Professional Documents
Culture Documents
WorldCement November 2015
WorldCement November 2015
November 2015
November 2015
www.worldcement.com
CONTENTS
NOVEMBER
26
39
05 Comment
09 News
19 Keynote: Milling in the Early British Cement
Industry
Edwin Trout, The Concrete Society, UK, details the history
and development of the early cement industry in Britain.
138 Product News
144 Regional Report Infographic
52 A Complete Solution
Eric Hartmann, HAVER & BOECKER, Germany, outlines the
turnkey project carried out for Cimfaso.
November 2015
November 2015
Long-term satisfied customers are our driving force and the aim of the
work we do every day. More than 3000 customers that we have worked in
partnership with over the years can confirm this. Whether public facilities,
medium-sized companies or large concerns: with the most modern of
technologies our experts help to make your processes more efficient when it
comes to technology, organisation and administration.
www.worldcement.com
18.10.14 18:36
ISSN 02636050
Email: [email protected]
Website: www.worldcement.com
November 2015
CONTENTS
75 Hot Gas Filtration
Pierre Henri Thifaine, Kermel, France, discusses the use of a
new fibre able to withstand high temperatures.
NOVEMBER
45
65
BURNERS, PREHEATERS,
PRECALCINERS, KILNS
111 Enhancing the Performance of Kiln Burners
Renata Favalli, Luis Filipe Fabiani & Luiz Felipe de Pinho,
Dynamis, Brazil, relate the findings of an investigation into
the performance of kiln burner heads.
119 Low-Cost Plant Upgrade Solutions
Tahir Abbas, Cinar Ltd., UK, & Josef Keuschnigg Jun.,
PM-Technologies GmbH, Austria, present case studies of
upgrade solutions.
ANALYTICS
71
91
/ 71
70-74_WCT_November_2015.indd 71
22/10/2015 14:49
HEKO components
www.heko.com
COMMENT
NOVEMBER
CONTACT DETAILS
SUBSCRIPTIONS
Production
Reprints
MISSION COMPLETED!
To further strengthen the vertical roller mills with a
higher dependability of the mills drives, our clients
clearly expressed these requirements:
no bevel gear
more redundancy
more simplicity
maximum maintainability under the mill
short commissioning
advanced spare part policy
to make the story short: lower TCO
We listened to these requirements and in cooperation
with RENK AG turned them into a new development.
The innovative COPE gearbox developed by RENK AG
features a redundancy of 8 motors. COPE drives
provide up to 13 MW using 8 identical maintenance
free induction motors. The customer advantage lies
in the fact that the COPE gearbox can reach up to
100% of the mill capacity performance even with a
reduced number of motors. COPE drives will increase
the availability of the mill drive by approx. 2,5 %. The
COPE gearbox has the same external dimensions as a
conventional planetary gear system and thus requires
no extensive enlargement of the mill foundations.
www.renk.eu
HAVE A LOOK!
THE NEW
www.loesche.com
PLUG
GRIND
by Ceme n gal
P&G Kenya
THE ONE
ONLY
www.cemengal.com
www.plugandgrind.com
WORLD NEWS
NOVEMBER
NEWS HIGHLIGHTS
November 2015
World Cement
/9
EVENTS
10 12 November 2015
01 04 December 2015
Cairo, Egypt
www.bauma.de
12 14 May 2016
Cementtech
15 19 May 2016
www.aucbm.org
19 21 April 2016
POWTECH
Nrnberg, Germany
www.powtech.de
10 \
November 2015
World Cement
11 17 April 2016
Bauma
Munich, Germany
BRUKER
The First Choice in Cement
S2 PUMA
Benchtop EDXRF
S8 TIGER
Sequential WDXRF
S8 LION
Simultaneous WDXRF
D8 ENDEAVOR
XRD Phase Analysis
XRF/XRD
IN BRIEF
On 19 September,
BuzziUnicems Robilante
plant celebrated its 50th
anniversary with a day of
celebrations for all those who
work or have worked for
and with the company. The
day, which commemorated
both Buzzi Unicem and its
predecessor PRESA Cements,
was attended by more than
670 current and former
employees and family
members, along with the
Mayor of Robilante.
12 \
November 2015
World Cement
4B Components Ltd.
announced that Randy
Longbrake has been
appointed as its National
Sales Manager for the
materials handling division.
With a wealth of industry
experience, he will enable
4B to continue to develop
innovative solutions for its
customers, thereby continuing
its success at providing
material handling products to
many of the top companies in
North America.
14 \
November 2015
World Cement
siemens.com/sps15
Integrated Drive
Systems:
Theres more to it!
siemens.com/ids
CEMENTABILITY
SICEMENT Reliability that enables you to reach the top
siemens.com/cement
Investing in training of
the local workforce has
no significant impact on
the bottom line
Wrong: At FLSmidth we not only design, build and operate cement plants
we also build a competent and reliable local workforce through training.
The results? A record-low employee turn-over rate of only 1,5%* helping to
ensure a utilisation rate of 83%* vs. the industry average of only 73%*. The
resulting high revenue proves that building people and communities also is
good, sustainable business.
*Source: Impact Assesment Study, Deloitte & Qbiz 2015
A-C Equipment Services 6737 W. Washington St., Suite 1400 Milwaukee, WI 53214
414.475.2554 Fax: 414.475.3328
www.a-cequipment.com
KEYNOTE
NOVEMBER
Introduction
For decades the ball mill has dominated the grinding
processes in cement production, although more recently
the vertical roller mill has gained popularity. The tonnages
involved in the modern industry require processing plants
on a substantial scale and huge inputs of electrical energy
to power them this hasnt always been so. In the early
days of cement production, the industrial enterprises
concerned were small in scale, and harnessed the existing
technology of corn milling, in much the same way as they
adapted the crushing methods used for the preparation
of clay and whiting, and the furnaces and bottle kilns used
for producing glass and lime. The early mills were based
November 2015
World Cement
/ 19
20 \
November 2015
World Cement
SI N C E 1 9 64
OV E R 1 6 ,000 IN S TAL L E D
OVE R 90 CO U NTRI E S
www.cstcovers.com
CST Covers | 498 N Loop 336 E | Conroe, TX 77301 USA | p: 936-539-1747 | f: 936-539-5355
2012 CST Industries, Inc.
22 \
November 2015
World Cement
no longer exist, the kiln is still standing, and the wheel pit
remains.
Another cement plant known to have harnessed
waterpower in the Roman cement era is the
Good Intent Mill at Isleworth. The Good Intent Society,
established in 1801, was one of several cooperative
societies set up to grind corn cheaply for members own
use. In order to build a mill, the Society bought land for
300 and cleared the Thames riverfront. The co-op was
wound up some time after 1826 and the site became a
cement plant owned by William Ashby of Staines. His
business, William Ashby & Son, was originally a river
haulage company specialising in building materials, but
very soon moved into cement manufacture. The raw
materials were dredged offshore at Brightlingsea and
bought up river to Isleworth where the mill was still
standing in 1888.
Water mills were also turned over to cement grinding
at Stoke on Trent and Ysceifiog, Flintshire in the first half
of the nineteenth century, but perhaps the best attested is
Lode Mill, on the Anglesey Abbey estate near Cambridge.
Here a Georgian corn mill was acquired by the Bottisham
Lode Cement & Brick Co in 1896, with four cement kilns
erected alongside and a low-grade clinker was produced
from the local marl. It was ground between five sets
of horizontally mounted millstones. Operations were
suspended when the market collapsed in 1903, but were
revived in 1908 with the addition of two further kilns.
Production ceased in 1920 and after Anglesey Abbeys
acquisition by the National Trust, the mill was restored to
its earlier state and the associated kilns demolished.4
Windmills
Windmills, perhaps, represent the least expected form of
cement mill from our present perspective, where surviving
examples are now deemed an almost picturesque feature
of the landscape. An early example is the translocated post
mill set up by John Pattrick on the cliff tops at Dovercourt,
Harwich in 1821, where he ground cement stones from the
beach. The works continued until 1906, but by then had
long been steam powered.
Another early example is the Victoria Road Mill,
Woodbridge, where William Lockwood made Roman and
then Portland cement. Originally builders, and agents for
Parker & Wyatt, Lockwoods company turned to cement
manufacture in 1821. Having started with a horse mill,
equipped with stones from Mountsorrel, Leicestershire,
Lockwood had a windmill built in 1825. It comprised a
tower mill, with patent sails and a fantail, was fitted out
with granite edge-runners from Aberdeen, and is assumed
to have used river-dredged material from the Deben.
Unfortunately the mill lost three sails in a storm during
1841, with further damage two years later: On Saturday
morning about two oclock the sails of Mr Lockwoods
cement mill were struck by lightning, shivering a 6ft length
of timber from the sails.5 Gale damage probably caused it
to cease wind-powered operations from that date.
Best known of the cement industrys windmills is
High Mill at Berney Arms in Norfolk. A mill has stood on
Tough challenges
need flexible drives
SEW-EURODRIVE offers heavy-duty drive solutions specially designed for the cement industry. Our solutions are optimized for long-life applications such as bucket wheel drives, ball mills, roller presses and conveying systems. Working
with SEW-EURODRIVE allows for unique product flexibility as well as successful project handling.
www.sew-eurodrive.com
24 \
November 2015
World Cement
UNIQUE
BURNING
EFFICIENCY
Unitherm CemCon is one of the leading manufacturers of burners and burning systems for industrial
applications and is a worldwide supplier for the cement, lime and mineral industry. With more than
65 years experience UNIthERm can provide a wide range of highly advanced tailormade firing systems
designed and manufactured in Austria.
m.A.S. Kiln Burner | Calciner Burner | hot Gas Generator | Fuel Supply System
EMCON
www.unitherm.at
Plant Tour:
HANSON
KETTON
PLANT
26 \
Introduction
As visitors wind their way through the scenic Rutland countryside, Hansons
Ketton Cement Plant strikes an imposing figure on the horizon. Drawing
closer, a real sense of energy and drive surrounds the plant, demonstrated
by the constant stream of Hanson trucks entering and leaving the works.
Driving through the entrance, visitors are met with the busy enthusiasm of a
plant tasked with providing nearly 10% of the UKs cement demand.
The Ketton plant started operations in 1928, beginning life with just one
kiln. Four kilns were constructed in the 1920s followed by an additional two
in the 1960s. The seventh was installed in the 1970s, marking the plants
switch to dry process kilns. Kiln 8 was designed and built in the 1980s, and
once operational, signalled the closure of Kilns 1 4. In 1987 Kilns 5 and 6
were also closed, leaving the Ketton site with two dry process kilns.
Today only Kiln 8 is operational at the Ketton Cement Plant after Kiln 7
was mothballed in September 2008. The plant boasts a cement production
capacity of 0.9 million tpy, stored within 16 towering silos, three of which
service London, six for bulk road transfer and seven for the packaged
product. A quarter of the product shipped to London is by rail, another
quarter in paper and plastic bags, with the remaining half travelling south
by bulk tanker.
Ian Evans, Technical Development Manager South, added that the
neighbouring Ketton quarry crushes around 1.3 million t of limestone a
year to feed the plant. The facility provides direct employment to around
220 people and has become increasingly prominent as a standard-bearer for
sustainability and safety.
Plant process
The Ketton quarry is located adjacent to the plant, is over a mile wide and
contains reserves of up to 20 years. Parts of the worked-out areas have been
designated as Sites of Special Scientific Interest (SSSI). The rocks on site have
been found to contain ammonites, brachiopods, bivalves, and fish remains.
The Lincoln Limestone Formation is exposed in the lower quarry, while the
top of this formation forms the floor of the upper quarry. The upper quarry
is in the Rutland Formation. At the very top of the exposures is the base of
The groundwater
recirculation system.
/ 27
28 \
November 2015
World Cement
VERSATILE SIZING
SOLUTIONS
MMD has been involved in sizing and handling of the disparate
raw materials used in cement production for over 30 years.
The Sizers breaking action is a reliable choice for energy
efficient sizing of sticky and hard material, either separately
or combined. The churning action of its twin shafts make it
ideal for blending material and centralizing it on the take-away
conveyor. Its compact profile, low weight and the generation
of minimal external loads enable it to be easily retro fitted in to
existing plants and eminently suitable for mobile units.
Our worldwide support structure, technical expertise and
service excellence will ensure your system always delivers
optimum performance and efficiency.
30 \
November 2015
World Cement
Environmental impact
Hansons Ketton Cement plant clearly takes its
environmental impact seriously. One area that the
plant is focusing its attention on is fuel consumption.
Ketton utilises a variety of different fuels including
biofuel. Waste and biomass account for over 70%
of the fuel burnt in Hansons three cement plants.
The company also has a 2020 target to reduce CO2
emissions by 10% and to have 35% of its fuel usage
made up of biofuel.
Another means by which the company is reducing
its carbon footprint is through an award-winning solar
farm. The renewable energy farm, which has been built
on restored quarry land close to the plant, contains
Conclusion
The enthusiasm and energy that meets visitors
upon entry to the Ketton Cement Plant extends to
its employees. It is clear that the Hanson staff at
the plant care about the quality of the project and
the developments that the plant is undergoing.
The truck drivers, technicians, kiln operators
and management share a goal to produce a
product recognisable for its quality. This can be
demonstrated with the recent supply of Ketton
cement as the preferred choice for sprayed concrete
to the Crossrail project. The drive surrounding the
plant is evidenced by the attention to all aspects of
health and safety, coupled with a determination to
push forward with innovative new ideas and turn
them in to reality.
Hansons Ketton Cement Plant still shows
the evidence of past projects and developments.
Walking through the plant it is possible to clearly
see how the place has grown and changed as
technology has advanced. With the addition of
the solar farm, the plant begins to represent a
movement from old to new, as Hanson endeavours
to move with the times and constantly seeks to
adapt its approach.
19/02/14
19:36
Bag Vacuumisers
Palletisers
Stretchhooders
CM
MY
CY
CMY
ARODO designs and develops bagging machines for cement in fully deaerated
plastic bags that dont feature perforations of any kind. This brings along a great
deal of advantages compared to conventional paper packing:
Environmental friendly solution, less wastage
Water and weather resistant, unprotected open air storage
Substantial longer life expectancy
Clean storage: no leaks
Dust and spillage free
Capacity on demand
Lower packaging costs
Better printing possibilities on plastic bags
ARODO BVBA
Tel. +32 14 67 23 32
[email protected]
www.arodo.com
NOVEMBER ISSUE