellent experience with the first one installed. It
installed at the bottom of the CCX cone. This pre- Their new CCX is far ahead went into production in December 2017. ■
vents the cyclone from being filled with dust from of anything else on the market
a blocked meal outlet pipe. This allows a much
larger cyclone to be installed, resulting in a lower
and enables us to increase
pressure drop across the cyclone. our outputs. We are very
happy with the results.”
Low-cost, fast installation
For new preheater projects, the CCX will de-
crease the initial cost of the preheater structure MYKOLA MAKOVIICHUK
and installation time. In existing preheater towers, PRODUCTION DIRECTOR
the acting loads on the structure usually limit AT IVANO-FRANKIVSKCEMENT
ALEXANDER TOKMAN
installation of larger top-stage cyclones than alexanderf.tokman@flsmidth.com
originally installed. However, due to its lightweight CARSTEN DAMSLUND JENSEN
design, the CCX is well suited for such upgrades. cdj@flsmidth.com
12 FLSmidth Discover Cement New orders FLSmidth Discover Cement 13
NEW ORDERS
1 ALGERIA 7 INDIA
ETHRB Group Relizane Ramco Cements
Engineering, procurement, equipment Supply of Luffing Stacker and Portal
supply, construction supervision and Reclaimer for coal and petcoke
commissioning of a 12,000 tpd production handling.
line. 14
12
1
11
16
9
2 BANGLADESH 8 INDIA 13
17 4
Meghna Cement Mills SAGAR Cements Ltd.
2
Engineering, procurement and supply Supply of an FLSmidth® Cross- 18 6
10 8 5
of equipment for cement grinding unit, Bar® cooler to handle 3,000 tpd 19
including an OK™ 71-6 cement mill, clinker production, as a complete
MAAG® planetary gear unit, Airtech replacement an existing grate cooler.
15 7
fabric filters, Pfister weigh feeders
and a Plant Control System.
3 BOLIVIA 9 KUWAIT
La Cooperativa Boliviana de Cemento, Alghanaem Industrial Company
Industrias y Servicios (COBOCE) A five-year operations and maintenance
Engineering, procurement and supply of (O&M) contract for a new cement grinding
equipment for an OK™ 43-4 cement mill. plant, including full O&M partnership, 3
supply of spare parts, training and full
access to the Online Support Centre.
20
4 INDIA 10 MEXICO
Chettinad Cement La Cooperativa Cruz Azul
A cement grinding unit (1.0 MTPA Upgrade of existing cooler, including
capacity), including the supply of an engineering, procurement and supply of
UMS™ ball mill in a closed circuit with equipment for an FLSmidth® Cross-Bar®
the Dynamic Separator Sepax® 425. cooler and a Heavy Duty Roller Breaker
with associated fans and auxilaries.
5 INDIA 11 NEPAL 13 NEPAL 15 NIGERIA 17 PAKISTAN 19 SAUDI ARABIA

India Cements Ltd Ambe Cement Nepal Shalimar Cement Sinoma International Engineering Flying Cement Company Riyadh Cement Company
Engineering, procurement and supply of Engineering, procurement and supply Engineering, procurement and supply Delivery of an OK™ 66-6 cement mill with Engineering, procurement and supply Conversion of existing grey cement
an OK™ 52-4 cement mill system, including of OK™ 28-3 cement mill system of an OK™ 28-3 cement mill system, ROKSH 108 separator to be installed of a 7,700 tonnes clinker production line to dual production.
MAAG® gear units. including MAAG®) gear units. including MAAG® gear units. at Dangote Cement's Obajana site. line with pyro processing system and
an FLSmidth® Cross-Bar® cooler.
6 INDIA 12 NEPAL 14 NEPAL 16 PAKISTAN 18 SAUDI ARABIA 20 URUGUAY

OCL CG Cement Industries Palpa Palpa Cement Industries Private Power Cement Limited Yanbu Cement Cielo Azul Cementos y Calizas
Supply of an FLSmidth® Cross-Bar® Supply of crushers, stacker/reclaimer Supply of a 1,800 tpd cement production Engineering, procurement and In a three-year contract, the client will be S.A. Engineering, procurement
cooler to handle 4,000tpd clinker machines and material handling equipment line, including an ATOX® raw mill, ATOX supply of equipment for a 7,700 connected to FLSmidth's Online Support and supply of equipment for a
production for complete inbox for new cement plant at Raina Devi coal mill, a new pyro system, three support tonnes per day production line. Centre in Cairo, where the team will complete 1,200 tpd cement plant.
modification of existing cooler. Chahara, Somadi, Palpa District. rotary kiln and an FLSmidth® Cross-Bar® monitor the incomming data and advise on
cooler. productivity improvements.
12 FLSmidth Discover Cement New orders FLSmidth Discover Cement 13
NEW ORDERS
1 ALGERIA 7 INDIA
ETHRB Group Relizane Ramco Cements
Engineering, procurement, equipment Supply of Luffing Stacker and Portal
supply, construction supervision and Reclaimer for coal and petcoke
commissioning of a 12,000 tpd production handling.
line. 14
12
1
11
16
9
2 BANGLADESH 8 INDIA 13
17 4
Meghna Cement Mills SAGAR Cements Ltd.
2
Engineering, procurement and supply Supply of an FLSmidth® Cross- 18 6
10 8 5
of equipment for cement grinding unit, Bar® cooler to handle 3,000 tpd 19
including an OK™ 71-6 cement mill, clinker production, as a complete
MAAG® planetary gear unit, Airtech replacement an existing grate cooler.
15 7
fabric filters, Pfister weigh feeders
and a Plant Control System.
3 BOLIVIA 9 KUWAIT
La Cooperativa Boliviana de Cemento, Alghanaem Industrial Company
Industrias y Servicios (COBOCE) A five-year operations and maintenance
Engineering, procurement and supply of (O&M) contract for a new cement grinding
equipment for an OK™ 43-4 cement mill. plant, including full O&M partnership, 3
supply of spare parts, training and full
access to the Online Support Centre.
20
4 INDIA 10 MEXICO
Chettinad Cement La Cooperativa Cruz Azul
A cement grinding unit (1.0 MTPA Upgrade of existing cooler, including
capacity), including the supply of an engineering, procurement and supply of
UMS™ ball mill in a closed circuit with equipment for an FLSmidth® Cross-Bar®
the Dynamic Separator Sepax® 425. cooler and a Heavy Duty Roller Breaker
with associated fans and auxilaries.
5 INDIA 11 NEPAL 13 NEPAL 15 NIGERIA 17 PAKISTAN 19 SAUDI ARABIA

India Cements Ltd Ambe Cement Nepal Shalimar Cement Sinoma International Engineering Flying Cement Company Riyadh Cement Company
Engineering, procurement and supply of Engineering, procurement and supply Engineering, procurement and supply Delivery of an OK™ 66-6 cement mill with Engineering, procurement and supply Conversion of existing grey cement
an OK™ 52-4 cement mill system, including of OK™ 28-3 cement mill system of an OK™ 28-3 cement mill system, ROKSH 108 separator to be installed of a 7,700 tonnes clinker production line to dual production.
MAAG® gear units. including MAAG®) gear units. including MAAG® gear units. at Dangote Cement's Obajana site. line with pyro processing system and
an FLSmidth® Cross-Bar® cooler.
6 INDIA 12 NEPAL 14 NEPAL 16 PAKISTAN 18 SAUDI ARABIA 20 URUGUAY

OCL CG Cement Industries Palpa Palpa Cement Industries Private Power Cement Limited Yanbu Cement Cielo Azul Cementos y Calizas
Supply of an FLSmidth® Cross-Bar® Supply of crushers, stacker/reclaimer Supply of a 1,800 tpd cement production Engineering, procurement and In a three-year contract, the client will be S.A. Engineering, procurement
cooler to handle 4,000tpd clinker machines and material handling equipment line, including an ATOX® raw mill, ATOX supply of equipment for a 7,700 connected to FLSmidth's Online Support and supply of equipment for a
production for complete inbox for new cement plant at Raina Devi coal mill, a new pyro system, three support tonnes per day production line. Centre in Cairo, where the team will complete 1,200 tpd cement plant.
modification of existing cooler. Chahara, Somadi, Palpa District. rotary kiln and an FLSmidth® Cross-Bar® monitor the incomming data and advise on
cooler. productivity improvements.
14 FLSmidth Discover Cement Theme Urbanisation drives Indian cement market FLSmidth Discover Cement 15
16 20 24 26 28
INDIAN MARKET PUSHES FORWARD MAKING GAINS WITH THE OK™ MILL STRONG EPC PARTNERSHIP DRIVES INDIAN CLINKER COOLER REPLACEMENT DELIVERS HYDRAULIC ROLLER PRESSES BOOST
Country Head and CEO of FLSmidth India Carsten Cement producers in India, Nepal and Bangladesh BROWNFIELD PROJECT IMPROVED PRODUCTIVITY AT RAIN CEMENT PRODUCTIVITY AT ORIENT CEMENT
Lund provides insights into on the cement market in demonstrate the success of using VRMs. FLSmidth and Larsen & Toubro teamed up to expand Impressive performance results were achieved when The installation of two hydraulic
India, Bangladesh and Nepal. TANCEM Cement’s operations in record time. the existing cooler was replaced by an FLSmidth® roller presses improved performance
Cross-Bar® cooler. at Orient Cement's Karnataka plant.
THEME
URBANISATION
DRIVES INDIAN
CEMENT MARKET
As the world’s second largest national
cement market, India has a strong growth
prospects. Despite a recent slowdown in
growth, the future remains quite positive,
thanks to new government infrastructure
initiatives and a fast-growing population.
16 20 24 26 28
INDIAN MARKET PUSHES FORWARD MAKING GAINS WITH THE OK™ MILL STRONG EPC PARTNERSHIP DRIVES INDIAN CLINKER COOLER REPLACEMENT DELIVERS HYDRAULIC ROLLER PRESSES BOOST
Country Head and CEO of FLSmidth India Carsten Cement producers in India, Nepal and Bangladesh BROWNFIELD PROJECT IMPROVED PRODUCTIVITY AT RAIN CEMENT PRODUCTIVITY AT ORIENT CEMENT
Lund provides insights into on the cement market in demonstrate the success of using VRMs. FLSmidth and Larsen & Toubro teamed up to expand Impressive performance results were achieved when The installation of two hydraulic
India, Bangladesh and Nepal. TANCEM Cement’s operations in record time. the existing cooler was replaced by an FLSmidth® roller presses improved performance
Cross-Bar® cooler. at Orient Cement's Karnataka plant.
THEME
URBANISATION
DRIVES INDIAN
CEMENT MARKET
As the world’s second largest national
cement market, India has a strong growth
prospects. Despite a recent slowdown in
growth, the future remains quite positive,
thanks to new government infrastructure
initiatives and a fast-growing population.
THEME
Urbanisation
drives Indian
cement market
MUMBAI, INDIA
19.0760° N, 72.8777° E
reforms including rural development, coal mining, tax reforms

and ease of doing business. The introduction of a nationwide
goods and services tax designed to simplify the tax system and In recent years,
encourage interstate business is a hopeful sign of an increas-
demand for
ingly strengthening economy to fuel future developments.
cement in India has
Increasing housing demands grown at around
In recent years, demand for cement in India has grown at four percent
around four percent annually. But that rate might increase even annually, but a nine
more. A nine percent compound annual growth rate in property percent compound
volume could now drive the demand up even further. Global annual growth
financing institution Morgan Stanley expects annual growth to rate in property
accelerate to 5.5-6 percent.
volume could now
Indian cement
India’s growing population and the need for housing has
conomist and business strategist, Michael Porter, been impacting cement demand for some time. It is estimated
drive the demand
E recently described the current growth in India as that around 65 percent of cement production is driven by the up even further
meaningful and significant, but not perfect: “The housing sector, amongst the highest in the world. The trend is to six percent”
market pushes
business environment is better, but it is not good. Infrastructure likely to continue, with the World Economic Forum predicting
is better, but it is not good.” India will become the most populous country in the world in, or MORGAN
Fourteen years ago, one of the biggest challenges talked around, the year 2027. STANLEY
forward
about in India was electricity. Many improvements have been The consumer trends of the population are also changing. GLOBAL
made since then fuelling growth and opportunities in the econ- Consumption now accounts for a larger share of India’s econo- FINANCING
INSTITUTION
omy, which is expanding rapidly with an already large, diverse my with the young work force also reaching ‘home buying’ age,
and growing population. as described by Alex Frew McMillan, Forbes magazine:
But even with the numerous improvements to date, many “The fast-growing population has very little household debt,
more are still required in this evolving environment, which and the finance industry has been maturing in a way that will
is characterised by increasing demand for real estate and suit their borrowing needs. Top that with repeated interest-rate
As the world’s second largest national cement continued infrastructure investment. These positive trends are cuts by the central bank, and you have almost perfect condi-
ensuring India remains the world’s second-largest national ce- tions for property purchases.”
market, India's growth prospects are promising. ment market and a somewhat optimistic corner of the industry It is thought that annual property market sales will increase
Despite a recent slowdown in growth, the future to watch. to $462 billion in 2025 (they were $105 billion in 2015) with
With India’s GDP trebling between 2000 and 2016, the rate over 600 million people living rurally in India, according to
remains quite positive, thanks to new government of growth has in part been driven by the continued popula- Morgan Stanley. This will ensure that rural development
infrastructure initiatives and a fast-growing population. tion growth, but is also a result of several Indian government remains a priority of the current government with healthcare,
THEME
Urbanisation
drives Indian
cement market
MUMBAI, INDIA
19.0760° N, 72.8777° E
reforms including rural development, coal mining, tax reforms

and ease of doing business. The introduction of a nationwide
goods and services tax designed to simplify the tax system and In recent years,
encourage interstate business is a hopeful sign of an increas-
demand for
ingly strengthening economy to fuel future developments.
cement in India has
Increasing housing demands grown at around
In recent years, demand for cement in India has grown at four percent
around four percent annually. But that rate might increase even annually, but a nine
more. A nine percent compound annual growth rate in property percent compound
volume could now drive the demand up even further. Global annual growth
financing institution Morgan Stanley expects annual growth to rate in property
accelerate to 5.5-6 percent.
volume could now
Indian cement
India’s growing population and the need for housing has
conomist and business strategist, Michael Porter, been impacting cement demand for some time. It is estimated
drive the demand
E recently described the current growth in India as that around 65 percent of cement production is driven by the up even further
meaningful and significant, but not perfect: “The housing sector, amongst the highest in the world. The trend is to six percent”
market pushes
business environment is better, but it is not good. Infrastructure likely to continue, with the World Economic Forum predicting
is better, but it is not good.” India will become the most populous country in the world in, or MORGAN
Fourteen years ago, one of the biggest challenges talked around, the year 2027. STANLEY
forward
about in India was electricity. Many improvements have been The consumer trends of the population are also changing. GLOBAL
made since then fuelling growth and opportunities in the econ- Consumption now accounts for a larger share of India’s econo- FINANCING
INSTITUTION
omy, which is expanding rapidly with an already large, diverse my with the young work force also reaching ‘home buying’ age,
and growing population. as described by Alex Frew McMillan, Forbes magazine:
But even with the numerous improvements to date, many “The fast-growing population has very little household debt,
more are still required in this evolving environment, which and the finance industry has been maturing in a way that will
is characterised by increasing demand for real estate and suit their borrowing needs. Top that with repeated interest-rate
As the world’s second largest national cement continued infrastructure investment. These positive trends are cuts by the central bank, and you have almost perfect condi-
ensuring India remains the world’s second-largest national ce- tions for property purchases.”
market, India's growth prospects are promising. ment market and a somewhat optimistic corner of the industry It is thought that annual property market sales will increase
Despite a recent slowdown in growth, the future to watch. to $462 billion in 2025 (they were $105 billion in 2015) with
With India’s GDP trebling between 2000 and 2016, the rate over 600 million people living rurally in India, according to
remains quite positive, thanks to new government of growth has in part been driven by the continued popula- Morgan Stanley. This will ensure that rural development
infrastructure initiatives and a fast-growing population. tion growth, but is also a result of several Indian government remains a priority of the current government with healthcare,
It is estimated that
INDIA IN NUMBERS
around 65 percent
of the cement
production in India
is driven by the
housing sector,
amongst the highest
Demography
in the world.
Population
1,328 billion
Urbanisation
33% NEW DELHI
Official language
Hindi,
Even with a few
employment opportunities and quality housing also being top
priorities. Several rural housing schemes have also been rolled
out that are directly impacting cement consumption. These
and political stability as well as rebuilding projects following the
2015 earthquake are proving to be significant growth factors.
“Projects in infrastructure have helped create optimism
English
head winds in include plans by the government to build 20 million housing within the Nepalese cement industry,” explains Carsten
recent times, units over the next five years. Riisberg Lund. “Specifically, we’ve seen a large effort in internal
it is certainly With its increasing per-capita income, the Indian market is development, hydropower and the modernisation of the road
also being noticed by private investors, who have started re- network, which in turn makes cement producers focus on new
an exciting
turning to a perhaps underrated market, breathing new energy clinker production lines and new grinding units with the goal of
environment and driving new developments in the region. self-sufficiency.”
to be part of as Greater interest in capacity expansion can also be seen in
urbanisation Competition heats up Bangladesh, which is already the world’s 20th largest cement
continues to In 2016, India’s cement consumption reached a record high of consumer and the leading importer of cement and clinker,
change the face 287.84 million tonnes. However, utilisation rates are down since according to ICR research. As an example of the eagerness to
of society - and consumption has failed to keep up with capacity. But many invest, the world’s biggest vertical roller mill was ordered from
is likely to for see this as a short-to-medium-term issue that will right itself as FLSmidth by Shah Cement Industries Ltd in 2016. Cement Economy
investment in new capacity, which has been low in recent years,
years to come” and consumption continue to increase. Cementing opportunities Current gross national
In the meantime, the low utilisation is creating even greater With an expanding economy, more government investments Per capita cement
income per capita
CARSTEN competition and many cement producers are turning their in infrastructure, and a plentiful supply of raw materials, Indian
RIISBERG LUND
COUNTRY HEAD
AND CEO OF
attention towards maximising productivity and production effi-
ciencies. Investments in technology, as well as the knowledge
of how best to apply the technology, have been key to ensuring
cement producers have grounds for careful optimism. Many are
well-placed to cope with the increased competition and meet
the challenges ahead. While maximising growth and perfor-
208 kg 6020 USD
FLSMIDTH INDIA
these cement producers are achieving the lowest energy mance opportunities, they can help build optimism by shaping
consumption and emission rates per tonne of clinker. future developments through best practice initiatives. These
“We’re seeing an increasing number of producers focussing include formalising corporate social responsibility programmes, Percentage of cement production Factor increase of gross domestic
on improving their efficiency and mitigating against equipment which have nevertheless always been core to the Indian driven by the housing sector product from 2000 to 2016
failure,” according to Carsten Riisberg Lund, Country Head and cement industry.
CEO of FLSmidth India, emphasising that even for producers
already well-equipped with relatively new lines, productivity en-
hancement is top of the agenda. He points to cement producers
“Even with a few head winds in recent times, it’s certainly an
exciting environment to be part of as urbanisation continues to
change the face of society – and is likely to for years to come,”
65% 300%
such as India Cements, which recently ordered a state-of-the-art says Carsten Riisberg Lund. ■
FLSmidth Vertical Roller Mill to improve grinding unit productivi-
ty, and Rain Cement, which successfully retrofitted a cooler. The demand for cement is predicted
to increase from 4 percent to
Beyond India
Opportunities in neighbouring Bangladesh and Nepal are also
continuing to emerge. In Nepal in particular, greater financial
CARSTEN RIISBERG LUND
crl@flsmidth.com 5.5-6%
It is estimated that
INDIA IN NUMBERS
around 65 percent
of the cement
production in India
is driven by the
housing sector,
amongst the highest
Demography
in the world.
Population
1,328 billion
Urbanisation
33% NEW DELHI
Official language
Hindi,
Even with a few
employment opportunities and quality housing also being top
priorities. Several rural housing schemes have also been rolled
out that are directly impacting cement consumption. These
and political stability as well as rebuilding projects following the
2015 earthquake are proving to be significant growth factors.
“Projects in infrastructure have helped create optimism
English
head winds in include plans by the government to build 20 million housing within the Nepalese cement industry,” explains Carsten
recent times, units over the next five years. Riisberg Lund. “Specifically, we’ve seen a large effort in internal
it is certainly With its increasing per-capita income, the Indian market is development, hydropower and the modernisation of the road
also being noticed by private investors, who have started re- network, which in turn makes cement producers focus on new
an exciting
turning to a perhaps underrated market, breathing new energy clinker production lines and new grinding units with the goal of
environment and driving new developments in the region. self-sufficiency.”
to be part of as Greater interest in capacity expansion can also be seen in
urbanisation Competition heats up Bangladesh, which is already the world’s 20th largest cement
continues to In 2016, India’s cement consumption reached a record high of consumer and the leading importer of cement and clinker,
change the face 287.84 million tonnes. However, utilisation rates are down since according to ICR research. As an example of the eagerness to
of society - and consumption has failed to keep up with capacity. But many invest, the world’s biggest vertical roller mill was ordered from
is likely to for see this as a short-to-medium-term issue that will right itself as FLSmidth by Shah Cement Industries Ltd in 2016. Cement Economy
investment in new capacity, which has been low in recent years,
years to come” and consumption continue to increase. Cementing opportunities Current gross national
In the meantime, the low utilisation is creating even greater With an expanding economy, more government investments Per capita cement
income per capita
CARSTEN competition and many cement producers are turning their in infrastructure, and a plentiful supply of raw materials, Indian
RIISBERG LUND
COUNTRY HEAD
AND CEO OF
attention towards maximising productivity and production effi-
ciencies. Investments in technology, as well as the knowledge
of how best to apply the technology, have been key to ensuring
cement producers have grounds for careful optimism. Many are
well-placed to cope with the increased competition and meet
the challenges ahead. While maximising growth and perfor-
208 kg 6020 USD
FLSMIDTH INDIA
these cement producers are achieving the lowest energy mance opportunities, they can help build optimism by shaping
consumption and emission rates per tonne of clinker. future developments through best practice initiatives. These
“We’re seeing an increasing number of producers focussing include formalising corporate social responsibility programmes, Percentage of cement production Factor increase of gross domestic
on improving their efficiency and mitigating against equipment which have nevertheless always been core to the Indian driven by the housing sector product from 2000 to 2016
failure,” according to Carsten Riisberg Lund, Country Head and cement industry.
CEO of FLSmidth India, emphasising that even for producers
already well-equipped with relatively new lines, productivity en-
hancement is top of the agenda. He points to cement producers
“Even with a few head winds in recent times, it’s certainly an
exciting environment to be part of as urbanisation continues to
change the face of society – and is likely to for years to come,”
65% 300%
such as India Cements, which recently ordered a state-of-the-art says Carsten Riisberg Lund. ■
FLSmidth Vertical Roller Mill to improve grinding unit productivi-
ty, and Rain Cement, which successfully retrofitted a cooler. The demand for cement is predicted
to increase from 4 percent to
Beyond India
Opportunities in neighbouring Bangladesh and Nepal are also
continuing to emerge. In Nepal in particular, greater financial
CARSTEN RIISBERG LUND
crl@flsmidth.com 5.5-6%
The unique design

elements in the roller
and table profile
improve operating We chose
stability and
reliability, resulting in FLSmidth as our
a typical availability partner to supply
of 90 to 95 percent.
two OK™ mills for
cement grinding
based on two
key merits of the
system - highest
efficiency in
terms of power
consumption and
proven reliability.”
SHYAM ASAWA
HEAD OF PROJECTS
AT ORIENT CEMENT
Making gains with

the OK™ mill
As cement producers continually seek reduced energy
consumption and lower maintenance costs, two emerging
trends are changing the face of cement production: the use
of grinding stations that support variable feed materials
and more widespread use of vertical roller mills (VRMs).
Cement producers in India, Nepal
and Bangladesh demonstrate
the success of using VRMs. positive economic outlook and an influx of foreign
A investments have driven up cement production in In-
dia and South Asia in recent times. While this creates
opportunities for major cement manufacturers, many of whom
are importing clinker to meet production demands, the rising
need for increased capacity requires larger and more flexible
grinding solutions. Manufacturers are increasingly turning to the
vertical roller mill (VRM) as a highly productive solution to meet
these increasing demands.
With VRMs already 30 to 50 percent more energy-efficient
than conventional ball mills, the OK™ mill delivers even greater
efficiencies. It uses around five-ten percent less power than
other cement VRMs, which means producers can save millions
of kilowatts each year.
All-purpose flexibility
In 2016 and 2017, a total of 21 VRMs were sold in South Asia
covering raw, coal and cement grinding applications. This
demonstrates the industry’s shift in selecting an option that can
be adapted to a plant's scale and needs. In Bangladesh, which
is stepping up efforts to improve infrastructure bottlenecks by
The unique design

elements in the roller
and table profile
improve operating We chose
stability and
reliability, resulting in FLSmidth as our
a typical availability partner to supply
of 90 to 95 percent.
two OK™ mills for
cement grinding
based on two
key merits of the
system - highest
efficiency in
terms of power
consumption and
proven reliability.”
SHYAM ASAWA
HEAD OF PROJECTS
AT ORIENT CEMENT
Making gains with

the OK™ mill
As cement producers continually seek reduced energy
consumption and lower maintenance costs, two emerging
trends are changing the face of cement production: the use
of grinding stations that support variable feed materials
and more widespread use of vertical roller mills (VRMs).
Cement producers in India, Nepal
and Bangladesh demonstrate
the success of using VRMs. positive economic outlook and an influx of foreign
A investments have driven up cement production in In-
dia and South Asia in recent times. While this creates
opportunities for major cement manufacturers, many of whom
are importing clinker to meet production demands, the rising
need for increased capacity requires larger and more flexible
grinding solutions. Manufacturers are increasingly turning to the
vertical roller mill (VRM) as a highly productive solution to meet
these increasing demands.
With VRMs already 30 to 50 percent more energy-efficient
than conventional ball mills, the OK™ mill delivers even greater
efficiencies. It uses around five-ten percent less power than
other cement VRMs, which means producers can save millions
of kilowatts each year.
All-purpose flexibility
In 2016 and 2017, a total of 21 VRMs were sold in South Asia
covering raw, coal and cement grinding applications. This
demonstrates the industry’s shift in selecting an option that can
be adapted to a plant's scale and needs. In Bangladesh, which
is stepping up efforts to improve infrastructure bottlenecks by
plant’s OK mill has the flexibility to adjust to changes in the feed ing a flexible mill option is key in meeting the needs of cement
composition and granulometry; a critical element for Orissa plants in the region.
Cement as the plant grinds both PSC and PPC.
In Karnataka, India, Orient Cement Limited has implement- A legacy of global productivity
ed two OK mills into its integrated greenfield cement plant. The success of the OK mill is not unique to the South Asia
Here, the mills produce a guaranteed capacity of 250 tph @ region. Similar performance results have been reported in Bra-
3000 Blaine for OPC and 265 tph @ 4000 Blaine for PPC, but zil, for example, where it is also common to produce multiple
FLSMIDTH OK™ RAW AND as shown in table 2, both mills exceed performance guarantees. cement types with a high percentage of clinker substitution in
CEMENT MILL HIGHLIGHTS Mr. Shyam Asawa, Head of Projects at Orient Cement Limit- a single mill. The success of the OK mill throughout the world
ed explains: “The OK mill system is the best choice for cement highlights the effectiveness of the vertical roller mill’s tech-
grinding application with the lowest power consumption in the nology and its contribution to the cement production industry
■■ Maximum parts commonality market. We chose FLSmidth as our partner to supply two OK amidst the rapidly emerging trends of greater variation in feed
■■ Flexibility to grind diverse materials and to mills for cement grinding based on two key merits of the system materials and larger production capacity. ■
change product within minutes – highest efficiency in terms of power consumption and proven
■■ 5-10% less power consumption than other reliability.”
cement VRMs India’s cement plants tend to require mid-capacity grinding JANARDHANAN ANANTHAKRISHNAN
■■ High run factor - achieve up to 60-70% availa- mills and produce one cement type in each unit, therefore, hav- Janardhanan.Ananthakrishnan@flsmidth.com
bility even with some rollers out of service

■■ 90-95% availability
The OK™ mill in use

Recently, several cement plants in India, Bangladesh and Nepal have
selected the OK mill as a grinding solution. Here is a selection:
attracting foreign capital, four cement producers have ordered Portland slag cement grinding at Orissa Cement Ltd
FLSmidth’s OK mill for expansion of their production lines.
Bangladesh Nepal India
Learn more about Parameters/description Audited data After optimisations
the OK™ mill: Among these is Shah Cement, which has ordered the world’s
Mill feed rate – wet (tph) 255 285
okmill.flsmidth.com largest OK mill. The OK 81-6 mill features six rollers and an
Mill output – dry (tph) 237 261
8.1-metre diameter grinding table, boasting an installed power
of 11,600 KW.
Premier cement mills Ltd. Nepal Shalimar Cements Orient Cement Ltd.
Cement fineness (Blaine cm2/gm) 3710 3750
The trend towards larger OK mills in Bangladesh is helping Feed compositions 67% slag + 3% gypsum + 30% clinker
OK™ mill 56-4 OK™ mill 28-3 OK™ mill 56-4
cement producers keep up with the boom in infrastructure
Specific poser consumptions of mill main
development. But they are also benefitting from greater flexi- drive, separator, and mill fan (kWh/t)
30.60 30.05
bility thanks to the OK mill’s ability to produce multiple types of

Table 1: The OK™ mill at Orissa Cement Limited has consistently met or
blended cement in each unit. exceeded performance guarantees
Premier cement mills Ltd. Ambe Cements Orient Cement Ltd.

Smaller in Nepal Grinding performance of Orient Cement’s two OK™ mills OK™ mill 71-6 OK™ mill 28-3 OK™ mill 56-4
In Nepal, cement producers typically have smaller capacity
requirements and use a single mill to produce a range of OPC Portland pozzolana cement grinding
and slag-based products. Although the demand on production Guaranteed Achieved performance
Cement mill parameter
is not as high as in Bangladesh, the OK mill remains a suitable performance as per contract
option, with many Nepal-based plants having ordered the mill Mil capacity (tph) 265 287 Akij Cement Company Ltd. Ridhi Sidhi Cement Orissa Cement Ltd.
recently. OK™ mill 56-4 OK™ mill 40-4 OK™ mill 61-4
Product fineness (Blaine cm /gm)
2
4000 4000
An example is Nepal Shalimar Cement, who will shortly be
Specific power consumption (SPC) 23.0 22.92
using the smallest OK mill available on the market. kWh/t for complete grinding circuit
including auxiliaries
Installations in India
Since the installation of an OK mill at India’s Orissa Cement Lim- Ordinary portland cement grinding Bashundhara Cements Shubha Shree Jagdamba India Cements
ited in Midnapore, the plant has consistently met or exceeded Guaranteed Achieved performance
the performance guarantees regarding capacity, fineness and performance as per contract
specific power consumption. Mil capacity (tph) 250 268
The mill at Orissa Cement was guaranteed to produce 212 Product fineness (Blaine cm /gm)
2
3000 3000
tonnes per hour of PSC at 3800 cm2/gm Blaine without the
Shah Cement Industries Ltd. Sarbottam Cement
use of grinding aid and with a mill area power consumption of kWh/t for complete grinding circuit OK™ mill 81-6 OK™ mill 37-3
39.3 kWh/tonne. However, as shown in table 1, its operational including auxiliaries
performance has exceeded this guarantee. Furthermore, the Table 2: Orient Cement's two OK™ mills exceed performance guarantees.
plant’s OK mill has the flexibility to adjust to changes in the feed ing a flexible mill option is key in meeting the needs of cement
composition and granulometry; a critical element for Orissa plants in the region.
Cement as the plant grinds both PSC and PPC.
In Karnataka, India, Orient Cement Limited has implement- A legacy of global productivity
ed two OK mills into its integrated greenfield cement plant. The success of the OK mill is not unique to the South Asia
Here, the mills produce a guaranteed capacity of 250 tph @ region. Similar performance results have been reported in Bra-
3000 Blaine for OPC and 265 tph @ 4000 Blaine for PPC, but zil, for example, where it is also common to produce multiple
FLSMIDTH OK™ RAW AND as shown in table 2, both mills exceed performance guarantees. cement types with a high percentage of clinker substitution in
CEMENT MILL HIGHLIGHTS Mr. Shyam Asawa, Head of Projects at Orient Cement Limit- a single mill. The success of the OK mill throughout the world
ed explains: “The OK mill system is the best choice for cement highlights the effectiveness of the vertical roller mill’s tech-
grinding application with the lowest power consumption in the nology and its contribution to the cement production industry
■■ Maximum parts commonality market. We chose FLSmidth as our partner to supply two OK amidst the rapidly emerging trends of greater variation in feed
■■ Flexibility to grind diverse materials and to mills for cement grinding based on two key merits of the system materials and larger production capacity. ■
change product within minutes – highest efficiency in terms of power consumption and proven
■■ 5-10% less power consumption than other reliability.”
cement VRMs India’s cement plants tend to require mid-capacity grinding JANARDHANAN ANANTHAKRISHNAN
■■ High run factor - achieve up to 60-70% availa- mills and produce one cement type in each unit, therefore, hav- Janardhanan.Ananthakrishnan@flsmidth.com
bility even with some rollers out of service

■■ 90-95% availability
The OK™ mill in use

Recently, several cement plants in India, Bangladesh and Nepal have
selected the OK mill as a grinding solution. Here is a selection:
attracting foreign capital, four cement producers have ordered Portland slag cement grinding at Orissa Cement Ltd
FLSmidth’s OK mill for expansion of their production lines.
Bangladesh Nepal India
Learn more about Parameters/description Audited data After optimisations
the OK™ mill: Among these is Shah Cement, which has ordered the world’s
Mill feed rate – wet (tph) 255 285
okmill.flsmidth.com largest OK mill. The OK 81-6 mill features six rollers and an
Mill output – dry (tph) 237 261
8.1-metre diameter grinding table, boasting an installed power
of 11,600 KW.
Premier cement mills Ltd. Nepal Shalimar Cements Orient Cement Ltd.
Cement fineness (Blaine cm2/gm) 3710 3750
The trend towards larger OK mills in Bangladesh is helping Feed compositions 67% slag + 3% gypsum + 30% clinker
cement producers keep up with the boom in infrastructure
Specific poser consumptions of mill main
development. But they are also benefitting from greater flexi- drive, separator, and mill fan (kWh/t)
30.60 30.05
bility thanks to the OK mill’s ability to produce multiple types of

Table 1: The OK™ mill at Orissa Cement Limited has consistently met or
blended cement in each unit. exceeded performance guarantees
Premier cement mills Ltd. Ambe Cements Orient Cement Ltd.

Smaller in Nepal Grinding performance of Orient Cement’s two OK™ mills OK™ mill 71-6 OK™ mill 28-3 OK™ mill 56-4
In Nepal, cement producers typically have smaller capacity
requirements and use a single mill to produce a range of OPC Portland pozzolana cement grinding
and slag-based products. Although the demand on production Guaranteed Achieved performance
is not as high as in Bangladesh, the OK mill remains a suitable performance as per contract
option, with many Nepal-based plants having ordered the mill Mil capacity (tph) 265 287 Akij Cement Company Ltd. Ridhi Sidhi Cement Orissa Cement Ltd.
recently. OK™ mill 56-4 OK™ mill 40-4 OK™ mill 61-4
Product fineness (Blaine cm /gm)
2
4000 4000
An example is Nepal Shalimar Cement, who will shortly be
using the smallest OK mill available on the market. kWh/t for complete grinding circuit
including auxiliaries
Installations in India
Since the installation of an OK mill at India’s Orissa Cement Lim- Ordinary portland cement grinding Bashundhara Cements Shubha Shree Jagdamba India Cements
ited in Midnapore, the plant has consistently met or exceeded Guaranteed Achieved performance
the performance guarantees regarding capacity, fineness and performance as per contract
specific power consumption. Mil capacity (tph) 250 268
The mill at Orissa Cement was guaranteed to produce 212 Product fineness (Blaine cm /gm)
2
3000 3000
tonnes per hour of PSC at 3800 cm2/gm Blaine without the
Shah Cement Industries Ltd. Sarbottam Cement
use of grinding aid and with a mill area power consumption of kWh/t for complete grinding circuit OK™ mill 81-6 OK™ mill 37-3
39.3 kWh/tonne. However, as shown in table 1, its operational including auxiliaries
performance has exceeded this guarantee. Furthermore, the Table 2: Orient Cement's two OK™ mills exceed performance guarantees.
With commissioning expected to take place during Q2 2018, First cement in 2018
erection works are almost complete. Miller Bahirathan, Deputy General Manager of Project Manage-
View of TANCEM's ment at FLSmidth, hails the engineering team for moving proac-
Ariyalur plant Successful EPC partnership tively in preparing the general arrangements drawings. “When
in Tamil Nadu,
For L&T, the cooperation with FLSmidth was a significant factor the drawings were completed, and by meticulous planning, we
southern India.
in winning the project, says L&T’s Head of EPC for Cement & could start supplying equipment four months after the effective
Process Plants, Mr. Raju Ganesan. He explains: date of contract.”
“From the tender prequalification through to being award- He also points out that the time required for layout was
ed the contract, we have experienced an excellent strategic drastically reduced thanks to the proactive engineering
association and collegial relationship with FLSmidth, whose approach and the close collaboration with procurement and
considerable technical support helped us gaining TANCEM’s project management.
confidence in L&T’s ability to execute the EPC contract.”
Hari TR, Vice President and Business Head of FLSmidth New competencies
India, says that the strong partnership is particularly important Major projects often introduce new opportunities. Previous
in the southern Indian market, where infrastructure needs are projects had involved importing the crusher, but the Ariyalur
growing. brownfield development marks the first time that major compo-
“The project has combined the strengths of FLSmidth as a nents of the DUI crusher have been sourced and manufactured
supplier of productive and energy-efficient cement plants with in India. This demonstrates the strong capabilities and capacity
that of Larsen & Toubro as a reliable turnkey construction player of local suppliers who are ready to contribute to the region’s
to provide a full EPC solution,” he comments. infrastructure development needs.
Given the success of the collaboration between FLSmidth
Keeping to deadlines and L&T, there is good reason to look towards future joint EPC
The strength of the partnership has driven the project quickly projects, according to Mr. Raju Ganesan, L&T, who says, “It is
forward and was key to overcoming administrative delays early clear we have similar ideas about strategy and commitment to
in the process. executing projects on time. The success of this project shows
“Following the letter of intent, hurdles and legal hindrances that this is a good reference for us to collaborate in future EPC
were successfully overcome through the close technical sup- executors in the cement industry.” ■
port provided by FLSmidth and the timely execution of project
engineering services and commencement of supplies,” says Mr.
Raju Ganesan, L&T.
He continues: “The relationship between FLSmidth and L&T
has benefited the client, too, because the hassle-free project
coordination has led to the plant engineering and civil and
Strong EPC partnership

structural design being completed on time, despite the early MILLER BAHIRATHAN
delays.” Miller.Bahirathan@flsmidth.com
drives Indian
brownfield project
FLSmidth and Larsen he Tamil Nadu Cement Corporation
T Limited (TANCEM) is a state-owned TANCEM LARSEN & TOUBRO SCOPE OF EQUIPMENT SUPPLY
& Toubro team up to cement producer with a capacity of
expand TANCEM’s approximately 1Mtpa. In 2016, TANCEM decided
Tamil Nadu Cements Corporation
to up the capacity of its Ariyalur plant with a 3,000 Larsen & Toubro is one of India’s FLSmidth’s scope of equipment
Ariyalur operations. tonnes-per-day brownfield plant. The aim was to Limited (TANCEM) is a wholly owned largest technology, engineering, con- supply covers all major equipment,
commission a modern cement production line enterprise of the Government of Tamil struction, manufacturing and financial including key components for raw
with lower emissions and energy consumption Nadu. Beginning operations at its services conglomerates. Operating material crushing equipment, lime-
and a reduced maintenance burden, while lifting Alangulam plant in 1976, TANCEM internationally, L&T addresses critical stone storage, raw and coal grinding,
productivity levels. quickly expanded capacity with its needs across a range of sectors, single-string ILC pyro processing
The India-based international construction second plant, Ariyalur, in 1979. The up- including hydrocarbons, infrastruc- system with cooler, cement grinding,
company Larsen & Toubro Limited (L&T) was en- graded Ariyular plant will have a capac- ture, power, process industries and and packing and loading systems.
gaged by TANCEM to manage and construct the ity of 3,000 tonnes per day, beginning defence, for customers in over 30
project, while FLSmidth was contracted by L&T to production during second Q2 2018. countries around the world.
provide the design, engineering, manufacturing
and supply of all equipment.
With commissioning expected to take place during Q2 2018, First cement in 2018
erection works are almost complete. Miller Bahirathan, Deputy General Manager of Project Manage-
View of TANCEM's ment at FLSmidth, hails the engineering team for moving proac-
Ariyalur plant Successful EPC partnership tively in preparing the general arrangements drawings. “When
in Tamil Nadu,
For L&T, the cooperation with FLSmidth was a significant factor the drawings were completed, and by meticulous planning, we
southern India.
in winning the project, says L&T’s Head of EPC for Cement & could start supplying equipment four months after the effective
Process Plants, Mr. Raju Ganesan. He explains: date of contract.”
“From the tender prequalification through to being award- He also points out that the time required for layout was
ed the contract, we have experienced an excellent strategic drastically reduced thanks to the proactive engineering
association and collegial relationship with FLSmidth, whose approach and the close collaboration with procurement and
considerable technical support helped us gaining TANCEM’s project management.
confidence in L&T’s ability to execute the EPC contract.”
Hari TR, Vice President and Business Head of FLSmidth New competencies
India, says that the strong partnership is particularly important Major projects often introduce new opportunities. Previous
in the southern Indian market, where infrastructure needs are projects had involved importing the crusher, but the Ariyalur
growing. brownfield development marks the first time that major compo-
“The project has combined the strengths of FLSmidth as a nents of the DUI crusher have been sourced and manufactured
supplier of productive and energy-efficient cement plants with in India. This demonstrates the strong capabilities and capacity
that of Larsen & Toubro as a reliable turnkey construction player of local suppliers who are ready to contribute to the region’s
to provide a full EPC solution,” he comments. infrastructure development needs.
Given the success of the collaboration between FLSmidth
Keeping to deadlines and L&T, there is good reason to look towards future joint EPC
The strength of the partnership has driven the project quickly projects, according to Mr. Raju Ganesan, L&T, who says, “It is
forward and was key to overcoming administrative delays early clear we have similar ideas about strategy and commitment to
in the process. executing projects on time. The success of this project shows
“Following the letter of intent, hurdles and legal hindrances that this is a good reference for us to collaborate in future EPC
were successfully overcome through the close technical sup- executors in the cement industry.” ■
port provided by FLSmidth and the timely execution of project
engineering services and commencement of supplies,” says Mr.
Raju Ganesan, L&T.
He continues: “The relationship between FLSmidth and L&T
has benefited the client, too, because the hassle-free project
coordination has led to the plant engineering and civil and
Strong EPC partnership

structural design being completed on time, despite the early MILLER BAHIRATHAN
delays.” Miller.Bahirathan@flsmidth.com
drives Indian
brownfield project
FLSmidth and Larsen he Tamil Nadu Cement Corporation
T Limited (TANCEM) is a state-owned TANCEM LARSEN & TOUBRO SCOPE OF EQUIPMENT SUPPLY
& Toubro team up to cement producer with a capacity of
expand TANCEM’s approximately 1Mtpa. In 2016, TANCEM decided
Tamil Nadu Cements Corporation
to up the capacity of its Ariyalur plant with a 3,000 Larsen & Toubro is one of India’s FLSmidth’s scope of equipment
Ariyalur operations. tonnes-per-day brownfield plant. The aim was to Limited (TANCEM) is a wholly owned largest technology, engineering, con- supply covers all major equipment,
commission a modern cement production line enterprise of the Government of Tamil struction, manufacturing and financial including key components for raw
with lower emissions and energy consumption Nadu. Beginning operations at its services conglomerates. Operating material crushing equipment, lime-
and a reduced maintenance burden, while lifting Alangulam plant in 1976, TANCEM internationally, L&T addresses critical stone storage, raw and coal grinding,
productivity levels. quickly expanded capacity with its needs across a range of sectors, single-string ILC pyro processing
The India-based international construction second plant, Ariyalur, in 1979. The up- including hydrocarbons, infrastruc- system with cooler, cement grinding,
company Larsen & Toubro Limited (L&T) was en- graded Ariyular plant will have a capac- ture, power, process industries and and packing and loading systems.
gaged by TANCEM to manage and construct the ity of 3,000 tonnes per day, beginning defence, for customers in over 30
project, while FLSmidth was contracted by L&T to production during second Q2 2018. countries around the world.
provide the design, engineering, manufacturing
and supply of all equipment.
Mr. VM Moorthy, VP (Tech) at RCL comments: “We previously Performance of Rain Cement's Cross-Bar® cooler
had an old-generation grate cooler, which was becoming
Performance parameter Before upgradation After upgradation
problematic for us. We wanted to improve thermal efficiency, so
Our decision
it was necessary to move to a new-generation cooler.” Production (Mtpd) 2864 2910
With a complete FLSmidth production line already imple- regarding choice of
mented at one of its plants, RCL approached FLSmidth to audit
Recuperation efficiency (%) 68 77
supplier was made
the cooler system in 2016. The audit involved taking detailed Actual cooler loss (Kcal/Kg Clinker) 149 110 largely based
measurements of the existing cooler’s performance. The find- on our previous
Standard cooler loss (Kcal/Kg Clinker) 131 92
ings identified the potential to reduce cooler losses and create
experience with
thermal and electrical energy savings, and as a result, FLSmidth Clinker temperature (Celsius) 112 degrees + ambient 57 degrees + ambient
recommended replacing and installing a more reliable, efficient FLSmidth, and we
Specific power consumption (Kwh/t)
cooler. (Fans, drives and breakers)
4.6 4.4 believe they offer
the most reliable
Making the right choice equipment and
The RCL project team emphasised that the quality of the
equipment, including its durability, was key, along with deliv- “We are satisfied with the outcome and especially pleased
service support”
ery of the equipment in time for its efficient installation within that we have achieved the guaranteed cooler losses and ener-
the planned shutdown period. They sought a commitment to gy savings,” says Mr. Moorthy, RCL.
MR. MOORTHY
TECHNICAL
performance guarantees along with ongoing service support Venkata Siva Ram Kollipara, Assistant General Manager at VICE PRESIDENT AT
after the upgrade. FLSmidth, sees the guarantees achieved on performance pa- RAIN CEMENTS LIMITED
“Our decision regarding choice of supplier was made rameters as an indication of the Cross-Bar cooler’s exceptional
largely based on our previous experience with FLSmidth, and performance and reliability:
we believe they offer the most reliable equipment and service “It pays to make the initial investment to reap the perfor-
support,” says Mr. Moorthy, RCL. mance benefits well into the future. The success of this project
The Cross-Bar cooler met the needs of RCL in terms of pos- demonstrates FLSmidth’s commitment to deliver impressive
sessing high thermal efficiency, reduced power consumption, results through collaboration with our valued customers.” ■
relatively low maintenance requirements and low civil con-
struction and operating costs. The optimised design is flexible
Clinker cooler
enough to enable partial or complete upgrades of most existing VENKATA SIVA RAM KOLLIPARA
old-generation clinker coolers. KVSR-IN@FLSMIDTH.COM
The return on investment for RCL can be realised within an RENGAPRASAD GOPALAKRISHNAN
estimated four-year period, just from the energy benefits and GRP-IN@FLSMIDTH.COM
replacement delivers
fuel savings alone. It was clear that this was the solution for
RCL, and FLSmidth’s extensive experience in retrofits gave a The existing cooler
certain boost of confidence. was replaced by
an FLSmidth®
improved productivity
Cross-Bar® cooler
Ambitious, but achievable timeline within the planned
The project team comprised of two FLSmidth supervisors, shutdown period.
whose role was to supervise the upgrade, together with a team
at Rain Cement
of RCL employees who were responsible for the civil construc-
tion and erection of the new cooler.
A crucial aspect of the project was that it needed to be
completed within the planned shutdown period, which encom-
passes delivery, civil works, dismantling, installation, refractory
works and start-up. The timeline of the project was ambitious
but necessary to minimise production downtime. Together, RCL
Rain Cement’s South India- ain Cements Limited (RCL) has been producing and FLSmidth displayed collaborative efforts to ensure plant
based Ramapuram plant R cement since 1986 at an annual output of up to 3.6 start up as scheduled in the stipulated short timeline.
million tonnes. Its two integrated plants located in “Despite requiring extensive civil structure modifications,
has achieved impressive South India are self-sufficient in all critical raw materials – lime- the project was completed on time thanks to the support
performance results following stone, additives and coal.
RCL made an important decision to address inefficiencies
and experience of FLSmidth in completing retrofits,” says Mr.
Moorthy, RCL.
the successful replacement with in one of its existing systems at the cement plant based in
an FLSmidth® Cross-Bar® cooler. Ramapuram, Mallacheruvu, Kodad in Nalgonda. The project Reaping performance benefits
team paid particular attention to the grate cooler, which was an Following the upgrade, the new Cross-Bar cooler has run well
older generation with low thermal efficiency, and high-energy without any issues, according to Mr. Moorthy, and the perfor-
consumption and requiring more maintenance. mance guarantee results showcasing the success of the project.
Mr. VM Moorthy, VP (Tech) at RCL comments: “We previously Performance of Rain Cement's Cross-Bar® cooler
had an old-generation grate cooler, which was becoming
Performance parameter Before upgradation After upgradation
problematic for us. We wanted to improve thermal efficiency, so
Our decision
it was necessary to move to a new-generation cooler.” Production (Mtpd) 2864 2910
With a complete FLSmidth production line already imple- regarding choice of
mented at one of its plants, RCL approached FLSmidth to audit
Recuperation efficiency (%) 68 77
supplier was made
the cooler system in 2016. The audit involved taking detailed Actual cooler loss (Kcal/Kg Clinker) 149 110 largely based
measurements of the existing cooler’s performance. The find- on our previous
Standard cooler loss (Kcal/Kg Clinker) 131 92
ings identified the potential to reduce cooler losses and create
experience with
thermal and electrical energy savings, and as a result, FLSmidth Clinker temperature (Celsius) 112 degrees + ambient 57 degrees + ambient
recommended replacing and installing a more reliable, efficient FLSmidth, and we
Specific power consumption (Kwh/t)
cooler. (Fans, drives and breakers)
4.6 4.4 believe they offer
the most reliable
Making the right choice equipment and
The RCL project team emphasised that the quality of the
equipment, including its durability, was key, along with deliv- “We are satisfied with the outcome and especially pleased
service support”
ery of the equipment in time for its efficient installation within that we have achieved the guaranteed cooler losses and ener-
the planned shutdown period. They sought a commitment to gy savings,” says Mr. Moorthy, RCL.
MR. MOORTHY
TECHNICAL
performance guarantees along with ongoing service support Venkata Siva Ram Kollipara, Assistant General Manager at VICE PRESIDENT AT
after the upgrade. FLSmidth, sees the guarantees achieved on performance pa- RAIN CEMENTS LIMITED
“Our decision regarding choice of supplier was made rameters as an indication of the Cross-Bar cooler’s exceptional
largely based on our previous experience with FLSmidth, and performance and reliability:
we believe they offer the most reliable equipment and service “It pays to make the initial investment to reap the perfor-
support,” says Mr. Moorthy, RCL. mance benefits well into the future. The success of this project
The Cross-Bar cooler met the needs of RCL in terms of pos- demonstrates FLSmidth’s commitment to deliver impressive
sessing high thermal efficiency, reduced power consumption, results through collaboration with our valued customers.” ■
relatively low maintenance requirements and low civil con-
struction and operating costs. The optimised design is flexible
Clinker cooler
enough to enable partial or complete upgrades of most existing VENKATA SIVA RAM KOLLIPARA
old-generation clinker coolers. KVSR-IN@FLSMIDTH.COM
The return on investment for RCL can be realised within an RENGAPRASAD GOPALAKRISHNAN
estimated four-year period, just from the energy benefits and GRP-IN@FLSMIDTH.COM
replacement delivers
fuel savings alone. It was clear that this was the solution for
RCL, and FLSmidth’s extensive experience in retrofits gave a The existing cooler
certain boost of confidence. was replaced by
an FLSmidth®
improved productivity
Cross-Bar® cooler
Ambitious, but achievable timeline within the planned
The project team comprised of two FLSmidth supervisors, shutdown period.
whose role was to supervise the upgrade, together with a team
at Rain Cement
of RCL employees who were responsible for the civil construc-
tion and erection of the new cooler.
A crucial aspect of the project was that it needed to be
completed within the planned shutdown period, which encom-
passes delivery, civil works, dismantling, installation, refractory
works and start-up. The timeline of the project was ambitious
but necessary to minimise production downtime. Together, RCL
Rain Cement’s South India- ain Cements Limited (RCL) has been producing and FLSmidth displayed collaborative efforts to ensure plant
based Ramapuram plant R cement since 1986 at an annual output of up to 3.6 start up as scheduled in the stipulated short timeline.
million tonnes. Its two integrated plants located in “Despite requiring extensive civil structure modifications,
has achieved impressive South India are self-sufficient in all critical raw materials – lime- the project was completed on time thanks to the support
performance results following stone, additives and coal.
RCL made an important decision to address inefficiencies
and experience of FLSmidth in completing retrofits,” says Mr.
Moorthy, RCL.
the successful replacement with in one of its existing systems at the cement plant based in
an FLSmidth® Cross-Bar® cooler. Ramapuram, Mallacheruvu, Kodad in Nalgonda. The project Reaping performance benefits
team paid particular attention to the grate cooler, which was an Following the upgrade, the new Cross-Bar cooler has run well
older generation with low thermal efficiency, and high-energy without any issues, according to Mr. Moorthy, and the perfor-
consumption and requiring more maintenance. mance guarantee results showcasing the success of the project.
Performance at Orient Cement

Unit Guaranteed Achieved during
Performance Test
Guaranteed capacity TPH 250 266
Product fineness (Wet sieve residue on 90µ) % 12 12
Hydraulic roller presses

Product moisture (Indicative only) % 1.0 0.8
Specific power consumption, includes roller press drive, separator Kwh/tonne@metre 16.8 14.6
drive, separator fan, booster fan and auxiliaries
boost productivity at TABLE 1: The grinding system’s performance after the installation of two hydraulic roller presses.
Orient Cement
Orient Cement shares how the installation of two
ORIENT CEMENT’S HYDRAULIC ROLLER
hydraulic roller press systems supported the efficiency PRESS SPECIFICATIONS
and sustainability objectives of their Karnataka plant.
■■ Raw material grindability: 12kWh/t at VRM shaft

for product residue of 12% on 90μm sieve
■■ Overall feed moisture: 4%
■■ Unit type: Roller Press HRP 3.0
■■ HRP dimension: 1920mm (diametre) ×
1563mm (width)
■■ Installed power: (1600kW *2) 
■■ HRP speed: 2m/s maximum
■■ Grinding pressure limit: 5500kN/m2 (maximum)
■■ Static separator size: RPGS – 3150
■■ Dynamic separator size: RARL 40
he limestone-rich belt of Karnataka in Head of Projects at Orient Cement Shyam Asawa

T India is home to many cement plants, explains: “Hydraulic roller press systems are the
and the market for roller presses in the best choice for the raw materials in our region
region is highly competitive. Given the numerous as the materials are quite dry in nature and have
different options on the market, choosing the high grindability. We also require a waterless
correct roller press solution and the equipment operation, so the HRP system was the obvious
supplier can be daunting for plant owners. For solution for us.”
Orient Cement, selecting the FLSmidth Hydraulic
Roller Press (HRP) has proven to be a cost-effec- Low power, no water
tive solution. Shortly after the installation, it was evident that
Orient Cement’s project objectives would be
Finding the right solution achieved, with all performance guarantees
With a desire to optimise productivity, Orient successfully delivered. As shown in table 1, actual
Cement established selection criteria for evaluat- production exceeded the intended capacity target
ing a new roller press system for use in its 6,600 by 6.5 percent – at a lower power consumption
tonnes-per-day integrated greenfield plant. The and with zero water consumption.
three most critical objectives were high produc- Today, the grinding system at the Karnataka
tion performance, low power consumption, and plant is performing well. After the initial 10,000
grinding without adding water. hours, the conventional wear surface remains in
Performance at Orient Cement

Unit Guaranteed Achieved during
Performance Test
Guaranteed capacity TPH 250 266
Product fineness (Wet sieve residue on 90µ) % 12 12
Hydraulic roller presses

Product moisture (Indicative only) % 1.0 0.8
Specific power consumption, includes roller press drive, separator Kwh/tonne@metre 16.8 14.6
drive, separator fan, booster fan and auxiliaries
boost productivity at TABLE 1: The grinding system’s performance after the installation of two hydraulic roller presses.
Orient Cement
Orient Cement shares how the installation of two
ORIENT CEMENT’S HYDRAULIC ROLLER
hydraulic roller press systems supported the efficiency PRESS SPECIFICATIONS
and sustainability objectives of their Karnataka plant.
■■ Raw material grindability: 12kWh/t at VRM shaft

for product residue of 12% on 90μm sieve
■■ Overall feed moisture: 4%
■■ Unit type: Roller Press HRP 3.0
■■ HRP dimension: 1920mm (diametre) ×
1563mm (width)
■■ Installed power: (1600kW *2) 
■■ HRP speed: 2m/s maximum
■■ Grinding pressure limit: 5500kN/m2 (maximum)
■■ Static separator size: RPGS – 3150
■■ Dynamic separator size: RARL 40
he limestone-rich belt of Karnataka in Head of Projects at Orient Cement Shyam Asawa

T India is home to many cement plants, explains: “Hydraulic roller press systems are the
and the market for roller presses in the best choice for the raw materials in our region
region is highly competitive. Given the numerous as the materials are quite dry in nature and have
different options on the market, choosing the high grindability. We also require a waterless
correct roller press solution and the equipment operation, so the HRP system was the obvious
supplier can be daunting for plant owners. For solution for us.”
Orient Cement, selecting the FLSmidth Hydraulic
Roller Press (HRP) has proven to be a cost-effec- Low power, no water
tive solution. Shortly after the installation, it was evident that
Orient Cement’s project objectives would be
Finding the right solution achieved, with all performance guarantees
With a desire to optimise productivity, Orient successfully delivered. As shown in table 1, actual
Cement established selection criteria for evaluat- production exceeded the intended capacity target
ing a new roller press system for use in its 6,600 by 6.5 percent – at a lower power consumption
tonnes-per-day integrated greenfield plant. The and with zero water consumption.
three most critical objectives were high produc- Today, the grinding system at the Karnataka
tion performance, low power consumption, and plant is performing well. After the initial 10,000
grinding without adding water. hours, the conventional wear surface remains in
The HRP is suitable

for upgrades and new
installations. In some
HIGH-PERFORMANCE HRP cases, an upgrade can
more than double the
capacity while reducing
ORIENT CEMENT'S HYDRAULIC ROLLER energy consumption
by 30%.
PRESS RAW GRINDING CIRCUIT FLSmidth’s latest hydraulic roller press sets the
bar with its efficient design and includes other
noticeable improvements in performance:
■■ Solid forged rollers (No hollow shaft)

■■ Spherical roller bearings to accommodate angular
Two identical raw grinding systems with a common bag house misalignments
■■ Oil for bearing lubrication, bearing cooling, and
Stack Main bag house From raw mill 2 filtering of foreign media
Mill fan ■■ Optimum roller Diameter to Width ratio
■■ Hinged frame for easy roller removal
Bag house
fan Product cyclones
These features enable the HRP to achieve high
Product to silo energy efficiency and contribute to a low total cost
Dilution Dynamic separator of ownership, largely due to its ease of operation
air fan and minimal maintenance costs.
Raw meal to silo
Reject WHEN TO CONSIDER AN HRP SYSTEM

bin
■■ In regions with a high price per kW/hr

Preheater gases Static ■■ In applications with an average feed moisture
to coal mill separator of less than 6%
■■ If water is scarce
Preheater fan
(hot gases to Choke ■■ Where waste heat recovery power generation
grinding) feed bin is important
Fresh
feed
Booster fan Preheater gases
(cooler vent gases) Roller press
to raw mill 2
good condition. No repair work has been required

or performed thus far. This strong result is a
testament to both the quality and durability of the
The FLSmidth Hydraulic roller press equipment.
Hydraulic Roller
Press installed at the systems are the best “We chose FLSmidth to supply the HRP sys-
Karnataka plant. choice for the raw tem for raw grinding based on its brand credibility
and industry experience. FLSmidth has yet again
materials in our region
proven itself and has clearly set a new standard
as the materials are quite with its superior performance and commendable
dry in nature and have results,” says Mr. Asawa.
high grindability. We Since the successful installation of the HRP,
also require a waterless Orient Cement has opened its plant doors
to other cement producers to showcase the
operation, so the HRP
successful grinding solution and welcomed any
system was the obvious discussion regarding its positive experiences. ■
solution for us.”
SHYAM ASAWA
HEAD OF PROJECTS AVANISH KARRAHE
AT ORIENT CEMENT Avanish.Karrahe@flsmidth.com
The HRP is suitable

for upgrades and new
installations. In some
HIGH-PERFORMANCE HRP cases, an upgrade can
more than double the
capacity while reducing
ORIENT CEMENT'S HYDRAULIC ROLLER energy consumption
by 30%.
PRESS RAW GRINDING CIRCUIT FLSmidth’s latest hydraulic roller press sets the
bar with its efficient design and includes other
noticeable improvements in performance:
■■ Solid forged rollers (No hollow shaft)

■■ Spherical roller bearings to accommodate angular
Two identical raw grinding systems with a common bag house misalignments
■■ Oil for bearing lubrication, bearing cooling, and
Stack Main bag house From raw mill 2 filtering of foreign media
Mill fan ■■ Optimum roller Diameter to Width ratio
■■ Hinged frame for easy roller removal
Bag house
fan Product cyclones
These features enable the HRP to achieve high
Product to silo energy efficiency and contribute to a low total cost
Dilution Dynamic separator of ownership, largely due to its ease of operation
air fan and minimal maintenance costs.
Raw meal to silo
Reject WHEN TO CONSIDER AN HRP SYSTEM

bin
■■ In regions with a high price per kW/hr

Preheater gases Static ■■ In applications with an average feed moisture
to coal mill separator of less than 6%
■■ If water is scarce
Preheater fan
(hot gases to Choke ■■ Where waste heat recovery power generation
grinding) feed bin is important
Fresh
feed
Booster fan Preheater gases
(cooler vent gases) Roller press
to raw mill 2
good condition. No repair work has been required

or performed thus far. This strong result is a
testament to both the quality and durability of the
The FLSmidth Hydraulic roller press equipment.
Hydraulic Roller
Press installed at the systems are the best “We chose FLSmidth to supply the HRP sys-
Karnataka plant. choice for the raw tem for raw grinding based on its brand credibility
and industry experience. FLSmidth has yet again
materials in our region
proven itself and has clearly set a new standard
as the materials are quite with its superior performance and commendable
dry in nature and have results,” says Mr. Asawa.
high grindability. We Since the successful installation of the HRP,
also require a waterless Orient Cement has opened its plant doors
to other cement producers to showcase the
operation, so the HRP
successful grinding solution and welcomed any
system was the obvious discussion regarding its positive experiences. ■
solution for us.”
SHYAM ASAWA
HEAD OF PROJECTS AVANISH KARRAHE
AT ORIENT CEMENT Avanish.Karrahe@flsmidth.com
32 FLSmidth Discover Cement Products and solutions FLSmidth Discover Cement 33
34 38 40 44
CATALYTIC FILTER SOLUTIONS COME OF AGE EMISSIONS REPORTING: POWER CEMENT ACCELERATES CEMENT PRODUCTION UNIQUE FINANCING PARTNERSHIP
Catalytic filtration solutions have proven to be effective in REDUCING CARBON FOOTPRINT "The choice facing cement producers is either to stay in the FLSmidth, IFU and two Danish pension funds have
reducing emissions efficiently and cost-effectively. Quinn Cement in Ireland has implemented a system for market by expanding - or leave it to other producers. We chose partnered up to invest in Power Cement's expansion
measuring carbon dioxide emissions. to stay," says Tahir Iqbal, CFO of Power Cement project.
Products
& Solutions
32 FLSmidth Discover Cement Products and solutions FLSmidth Discover Cement 33
34 38 40 44
CATALYTIC FILTER SOLUTIONS COME OF AGE EMISSIONS REPORTING: POWER CEMENT ACCELERATES CEMENT PRODUCTION UNIQUE FINANCING PARTNERSHIP
Catalytic filtration solutions have proven to be effective in REDUCING CARBON FOOTPRINT "The choice facing cement producers is either to stay in the FLSmidth, IFU and two Danish pension funds have
reducing emissions efficiently and cost-effectively. Quinn Cement in Ireland has implemented a system for market by expanding - or leave it to other producers. We chose partnered up to invest in Power Cement's expansion
measuring carbon dioxide emissions. to stay," says Tahir Iqbal, CFO of Power Cement project.
Products
& Solutions
34 FLSmidth Discover Cement Products & solutions FLSmidth Discover Cement 35
Catalytic filter
solutions
“Unfortunately, it can’t be solved simply by optimising the
selective non-catalytic reduction (SNCR) with high-efficiency
techniques, since ammonia is released downstream at higher
stages of the preheating tower,” says Pietro Aresta.
Instead, catalytic filtration solutions are proving to be high-
ly effective and increasingly important in the cement industry.
Catalytic filtration can be implemented in different solutions on CATAMAX™
a cement plant to achieve NOx reduction targets. Depending
on the efficiency of SNCR, the ammonia baseline and the plant An all-in-one multi-pollution catalytic solution, FLSmidth's
come of age
configuration, catalytic filtration can achieve the most effective CataMax™ is constructed similarly to a traditional bag filter,
CAPEX and OPEX solution in different ways. but using porous ceramic elements. It removes dust, NOx,
NH3 and organic hazardous air pollutants (OHAPs) from
Reduced ammonia usage the flue gas in a single step.
A recent installation of a single-layer catalytic filter at a Ger-
man cement plant has given extremely positive results. The
mechanical filtration process (differential pressure and dust
emissions) and the catalytic performance (NOx and ammonia
removal rates) have been outstanding from day one. This

solution combined with an existing SNCR has helped the plant
achieve yearly savings of approximately 75,000 Euros from
Dealing with emissions t is widely recognised that Germany, with its stringent reduced ammonia usage.
I regulations on gaseous hazardous pollutants, leads Auxiliary systems can be used to enable a catalytic
responsibly and efficiently the way in emissions control. In January 2019, cement conversion process, if the current temperature level is not
is a fact of life for today’s producers in Germany will be required to restrict NOx and NH3 sufficient to allow a catalytic conversion process. But when
emissions even more. the available heat in the system reaches the temperatures
production facilities.
But several other countries are not far behind, according CATAFLEX® required by the catalytic reaction, modification only requires
Authorities are ever-more to Pietro Aresta, Global Product Manager for Catalytic Filtration replacement of the bags and heat-balance adjustment. Such
demanding, enforcing tighter Technologies at FLSmidth. “While it’s important to look at the The FLSmidth CataFlex® catalytic filter bags consist of cases can be implemented very easily. For example, it took
developments in Germany, we are also constantly monitoring up to three layers of woven fiberglass. Each layer has a just three days to retrofit the fabric filter, with the biggest task
limits on specific substances developments in other countries focused on strict emissions catalytic material embedded in the fabric with a unique being the bag and cage replacement.
and their allowable limits. limits,” he says. formula that promotes chemical reactions to remove A total retrofit to achieve a full deNOx solution reduces
One important development is that ammonia emissions will pollutants (converting them into harmless species such ammonia costs even more. It is estimated that savings in the
be included as part of the baseline limit. The limits will in fact as water, nitrogen and carbon dioxide) and dust in a one- range of 0.3 Euros per tonne of clinker can be achieved by
apply to the ammonia concentration in the stack. Ammonia is step process. using the ammonia released by the raw material and replacing
emitted from the raw materials and alternative fuels in the pre- SNCR with a more efficient catalytic NOx conversion method.
heater tower, so this will have dramatic consequences for many
plants, where certain alternative fuels, or even the raw materi- Effective all-in-one gaseous
als from the quarry, can give very high baseline level values. pollutants and dust removal
As a result of these developments, cement producers FLSmidth Airtech provides two catalytic filtration solutions that
are under pressure to find new solutions to reduce emissions effectively meet cement producers’ toughest demands for air
efficiently and cost-effectively. pollution control. They are the first solutions on the market to
Catalytic filter
solutions
“Unfortunately, it can’t be solved simply by optimising the
selective non-catalytic reduction (SNCR) with high-efficiency
techniques, since ammonia is released downstream at higher
stages of the preheating tower,” says Pietro Aresta.
Instead, catalytic filtration solutions are proving to be high-
ly effective and increasingly important in the cement industry.
Catalytic filtration can be implemented in different solutions on CATAMAX™
a cement plant to achieve NOx reduction targets. Depending
on the efficiency of SNCR, the ammonia baseline and the plant An all-in-one multi-pollution catalytic solution, FLSmidth's
come of age
configuration, catalytic filtration can achieve the most effective CataMax™ is constructed similarly to a traditional bag filter,
CAPEX and OPEX solution in different ways. but using porous ceramic elements. It removes dust, NOx,
NH3 and organic hazardous air pollutants (OHAPs) from
Reduced ammonia usage the flue gas in a single step.
A recent installation of a single-layer catalytic filter at a Ger-
man cement plant has given extremely positive results. The
mechanical filtration process (differential pressure and dust
emissions) and the catalytic performance (NOx and ammonia
removal rates) have been outstanding from day one. This

solution combined with an existing SNCR has helped the plant
achieve yearly savings of approximately 75,000 Euros from
Dealing with emissions t is widely recognised that Germany, with its stringent reduced ammonia usage.
I regulations on gaseous hazardous pollutants, leads Auxiliary systems can be used to enable a catalytic
responsibly and efficiently the way in emissions control. In January 2019, cement conversion process, if the current temperature level is not
is a fact of life for today’s producers in Germany will be required to restrict NOx and NH3 sufficient to allow a catalytic conversion process. But when
emissions even more. the available heat in the system reaches the temperatures
production facilities.
But several other countries are not far behind, according CATAFLEX® required by the catalytic reaction, modification only requires
Authorities are ever-more to Pietro Aresta, Global Product Manager for Catalytic Filtration replacement of the bags and heat-balance adjustment. Such
demanding, enforcing tighter Technologies at FLSmidth. “While it’s important to look at the The FLSmidth CataFlex® catalytic filter bags consist of cases can be implemented very easily. For example, it took
developments in Germany, we are also constantly monitoring up to three layers of woven fiberglass. Each layer has a just three days to retrofit the fabric filter, with the biggest task
limits on specific substances developments in other countries focused on strict emissions catalytic material embedded in the fabric with a unique being the bag and cage replacement.
and their allowable limits. limits,” he says. formula that promotes chemical reactions to remove A total retrofit to achieve a full deNOx solution reduces
One important development is that ammonia emissions will pollutants (converting them into harmless species such ammonia costs even more. It is estimated that savings in the
be included as part of the baseline limit. The limits will in fact as water, nitrogen and carbon dioxide) and dust in a one- range of 0.3 Euros per tonne of clinker can be achieved by
apply to the ammonia concentration in the stack. Ammonia is step process. using the ammonia released by the raw material and replacing
emitted from the raw materials and alternative fuels in the pre- SNCR with a more efficient catalytic NOx conversion method.
heater tower, so this will have dramatic consequences for many
plants, where certain alternative fuels, or even the raw materi- Effective all-in-one gaseous
als from the quarry, can give very high baseline level values. pollutants and dust removal
As a result of these developments, cement producers FLSmidth Airtech provides two catalytic filtration solutions that
are under pressure to find new solutions to reduce emissions effectively meet cement producers’ toughest demands for air
efficiently and cost-effectively. pollution control. They are the first solutions on the market to
NEW EMISSIONS LIMITS IN GERMANY
Effectively from January 2019, cement producers in

While it's important to
German plants will be required to restrict NOx and
look at the developments
NH3 emissions even more. This implies that emissions
in Germany, we are also need to fall within daily averages of 200 mg/Nm3 (dry,
constantly monitoring 10% O2) of NOx. Short-period peaks will be tolerated,
developments in other but 30-minute average values may never exceed 400
countries focused on mg/Nm3 (dry, 10% O2). For ammonia (NH3), limits will
strict emissions limits.” be 30 and 60 mg/Nm3 (dry, 10% O2) respectively.
PIETRO ARESTA
GLOBAL PRODUCT MANAGER
FOR CATALYTIC FILTRATION
TECHNOLOGIES
filter, together with the SNCR for the preheater/calciner gases,

can be a very cost-effective solution.
High conversion rates

A catalytic fabric filter conversion of a bypass fabric filter with
FLSmidth CataFlex® catalytic filter bags was commissioned at a
German cement plant in October 2015. Tests have shown very
good conversion rates with mechanical properties in line with
FIGURE 1: DENOX PERFORMANCE VS. the highest fabric filter quality standards. Satisfactory deNOx
AMMONIA TO NOX RATIO IN A FULL-SCALE conversion rates were obtained at two different temperature
KILN BYPASS CATALYTIC FABRIC FILTER levels (220°C and 240°C) with two-layer catalytic bags (plus
100 one external, non-catalytic). Conversions above 80 percent
90 were achieved easily, keeping ammonia slip below 10 mg/Nm3
80
dry (see figure 1).
70
remove gaseous pollutants and dust in a single, compact instal- Efficient multi-pollution control
deNOx eﬀ. [%]
60
lation. Both combine FLSmidth’s extensive process know-how FIGURE 2: COMPARISON OF TOTAL COST Catalytic filtration is not only efficient in removing NOx and
and the newest ground-breaking technologies. The CataMax™ 50
OF OWNERSHIP (OVER FIVE YEARS) NH3, and the catalyst has proven its efficiency in converting a
catalytic solution is based on ceramic filtration technology, 40
OF DIFFERENT FILTRATION SOLUTIONS. wide range of organic compounds into harmless species. As an
while the CataFlex® catalytic filter bag applies unique, specially 30 Competitors
example of this, a CataMax catalytic filter was commissioned
developed catalytic technologies to woven-glass bags. 20 recently in an American cement plant with the main purpose of
10
removing high concentrations of organic hazardous air pollut-
Simple conversion of the kiln and raw mill fabric filter FLSmidth Airtech ants (OHAPs) according to local NESHAP rules.
0
OPEX in 5 years
Replacing ordinary bags with catalytic filter bags can be done
0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6
without major plant layout modifications. It is an ideal solution Lower costs
NH3:NOx ratio
when the SNCR system reduces NOx emissions to below or A comparison of the total cost of ownership (over five years) of
2+1 layer bag, 240ºC 2+1 layer bag, 220ºC
slightly above necessary limits. In such cases, the catalytic filter five different scenarios shows attractive savings (see figure 2).
bags reduce ammonia emissions to below required limits, also The cost levels of the three scenarios involving catalytic fabric
removing approximately the same molar quantity of NOx. filtration systems are significantly lower than common filtration
A key difference with FLSmidth’s catalytic filtration solu- solutions based on high and low-dust SCR. ■
CAPEX
tions is that gases from the bypass do not pass through the
preheater tower’s SNCR-active zones. They must be dealt with
separately, if they contribute significantly to the combined
NOx stack emission. In such cases, converting the bypass filter CataFlex CataFlex CataFlex High dust Low dust PIETRO ARESTA
Ammonia Bypass Complete SCR SCR
(electrostatic precipitator or fabric filter) into a catalytic fabric slip killer SCR pietro.aresta@flsmidth.com
NEW EMISSIONS LIMITS IN GERMANY
Effectively from January 2019, cement producers in

While it's important to
German plants will be required to restrict NOx and
look at the developments
NH3 emissions even more. This implies that emissions
in Germany, we are also need to fall within daily averages of 200 mg/Nm3 (dry,
constantly monitoring 10% O2) of NOx. Short-period peaks will be tolerated,
developments in other but 30-minute average values may never exceed 400
countries focused on mg/Nm3 (dry, 10% O2). For ammonia (NH3), limits will
strict emissions limits.” be 30 and 60 mg/Nm3 (dry, 10% O2) respectively.
PIETRO ARESTA
GLOBAL PRODUCT MANAGER
FOR CATALYTIC FILTRATION
TECHNOLOGIES
filter, together with the SNCR for the preheater/calciner gases,

can be a very cost-effective solution.
High conversion rates

A catalytic fabric filter conversion of a bypass fabric filter with
FLSmidth CataFlex® catalytic filter bags was commissioned at a
German cement plant in October 2015. Tests have shown very
good conversion rates with mechanical properties in line with
FIGURE 1: DENOX PERFORMANCE VS. the highest fabric filter quality standards. Satisfactory deNOx
AMMONIA TO NOX RATIO IN A FULL-SCALE conversion rates were obtained at two different temperature
KILN BYPASS CATALYTIC FABRIC FILTER levels (220°C and 240°C) with two-layer catalytic bags (plus
100 one external, non-catalytic). Conversions above 80 percent
90 were achieved easily, keeping ammonia slip below 10 mg/Nm3
80
dry (see figure 1).
70
remove gaseous pollutants and dust in a single, compact instal- Efficient multi-pollution control
deNOx eﬀ. [%]
60
lation. Both combine FLSmidth’s extensive process know-how FIGURE 2: COMPARISON OF TOTAL COST Catalytic filtration is not only efficient in removing NOx and
and the newest ground-breaking technologies. The CataMax™ 50
OF OWNERSHIP (OVER FIVE YEARS) NH3, and the catalyst has proven its efficiency in converting a
catalytic solution is based on ceramic filtration technology, 40
OF DIFFERENT FILTRATION SOLUTIONS. wide range of organic compounds into harmless species. As an
while the CataFlex® catalytic filter bag applies unique, specially 30 Competitors
example of this, a CataMax catalytic filter was commissioned
developed catalytic technologies to woven-glass bags. 20 recently in an American cement plant with the main purpose of
10
removing high concentrations of organic hazardous air pollut-
Simple conversion of the kiln and raw mill fabric filter FLSmidth Airtech ants (OHAPs) according to local NESHAP rules.
0
OPEX in 5 years
Replacing ordinary bags with catalytic filter bags can be done
0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6
without major plant layout modifications. It is an ideal solution Lower costs
NH3:NOx ratio
when the SNCR system reduces NOx emissions to below or A comparison of the total cost of ownership (over five years) of
2+1 layer bag, 240ºC 2+1 layer bag, 220ºC
slightly above necessary limits. In such cases, the catalytic filter five different scenarios shows attractive savings (see figure 2).
bags reduce ammonia emissions to below required limits, also The cost levels of the three scenarios involving catalytic fabric
removing approximately the same molar quantity of NOx. filtration systems are significantly lower than common filtration
A key difference with FLSmidth’s catalytic filtration solu- solutions based on high and low-dust SCR. ■
CAPEX
tions is that gases from the bypass do not pass through the
preheater tower’s SNCR-active zones. They must be dealt with
separately, if they contribute significantly to the combined
NOx stack emission. In such cases, converting the bypass filter CataFlex CataFlex CataFlex High dust Low dust PIETRO ARESTA
Ammonia Bypass Complete SCR SCR
(electrostatic precipitator or fabric filter) into a catalytic fabric slip killer SCR pietro.aresta@flsmidth.com
Emissions
the form of solid recovered fuel. The system needed to record
exceedances as specified in the new license. We needed to
enter Quality Assurance Level 2 (QAL2) and QAL3 data and
produce CUSUM charts according to the quality assurance
reporting:
standard EN14181.”
For Quinn Cement, one of the challenges when considering
the ReportLoq system was that the data would be stored and
maintained off premises. But Kevin Feehan now appreciates the
benefits offered by the web-based solution, saying:
Reducing
“We do not have to maintain or update the reporting system
as this is carried out by FLSmidth as part of the subscription
service, and we can still check on the data even though it is
off site. It is easy to operate and has saved us time producing
CUSUM charts and calculating exceedance compliance.”
carbon footprint
How FLSmidth ReportLoq works
The ReportLoq system is a web-based reporting system that
enables cement plant operators and environmental coordina-
tors to measure, collect and report emissions data. It measures
data every ten seconds and stores the values for a minimum
five years as required by the environmental authorities. It also
provides a comprehensive report via email.
The data is stored on an onsite controller and server that
collects all environmental data from the analysis equipment as
raw values. These values are then transferred to the secure
FLSmidth data centre, which also ensures automatic backup
and eliminates the need for operating and maintaining local
server solutions. The onsite server can store up to six months
of data and for extra security, the controller stores data for up to
30 days.
The ReportLoq system ensures that operating technicians
With approximately six percent of the world’s can monitor the current emissions values, not only as raw
carbon dioxide emissions released from cement values, but also QAL2 and QAL3 corrected, normalised and
validated values. The comments can be printed for reporting
production, the cement industry is increasing its internally or externally. The ReportLoq system also provides
focus on reducing its carbon footprint. Quinn Cement real-time online calculations, which allows operators to monitor
in Ireland has implemented a web-based reporting predicted values and avoid exceedances. The system also
recognises that the values recorded during shutdown, calibra-
system to reliably measure emissions, ensuring tion and analyser faults should not affect calculations. All these
strict adherence to environmental requirements. validation methods are used together with system updates,
ensuring that the emissions data collected is correct and
ABOUT THE REPORTLOQ SYSTEM functional.
The ReportLoq system is a subscription-based system that
he Cement Sustainability Initiative (CSI) was formed islation requirements, provides trends and reports, and records covers all software costs associated with operation, service and
T by a group of 24 major cement producers covering comments on alarms and events. maintenance of the system. The system helps organise your
more than 100 countries and representing around Christian Markussen, Global Product Line Manager in Gas ■■ Real-time reporting with data collection environmental reporting and ensures a solution that complies
30 percent of the world’s cement production. A primary focus Analysis and Reporting, FLSmidth, explains: every 10 seconds with the specific statutory requirements. Furthermore, the
of the group is emissions measurement and reporting, and it “Analysis and reporting is a laborious, time-consuming ■■ Can be launched from any browser and ReportLoq system has been certified by MCERTS confirming
has been instrumental in setting an expectation that all cement process. In a normal cement plant, it might take about 40 any mobile device that data is handled with care and not subject to obscure
plants report on their emissions. million calculations in a year to crunch through the raw data. ■■ User-friendly interface or secret manipulation. Raw data is safely transferred to the
With this increasing focus to reduce the industry’s carbon The analysis system provides all the raw data to the reporting ■■ A wide range of reporting functions FLSmidth data centre. ■
footprint, a reliable and accurate means for environmental system for calculation, and then the reporting system needs ■■ Advanced prevention alarms for any
reporting is needed. The ideal reporting system should provide to generate automatic reports that can be sent directly to local environmental breaches
a quick overview of greenhouse gas emissions. Cement authorities, such as the Environmental Protection Agency.” ■■ Functionality to trend and export raw and
producers that can report accurately on their emissions not only aggregated data
demonstrate a commitment to reducing their environmental Boosting efficiency ■■ Quality Assurance Level functionality
impact, they can also respond quickly to any changes in legisla- Quinn Cement has been improving its emissions reporting
tion involving mandatory reporting. since late 2014, following the implementation of the ReportLoq
system and a gas analysis and control system at its Ballyconnell
Easier environmental reporting plant. Kevin Feehan, Control & Instrumentation Engineer at
An environmental reporting system, such as FLSmidth’s Quinn Cement, explains:
ReportLoq™ system, collects and analyses emissions data from “The plant needed to fulfil additional requirements in a CHRISTIAN MARKUSSEN
the analysis equipment at regular intervals. This fulfils local leg- new EPA license, which granted permission to burn waste in chma@flsmidth.com
Emissions
the form of solid recovered fuel. The system needed to record
exceedances as specified in the new license. We needed to
enter Quality Assurance Level 2 (QAL2) and QAL3 data and
produce CUSUM charts according to the quality assurance
reporting:
standard EN14181.”
For Quinn Cement, one of the challenges when considering
the ReportLoq system was that the data would be stored and
maintained off premises. But Kevin Feehan now appreciates the
benefits offered by the web-based solution, saying:
Reducing
“We do not have to maintain or update the reporting system
as this is carried out by FLSmidth as part of the subscription
service, and we can still check on the data even though it is
off site. It is easy to operate and has saved us time producing
CUSUM charts and calculating exceedance compliance.”
carbon footprint
How FLSmidth ReportLoq works
The ReportLoq system is a web-based reporting system that
enables cement plant operators and environmental coordina-
tors to measure, collect and report emissions data. It measures
data every ten seconds and stores the values for a minimum
five years as required by the environmental authorities. It also
provides a comprehensive report via email.
The data is stored on an onsite controller and server that
collects all environmental data from the analysis equipment as
raw values. These values are then transferred to the secure
FLSmidth data centre, which also ensures automatic backup
and eliminates the need for operating and maintaining local
server solutions. The onsite server can store up to six months
of data and for extra security, the controller stores data for up to
30 days.
The ReportLoq system ensures that operating technicians
With approximately six percent of the world’s can monitor the current emissions values, not only as raw
carbon dioxide emissions released from cement values, but also QAL2 and QAL3 corrected, normalised and
validated values. The comments can be printed for reporting
production, the cement industry is increasing its internally or externally. The ReportLoq system also provides
focus on reducing its carbon footprint. Quinn Cement real-time online calculations, which allows operators to monitor
in Ireland has implemented a web-based reporting predicted values and avoid exceedances. The system also
recognises that the values recorded during shutdown, calibra-
system to reliably measure emissions, ensuring tion and analyser faults should not affect calculations. All these
strict adherence to environmental requirements. validation methods are used together with system updates,
ensuring that the emissions data collected is correct and
ABOUT THE REPORTLOQ SYSTEM functional.
The ReportLoq system is a subscription-based system that
he Cement Sustainability Initiative (CSI) was formed islation requirements, provides trends and reports, and records covers all software costs associated with operation, service and
T by a group of 24 major cement producers covering comments on alarms and events. maintenance of the system. The system helps organise your
more than 100 countries and representing around Christian Markussen, Global Product Line Manager in Gas ■■ Real-time reporting with data collection environmental reporting and ensures a solution that complies
30 percent of the world’s cement production. A primary focus Analysis and Reporting, FLSmidth, explains: every 10 seconds with the specific statutory requirements. Furthermore, the
of the group is emissions measurement and reporting, and it “Analysis and reporting is a laborious, time-consuming ■■ Can be launched from any browser and ReportLoq system has been certified by MCERTS confirming
has been instrumental in setting an expectation that all cement process. In a normal cement plant, it might take about 40 any mobile device that data is handled with care and not subject to obscure
plants report on their emissions. million calculations in a year to crunch through the raw data. ■■ User-friendly interface or secret manipulation. Raw data is safely transferred to the
With this increasing focus to reduce the industry’s carbon The analysis system provides all the raw data to the reporting ■■ A wide range of reporting functions FLSmidth data centre. ■
footprint, a reliable and accurate means for environmental system for calculation, and then the reporting system needs ■■ Advanced prevention alarms for any
reporting is needed. The ideal reporting system should provide to generate automatic reports that can be sent directly to local environmental breaches
a quick overview of greenhouse gas emissions. Cement authorities, such as the Environmental Protection Agency.” ■■ Functionality to trend and export raw and
producers that can report accurately on their emissions not only aggregated data
demonstrate a commitment to reducing their environmental Boosting efficiency ■■ Quality Assurance Level functionality
impact, they can also respond quickly to any changes in legisla- Quinn Cement has been improving its emissions reporting
tion involving mandatory reporting. since late 2014, following the implementation of the ReportLoq
system and a gas analysis and control system at its Ballyconnell
Easier environmental reporting plant. Kevin Feehan, Control & Instrumentation Engineer at
An environmental reporting system, such as FLSmidth’s Quinn Cement, explains:
ReportLoq™ system, collects and analyses emissions data from “The plant needed to fulfil additional requirements in a CHRISTIAN MARKUSSEN
the analysis equipment at regular intervals. This fulfils local leg- new EPA license, which granted permission to burn waste in chma@flsmidth.com
KARACHI, PAKISTAN
25.0700° N, 67.2848° E
As the economy accelerates

in Pakistan, cement
producers such as Power
Cement are facing a stark
choice: move quickly to
retain a solid foothold in a
growing market, or leave
it to others. The ability to
access the right financing
and cement production know-
how is crucial to their ability
to grab the opportunity.
conomic development in Pakistan has

E accelerated in recent years. In addition
to an ever-larger population, develop-
ment is largely fuelled by greater political stability
and, not least, foreign investments, in particular a
notable USD 56 billion investment by China over
the medium term.
Mr Tahir Iqbal, CFO of Power Cement, explains
the impact on the cement market, in which the de-
mand for cement has increased by around eight
percent annually over the last decade. “There is a
shortfall of around seven million housing units and
Power Cement
a growing need for better infrastructure, including
roads and water reservoirs for power stations. It
all adds up to a greater need for cement.”
Power Cement is part of the Arif Habib Group,
a conglomerate with major interests in infrastruc-
accelerates
ture projects and an important role in the regional
development of Pakistan. In early 2015, the group
reviewed its business activities and identified
several development opportunities, including an
expansion of its cement production capacity at
cement production
Power Cement, located in Nooriabad, north-east
of Karachi. The company decided to increase
capacity from 3,000 tonnes per day delivered by
the existing two lines, to 10,700 tonnes by adding
a new production line.
Tahir Iqbal says: “The choice facing cement
producers is either to stay in the game by expand-
ing capacity and improving productivity – or to
KARACHI, PAKISTAN
25.0700° N, 67.2848° E
As the economy accelerates

in Pakistan, cement
producers such as Power
Cement are facing a stark
choice: move quickly to
retain a solid foothold in a
growing market, or leave
it to others. The ability to
access the right financing
and cement production know-
how is crucial to their ability
to grab the opportunity.
conomic development in Pakistan has

E accelerated in recent years. In addition
to an ever-larger population, develop-
ment is largely fuelled by greater political stability
and, not least, foreign investments, in particular a
notable USD 56 billion investment by China over
the medium term.
Mr Tahir Iqbal, CFO of Power Cement, explains
the impact on the cement market, in which the de-
mand for cement has increased by around eight
percent annually over the last decade. “There is a
shortfall of around seven million housing units and
Power Cement
a growing need for better infrastructure, including
roads and water reservoirs for power stations. It
all adds up to a greater need for cement.”
Power Cement is part of the Arif Habib Group,
a conglomerate with major interests in infrastruc-
accelerates
ture projects and an important role in the regional
development of Pakistan. In early 2015, the group
reviewed its business activities and identified
several development opportunities, including an
expansion of its cement production capacity at
cement production
Power Cement, located in Nooriabad, north-east
of Karachi. The company decided to increase
capacity from 3,000 tonnes per day delivered by
the existing two lines, to 10,700 tonnes by adding
a new production line.
Tahir Iqbal says: “The choice facing cement
producers is either to stay in the game by expand-
ing capacity and improving productivity – or to
finance institutions The master plan for the project financing is

providing international based on four pillars – in which one of Power
financing, in particular Cement’s internal resources, Abdul Rahim Butt,
the Investment Fund has also contributed. The mix of the four pillars –
ABOUT THE ARIF HABIB GROUP for Developing Coun- local equity, local debt, foreign equity and foreign
tries (IFU). debt – provides the optimum solution of minimum
Kashif Shah says: financial cost and foreign exchange coverage.
“We are pleased with
The Arif Habib Group is a conglomerate operating within a
the partnership with Choosing the right supplier
highly diverse range of industries and business areas. With
IFU. As we look to For such a flagship project, Arif Habib Group
roots in the financial sector, the conglomerate was founded
expand our operations wanted the market’s leading equipment. A strict
in 1970 by the successful stock broker Mr. Arif Habib, who is
internationally into evaluation procedure of several vendors man-
today Chairman of the Group.
areas such as Africa aged by Power Cement’s team of highly qualified
and the Middle East, advisors led to FLSmidth being chosen as the
Mr. Arif Habib evolved the company from a financial services
we are convinced equipment supplier.
company into a broad range of industries. Today, it operates
partnerships of this According to Kashif Shah, Power Cement was
within energy, fertilizers, steel, construction and building
kind will help us in our aware of FLSmidth’s track record and longstand-
materials, real estate and cement.
future projects.” ing reputation, so it was natural to consider the
company’s offering. The major factors evaluated
Based on a firm desire to contribute to society, his and the
A solid financial were not only the capital cost per tonnes of
corporation’s vision is to enable economic development
Tahir Iqbal, Gregers Schmidt partnership produced cement, but also all factors contributing
opportunities within Pakistan. The group companies focus
and Kashif Shah (standing, left to In addition to acquiring to running a productive operation: equipment
mainly on development and expansion projects.
right). Tine Bremholm Kokfelt and an ownership stake efficiency, energy consumption, emissions control
Zainab Muhammed (seated). in the cement plant, and ease of maintenance. The evaluation con-
FLSmidth secured the cluded that FLSmidth’s proposition provided the
participation of IFU, lowest total cost of ownership.
supported by a Danish The evaluation was not just down to economic
pension fund. Togeth- and operational factors, however. With a dedica-
internationally, so management decided to pursue er, the Danish consortium holds a 9.8 percent of tion to providing the highest quality cement, Arif
financial partners outside of the country. the share capital after expansion. Habib Group wanted a supplier whose brand was
This was one of the reasons FLSmidth was Tine Bremholm Kokfelt, Global Project & built on quality.
invited to bid for the project, explains Kashif Shah. Export Finance at FLSmidth, helped facilitate dis- “It was quite clear to us,” says Kashif Shah.
Not only would FLSmidth bring its industry-lead- cussions between Arif Habib Group and IFU from “We want to be a quality player, so we need
ing cement plant equipment and expertise to the outset. She comments: “Cement plant projects quality equipment, and one of the key reasons for
the table, but FLSmidth would also be able to are attractive to pension funds, because of the choosing FLSmidth was that the FLSmidth brand
support the group’s objectives by structuring an consistent, long-term expected returns. Another will help Power Cement build its own brand.
international financing package through its strong benefit has been the already listing of Power
connections with financial institutions. Cement on the Pakistani stock exchange.” “Having FLSmidth involved in this project gives us
FLSmidth has helped facilitate financing Although Pakistan is not new investment territory peace of mind. Whatever they commit to, they go
for many large-scale development projects in to IFU, there have been none in the last few years. out of their way to ensure it happens, overcoming
developing regions over many years. Strong “IFU’s participation provides a vote of confidence any challenges along the way.”
relationships have been established by FLSmidth in the local growth opportunities,” says Kashif
leave it up to other producers. We chose to stay, with several international financial institutions, and Shah. Committed to a successful project
not just because of the economic opportunity, but it has a history of working with Denmark’s official Now that the commitment has been made, there
also because we have a responsibility to contrib- is of course an expectation that all parties will
ute to our region’s development.” The choice facing cement deliver. According to Kashif Shah, the importance
Such initiatives resonate well with the producers is either to stay in the of this project cannot be overstated, as the
Pakistani government’s drive for development government is offering significant tax exemptions
game by expanding capacity and
and investment, which have been aided by tax for such infrastructure development projects
incentives to ensure speedy implementation of improving productivity – or to The construction of the plant is – if deadlines are met. The deadline for Power
growth initiatives. leave it up to other producers. We progressing. The clinker silo will have a Cement’s new commercial operation is 30 June
“Power Cement’s intention is to operate at full chose to stay, not just because storage capacity of 110,000 tonnes. 2019, but operations are expected to begin well
capacity, where we serve the domestic market, of the economic opportunity, before.
and any excess capacity will be exported,” says And the early signs are good. “Most of the
but also because we have a
Kashif Shah, Advisor to the Arif Habib Group. equipment has already been ordered, the initial
responsibility to contribute to design plans have already been completed,
Preparing for international expansion our region’s development.” and we are confident that our project team and
Major expansions need major financing. Even FLSmidth will work well together,” says Kashif
though the Arif Habib Group has good relation- TAHIR IQBAL Shah. ■
ships with financial institutions in Pakistan, this CFO OF POWER CEMENT
project was a good opportunity to establish
relationships with other international financial TINE BREMHOLM KOKFELT
institutions. This supports the group's business tbk@flsmidth.com
finance institutions The master plan for the project financing is

providing international based on four pillars – in which one of Power
financing, in particular Cement’s internal resources, Abdul Rahim Butt,
the Investment Fund has also contributed. The mix of the four pillars –
ABOUT THE ARIF HABIB GROUP for Developing Coun- local equity, local debt, foreign equity and foreign
tries (IFU). debt – provides the optimum solution of minimum
Kashif Shah says: financial cost and foreign exchange coverage.
“We are pleased with
The Arif Habib Group is a conglomerate operating within a
the partnership with Choosing the right supplier
highly diverse range of industries and business areas. With
IFU. As we look to For such a flagship project, Arif Habib Group
roots in the financial sector, the conglomerate was founded
expand our operations wanted the market’s leading equipment. A strict
in 1970 by the successful stock broker Mr. Arif Habib, who is
internationally into evaluation procedure of several vendors man-
today Chairman of the Group.
areas such as Africa aged by Power Cement’s team of highly qualified
and the Middle East, advisors led to FLSmidth being chosen as the
Mr. Arif Habib evolved the company from a financial services
we are convinced equipment supplier.
company into a broad range of industries. Today, it operates
partnerships of this According to Kashif Shah, Power Cement was
within energy, fertilizers, steel, construction and building
kind will help us in our aware of FLSmidth’s track record and longstand-
materials, real estate and cement.
future projects.” ing reputation, so it was natural to consider the
company’s offering. The major factors evaluated
Based on a firm desire to contribute to society, his and the
A solid financial were not only the capital cost per tonnes of
corporation’s vision is to enable economic development
Tahir Iqbal, Gregers Schmidt partnership produced cement, but also all factors contributing
opportunities within Pakistan. The group companies focus
and Kashif Shah (standing, left to In addition to acquiring to running a productive operation: equipment
mainly on development and expansion projects.
right). Tine Bremholm Kokfelt and an ownership stake efficiency, energy consumption, emissions control
Zainab Muhammed (seated). in the cement plant, and ease of maintenance. The evaluation con-
FLSmidth secured the cluded that FLSmidth’s proposition provided the
participation of IFU, lowest total cost of ownership.
supported by a Danish The evaluation was not just down to economic
pension fund. Togeth- and operational factors, however. With a dedica-
internationally, so management decided to pursue er, the Danish consortium holds a 9.8 percent of tion to providing the highest quality cement, Arif
financial partners outside of the country. the share capital after expansion. Habib Group wanted a supplier whose brand was
This was one of the reasons FLSmidth was Tine Bremholm Kokfelt, Global Project & built on quality.
invited to bid for the project, explains Kashif Shah. Export Finance at FLSmidth, helped facilitate dis- “It was quite clear to us,” says Kashif Shah.
Not only would FLSmidth bring its industry-lead- cussions between Arif Habib Group and IFU from “We want to be a quality player, so we need
ing cement plant equipment and expertise to the outset. She comments: “Cement plant projects quality equipment, and one of the key reasons for
the table, but FLSmidth would also be able to are attractive to pension funds, because of the choosing FLSmidth was that the FLSmidth brand
support the group’s objectives by structuring an consistent, long-term expected returns. Another will help Power Cement build its own brand.
international financing package through its strong benefit has been the already listing of Power
connections with financial institutions. Cement on the Pakistani stock exchange.” “Having FLSmidth involved in this project gives us
FLSmidth has helped facilitate financing Although Pakistan is not new investment territory peace of mind. Whatever they commit to, they go
for many large-scale development projects in to IFU, there have been none in the last few years. out of their way to ensure it happens, overcoming
developing regions over many years. Strong “IFU’s participation provides a vote of confidence any challenges along the way.”
relationships have been established by FLSmidth in the local growth opportunities,” says Kashif
leave it up to other producers. We chose to stay, with several international financial institutions, and Shah. Committed to a successful project
not just because of the economic opportunity, but it has a history of working with Denmark’s official Now that the commitment has been made, there
also because we have a responsibility to contrib- is of course an expectation that all parties will
ute to our region’s development.” The choice facing cement deliver. According to Kashif Shah, the importance
Such initiatives resonate well with the producers is either to stay in the of this project cannot be overstated, as the
Pakistani government’s drive for development government is offering significant tax exemptions
game by expanding capacity and
and investment, which have been aided by tax for such infrastructure development projects
incentives to ensure speedy implementation of improving productivity – or to The construction of the plant is – if deadlines are met. The deadline for Power
growth initiatives. leave it up to other producers. We progressing. The clinker silo will have a Cement’s new commercial operation is 30 June
“Power Cement’s intention is to operate at full chose to stay, not just because storage capacity of 110,000 tonnes. 2019, but operations are expected to begin well
capacity, where we serve the domestic market, of the economic opportunity, before.
and any excess capacity will be exported,” says And the early signs are good. “Most of the
but also because we have a
Kashif Shah, Advisor to the Arif Habib Group. equipment has already been ordered, the initial
responsibility to contribute to design plans have already been completed,
Preparing for international expansion our region’s development.” and we are confident that our project team and
Major expansions need major financing. Even FLSmidth will work well together,” says Kashif
though the Arif Habib Group has good relation- TAHIR IQBAL Shah. ■
ships with financial institutions in Pakistan, this CFO OF POWER CEMENT
project was a good opportunity to establish
relationships with other international financial TINE BREMHOLM KOKFELT
institutions. This supports the group's business tbk@flsmidth.com
The investment marks IFU's Cement project does carry several risk factors,
return to Pakistan after a explains Anders Paludan-Müller:
five-year break. “Pakistan’s country risk is considered high.
This assessment is based on risks associated with
personal safety, the political situation, instability in
the business climate, and scarcity of transparency. It
is a highly regulated economy with a lot of red tape
and currency constraints.”
With risk comes opportunity. From an invest-
ment perspective, it was clearly an upside that the
plant’s existing infrastructure could be transformed
into a modern, profitable operation. But according
to Anders Paludan-Müller, it also depends on having
strong partners who are used to operating in such
a climate:
Unique financing
“We need to be able to trust our partners, and
we carry out strict due diligence. Our evaluation of
the owner of Power Cement, the Arif Habib Group
revealed a solid track record in turning around
underperforming enterprises as well as a strong
partnership
management team who knows how to navigate
within the local environment.”
Mutual commitment
IFU expects the other financial partners to accept
financial risk, too. This collective risk-sharing
perspective is central to the way IFU operates.
In a blended financing Anders Paludan-Müller says:
agreement, FLSmidth, IFU “It’s important we are aligned towards the
customer as one party. Part of our model is that the
and two Danish pension partner assumes project risk, for example through
funds have partnered a minority shareholding, which demonstrates a
long-term commitment to the project. We have seen
up to invest in Power this commitment from FLSmidth many times before,
Cement’s extensive and we see it again now with the Power Cement
project.”
brownfield expansion Among IFU’s demands when investing in these
project in Pakistan. projects, is a seat on the Board of the business
being supported. But rather than being a barrier,
ith the key purpose of contributing to the two dates back to 1975, and since then, IFU partnership between FLSmidth and IFU is one of this was in fact welcomed by Power Cement’s
W economic and social development, and FLSmidth have teamed up in more than 20 the key reasons this project got off the ground. owners, who were seeking the unique expertise
Denmark’s Investment Fund for cement projects worldwide. Most recently, IFU He comments: and knowledge of IFU, according to Kashif Shah,
Developing Countries (IFU) constantly seeks and FLSmidth have come together to help finance “When we appraise project proposals, one of
FLSmidth is there to Advisor to Arif Habib Group.
solid, far-sighted investment opportunities. The the expansion of Power Cement Ltd.’s operations the most important factors is the project partner. develop long-term relations Anders Paludan-Müller, who will represent IFU
state-owned organisation provides risk capital in Nooriabad, Pakistan. FLSmidth is a trusted, reputable, and high-quality with cement manufacturers. and FLSmidth on Power Cement’s Board of Direc-
and advice to companies establishing businesses But IFU’s own funds make up only a part of the player in the cement production industry, so it’s a tors, explains that it is a part of the mutual commit-
in emerging economies, particularly in Africa, Asia, financing package. In what’s known as ‘blended fi- big plus they are involved.” We're there to help people ment between IFU and the project owner:
Latin America and parts of Europe. To date, IFU nancing’ – the strategic use of development finance Rune Nørgaard agrees: “FLSmidth is there to with their livelihoods. “We want to have a finger on the pulse and
and its managed funds have co-invested in more and private funding to raise capital for projects develop long-term relations with cement manu- to have some influence on the project. But it’s not
than 1200 companies in 100 countries. in emerging markets and developing countries – facturers. We’re there to help people with their
It's a partnership all just about control, it’s also because we have a lot
“We help to establish companies that provide equity has also been provided by an independent livelihoods. It’s a partnership all the way around.” the way around.” of good advice to offer, based on our experience
a bottom line profit and have a positive effect investment fund administered by IFU. This fund con- across 1200 investments. For the project owner, IFU
for employees, partners and society,” says Rune sists of equity from two Danish pension funds, PBU Solid investment RUNE NØRGAARD provides a stamp of approval, particularly because
Nørgaard, IFU Communications Director, adding, and PKA. Together with these partners, FLSmidth is Although IFU’s objectives are closely tied with COMMUNICATIONS DIRECTOR AT IFU we are backed by the Danish state. This carries
“At the same time, we are careful to invest only in providing approximately EUR 11 million in funding to contributing to a country’s Sustainable Develop- an inherent credibility towards the project’s other
companies that maintain high environmental, social the Power Cement project. ment Goals (SDGs), there is no doubting in the stakeholders.”
and governance standards.” importance of its commercial objectives as well. It is all part of realising the objective of contrib-
Building on a strong relationship Investments are made on commercial terms in uting to Pakistan’s development and delivering to
Blended financing This is the fifth joint project in Pakistan, and the form of equity and loans with the objective of IFU’s own investment goals. ■
Over the years, IFU has invested together with sees the return of IFU to Pakistan after a five- a healthy return on its investments. However, IFU
many Danish companies, of which FLSmidth is year break. Anders Paludan-Müller, Investment is willing to accept a greater risk than many other TINE BREMHOLM KOKFELT
a noteworthy partner. The partnership between Director at IFU, is convinced that the longstanding traditional financial institutions, and the Power tbk@flsmidth.com
The investment marks IFU's Cement project does carry several risk factors,
return to Pakistan after a explains Anders Paludan-Müller:
five-year break. “Pakistan’s country risk is considered high.
This assessment is based on risks associated with
personal safety, the political situation, instability in
the business climate, and scarcity of transparency. It
is a highly regulated economy with a lot of red tape
and currency constraints.”
With risk comes opportunity. From an invest-
ment perspective, it was clearly an upside that the
plant’s existing infrastructure could be transformed
into a modern, profitable operation. But according
to Anders Paludan-Müller, it also depends on having
strong partners who are used to operating in such
a climate:
Unique financing
“We need to be able to trust our partners, and
we carry out strict due diligence. Our evaluation of
the owner of Power Cement, the Arif Habib Group
revealed a solid track record in turning around
underperforming enterprises as well as a strong
partnership
management team who knows how to navigate
within the local environment.”
Mutual commitment
IFU expects the other financial partners to accept
financial risk, too. This collective risk-sharing
perspective is central to the way IFU operates.
In a blended financing Anders Paludan-Müller says:
agreement, FLSmidth, IFU “It’s important we are aligned towards the
customer as one party. Part of our model is that the
and two Danish pension partner assumes project risk, for example through
funds have partnered a minority shareholding, which demonstrates a
long-term commitment to the project. We have seen
up to invest in Power this commitment from FLSmidth many times before,
Cement’s extensive and we see it again now with the Power Cement
project.”
brownfield expansion Among IFU’s demands when investing in these
project in Pakistan. projects, is a seat on the Board of the business
being supported. But rather than being a barrier,
ith the key purpose of contributing to the two dates back to 1975, and since then, IFU partnership between FLSmidth and IFU is one of this was in fact welcomed by Power Cement’s
W economic and social development, and FLSmidth have teamed up in more than 20 the key reasons this project got off the ground. owners, who were seeking the unique expertise
Denmark’s Investment Fund for cement projects worldwide. Most recently, IFU He comments: and knowledge of IFU, according to Kashif Shah,
Developing Countries (IFU) constantly seeks and FLSmidth have come together to help finance “When we appraise project proposals, one of
FLSmidth is there to Advisor to Arif Habib Group.
solid, far-sighted investment opportunities. The the expansion of Power Cement Ltd.’s operations the most important factors is the project partner. develop long-term relations Anders Paludan-Müller, who will represent IFU
state-owned organisation provides risk capital in Nooriabad, Pakistan. FLSmidth is a trusted, reputable, and high-quality with cement manufacturers. and FLSmidth on Power Cement’s Board of Direc-
and advice to companies establishing businesses But IFU’s own funds make up only a part of the player in the cement production industry, so it’s a tors, explains that it is a part of the mutual commit-
in emerging economies, particularly in Africa, Asia, financing package. In what’s known as ‘blended fi- big plus they are involved.” We're there to help people ment between IFU and the project owner:
Latin America and parts of Europe. To date, IFU nancing’ – the strategic use of development finance Rune Nørgaard agrees: “FLSmidth is there to with their livelihoods. “We want to have a finger on the pulse and
and its managed funds have co-invested in more and private funding to raise capital for projects develop long-term relations with cement manu- to have some influence on the project. But it’s not
than 1200 companies in 100 countries. in emerging markets and developing countries – facturers. We’re there to help people with their
It's a partnership all just about control, it’s also because we have a lot
“We help to establish companies that provide equity has also been provided by an independent livelihoods. It’s a partnership all the way around.” the way around.” of good advice to offer, based on our experience
a bottom line profit and have a positive effect investment fund administered by IFU. This fund con- across 1200 investments. For the project owner, IFU
for employees, partners and society,” says Rune sists of equity from two Danish pension funds, PBU Solid investment RUNE NØRGAARD provides a stamp of approval, particularly because
Nørgaard, IFU Communications Director, adding, and PKA. Together with these partners, FLSmidth is Although IFU’s objectives are closely tied with COMMUNICATIONS DIRECTOR AT IFU we are backed by the Danish state. This carries
“At the same time, we are careful to invest only in providing approximately EUR 11 million in funding to contributing to a country’s Sustainable Develop- an inherent credibility towards the project’s other
companies that maintain high environmental, social the Power Cement project. ment Goals (SDGs), there is no doubting in the stakeholders.”
and governance standards.” importance of its commercial objectives as well. It is all part of realising the objective of contrib-
Building on a strong relationship Investments are made on commercial terms in uting to Pakistan’s development and delivering to
Blended financing This is the fifth joint project in Pakistan, and the form of equity and loans with the objective of IFU’s own investment goals. ■
Over the years, IFU has invested together with sees the return of IFU to Pakistan after a five- a healthy return on its investments. However, IFU
many Danish companies, of which FLSmidth is year break. Anders Paludan-Müller, Investment is willing to accept a greater risk than many other TINE BREMHOLM KOKFELT
a noteworthy partner. The partnership between Director at IFU, is convinced that the longstanding traditional financial institutions, and the Power tbk@flsmidth.com
46 FLSmidth Discover Cement Site reports FLSmidth Discover Cement 47
Grey/white
production:
CONVERSION FACTS
Instead of constructing a new
white cement line, Riyadh
an achievable
Cement saw significant economic The conversion of one of Riyadh Cement's existing
benefits in converting an existing grey cement lines to a dual process cement line for
grey line to dual production. white and grey cement includes modifying the kiln and
preheater area:
ambition
■■ Minor modification to the preheater tower
■■ The FLSmidth Duoflex® burner, which is ideal for
white cement production
■■ Quenching equipment, including water pumps
■■ A complete electrical package, including
modifications to the control system
In a climate of ambitious public housing construction

projects, the demand for white cement is growing
in Saudi Arabia. Riyadh Cement has turned to
FLSmidth to realise its vision of capturing 100
percent of the local white cement market.
fter its commissioning in 2007, Riyadh can be used for dual production of white and grey
A Cement Company (RCC) quickly began cement. In recent years, FLSmidth has conducted
to meet the growing demand for several such conversions, including for Adana
grey cement in the domestic Saudi Arabian and Cement in Turkey.
neighbouring markets. A second grey line was Before determining on the proposed solution,
commissioned in 2010, increasing the combined RCC representatives visited the Turkish site to
production capacity to 11,000 tonnes per day. observe the plant in operation. This visit, along
In 2011, RCC became a subsidiary of Saudi with FLSmidth’s track record with RCC, led to the
White Cement Company. As market demand for decision to convert the existing grey cement line
white cement was increasing, RCC sought ways to dual production, instead of building a complete-
to increase its flexibility by switching from grey ly new production line. Early in the project, testing
to white production. Saudi White Cement Com- of the raw materials was conducted at FLSmidth’s
pany was already a renowned producer of white Research and Development facility in Denmark to
cement and sufficient raw materials were readily ensure guarantees in whiteness and quality would
accessible to the plant. be met. Upgrade benefits pleted, as well as most of the purchasing, with final
Mr Sultan Al Dhuwaihi, Chief Projects Officer at Mr Sultan Al Dhuwaihi says: “We have a good The main part of the project involves installing delivery expected in the beginning of 2018. The
RCC’s owner, Saudi White Cement Company, says: relationship with FLSmidth as they have supplied an FLSmidth Duoflex® burner inside the kiln with construction partner for the project is the Turkish
“We already have about a 30 percent mar- us with various equipment and services, through quenching to take place inside the kiln tube and
We already have about a 30 company, Partner Teknik.
ket share within white cement and we want to the years, so we had a good impression of their implementing relatively minor changes to the percent market share within Mr Sultan Al Dhuwaihi comments: “The
increase our capacity to achieve our ambition of ability to deliver. It is advantageous to have an existing preheater. white cement and we want to process so far has been good. We have had good
capturing 100 percent of the market.” equipment supplier with proven know-how about A considerable amount of existing equip- design meetings and have received almost all
The project team first considered constructing the technology for white cement production. In ment is being reused, including the oil handling increase our capacity to achieve engineering documentation, so we are looking
a new line specifically for white cement. However, fact, nobody else has the same high level of know- equipment, clinker cooler, raw material storage our ambition of capturing forward to the mobilisation phase. I am confident
following discussions with FLSmidth, it was quickly how.” system and raw mill grinding equipment. With the we can rely on FLSmidth’s capabilities and tools
determined that converting one of the existing Omar Rabia, Sales Manager at FLSmidth, proposed modifications, the kiln is expected to
100 percent of the market.” as well as their know-how and experience so that
grey lines to produce white cement was a highly explains that the aim was to achieve a payback of produce a minimum of 2,000 tpd white clinker we can quickly achieve our ambition of having full
MR. SULTAN AL DHUWAIHI
economical option. one year or less. with a maximum heat consumption of 1,350 kcal/ capacity of white cement in 2018.” ■
CHIEF PROJECTS OFFICER AT RCC’S
“It was important to be able to show the value kg clinker. OWNER, SAUDI WHITE CEMENT COMPANY
Reusing assets of proceeding with the proposal by demonstrating
FLSmidth has developed a concept for modifying experience, flexibility and the right pricing,” he Next steps
the existing equipment typically used in grey says. With a mid-2018 target for commissioning, the OMAR RABIA
cement production in a cost-efficient way so that it engineering phase of the project has been com- ora@flsmidth.com
46 FLSmidth Discover Cement Site reports FLSmidth Discover Cement 47
Grey/white
production:
CONVERSION FACTS
Instead of constructing a new
white cement line, Riyadh
an achievable
Cement saw significant economic The conversion of one of Riyadh Cement's existing
benefits in converting an existing grey cement lines to a dual process cement line for
grey line to dual production. white and grey cement includes modifying the kiln and
preheater area:
ambition
■■ Minor modification to the preheater tower
■■ The FLSmidth Duoflex® burner, which is ideal for
white cement production
■■ Quenching equipment, including water pumps
■■ A complete electrical package, including
modifications to the control system
In a climate of ambitious public housing construction

projects, the demand for white cement is growing
in Saudi Arabia. Riyadh Cement has turned to
FLSmidth to realise its vision of capturing 100
percent of the local white cement market.
fter its commissioning in 2007, Riyadh can be used for dual production of white and grey
A Cement Company (RCC) quickly began cement. In recent years, FLSmidth has conducted
to meet the growing demand for several such conversions, including for Adana
grey cement in the domestic Saudi Arabian and Cement in Turkey.
neighbouring markets. A second grey line was Before determining on the proposed solution,
commissioned in 2010, increasing the combined RCC representatives visited the Turkish site to
production capacity to 11,000 tonnes per day. observe the plant in operation. This visit, along
In 2011, RCC became a subsidiary of Saudi with FLSmidth’s track record with RCC, led to the
White Cement Company. As market demand for decision to convert the existing grey cement line
white cement was increasing, RCC sought ways to dual production, instead of building a complete-
to increase its flexibility by switching from grey ly new production line. Early in the project, testing
to white production. Saudi White Cement Com- of the raw materials was conducted at FLSmidth’s
pany was already a renowned producer of white Research and Development facility in Denmark to
cement and sufficient raw materials were readily ensure guarantees in whiteness and quality would
accessible to the plant. be met. Upgrade benefits pleted, as well as most of the purchasing, with final
Mr Sultan Al Dhuwaihi, Chief Projects Officer at Mr Sultan Al Dhuwaihi says: “We have a good The main part of the project involves installing delivery expected in the beginning of 2018. The
RCC’s owner, Saudi White Cement Company, says: relationship with FLSmidth as they have supplied an FLSmidth Duoflex® burner inside the kiln with construction partner for the project is the Turkish
“We already have about a 30 percent mar- us with various equipment and services, through quenching to take place inside the kiln tube and
We already have about a 30 company, Partner Teknik.
ket share within white cement and we want to the years, so we had a good impression of their implementing relatively minor changes to the percent market share within Mr Sultan Al Dhuwaihi comments: “The
increase our capacity to achieve our ambition of ability to deliver. It is advantageous to have an existing preheater. white cement and we want to process so far has been good. We have had good
capturing 100 percent of the market.” equipment supplier with proven know-how about A considerable amount of existing equip- design meetings and have received almost all
The project team first considered constructing the technology for white cement production. In ment is being reused, including the oil handling increase our capacity to achieve engineering documentation, so we are looking
a new line specifically for white cement. However, fact, nobody else has the same high level of know- equipment, clinker cooler, raw material storage our ambition of capturing forward to the mobilisation phase. I am confident
following discussions with FLSmidth, it was quickly how.” system and raw mill grinding equipment. With the we can rely on FLSmidth’s capabilities and tools
determined that converting one of the existing Omar Rabia, Sales Manager at FLSmidth, proposed modifications, the kiln is expected to
100 percent of the market.” as well as their know-how and experience so that
grey lines to produce white cement was a highly explains that the aim was to achieve a payback of produce a minimum of 2,000 tpd white clinker we can quickly achieve our ambition of having full
MR. SULTAN AL DHUWAIHI
economical option. one year or less. with a maximum heat consumption of 1,350 kcal/ capacity of white cement in 2018.” ■
CHIEF PROJECTS OFFICER AT RCC’S
“It was important to be able to show the value kg clinker. OWNER, SAUDI WHITE CEMENT COMPANY
Reusing assets of proceeding with the proposal by demonstrating
FLSmidth has developed a concept for modifying experience, flexibility and the right pricing,” he Next steps
the existing equipment typically used in grey says. With a mid-2018 target for commissioning, the OMAR RABIA
cement production in a cost-efficient way so that it engineering phase of the project has been com- ora@flsmidth.com
48 FLSmidth Discover Cement Features FLSmidth Discover Cement 49
Industry-leading
technology and
streamlined processes PRODUCT LINE MANAGEMENT
are vital to our
company. But they
are only of value if
we have the people
who can put them into Avanish Karrahe is Global Product Line Manager
practice. Each and
for HRP systems. The purpose of Product Line
every individual at
FLSmidth has a role
Management (PLM) is to increase competitiveness
to play in bringing our of FLSmidth products with a focus on global
capabilities to life. market share, order intake and margin. PLM
supports FLSmidth’s sales functions, helping
to ensure the right product and quality is being
OUR PEOPLE
brought to market, including pricing, value
proposition, and sales material. In addition, PLM
ompleting his studies in 1993, chemical doing; what challenges they were facing? How did they collaborates with R&D and Engineering to develop
C engineer Avanish Karrahe entered the optimise? How did they go about commissioning and new products and improve existing products as
cement industry right when he was trouble-shooting?” well as with Procurement to streamline the supply
needed the most. The burgeoning industry was “The cement It was a period of enhanced learning and an chain and reduce costs.
recognising the value of having chemical engi- world was opening opportunity to travel the world. Seeing how other
neers on board more and more. its eyes to the cement plants operated showed him the vast variety
When he broke into the job market, Avanish need for greater of methods and technologies used in production. He
cemented himself with Aditya Cement in India – a soon mastered his technique of identifying ways to
improvements
unit of UltraTech Cement Limited – where he started solve problems, gaining more insight into product
as graduate engineer trainee. The position encom- in fuel efficiency design improvements. them requires agility and a willingness to be open and transpar-
passed different capacities including plant oper- and design, so For Avanish, commissioning was a huge learning that will ent with each other. This is something he deeply values.
ations, troubleshooting and optimisation; a good cement producers never stop. He recognised that his experience gained from
starting point to what would become a well-round-
needed to employ being around machinery supported his new role in commission- Collaboration success
ed and successful career within the industry. ing. And finally, in a customer-facing role, he got to meet with Avanish identifies that collaboration is very important and
more people them directly and discovered that he enjoyed – and excelled believes that a successful team should discuss research and
Problem solving with the right in – this interaction. development ideas, listen to feedback from the sales team and
He was drawn into spending a lot of time at the qualifications to Keen to continue learning, Avanish became department include the process design and procurement teams. Working
cement plant early in his career by the over- meet these needs.” manager at FLSmidth for alternative fuels in the India region in closely with the innovation manager is also crucial.
whelming concept of automation and the sheer 2009. Solid and liquid alternative fuel was a reasonably new With the increasing pressure on the cement industry to meet
size of the different machinery. “Getting to know AVANISH concept to the cement industry and appeared to have great supply demands and the focus on reducing the carbon foot-
the cement plant and its systems and components KARRAHE potential. It involved converting non-recyclable waste materials print in the cement industry, there’s a long road ahead, which
was a thrill,” he says. GLOBAL PRODUCT LINE
into usable heat, electricity or fuel. He worked hard to increase requires team work and a collaborative approach. He says:
After working at Aditya Cement for a few MANAGER FOR HRP SYSTEMS the knowledge and use of alternative fuels within the region, “We are working hard together for continual improvement
years, Avanish realised his passion was in energy further developing his customer connections. Many first-time with the aim of being the market leaders when it comes to
efficiency improvements and investigating ma- alternative fuel projects in India were implemented by FLSmidth building and supplying HRPs.”
chinery breakdowns. He found himself continually during this time, involving both solid and liquid waste fuel-firing
Cementing
asking, how can we increase productivity? What projects. Proudest moment
was behind the breakdown? How can we fix A career highlight for Avanish was when he gave a presenta-
it? How can we do it better? It was satisfying to Broad experience tion about the FLSmidth Hydraulic Roller Press at the 14th NCB
consider all these questions and to find a solution Avanish was appointed as product line manager for the HRP International Seminar on Cement and Building Materials in
customer
to the problem, which at the end of the day, kept system after five years in his sales role. His experience in 2015. He says:
customers happy. different areas, including commissioning, process design, sales, “A customer, who was close to finalising a closed-circuit ball
In his close to six-year tenure at Aditya engineering, procurement and quality management, meant that mill cement grinding system, heard the presentation and was
connections
Cement, Avanish developed his knowledge and he could bring a broader overview of products to the team. impressed with the advantages of the HRP system. Afterwards,
skill-base in the operations, trouble shooting, and Through collaboration with different divisions comes much we discussed the benefits and how it could reduce the total
optimisation of a cement plant. He became adept scope for learning and improvement. He explains: cost of ownership. In less than a month, the contract for a new
at various processes involved in cement making “We listened to what our customers wanted and are cur- HRP system (semi-finish cement grinding, HRP and ball mill)
such as grinding and clinkerisation. He took his rently transitioning from being project-focused to product- was signed.”
first steps in working with the hydraulic roller focused. I had gained a broad view of customers’ needs and This was just one of the many positive customer experienc-
An inquisitive mind, a customer-oriented press (HRP) system. However, his fascination with where we needed to go. We could see that HRP was requiring es that Avanish has encountered in his role as Global Product
approach and a willingness to continue optimising systems was calling and he turned his some attention and decided to give it more focus. Line Manager of the HRP system. It showcases his ability to
focus towards design. “The HRP systems that are being offered today are much find the most suitable technologies to address the customer’s
his professional development has led more competitive than what they were in the past and we strive critical issues and needs, keeping them happy, which he finds
Avanish Karrahe to the position of Global Enriching learning to keep them ahead of competition. This has resulted from the truly satisfying. ■
Soon after, Avanish joined FLSmidth and became hard work and dedication of the team, an achievement I am
Product Line Manager for HRP systems. a part of the process design and commissioning extremely proud of. It demonstrates the positive results of what
He shares how he ended up working with team. This was a completely different side of the we can achieve when we work together.”
cement industry. He says: It is clear that Avanish is motivated by staying one step
FLSmidth’s customers to fully understand “I wanted to learn how to design a cement ahead of the competition and succeeding in a dynamic market. HANNE FLYGER
their concerns and address their needs. plant and was interested in what other plants were Working closely with customers to find innovative solutions for haf@flsmidth.com
Industry-leading
technology and
streamlined processes PRODUCT LINE MANAGEMENT
are vital to our
company. But they
are only of value if
we have the people
who can put them into Avanish Karrahe is Global Product Line Manager
practice. Each and
for HRP systems. The purpose of Product Line
every individual at
FLSmidth has a role
Management (PLM) is to increase competitiveness
to play in bringing our of FLSmidth products with a focus on global
capabilities to life. market share, order intake and margin. PLM
supports FLSmidth’s sales functions, helping
to ensure the right product and quality is being
OUR PEOPLE
brought to market, including pricing, value
proposition, and sales material. In addition, PLM
ompleting his studies in 1993, chemical doing; what challenges they were facing? How did they collaborates with R&D and Engineering to develop
C engineer Avanish Karrahe entered the optimise? How did they go about commissioning and new products and improve existing products as
cement industry right when he was trouble-shooting?” well as with Procurement to streamline the supply
needed the most. The burgeoning industry was “The cement It was a period of enhanced learning and an chain and reduce costs.
recognising the value of having chemical engi- world was opening opportunity to travel the world. Seeing how other
neers on board more and more. its eyes to the cement plants operated showed him the vast variety
When he broke into the job market, Avanish need for greater of methods and technologies used in production. He
cemented himself with Aditya Cement in India – a soon mastered his technique of identifying ways to
improvements
unit of UltraTech Cement Limited – where he started solve problems, gaining more insight into product
as graduate engineer trainee. The position encom- in fuel efficiency design improvements. them requires agility and a willingness to be open and transpar-
passed different capacities including plant oper- and design, so For Avanish, commissioning was a huge learning that will ent with each other. This is something he deeply values.
ations, troubleshooting and optimisation; a good cement producers never stop. He recognised that his experience gained from
starting point to what would become a well-round-
needed to employ being around machinery supported his new role in commission- Collaboration success
ed and successful career within the industry. ing. And finally, in a customer-facing role, he got to meet with Avanish identifies that collaboration is very important and
more people them directly and discovered that he enjoyed – and excelled believes that a successful team should discuss research and
Problem solving with the right in – this interaction. development ideas, listen to feedback from the sales team and
He was drawn into spending a lot of time at the qualifications to Keen to continue learning, Avanish became department include the process design and procurement teams. Working
cement plant early in his career by the over- meet these needs.” manager at FLSmidth for alternative fuels in the India region in closely with the innovation manager is also crucial.
whelming concept of automation and the sheer 2009. Solid and liquid alternative fuel was a reasonably new With the increasing pressure on the cement industry to meet
size of the different machinery. “Getting to know AVANISH concept to the cement industry and appeared to have great supply demands and the focus on reducing the carbon foot-
the cement plant and its systems and components KARRAHE potential. It involved converting non-recyclable waste materials print in the cement industry, there’s a long road ahead, which
was a thrill,” he says. GLOBAL PRODUCT LINE
into usable heat, electricity or fuel. He worked hard to increase requires team work and a collaborative approach. He says:
After working at Aditya Cement for a few MANAGER FOR HRP SYSTEMS the knowledge and use of alternative fuels within the region, “We are working hard together for continual improvement
years, Avanish realised his passion was in energy further developing his customer connections. Many first-time with the aim of being the market leaders when it comes to
efficiency improvements and investigating ma- alternative fuel projects in India were implemented by FLSmidth building and supplying HRPs.”
chinery breakdowns. He found himself continually during this time, involving both solid and liquid waste fuel-firing
Cementing
asking, how can we increase productivity? What projects. Proudest moment
was behind the breakdown? How can we fix A career highlight for Avanish was when he gave a presenta-
it? How can we do it better? It was satisfying to Broad experience tion about the FLSmidth Hydraulic Roller Press at the 14th NCB
consider all these questions and to find a solution Avanish was appointed as product line manager for the HRP International Seminar on Cement and Building Materials in
customer
to the problem, which at the end of the day, kept system after five years in his sales role. His experience in 2015. He says:
customers happy. different areas, including commissioning, process design, sales, “A customer, who was close to finalising a closed-circuit ball
In his close to six-year tenure at Aditya engineering, procurement and quality management, meant that mill cement grinding system, heard the presentation and was
connections
Cement, Avanish developed his knowledge and he could bring a broader overview of products to the team. impressed with the advantages of the HRP system. Afterwards,
skill-base in the operations, trouble shooting, and Through collaboration with different divisions comes much we discussed the benefits and how it could reduce the total
optimisation of a cement plant. He became adept scope for learning and improvement. He explains: cost of ownership. In less than a month, the contract for a new
at various processes involved in cement making “We listened to what our customers wanted and are cur- HRP system (semi-finish cement grinding, HRP and ball mill)
such as grinding and clinkerisation. He took his rently transitioning from being project-focused to product- was signed.”
first steps in working with the hydraulic roller focused. I had gained a broad view of customers’ needs and This was just one of the many positive customer experienc-
An inquisitive mind, a customer-oriented press (HRP) system. However, his fascination with where we needed to go. We could see that HRP was requiring es that Avanish has encountered in his role as Global Product
approach and a willingness to continue optimising systems was calling and he turned his some attention and decided to give it more focus. Line Manager of the HRP system. It showcases his ability to
focus towards design. “The HRP systems that are being offered today are much find the most suitable technologies to address the customer’s
his professional development has led more competitive than what they were in the past and we strive critical issues and needs, keeping them happy, which he finds
Avanish Karrahe to the position of Global Enriching learning to keep them ahead of competition. This has resulted from the truly satisfying. ■
Soon after, Avanish joined FLSmidth and became hard work and dedication of the team, an achievement I am
Product Line Manager for HRP systems. a part of the process design and commissioning extremely proud of. It demonstrates the positive results of what
He shares how he ended up working with team. This was a completely different side of the we can achieve when we work together.”
cement industry. He says: It is clear that Avanish is motivated by staying one step
FLSmidth’s customers to fully understand “I wanted to learn how to design a cement ahead of the competition and succeeding in a dynamic market. HANNE FLYGER
their concerns and address their needs. plant and was interested in what other plants were Working closely with customers to find innovative solutions for haf@flsmidth.com
FLSMIDTH’S
KILN CALCULATION In 1967, prior to the invention of the PC, punch cards were
used to input the program with the output printed on paper.
PROGRAM CELEBRATES WHAT IS A KILN

CALCULATION PROGRAM?
■■ It is a software program used by mechanical

engineers to design, inspect and service
rotary kilns
■■ It allows engineers to thoroughly evaluate
the mechanical design of the rotary kiln
■■ It provides the basic input data required
he heart of any cement plant, the rotary “Our program is to produce the advanced 3-D kiln model improved throughout
T kiln, has always demanded a high level the ‘father’ of over automatic development of O&L (Outline the past 50 years to
of expertise. Specifically, this requires 1000 kilns through- and Load) and GA (General Arrangement) meet current needs.
complex mechanical calculations to ensure a out the world and drawings Its theoretical foun-
mechanically sound and reliable kiln that can pro- is also used by our ■■ Before it was invented, engineers had to dation has proven to
duce the highest quality clinker over a long life- customer service perform lengthy manual calculations be robust enough to
time. These calculations consist of thousands of department to handle vastly different
engineering formulas that provide the necessary assess the mechan- rotary kilns.
output for experienced kiln engineers to assess ical condition of Since its inception,
whether all parameters are within acceptable older rotary kilns. the program has been
design limits. If done manually, the process may Our continual investment in the program will ensure continually reviewed by FLSmidth engineers en-
take several weeks, if not more. it remains relevant and ready for future technologi- suring its relevancy with technological advances.
The kiln calculation program began to take cal developments in kilns.” In 1988, Mechanical Engineer Henning Jacobsen
shape in the 1960s, when promising young was made responsible for keeping the kiln pro-
mechanical engineer Knud T Andersen began A lasting theoretical basis gram up to date. He still works with it today:
sketching out ideas for automating many of the Fifty years ago, rotary cement kilns were likely “In 2000, we decided to move the kiln
calculations required when designing or inspect- to have five to seven supports, a diameter of calculation program onto a new platform based
ing a kiln. Recognising that manual calculations between four and six metres, and a production on a Microsoft Excel interface with Visual Basic
were neither efficient or future-focussed, he capacity of no more than 2,000 tonnes per day. calculations. This meant we could make great
discussed his ideas with the manager of the Today, the picture is quite different. As technol- improvements to the user interface, which was
engineering department, Halvor Meedom, and ogy has developed, kilns have become shorter an important step in its development. Apart from
together they developed the first iterations of the with only two or three supports, but with signif- this, however, the fundamental mathematics of the
FLSmidth Kiln Calculation Program. icantly increased production due to preheaters program has not changed over the years.”
In doing so, they created probably the oldest and calciners. The kiln calculation program has Continuous development of the program
engineering computer program in FLSmidth – had to be flexible and robust enough to keep up includes modifying the dimension formulas and
which has now been used for 50 years – and with these developments. adjusting data based on experience and input
has revolutionised the mechanical calculation of The program involves several modules that from kiln engineers in the field. The program is
YEARS
FLSmidth kilns. Today, the program is used to de- derive the loads on the kiln shell and the kiln a valuable tool in designing new kilns, as well as
sign new rotary kilns and mechanically diagnose supports as a static indetermine beam. It can reviewing older kilns and their components, such
and analyse FLSmidth kilns in operation as well as calculate kilns with up to eight supports and cal- as kiln supports and kiln drive station.
those produced by other manufacturers. culates the ovality of the kiln shell and live rings. Henning is now working on a manual that
This is done using: will allow other programmers to continue the
Mechanical foundation ■■ Newton’s rules maintenance of the program to ensure it remains
Prior to the program’s creation, kiln design was a ■■ Clapeyron's equation as a solid mechanical foundation for FLSmidth’s
Since 1967, continuous updates and lengthy and time-consuming project, involving a ■■ Kiln ovality theory kiln engineers for at least another 50 years. ■
improvements have made FLSmidth’s kiln huge amount of manual calculations. FLSmidth’s
Department Manager of Pyro, Keld Hjortshøj, Continual development
calculation program an even more valuable describes the kiln calculation program as the Still following these principles, the kiln calculation KELD HJORTSHØJ
tool for designing and maintaining kilns. mechanical foundation for kiln engineers: program has been continually developed and kelh@flsmidth.com
FLSMIDTH’S
KILN CALCULATION In 1967, prior to the invention of the PC, punch cards were
used to input the program with the output printed on paper.
PROGRAM CELEBRATES WHAT IS A KILN

CALCULATION PROGRAM?
■■ It is a software program used by mechanical

engineers to design, inspect and service
rotary kilns
■■ It allows engineers to thoroughly evaluate
the mechanical design of the rotary kiln
■■ It provides the basic input data required
he heart of any cement plant, the rotary “Our program is to produce the advanced 3-D kiln model improved throughout
T kiln, has always demanded a high level the ‘father’ of over automatic development of O&L (Outline the past 50 years to
of expertise. Specifically, this requires 1000 kilns through- and Load) and GA (General Arrangement) meet current needs.
complex mechanical calculations to ensure a out the world and drawings Its theoretical foun-
mechanically sound and reliable kiln that can pro- is also used by our ■■ Before it was invented, engineers had to dation has proven to
duce the highest quality clinker over a long life- customer service perform lengthy manual calculations be robust enough to
time. These calculations consist of thousands of department to handle vastly different
engineering formulas that provide the necessary assess the mechan- rotary kilns.
output for experienced kiln engineers to assess ical condition of Since its inception,
whether all parameters are within acceptable older rotary kilns. the program has been
design limits. If done manually, the process may Our continual investment in the program will ensure continually reviewed by FLSmidth engineers en-
take several weeks, if not more. it remains relevant and ready for future technologi- suring its relevancy with technological advances.
The kiln calculation program began to take cal developments in kilns.” In 1988, Mechanical Engineer Henning Jacobsen
shape in the 1960s, when promising young was made responsible for keeping the kiln pro-
mechanical engineer Knud T Andersen began A lasting theoretical basis gram up to date. He still works with it today:
sketching out ideas for automating many of the Fifty years ago, rotary cement kilns were likely “In 2000, we decided to move the kiln
calculations required when designing or inspect- to have five to seven supports, a diameter of calculation program onto a new platform based
ing a kiln. Recognising that manual calculations between four and six metres, and a production on a Microsoft Excel interface with Visual Basic
were neither efficient or future-focussed, he capacity of no more than 2,000 tonnes per day. calculations. This meant we could make great
discussed his ideas with the manager of the Today, the picture is quite different. As technol- improvements to the user interface, which was
engineering department, Halvor Meedom, and ogy has developed, kilns have become shorter an important step in its development. Apart from
together they developed the first iterations of the with only two or three supports, but with signif- this, however, the fundamental mathematics of the
FLSmidth Kiln Calculation Program. icantly increased production due to preheaters program has not changed over the years.”
In doing so, they created probably the oldest and calciners. The kiln calculation program has Continuous development of the program
engineering computer program in FLSmidth – had to be flexible and robust enough to keep up includes modifying the dimension formulas and
which has now been used for 50 years – and with these developments. adjusting data based on experience and input
has revolutionised the mechanical calculation of The program involves several modules that from kiln engineers in the field. The program is
YEARS
FLSmidth kilns. Today, the program is used to de- derive the loads on the kiln shell and the kiln a valuable tool in designing new kilns, as well as
sign new rotary kilns and mechanically diagnose supports as a static indetermine beam. It can reviewing older kilns and their components, such
and analyse FLSmidth kilns in operation as well as calculate kilns with up to eight supports and cal- as kiln supports and kiln drive station.
those produced by other manufacturers. culates the ovality of the kiln shell and live rings. Henning is now working on a manual that
This is done using: will allow other programmers to continue the
Mechanical foundation ■■ Newton’s rules maintenance of the program to ensure it remains
Prior to the program’s creation, kiln design was a ■■ Clapeyron's equation as a solid mechanical foundation for FLSmidth’s
Since 1967, continuous updates and lengthy and time-consuming project, involving a ■■ Kiln ovality theory kiln engineers for at least another 50 years. ■
improvements have made FLSmidth’s kiln huge amount of manual calculations. FLSmidth’s
Department Manager of Pyro, Keld Hjortshøj, Continual development
calculation program an even more valuable describes the kiln calculation program as the Still following these principles, the kiln calculation KELD HJORTSHØJ
tool for designing and maintaining kilns. mechanical foundation for kiln engineers: program has been continually developed and kelh@flsmidth.com
SALT INSPIRED
If bike lanes and roads can be better navigated when salt is

evenly distributed, why couldn’t cement cyclone processing?
Driving along an icy road in the dead of winter can be a pretty

harrowing experience. Of course, it helps if state agencies
responsible for road safety lay down a nice, even layer of road
salt. Salt, a natural counter-force to snowy, slushy roads, when
applied correctly, gets us all home safer and a bit more at ease.
One snowy winter evening, three FLSmidth engineers had been

grappling with heat exchange and meal distribution issues in traditional
cement cyclones, particularly the challenge of getting raw meal to
distribute evenly throughout the cyclone. One of them noticed an
even layer of salt being spread on the road on his way home. Could
the same type of ingenuity be applied to a cement cyclone?
Suppose we could develop and implement some sort of

carrier technology that could evenly distribute raw meal?
Voila! The new raw meal spreader in the Counter

Current Cyclone (CCX) was born.
Being stuck behind a salt spreader may not be the most

desirable place to be, but for these engineers, it did
provide a much-needed boost of inspiration.
WE DISCOVER POTENTIAL

Flsmidth Discover Cement

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Grey/white Emissions reporting: Breakthrough in Unique

production: an reducing carbon cyclone financing

Editorial Innovation New orders Products and solutions

Urbanisation drives the system for measuring carbon dioxide emissions.

Indian cement market

Site reports Features

STRONG EPC PARTNERSHIP DRIVES

Editorial Innovation New orders Products and solutions

Urbanisation drives the system for measuring carbon dioxide emissions.

Indian cement market

Site reports Features

STRONG EPC PARTNERSHIP DRIVES

The design power of

The challenge with the

The design power of

The challenge with the

Leading the way as the next generation of top-stage

ith cement production in Ukraine 1.8. Mykola Makoviichuk, Production Director at

Leading the way as the next generation of top-stage

ith cement production in Ukraine 1.8. Mykola Makoviichuk, Production Director at

5 INDIA 11 NEPAL 13 NEPAL 15 NIGERIA 17 PAKISTAN 19 SAUDI ARABIA

6 INDIA 12 NEPAL 14 NEPAL 16 PAKISTAN 18 SAUDI ARABIA 20 URUGUAY

5 INDIA 11 NEPAL 13 NEPAL 15 NIGERIA 17 PAKISTAN 19 SAUDI ARABIA

6 INDIA 12 NEPAL 14 NEPAL 16 PAKISTAN 18 SAUDI ARABIA 20 URUGUAY

reforms including rural development, coal mining, tax reforms

reforms including rural development, coal mining, tax reforms

33% NEW DELHI

33% NEW DELHI

The unique design

Making gains with

The unique design

Making gains with

bility even with some rollers out of service

The OK™ mill in use

bility thanks to the OK mill’s ability to produce multiple types of

Premier cement mills Ltd. Ambe Cements Orient Cement Ltd.

specific power consumption. Mil capacity (tph) 250 268

bility even with some rollers out of service

The OK™ mill in use

bility thanks to the OK mill’s ability to produce multiple types of

Premier cement mills Ltd. Ambe Cements Orient Cement Ltd.

specific power consumption. Mil capacity (tph) 250 268

Strong EPC partnership

Strong EPC partnership

Performance at Orient Cement

Guaranteed capacity TPH 250 266

Product fineness (Wet sieve residue on 90µ) % 12 12

Hydraulic roller presses

■■ Raw material grindability: 12kWh/t at VRM shaft

he limestone-rich belt of Karnataka in Head of Projects at Orient Cement Shyam Asawa

Performance at Orient Cement

Guaranteed capacity TPH 250 266

Product fineness (Wet sieve residue on 90µ) % 12 12

Hydraulic roller presses

■■ Raw material grindability: 12kWh/t at VRM shaft

he limestone-rich belt of Karnataka in Head of Projects at Orient Cement Shyam Asawa

The HRP is suitable

■■ Solid forged rollers (No hollow shaft)

Raw meal to silo

Reject WHEN TO CONSIDER AN HRP SYSTEM

■■ In regions with a high price per kW/hr

good condition. No repair work has been required

The HRP is suitable

■■ Solid forged rollers (No hollow shaft)

■■ Raw material grindability: 12kWh/t at VRM shaft

■■ Raw material grindability: 12kWh/t at VRM shaft