1. business and industrial
2. construction

WORLD CEMENT
March 2015
March 2015
www.worldcement.com
Following our very successful Loesche Symposium in 2014, we are glad to introduce
a new series of Loesche Seminars for which we will invite a group of experts to look
into one specific subject. Our first Loesche Seminar will focus on “Alternative Fuels”
and will take place on 7th - 8th May 2015 at the Hilton Danube Hotel in Vienna.
Seminar Day 1 – 7th May:
Seminar Day 2 – 8th May:
• Step by step approach – alternative fuels
• Oil sinks below 50 US$/Barrel, Holcim – Lafarge Merger; What will be the future of alternative fuels? Trends in alternative fuels for the
cement & lime industry
• Experiences with ReduDust
• Process optimization for the cement industry
with technology from aixergee
• Filter technology - latest trends
• A TEC‘s solution for NOX reduction below
200 mg/Nm³
• Plant visit Rohožnik
• Ultimate cement kiln process technologies
• A TEC GRECO‘s new main burner for 100 %
alternative fuels – introduction and first results
• Processing alternative fuels in a Rocket Mill:
first operating experiences
• Mercury emission reduction in cement plants
• Plant visit Wietersdorf
Please be aware that the number of participants to the seminar is limited. Make
sure to register early to learn more about the trends in alternative fuels. Kindly
take advantage of the early bird reservation for participation.
Early bird registration up to 15th March, 2015: 775 EUR excl. VAT
Registration as of 16th March, 2015: 950 EUR excl. VAT
Hotel rooms will be available at a special rate at the Hilton Danube Hotel.
LOESCHE GmbH
Hansaallee 243
40549 Düsseldorf, Germany
www.loesche.com
Contact Mrs. Kathrin Repa-Lengauer via E-Mail:
[email protected]
STEP BY
STEP TOWARDS
ALTERNATIVE FUELS
Cimprogetti Srl - A. Grellier - 02.2015
Cim-RD
Vanguard ®
«State of the art»
of the new TSR kiln
Radial Crossover technology
from 500 to 700 tpd
A bespoke design
that will provide you with:
Larger production capacity
Compact design
Shorter inversion time
Foregone CAPEX by reduced
Steel and Refractory quantities
A wide range of fuels from
traditional to alternative
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Cimprogetti Srl | Via Pasubio, 5 | 24044 Dalmine (Italy) | ph.+39 035 4550 111 | fax +39 035 4550 335 | email: [email protected]
CONTENTS
MARCH
WORLD CEMENT REGULARS
CRUSHERS, GEARS, DRIVES & MOTORS
05 Comment
55 Product and Project News
Featuring Volvo, Siemens, ABB and Sandvik Construction.
09 News
17 Keynote: Financing a Greener Future
Michel Folliet, Chief Industry Specialist for the Building
Materials Sector, International Finance Corporation.
112 Regional Report Infographic
REGIONAL REPORT: SOUTHEAST ASIA
22 ESP Conversion Projects in Thailand
Rasmus Ellefsen, General Manager, Southeast Asia &
Pacific, FLSmidth Airtech – Air Pollution Control.
FILTERS, DEDUSTING, BAGHOUSES & ESPS
59 A Model Solution
Matteo Giavazzi, Boldrocchi s.r.l., Italy.
71 Secrets to Compliance
Andy Winston, BWF Envirotec, USA.
75 Clever Cleaning
Roberto Binago, CTP Team S.r.l., Italy.
81 Stepping Towards Efficiency
Gerry Kaelin, FilterSense, USA.
29 Enhancing ESP Efficiency in Southeast Asia
Thompson Tsai, Tina Antig, Elisa Melati Putri,
Willy Stevanus and Poh Hong Liew, Tai & Chyun
Associates Industries, Inc., Taiwan.
87 First-Class Filters
Paul Rzepka, Midwesco/TDC Filter, USA.
90 Product News
Testori, Italy.
DOMES, SILOS, STACKING &
RECLAIMING
LOGISTICS & AUTOMATION
34 Smart Storage Solutions
Melanie Saxton, Geometrica, Inc., USA.
91 Lightening The Load of Logistics
Jeff Stobbart, National Logistics Manager UK, Aggregate
Industries.
41 Meeting Material Challenges
Michael A. Lacognato, Laidig Systems, Inc., USA.
95 Fleets, Logistics & Automation Update
Featuring Trimble, Lafarge Tarmac, Babcock International,
Cemex UK, Hope Construction Materials and
Savannah Cement.
LIME
44 The Age of the Industrial Internet
Dr Carlo Cella, QualiCal International, Italy.
50 Lime Industry Update
World Cement takes a look at the latest news from the
lime industry.
THERMAL IMAGING
99 Scanning For Savings
Gildas Chauvel, HGH Infrared Systems, France.
103 Optimised Optical Analysis
Frank Steffens, DURAG process & system technology GmbH,
Germany.
WORLD CEMENT
GENERAL INTEREST
March 2015
107 AFT: Determination & Prediction
S. Roy, S. Srivastava and L. Rajasekar, Technical Research
Centre, UltraTech Cement Ltd, India.
March 2015
THIS MONTH’S COVER
HEKO Ketten GmbH, Germany, is head of a group of companies supplying
wear parts like chains, and also complete conveyors to the cement
industry. Founded in 1917, HEKO has a lot of experience in all kinds of
chains for bucket elevators and chain conveyors. With offices in China and
India and deliveries in more than 90 countries, HEKO is very close to the
customer and their demands.
www.worldcement.com
OFC_WCT_March-2015.indd 1
24/02/2015 12:59
Palladian Publications Ltd
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Volume 46: Number 3
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Email: www.worldcement.com
Website: www.worldcement.com
March 2015
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COMMENT
MARCH
Katherine Guenioui, Editor
[email protected]
The proposed merger of
Holcim and Lafarge was
the biggest news story in
the cement industry last
year. After the initial shock
was over, talk immediately
turned to who would get
what when the necessary
assets were divested to get
the merger past regulators.
In recent weeks, that
question has been answered,
with the announcement
that Irish building materials
company CRH has agreed a e6.5 billion acquisition
deal. This deal – thought to be the largest ever
acquisition by an Irish company – would make CRH
the world’s third largest building materials supplier.
That’s quite a leap from its previous position way
outside the top ten.
Driving this huge acquisition is CEO
Albert Manifold, who reportedly told journalists
that the deal was just ‘too good to turn down’.
Manifold took over as CEO in January 2014 and soon
announced a multi-year divestment programme that
proposed e1.5 – 2 billion in divestments. The idea was
not only to trim costs, but also to refine the group’s
focus and so alongside divestments amounting
to e0.35 billion in 2014, the group also spent
e0.19 billion on acquisitions. In this latest deal, the
majority of the assets – some two-thirds – are within
Europe, where CRH already has a leading presence.
The new units will fit well within CRH’s existing
portfolio (and according to media speculation,
those that don’t – or that would cause competition
complications – will be offloaded to private equity
house KKR). CRH will also be able to extend its reach
in Asia, where it currently has operations in India and
China, and enter South America.
The response to the deal announcement was
mixed. Shares rose, so clearly investors were pleased,
but some analysts voiced their concern that the
firm had overpaid, pointing out that the majority
of the assets are in Europe, where cement demand
is suffering from a depressed construction industry.
However, recently released figures from the European
Commission give us some basis for optimism. The
figures state that average production in construction
in 2014 increased by 2% in the euro area and
by 3% in the EU28. Unfortunately, the positive
performance was by no means universal; CRH will
be acquiring assets in both ‘winning’ and ‘losing’
markets. For example, it will acquire Lafarge’s assets
in Romania, which saw a 15% increase in production
in construction in 2014, and in the UK, which saw a
4.7% increase. On the flip side, CRH is also acquiring
assets in France, which saw a 7.5% decrease, Germany
(down 4.7%) and Slovakia (down 9.8%). We will have
to wait and see what 2015 brings. Could lower oil
prices free up funds for much-needed infrastructure
projects?
Construction statistics aren’t generally featured
in World Cement, but it is an area we cover on our
website, www.worldcement.com. Join us there and
on Twitter, Facebook and LinkedIn for the latest news
and industry trends.
CONTACT DETAILS
SUBSCRIPTIONS
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Website Editor: Callum O’Reilly
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Editor: Katherine Guenioui
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Assistant Editor: Louise Fordham
Digital Editorial Assistant: Joseph Green
[email protected]
[email protected]
Contributing Editor: Paul Maxwell-Cook
Circulation Manager: Victoria McConnell
Production: Sophie Awcock
[email protected]
[email protected]
Subscriptions: Laura Cowell
Advertisement Director: Rod Hardy
[email protected]
[email protected]
Office Administrator: Jo Repton
Advertisement Manager: Ian Lewis
[email protected]
[email protected]
Reprints
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WORLD NEWS
Worldwide Holcim and Lafarge
enter into exclusive negotiations
with CRH
Lafarge and Holcim have entered into exclusive
negotiations with CRH regarding the sale of assets,
which are being divested to facilitate the proposed
LafargeHolcim merger. The announcement follows a
binding commitment made by CRH.
With an enterprise value of e6.5 billion, the assets
involved in the negotiations with CRH generated an
estimated e5.2 billion in sales in 2014, and an estimated
operating EBITDA of e744 million.
The divestments will be submitted to CRH’s
shareholders and the relevant competition authorities.
They are subject to the completion of the merger,
including a successful public exchange offering and
approval by Holcim’s shareholders in 2Q15. Lafarge and
Holcim have confirmed that the divestment process will
be conducted within the framework of all relevant social
processes and the ongoing dialogue with employee
representative bodies.
MARCH
Mexico Cemex creates new
energy division
Cemex has announced the creation of a new energy division,
Cemex Energia. The division will develop a portfolio of
power projects in Mexico, with the aim of meeting around
3 – 5% of the country’s electricity needs over the next
5 years.
Cemex Energia has formed a joint venture with Pattern
Development, a subsidiary of Riverstone, which will provide
its development expertise in order to create a pipeline
of renewable energy projects, in addition to sharing the
development costs.
Cemex Energia will have the option of taking minority
equity stakes in the projects developed by this joint venture.
Cemex will not consolidate any projects from the joint
venture and any debt incurred to fund these projects will
have no recourse to Cemex. The building materials producer
has said that it expects to contribute some US$30 million into
its new energy division over the coming 5 years.
Cemex Energia will be led by Luis Farias, previously
Vice President of Energy at Cemex.
USA FLSmidth and Haldor Topsoe announce catalytic filter bag
partnership
FLSmidth A/S and Haldor Topsoe A/S have signed a
cooperation agreement that will see them launch
a global effort to commercialise a newly developed
catalytic filter bag technology.
The two companies have been working together
for the last 4 years to develop the new EnviroTex™
catalytic filter bags. The patent-pending technology
includes a three-layer filter fabric design. Each of
these layers contains a tailored catalyst optimised for
the removal of specific types of compounds from the
off-gas that passes through it. The catalytic filter bags
can be used in a range of industries, including cement,
power, biomass, waste incineration, glass and metal
production.
The new product will be manufactured at
FLSmidth’s bag production facilities in Georgia, USA.
They will then be catalysed and assembled at Topsoe’s
catalyst production facility in Houston, Texas. A
new production line dedicated to the EnviroTex™
catalytic filter bags will be established at Topsoe’s site.
Construction is expected to be completed by the end
of 2015.
NEWS HIGHLIGHTS
•
Holcim reports rise in cement sales volumes and
net income in FY14
•
Ports of Auckland prepares for increase in
cement imports
•
Construction Trade Survey indicates increase in
activity but highlights skills concerns
To read more about these
articles go to:
March 2015
World Cement
/9
Brazil Aumund opens new Service Centre in Ipatinga
Aumund Brazil has expanded its After Sales Service
Department with the establishment of a new Service
Centre and integrated warehouse in Ipatinga,
Minas Gerais. This is Aumund’s fourth Service Centre
worldwide, having already opened warehouses in
Rheinberg – Germany, Atlanta – USA, and Hong Kong.
The new facility will offer a range of services to the
cement, mining and minerals industry both in Brazil
and elsewhere in South America. The Service Centre
will provide maintenance services, such as inspections,
conversions and field service activities, in order to
guarantee the availability and operation of customers’
equipment. In addition to stocking spare parts,
manufacturing pan conveyors and assembling chains,
the facility in Brazil will service and repair components
and equipments from across the Aumund Group,
including SCHADE Lagertechnik GmbH and SAMSON
Materials Handling Ltd.
Brazil Votorantim selects Bedeschi for limestone storage project
Bedeschi has been chosen to carry out a limestone
storage project for Votorantim Cimentos in
Curimba. Bedeschi’s scope of supply includes
a storage system with two STKP type stacking
bridges (Tripper TRP 16/1400) and a BEL C type
reclaimer with a stacking capacity of 700 tph and
a reclaiming capacity of 100 – 500 tph. In addition,
Bedeschi will provide a crushing group with an
apron feeder (CAN 10/2200 B), a primary and a
secondary toothed roller crusher (RL 650/2200).
Commissioning is due to take place by the end of
2015.
Turkey Another Siwertell mobile unloader for Medcem Global
Medcem Global Pazarlama AS has ordered a roadmobile unloader from Siwertell, the third such order
within an 18-month period. As with the previous two
orders, Siwertell will provide a 10 000 S, trailer-based,
diesel-powered mobile unloader. This will discharge
cement at a rated capacity of 300 tph and will comprise
a dust filter and double bellows system to ensure
uninterrupted loading of trucks and rail wagons.
“We are planning and processing cement terminal
projects in various countries; therefore, to get maximum
benefit, we have to be very careful when choosing
project equipment,” explains Mr Koray Kandemir,
Director of Projects for Medcem Global. “Siwertell
mobile unloaders provide the ability to operate in
different ports, which is an important condition for
our business. Factors including the efficient unloading
capacity, low maintenance costs and technically
well-designed system influenced our decision to buy a
third screw-conveyor mobile unloader.”
EVENTS
21 – 24 April 2015
26 – 30 April 2015
27 – 29 April 2015
24th AFCM Technology
Symposium & Exhibition
IEEE-IAS/PCA Conference
Cementtech 2015
Toronto, Canada
Beijing, China
Hanoi, Vietnam
www.cementconference.org
www.cementtech.com
3 – 7 May 2015
10 – 12 June 2015
15 – 18 September 2015
37th International Cement
Microscopy Association Conference
WCSB7
UNITECR 2015
Bordeaux, France
Vienna, Austria
www.wcsb7.com
www.unitecr2015.org
[email protected]
Seattle, USA
www.cemmicro.org
10 \
March 2015
World Cement
UAE Nordic Air Filtration inaugurates new production plant
Nordic Air Filtration has expanded its
presence in the Middle East with the
official opening of its new plant in
Fujairah, UAE, on 13 January 2015. At
the 1500 m2 production facility, Nordic
Air Filtration Middle East Limited FZC
will primarily manufacture intake filter
cartridges, helping to meet growing
demand across a range of industries in the
region.
Over the past year, Nordic Air Filtration
has been installing and testing equipment
at the new facility under the supervision of
an engineering team from its headquarters
in Denmark. Employees at the Fujairah plant
have undergone training at the company’s
plant in Nakskov, Denmark, and they will
continue to receive support from Nordic Air
Filtration’s headquarters to align product
quality in Denmark and the Middle East.
UK Commissioning underway at SRF facility
Commissioning has begun at SITA UK’s new solid
recovered fuel (SRF) manufacturing facility at
Malpass Farm in Rugby. Following a series of
commissioning tests over the coming months, the
facility will commence full-scale production of
Climafuel. This will be used to power the kiln at
Cemex UK’s Rugby cement plant.
The facility will receive residual waste collected
from commercial and industrial businesses in the
region, which would otherwise end up as landfill.
Metals, plastics, paper and any materials with
a high chlorine content are then extracted for
recycling. Residual waste material that is removed
from the facility’s production process will be turned
into RDF. The material that remains in the process
will be sifted, shredded and blended. Infrared
technology will be utilised to continuously analyse
the SRF and ensure that it meets the calorific value
and chemical composition required by Cemex.
SITA UK has hired 20 permanent members
of staff to operate Malpass Farm on a single
shift throughout the commissioning process. On
completion of commissioning, the company expects
to employ a further 20 people to run a second shift.
The new facility will receive some 20 deliveries of
waste material per day during the commissioning
phase and about 50 – 60 deliveries/day thereafter.
Commissioning is expected to be completed in July.
India Expansion plans at Wonder Cement
Wonder Cement Ltd, part of the RK Marble Group is
investing Rs.1600 crore in the expansion of its plant in
RK Nagar, District Chittorgarh. The company plans to
ramp up the plant’s capacity from 3.25 million tpy to
6.75 million tpy by the fourth quarter of 2015.
Wonder Cement is also installing a waste heat
recovery system, and has invested in a thermal
12 \
March 2015
World Cement
power plant and its own railway line to increase its
independence.
The plant’s strategic location in Rajasthan enables it
to serve India’s northern markets, and Wonder Cement
has been working to strengthen its dealer network
in key markets such as Gujarat, Madhya Pradesh,
Uttar Pradesh, Haryana and Delhi.
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Bags of cement and other dry building materials are often exposed to weather on construction
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spoil. Mondi has the solution to this problem: Advantage Protect, a new grade in the sack
kraft paper range. Industrial bags based on Advantage Protect can be eight times more waterresistant than standard bags. This new paper grade offers both a water-repellent surface and
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South Africa Wind farm under commissioning at PPC’s Grassridge
Quarry
EDF Energies Nouvelles has announced the
commissioning of its first wind farm in South Africa,
which is located at PPC Cement’s Grassridge Quarry in
Port Elizabeth. Commissioning is being carried out by
EDF EN’s local subsidiary, InnoWind.
The Grassridge Wind Energy Facility includes
20 Vestas V-112 3 MW wind turbines, which have a total
capacity of 61.5 MW. This is equivalent to the annual
electricity consumption of around 40 000 households.
The wind farm was developed as part of the
Renewable Energy Independent Power Producer
Procurement Programme of South Africa, the aim of
which is 3725 MW renewable energy capacity by 2016.
The Grassridge project is the first of three schemes that
EDF EN won in a competitive tender in 2012.
“We would like to congratulate EDF EN on the
commissioning of the wind farm,” commented Egmont
Ottermann, Group Energy Manager at PPC Ltd. “The
wind farm forms part of PPC’s long-term rehabilitation
plans for the mine. PPC is committed to becoming a
more sustainable company. This project is the first step
in procuring power from renewable sources.”
Worldwide Latest industry appointments
ll India’s Wonder Cement Ltd has named
Jagdish Chandra Toshniwal as Executive Director.
Toshniwal has more than four decades of
experience, including 18 years at Ambuja Cement.
He brings with him a broad understanding of
marketing and branding, along with commercial
and operational skills.
ll HeidelbergCement has updated the
structure of its Managing Board, appointing
Dr Dominik von Achten as Deputy Chairman.
Dr Bernd Scheifele, Chairman of the Managing
Board, has been appointed for a further 5 years. ll Lucinda Riches will join the Board of CRH as a
Non-Executive Director, effective 1 March 2015.
Riches has spent much of her career in investment
banking, including 21 years at UBS Investment
Bank.
ll Ash Grove Cement Company has announced
David G. Meyer as Vice President and Chief
Financial Officer. Based at the company’s
headquarters in Overland Park, Kansas, Meyer
will direct accounting, treasury, internal audit, tax
and information technology functions. He joins
Ash Grove from Dairy Farmers of America, where
he served as Senior Vice President.
ll McInnis Cement has appointed Alexandre Rail
as Plant Manager of the Port-Daniel-Gascons
cement plant in Canada, effective immediately.
Rail is an experienced manager in heavy industry,
including metal powder manufacturing and steel
plants.
ll McInnis Cement has also named Mark T. Newhart
as Vice President, Logistics and Distribution, and as
a member of the company’s management team.
IN BRIEF
Lafarge Africa Plc has
signed a Memorandum of
Understanding with Shelter
Afrique to facilitate access to
affordable housing for low
income earners in Nigeria.
The terms of the MoU include
the provision of assistance
to establish the best
construction technologies
for affordable housing and
micro-finance projects, along
with the supply of cement
and concrete products.
14 \
March 2015
World Cement
The 11th edition of the
Birla White YuvaRatna
Awards was held in
Mumbai in February.
Organised by Birla White,
the white cement brand
of UltraTech Cement,
the awards celebrate
the talents of young
architects and civil
engineers. This year’s
theme was ‘a skill-based
learning environment with
sustainability’.
The Prometheus Group
and SMEC have formed
a global partnership that
will combine Prometheus
Group’s enterprise asset
management software
with SMEC’s asset
management consulting
group. The new
partnership will initially
focus on the cement and
aggregates industry,
particularly in Australia
and Asia.
EXHIBITORS
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KEYNOTE
MARCH
Financing a Greener
Future
Michel Folliet, Chief Industry Specialist for the Building Materials
Sector, International Finance Corporation – a member of the World
Bank Group, talks through the financing programmes and support
available to help the cement industry limit its environmental footprint.
C
limate change and urbanisation are two
of the most important trends shaping the
world, trends with profound implications
for the cement industry. Cement is the key
ingredient of concrete, the world’s most widely used
building material, but it is also the product of an
energy-intensive process that accounts for about 6%
of global greenhouse gases. These emissions threaten
to increase as developing countries urbanise and
construct roads, buildings and other infrastructure in
the decades ahead. To pursue a low carbon growth
path, the industry needs to adopt the most efficient
technologies, develop innovative products and
explore promising technologies for alternative fuels,
including wind and solar.
International Finance Corporation (IFC), the
member of the World Bank Group dedicated to
private sector development, invests in the cement
industry because of its fundamental importance
for economic development and poverty reduction
in developing countries. Concrete is an essential
building material for the construction sector, a major
March 2015
World Cement
/ 17
Waste heat recovery potential in 11 countries.
global employer that is vitally important to housing
and basic infrastructure. The cement sector is capital
intensive and subject to economic construction
cycles. It requires a long-term perspective on
financing and returns. Development institutions
such as IFC often play a role in supporting cement
projects in developing countries, where 90% of
cement is consumed. IFC has an active cement
portfolio of about 35 projects, representing over
US$1.1 billion of IFC investment.
IFC’s strategy in the cement sector aims to
encourage a shift to ‘greener’ cement. In addition to
maximising the use of less carbon intensive cement
and concrete, IFC works with companies who want
to reduce energy consumption and reliance on
fossil fuels. We believe there is incredible upside
potential for reducing emissions and reducing
energy costs in the cement industry, and these goals
can be supported by employing the right financing
structures and regulatory incentives for investment.
Cheaper, cleaner power
One of the strongest cases for investment in
alternative technologies is for adopting waste heat
recovery (WHR). This involves capturing the excess
heat of an industrial process and using it to generate
electric power. The financial payback can be rapid
for a number of heavy industries, including steel
and chemicals. Yet uptake in the cement industry
has been limited except in Japan, Thailand, India
and especially China, home to over 85% of the WHR
installations in the world today.
A recent report by IFC and the Institute for
Industrial Productivity estimated that WHR
investments could reduce operating costs and
improve EBITDA margins of cement plants by
between 10 and 15%.
In developing these estimates, we considered
country-specific business enabling environments to
deploy the technology. We took into account the
state of the cement industry, industrial electricity
tariffs and concerns over reliability of grid-supplied
18 \
March 2015
World Cement
electricity, regulatory and sustainability drivers, as
well as political stability.
On average, electric power expenses account
for up to 25% of total operating costs of a cement
plant. Waste heat recovery technology utilises
residual heat in the exhaust gases generated in the
cement manufacturing process and can provide
low-temperature heating or generate up to 30%
of overall plant electricity needs. Other advantages
include reductions in purchased power consumption,
reductions in reliance on fossil fuel-based captive
power plants and increased resilience to further
fluctuations in electricity prices.
In other words, we can get more reliable and
cheaper energy, while at the same time cutting
greenhouse gas emissions.
Exploring business opportunities in Asia and
beyond
Our research analysed 11 country-markets in five
regions where the cement industry is expected to
grow. We estimated that US$5 billion in investment
could introduce about 2 gigawatts (GW) of WHR
technology in developing countries. To put that
amount in perspective, 2 GW of electric power
produced by WHR would be enough to power about
1.3 million – 1.5 million homes.
Spearheaded by Japan in the 1980s, waste
heat recovery was introduced to China through a
joint venture between Kawasaki Engineering Co.,
Japan, and Anhui Conch, China. The technology
has greatly expanded in China since 1998 in
response to escalating energy costs and government
policy, including tax breaks and 2011 national
energy efficiency regulations, which mandated
the technology’s use at newly constructed cement
plants. Today, China is the world’s leader for waste
heat power generation.
IFC is exploring opportunities to partner with
major equipment manufacturers and vendors and
otherwise help promote waste heat recovery,
drawing on Asia’s experience with the technology.
One of the major issues IFC hopes to address is
the need to reduce the financial risk of WHR. IFC
is building on its experience in structuring project
finance to offer new ways to promote waste heat
recovery, including off-balance sheet finance
models that satisfy cement producers, operators and
bankers.
IFC has supported a number of waste heat
recovery projects. The China Utility Based Energy
Efficiency Finance Program provided access to
finance through commercial banks to numerous
projects. The World Bank’s China Energy Efficiency
Financing Program also supported energy efficiency
development. In 2014, IFC provided a US$40 million
loan and helped to mobilise US$25 million for
energy efficiency improvements, including a WHR
project in Turkey at Cimko Cimento ve Beton Sanayi
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Air quenching cooler (AQC) boiler at the kiln head.
One man’s trash is another’s treasure
The use of waste materials to fuel the kiln is another way
cement producers can reduce dependence on fossil fuels
and reduce greenhouse gases. This method holds the
added environmental benefit of recycling materials that
would otherwise need to be processed and eliminated.
Waste can be trash collected by municipalities, straw and
other agricultural materials, old tyres, forestry byproducts
or petroleum-based waste like solvents and paints. The
waste becomes a renewable resource, and its use by the
cement industry eases pressure on landfills, and reduces
risks of groundwater contamination.
Recently, IFC, Proparco and Lafarge agreed to
establish a programme for converting municipal trash
into fuel in Iraq. The programme’s first project will
be located in the Kurdistan region of Iraq, where IFC
will help fund construction of a modern landfill and
facilities for prepping the waste, which is currently
disposed of in a poorly managed landfill that
generates significant water pollution. Not only will
the renewable energy source displace carbon-emitting
fossil fuel consumption, the reduction of landfill waste
will emit less methane, a greenhouse gas even more
harmful than carbon dioxide.
The sun and wind story
Power reliability can be an issue in almost every
region of the world. Businesses worldwide adopt
captive use of power to secure electricity supply. The
use of renewable technologies can be cheaper than
the grid and can be significantly cheaper than diesel
20 \
March 2015
World Cement
generation. Plus, renewables come with
significant environmental benefits that
allow companies to meet Corporate
Social Responsibility goals.
Commercial and industrial
installations include photovoltaic
(PV) power plants ranging from a few
hundred kilowatts to a few megawatts.
They can be rooftop or ground mounted,
built in six months or less, and can
promote independence from unreliable
grids or inflated electricity rates. Since
2007, IFC has invested almost US$1 billion
in 60 deals across the solar industry
supply chain, and we are interested in
working with companies to develop the
potential for solar in the cement industry.
There are some interesting examples
of how it can work in the industry.
Lark Energy’s 9 MW solar farm at
Hanson Cement’s Ketton plant in the
UK covers 10% of the plant’s annual
electricity consumption. Emerging market
governments are looking at this example
for how solar can be deployed for
industrial use.
Wind farms must be located in areas
of high wind, usually at some distance
to the manufacturing facility. The most common
approach for wind power procurement is through
agreements to take power generated by wind farms
and transmitted through the national power grid. For
example, in Mexico, Cemex has long-term bilateral
agreements to buy power generated by the 250 MW
Eurus wind farm in Oaxaca, a project financed by IFC.
Conclusion
Demand for cement is booming in the developing
world. Global cement consumption has more than
doubled over the last 15 years, reaching over
4.0 billion t. Most of this growth has been in the
emerging markets, which consume over 90% of the
world’s cement production. New technologies and
more efficient use of resources are crucial to help
the cement industry fulfil this demand and limit the
industry’s environmental footprint. China’s experience
shows that regulation can spur investment in efficiency.
IFC is committed to providing leadership in developing
innovative financing models and advice to promote a
greener cement industry.
Note
IFC is the world’s largest global institution dedicated
to private sector development. It has a presence in
more than 100 countries and a committed portfolio of
over US$65 billion. An electronic version of the ‘Waste
Heat Recovery for the Cement Sector: Market and
Supplier Analysis’ report can be found on the IFC’s
website: www.ifc.org.
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ESP
CONVERSION
PROJECTS IN
Introduction
For the Siam Cement Company in Thung Song,
Thailand, dust emissions were a growing
problem. Dust emissions from three of its raw mill
departments were putting unnecessary strain on
the plant’s existing electrostatic precipitators (ESPs).
It turned out that the ESPs had deteriorated to such
a state that they needed replacing.
In Thailand, as in many other countries,
emissions legislation is becoming ever more
stringent and the Thung Song plant was unable to
meet the limits with its existing installations. For
the key reason that some fabric filters can now
deliver extremely low emission levels (less than
2 mg/Nm3), the decision was made to convert from
ESPs to fabric filters. The fabric filter’s larger, more
efficient process filtration ability would increase the
production capacity of the plant’s kilns and mills.
Moreover, with the right fabric filter solution, the
costs of conversion could be offset thanks to the
22 \
ability to reuse elements of the ESP, such as the
casing, steel support and transport dust system.
Siam Cement Company’s management had a
number of objectives for the implementation of
its new air pollution control (APC) solution. Local
legislation in Thailand demands that dust emissions
from stacks are less than 80 mg/Nm3; however,
according to Khun Wichet Chuchaeu, Production
Manager at Siam Cement Thung Song, the plant’s
goal is to keep emissions under 30 mg/Nm3: “We
required a filter system that was effective and easy
to operate and that could give us 100% control
over dust emissions.”
An increasing number of ESP filters are
being converted to fabric filters, according to
Henrik Vittrup Pedersen, General Manager of
FLSmidth Airtech – Air Pollution Control, and in
response to the demand, FLSmidth has developed
specialist competencies. “At our project office in
Denmark, we combine knowledge and utilise global
Rasmus Ellefsen, General Manager, Southeast Asia & Pacific,
FLSmidth Airtech – Air Pollution Control, describes how a combination of
new fabric filter technology and local support has helped Siam Cement’s
Thung Song plant to dramatically reduce dust emission levels.
/ 23
FLSmidth RetroClean filter at Siam Cement Thung Song,Thailand.
engineering resources to provide fast, efficient support to
customers in these types of projects,” says Pedersen.
A long-standing relationship
Siam Cement Company is owned by the Siam Cement
Public Company Limited (SCG). In 1913, when FLSmidth
was contracted to build SCG’s first cement production
line in Thailand, a good working relationship was already
established between the two companies, and this has
continued with the supply of spare parts and new
equipment to various SCG cement plants. For example,
FLSmidth installed FLS® GSA gas suspension absorbers in
three of the plant’s raw mill systems in 2012.
The installation at the Siam Cement Company
involved removing the entire ESP casing, which had
deteriorated over the years, and replacing it with a
new fabric filter solution – the RetroClean™ fabric filter
type. Behind the plant’s decision to choose FLSmidth
to provide the new filter equipment was the ability
for online maintenance. Plant operators can perform
maintenance tasks, such as changing filter bags, when the
raw mill is in operation. FLSmidth has provided this ability
with a unique design that divides the filter into several
compartments that can be completely isolated from
the gas stream. Inside the filter, gas-blocking walls are
installed between the fabric filter compartments, and the
inlet and outlet can be blocked as required.
The filters allow the use of long filter bags – typically
10 m in length – meaning fewer bags, pulse cleaning
valves and other key parts are needed to cope with the
gas flow. In addition to reducing maintenance costs,
the space within the refurbished ESP is utilised to fit the
long bags and top box complete with purging tubes.
24 \
March 2015
World Cement
Two other features provide important benefits to plant
owners, including increased operational efficiency and
prolonged filter lifetime. These features are the unique
gas distribution system, which ensures that gas is evenly
spread over the entire filtration area, and the Smart Pulse
Controller®, FLSmidth’s advanced control system.
However, technology is not the only prerequisite to an
effective solution. When assisting with filter conversions
or new installations, FLSmidth works closely with plant
staff in seeing the project through to completion and
ensuring that the installation performs to specification.
Fast conversion minimises downtime
FLSmidth has been a leader within air pollution control
technologies for more than 40 years. Products and
technologies are fully tested at Dania, FLSmidth’s
state-of-the-art global R&D centre in Denmark, before
they are brought to market. The company takes a
responsible, research-based approach to product
development, often in partnership with customers.
For the Siam Cement Company, it was not just a
matter of providing the best solution for the plant’s
future; it was also a matter of close teamwork, good
service and attending to the customer’s needs. A short
shutdown time of 35 days was planned for the filter
exchange. During this time, the upper part of the existing
ESP was removed, the longitudinal hopper was rebuilt
into a pyramid hopper, and, finally, the new fabric filter
internals were installed. In addition to engineering a new
layout for the inlet and outlet ducts and supervising the
erection and commissioning, FLSmidth ensured support
for the entire preassembly process and provided project
management assistance to the local contractor. During
and after the process, the plant’s operators were trained
in how to make the best use of the filters by FLSmidth’s
specialist engineers.
Michael Thorsfelt, Project Manager at FLSmidth,
was responsible for this RetroClean filter project at
Siam Cement. He explains that to achieve the most
effective solution and to meet performance objectives,
a thorough analysis of the process data was necessary.
“Thanks to the analysis of process data upfront, we could
design a perfectly suited solution, and it was actually
different than the solution originally intended. We
also discovered we could reuse the original hoppers by
redesigning them to the benefit of the customer and the
environment.”
“We use advanced techniques such as 3D onsite
scanning, which enables us to design a solution matching
the existing plant layout. For example, this helped us
to design an effective and accurate solution for access
facilities and ducts without physical collisions that may
be overlooked if just using drawings as the design basis,”
Thorsfelt explains.
Lifting of filter modules during installation.
Local setup, better support
For FLSmidth, an important goal is quite simply to help
achieve cleaner air. It is a daily reality that cement
and minerals plants around the world need to reduce
emissions and the impact on air quality. The company
works side-by-side with customers, understanding
their business and advising them on what they can do
to minimise emissions. Drawing upon a strong global
network of expert resources, it provides process expertise,
maintenance and service, spare parts, quality assurance,
commissioning and troubleshooting to customers
throughout Southeast Asia.
For this reason, customer service is an important part of
FLSmidth’s business model. Customers look for up-to-date,
expert advice and the company is committed to delivering
on this promise by recruiting and developing experts and
specialists within air pollution control. Plant operators can
be assured of receiving the assistance they need to achieve
their specific goals, whether technical or business related.
In recent years, Siam Cement Company and a number
of other cement plants in the Southeast Asia and Pacific
region have achieved benefits such as lower equipment
lifecycle costs as a result of FLSmidth’s local setup. The
company has invested considerably in creating a strong
local network in the region. This has been driven by the
desire to provide effective support to local customers
and to gain an even higher level of understanding of
customers’ specific challenges. At the Siam Cement
conversion project, FLSmidth deployed Southeast Asian
field engineers and European supervisors to achieve an
appropriate balance between the right knowhow for the
project and a higher level of local involvement. The local
field engineers received specialist training before, during
and after the installation.
Teamwork was very important to meeting the project
deadline, which of course was critical to Siam Cement’s
ability to resume production. “We often need to make
fast decisions during installation and we see that the mix
Weather enclosure.
of highly experienced supervisors and local field engineers
is very effective. The supervisors know the importance of
the fast decisions that need to be made and the local field
engineers can act on the decisions quickly based on their
knowledge and experience of the local environment,”
explains Thorsfelt.
“We have seen situations where plants have purchased
filters from other suppliers but have been unable to get
support,” says Henrik Vittrup Pedersen, commenting on
the importance of a local and global support network.
“When repairs were needed, plant managers needed
to source support from abroad, which was expensive, or
alternatively get help from local suppliers who may lack
the necessary experience. The result was a poorly operating
installation, which is simply not acceptable in today’s
competitive environment. FLSmidth’s local setup makes it
affordable to get skilled support.”
Conclusion
“Thanks to the solution provided by FLSmidth, we have
been able to reduce dust emission levels significantly by
converting our ESPs to much more efficient fabric filters.
The cost of the conversion process was reduced by reusing
existing elements of our ESPs, and the support we have
received throughout the process ensures that we will be
able to maintain efficient operations in the future,” says
Khun Wichet Chuchaeu.
March 2015
World Cement
/ 25
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