Highlight_1_2007

Transcription

Highlight_1_2007

Highlights
2007
April
Highlights
Highlights
Equipped for
the future
Editor: Anders Klinkby Godiksen
(responsible under Danish law)
Brenda Kaplan
V. Ragini Shah
Henrik Vinther
Production: Gunnar Andreasen
Translations: Martin Bojesen
Tuesday 2 January 2007 was a historical day for FLSmidth as it
celebrated the 125 years that have passed since the company
was established. The day also marked the beginning of another
exciting year for the global cement industry. Highlights asked
CEO Jørgen Huno Rasmussen to comment on the company’s
anniversary.
Editorial office:
FLSmidth A/S
Vigerslev Allé 77,
DK-2500 Valby, Copenhagen, Denmark
Tel: +45 36 18 10 00
Fax: +45 36 45 44 27
Email: [email protected]
Internet: www.flsmidth.com
All rights reserved
Contents
Equipped for the future
2
Breaking records in Mexico
4
Another major project for Kazakhstan
4
Green cement plant for the Emerald Isle
6
One of largest white cement plants
7
Largest-scale ATOX mills on stream
8
China’s leading cement producer
10
Americas’ next generation of plants
12
The preferred supplier for 125 years
16
D.G.Khan upgrades cooler
18
New ship unloader for Eastern Portland
19
KOCH strengthens FLSmidth
20
New workshop in China
21
Airtech fabric filter technology
22
Sanghi Cement at historic 10,500 tpd
24
Cost-effective shortcut to dry conversion
25
Thumbs-up to kiln simulator
26
New FLSmidth literature
27
Vasavadatta Cement commissioned
28
Take the e-highway to spare parts
28
Sebryakovcement sets ball rolling
30
On the job
32
Front cover: This year FLSmidth is celebrating the
125 years since the company was founded in 1882.
On pages 16-17 we have collected some of
FLSmidth’s major contributions to the technological
development of the cement industry for more than
a century.
Layout: Blue Business A/S · ISSN 0909-8992
2
Highlights April 2007
Is FLSmidth equipped
for the future?
My answer is definitely yes. Considering the success we’re experiencing
just now, it may even be a challenge
to keep both feet on the ground and
not become overwhelmed by our
good fortune. The demand for cement machinery is at an all-time high,
which is challenging our organisation.
We are well equipped because we
have chosen a precise strategy and
returned to our roots within cement
and minerals. This focused strategy is
based on a solid financial platform, a
dedicated workforce and 125 years
of expertise as a global and forwardthinking engineering company. All in
all, we are well prepared to supply
the plant and service solutions of the
future.
You’ve also been favoured
by fortune?
True, when I took over the helm in
2004, I knew that the prospects were
good. But the present size of the market has exceeded all expectations. The
cement industry has its ups and
downs, a fact to which the FLSmidth
organisation can certainly testify. The
company’s present success derives not
only from the size of the market, but
also from our own history and flexibility. The FLSmidth flag is planted across
the globe and is testament to the actions of our predecessors at all levels
in FLSmidth. They took up the baton
and paved the way for future successes. We still see old, well-maintained
plants running seamlessly. By continuing the same actions today and making the appropriate decisions, we are
also paving the way for future generations.
New ways?
FLSmidth will grow considerably over the
coming years. In Cement, our aftermarket activities and the design of new
technological solutions are making good
progress. In Minerals, we have recently
taken a positive step forward by acquiring KOCH Transporttechnik, the German
materials handling group. Their extensive know-how will prove highly useful
to FFE Minerals, which we plan to grow
to a size comparable to Cement.
How about specific FLSmidth
values?
We don’t blow our own trumpet with
trendy slogans. Our customers know
perfectly well what we stand for. We
show it in practice. And you can read
about it in this magazine. Our values can
be expressed in different ways, but I venture to say that everyone in FLSmidth is
proud of the company’s reputation as
the industry’s preferred partner. If you
see an FLSmidth logo on a machine,
there is no doubt that this is top-quality
equipment backed by a global organisation willing to provide top-level service
when needed.
Will the anniversary year see
any special events?
We’re already busy with one of the company’s most important years in recent
times. Of course, our anniversary has
been highlighted in the press. Meanwhile we’re sticking to our normal principle: business as usual. That’s because
we intend to remain the preferred part-
ner for at least another hundred years.
But the anniversary celebrations will
include customers. In May, we’ll embark
on a road show with seminars in Denmark, Egypt, India, Indonesia and the
USA. These will be high-profile events
shared with management executives
from our customers. There is every reason to celebrate.
I wish you pleasant reading of this
new issue of Highlights, which as usual
also comes in an electronic version,
eHighlights on www.flsmidth.com
J. Huno Rasmussen
CEO, FLSmidth
3
Breaking records
in Mexico
Another major
project for
Kazakhstan
CEMEX S.A.B. DE C.V. (CEMEX), a global building
solutions company that provides high quality
products and reliable service to customers and
communities in more than 50 countries, has
awarded FLSmidth a contract to build the largest
kiln system in South America.
The last issue of Highlights reported on
FLSmidth’s first major order in Kazakhstan, a
3,500 tpd modernisation project. More recently,
East Energy Company (EEC), part owner of
Kokshe Cement, has placed a EUR 90 million
contract for a complete new greenfield plant,
confirming Kazakhstan as a major new market.
Situated at the Tepeaca plant in Mexico, the new line will have
a capacity of 10,000 metric tonnes clinker per day. The kiln system is part of a 4.4 million tonnes per year expansion project
to mark CEMEX’s 100-year anniversary. Additional equipment
packages will be tendered later on.
Meeting strict environmental standards
The USD 35.9m project demonstrates FLSmidth's leadership
and capability in designing large clinker production systems.
The contract includes the latest generation Multi-Movable
Cross-Bar Cooler. In addition, the ILC 5-stage preheater with
low NOx and CO calciner will ensure that the strict environmental and efficiency demands are met.
With a strong local presence in North America, FLSmidth
was able to differentiate itself from possible competitors.
FLSmidth's US project centre based in Bethlehem, Pennsylvania, which is responsible for the project, attributes the success
of the contract to its ability to act as a complete partner for
the supply of engineering services, project management, and
commissioning as well as all major machines for the clinker
production line.
Seated (l to r):Peter Westring and Hugo Bolio.
Standing (l to r):Richardt Fangel, Enrique Mendez, Elias Garza,
Edmo Gutierrez, Hector Trevino, Hector Mendez, Emiliano Quiroga.
Kazakhstan, a country rich in oil, gas and minerals, is seeing double-digit growth in construction activity. The country’s 15 million people, who inhabit an area comparable to
Western Europe, need increasing volumes of cement for
roads, homes and industrial development. Several new
cement plant projects are being considered, but the first
one to begin operation will be Kokshe Cement’s two
million tpy plant.
Mutual trust
Most of 2006 saw a very constructive dialogue between
the customer, its German advisor and project developer
Evagor GmbH and FLSmidth, which was chosen to design
and supply the plant. The talks, which took place in an
open atmosphere of mutual trust, culminated in the signing of a contract in late 2006.
The new greenfield plant will be situated 270 km
northwest of Astana, the Kazakhstani capital. The regions
surrounding Astana, in the centre of the country, and
Almaty, the country’s commercial centre in the south-east,
together account for 60 percent of the nation’s cement
consumption. The decision to invest in cement production
therefore came naturally for EEC of Kazakhstan whose
current interests are mainly in oil and gas production.
EEC also has a construction business which will handle some
of the civil works for the new plant.
Kokshe Cement’s new 2m tpy greenfield plant will be situated way out in the
Kazakhstan steppes, some 270 km northwest of the nation’s capital, Astana.
4
The plant site is strategically located
with plenty of limestone and clay reserves nearby. A special railway line will
be built to the plant for deliveries of
equipment and, subsequently, additives
and other materials needed in cement
production. Distribution of cement,
mainly in bulk, will also primarily take
place by rail.
State-of-the art project
With temperatures dropping to -40o C in
the winter, building the plant and designing equipment that can withstand
the cold will be a major challenge. Civil
works, plant installation and commissioning are planned to take place during
the frost-free months of 2007, 2008 and
2009, respectively.
The plant will feature state-of-the-art
production equipment and control systems, all designed to achieve maximum
production efficiency and best practice
environmental performance. The contract includes not only equipment supplies, but also engineering, training and
spare parts. FLSmidth is responsible for
transporting the equipment to the site, a
major operation involving deliveries from
selected manufacturing plants by rail,
ship and truck. Another major assign-
ment will be to provide the bulk of technical documentation in both English and
Russian.
First modern cement plant
“This contract confirms our expectations
of growing cement industry activity in
the former Soviet Union countries, and
FLSmidth is actively pursuing the vast
opportunities in this fast growing region”, FLSmidth Group CEO Jørgen
Huno Rasmussen says.
Leif Kirk, Vice President, Sales, FLSmidth and Kapanov
Sailaubek, Director Kokshe Cement, sign the contract.
Scope of equipment supplies
EV 200x200 limestone crusher
Side Scraper store for limestone and clay
ATOX 47.5 raw mill
CF silo dia. 20x56 m (21,500 tonnes)
ATOX 22.5 coal mill
5-stage ILC preheater with ammonia injection to reduce NOx
Two-support kiln 5.25x62 m (5,500 tonnes per day)
SF Cross-Bar cooler 4x6
Clinker store dia. 60x46 m (100,000 t)
Two OK 33-4 cement mills
Four CFS cement silos dia. 20x40 m
MAAG Gear units
Two Ventomatic packing lines
Pfister feeders
FLSmidth Automation control system, including RoboLab
FLSmidth Airtech bag filters and electrostatic precipitators
5
Green cement plant for
the Emerald Isle
FLSmidth has been entrusted
with a 4,000 tpd project for Irish
Cement Ltd.’s Platin Works north
of Dublin. The state-of-the-art
plant will be designed to comply
with the most stringent environmental requirements.
The signing of a contract with Irish Cement Ltd. (ICL) for a new 4,000 tpd
clinker production line practically coincided with FLSmidth’s 125th anniversary
around New Year 2007. This is not the
first time ICL and FLSmidth have celebrated an anniversary by signing a contract. On 5 December 1996, the two
parties marked the 60th anniversary of
their mutual relationship by signing a
contract for the rehabilitation of Kiln 2
at ICL’s Platin Works. The highlight of
that project was the replacement of a
UNAX planetary cooler by a COOLAX
grate cooler within only 47 days of kiln
downtime.
This time, the contract signed is for
a complete line 3. This will be an ultramodern, energy-efficient production
6
line, meeting best practice environmental standards. The new line will both
increase the overall plant capacity from
2 to 2.8 million tpy and lower carbon
dioxide emissions. Once line 3 is in operation by late 2008, it is expected that
the existing line 1 dating back to 1972
will be closed down.
FLSmidth’s role in the new project
consists of supplying a total package of
machinery and equipment plus engineering services. The main equipment
items are:
• MVT raw material store, 95 metres in
diameter
• ATOX 47.5 raw mill
• ATOX 25 coal mill
• Pfister coal feeders
• ILC preheater and ROTAX twosupport kiln dia. 5 x 60 m
• MMC 11x97 cooler
• OK 36-4 cement mill
• MAAG gear units
Platin Cement Works is located near
Drogheda in eastern Ireland, some
50 km north of Dublin. The new production line will be the biggest investment
ever in Ireland by Cement Roadstone
Holding (CRH), the leading international
materials group which owns ICL. Platin’s
expansion project will ensure adequate
supplies for Ireland’s thriving economy
and growing construction sector.
Signing the contract for Irish Cement Platin’s new 4,000 tpd line,
seated l to r: John McKeon, Jørgen Huno Rasmussen, Ken McKnight,
Peter Thomsen. Standing l to r: Richard Cunningham, Barry Leonard,
Michael Keatings, Niels Chr. Tew, Ivor Reese.
Helping to build one of largest
white cement plants
Sinai White Cement Company has decided to add a new 1,300 tpd
line to its existing plant with FLSmidth supplying equipment and
engineering. With a total capacity of 1.1 to 1.2 million tonnes per
year, Sinai White will become one of the world’s largest white
cement plants.
The market for cement is booming in
the Middle East and in the countries
around the Mediterranean. This is a region with a particularly high demand for
white cement, and the Sinai White Cement Company is producing at capacity,
despite only being six-years-old. So the
company is investing in a new line to
satisfy the market.
As was the case with the first line
commissioned in 2001, FLSmidth has
been chosen as supplier for the new
project. This decision was prompted by
the successful performance of the existing plant and FLSmidth’s great expertise
and experience in white cement technology. The scope of FLSmidth’s supplies is:
• UMS 42 x 14.5 cement mill
• Electrostatic precipitators from
FLSmidth Airtech
• Feeding equipment from Pfister
The contract with FLSmidth comprises
not only the supplies of mechanical and
electrical equipment but also drawings
and documentation for local manufacture and procurement. The range of
equipment for Sinai White’s second line
is similar to that of the first line, but the
new line will feature a rotary cooler instead of a grate cooler, this being a more
efficient solution which is now the standard choice for white cement projects
from FLSmidth.
Sinai White Company, which is
57 percent-owned by Aalborg Portland
White of Denmark, expects its new
production line to be operational by the
end of 2008.
• ATOX 25 raw mill including MAAG
gear unit
• Two UM 29 x 16.0 sand mills
• ILC pyro system including 4-stage
preheater, calciner, 3.75 x 57 m
three-support kiln
• Rotary cooler
Celebrating the signing of the contract for Sinai White Cement Company’s second line.
7
Largest-scale ATOX mills come on stream
As cement production plants
continue to grow in size, there
is a corresponding demand for
larger mills. In the previous issue
of Highlights, we discussed the
increasing size of OK vertical
mills used for finish grinding
of cement and slag. This article
focuses on the ATOX vertical mill
used for raw material and coal
grinding.
More than 300 ATOX mills have been
sold since the first mills were commissioned during the early to mid-1980s.
The ATOX range originally comprised of
11 sizes, the largest being an ATOX 50
– a mill with a grinding table measuring
five metres in diameter.
At the beginning of this century,
FLSmidth expanded its range to meet
the industry’s need for higher capacity.
Four new mill sizes were introduced:
ATOX 52.5, 55, 57.5 and 60. The total
8
range of ATOX mills now spans from
665 to 5,931 kW installed power.
Chinese cement company
has success with mega-sized
ATOX mills
In 2003, FLSmidth sold the first of its
new larger-sized mills to the Chinese
state-owned organisation Anhui Wanwei Update High-Tech Material Industry
Co. Ltd (known as Wanwei). Located in
Chaohu City in the Chinese province of
Anhui, Wanwei is active in chemicals,
fabrics and cement.
Founded in the 1970s, Wanwei originally manufactured fabric. But growth
in chemical and fabric production resulted in an increasing amount of calcium
carbide residue – which led to the
development of cement production at
Wanwei.
Wanwei now has three cement production lines: a 1,000 tonnes per day
(tpd) line commissioned in 2000; a
1,200 tpd line commissioned in 2003;
and a 6,000 tpd line commissioned in
2005. The latter is equipped with an
ATOX 52.5 raw mill, the first of the
mega-sized vertical grinding units to
enter into operation. The mill has a main
drive of 4,266 kW, a MAAG gear and an
RAR-LVT 52.5 separator. Following its
successful commissioning, the mill comfortably achieved its performance expectations.
Accepted by the industry
Since 2004, FLSmidth has sold nine
more mills like the one used by Wanwei,
and even some larger ATOX mills. These
will be featured in the next issue of
Highlights.
Today vertical mills are widely accepted as the most efficient means of preparing kiln feed for the production of cement clinker. The mills can finely grind a
wide range of feed materials using a
highly energy-efficient process. Raw
materials vary considerably in grindability,
drying requirements and abrasion, but
the vertical roller mill has the flexibility to
handle these variations.
The ATOX mill combines the grinding, separation and drying processes into
a single unit. Its excellent drying capacity
means the mill is suited to grinding materials containing up to 20 percent moisture. It is also extremely compact compared to other vertical mills and produces very little noise – which allows for
outdoor installation.
ATOX raw mill selected for the
world’s largest production line
Further proving its versatility, the ATOX
raw mill has been chosen by Holcim for
use in the world’s biggest production
line. Located in Ste. Genevieve in Missouri, USA, the plant will have a capacity
of 12,000 tpd.
Wanwei’s cement plant in Central Eastern China was the first to commission a
mega-size raw grinding mill (ATOX 52.5).
Since the early eighties, FLSmidth has sold 300
ATOX mills used for grinding either raw materials
or coal. In China, alone, the cement industry has
invested in 100 ATOX’es. In December 2006,
FLSmidth’s Beijing office staff and families duly
celebrated this landmark achievement.
9
China’s leading cement producer
confident of future growth
Anhui Conch Cement Co.
Tongling is one of the world’s
largest cement plants. FLSmidth
has provided vital parts of the
technology including the recently commissioned twin 10,000 tpd
pyroprocessing lines.
Large kilns have always exerted a strong
attraction on cement people, both because of their sheer size and because of
their huge production capacity.
To gain a good impression of a gigantic cement facility, there is no better
place to go than Tongling, China, the
Anhui Conch Group’s largest production
complex. The plant is able to produce 10
million tonnes clinker per year and consists of four lines located at two interconnected sites a few kilometres from
the Yangtze River in the Anhui province
of eastern China. The cement plant is
close to plentiful reserves of high-grade
limestone.
10
World leader in huge cement
plants
The two most recent lines, which are
also the largest, are very impressive with
their twin preheater towers rising 146
metres up in the horizon. By contrast,
the relative peace and quiet of this massive installation is quite remarkable, as
there are no clinker grinding facilities at
the site.
The two 10,000 tpd clinker production lines were the first of their kind in
China. At the time, the world’s only other lines of that capacity were the three
which FLSmidth had previously supplied
to cement producers in Thailand.
This experience confirms FLSmidth’s
position as the leading supplier of very
large kiln systems to the global cement
industry.
A successful start
At 20:38 on 26 May 2004, Tongling
Conch ignited the first of its 10,000 tpd
kilns which on 5 June produced the first
actual clinker. A grand opening ceremony attended by cement industry executives and provincial government officials
celebrated both the first and the next
10,000 tpd pyro systems plus the four
new ATOX raw mills at Tongling.
After a brief commissioning period,
the first line was steadily producing
more than 11,000 tpd. Construction of
the first of the two new clinker lines
took only 18 months from erection to
production – an impressive achievement
considering the scale of the project.
The second line entered production
six months later, boosting Tongling’s total production capacity to 2 x 10,000 +
1 x 5,000 + 1 x 4,000 = 29,000 tpd.
Scope of contract
FLSmidth has a long standing and strong
relationship with Conch dating back to
the early 1990s when it signed the contract for Tongling’s first line (4,000 tpd).
The successful implementation of that
project led to a number of orders from
Conch over the following years. FLSmidth
has been a supplier of cement-making
machinery to China since 1906.
In 2002 Anhui Conch Cement Co.
awarded FLSmidth the contract for key
technology and equipment for the two
new lines at Tongling. The scope of supply was
•
•
•
•
•
Two 2-string, 5-stage ILC preheaters
Two 10,000 tpd rotary kilns
Two Duoflex kiln burners for coal
Four ATOX 50 raw mills
Four 3,800 kW planetary gears supplied by MAAG Gear
• Pfister coal feeders.
Distribution
The ‘new’ Tongling site does not grind
finished cement. Instead the clinker is
transported to grinding plants located
on China’s east coast or at major cities
along the Yangtze river where cement
consumption is high.
A covered belt conveyor carries the
clinker from the plant to the distribution
terminal on the Yangtze river, a distance
of 7 km. On its way back the belt carries
coal. The pier at the busy terminal receives vessels up to 5,000 dwt. It has
three loading stations each with a capacity of 1,200 tph of clinker or 800 tpd
of cement from the ‘old’ Tongling site.
and boosting of exports from the present level of nearly five million tonnes per
year. The ‘new’ Tongling site has therefore been designed to accommodate a
third line, but the final decision to expand the plant has yet to be made.
Within the next five years, Conch
hopes to boost its annual clinker production capacity from approximately 50
million tonnes to 100 million tonnes. If
this growth materialises, Conch will join
the world’s top ten league of cement
producers.
Ambitious plans for the future
The Conch Group is already China’s
largest cement producer, accounting for
4-5 percent of the nation’s current consumption. Conch’s plans for the future
include further expansion of production
China’s leading cement producer, the Anhui Conch Group, successfully operates
these two 10,000 tpd production lines at the Tongling plant. FLSmidth supplied
the principal equipment, testament to the company’s experience and expertise
in supplying mega-size cement production plants.
11
The Americas’ next generation of plants
The world has seen an unprecedented rise in new plant capacity
in the past couple of years with
North America playing a leading
role. New plants there have the
most modern equipment and
a number of special design features and operational requirements.
Since 2005 about 22 million metric
tonnes per year of new capacity has
been sold in North America, and a similar amount is identified in future projects. FLSmidth was well prepared for this
wave of activity and is proud to have
captured the majority of the new production market in the Americas. This latest generation of contracted projects will
be built and commissioned over the next
couple of years.
Of particular interest is Holcim’s massive
greenfield plant being built alongside the
Mississippi River in Ste. Genevieve County, Missouri, USA. This facility will feature
the largest single clinker production line
anywhere in the world with an annual
cement capacity of four million metric
tonnes. Similarly, the new CEMEX S.A.B.
DE C.V. (CEMEX) Tepeaca plant will, at
2,300 metres above sea level, be the
largest single clinker production line ever
built in Mexico and Latin America.
So, what state-of-the-art solutions in
the pyroprocess and milling areas is
FLSmidth supplying?
The pyroprocess solution
Two- or three-support kiln
At the heart of the clinker production
line is the kiln, and all of the projects
with the exception of the large Holcim
and CEMEX plants will incorporate the
ROTAX-2 kiln, Figure 1. This two-support
design uses the standard features of tangential suspension, electro-mechanical
friction drive through the supporting
rollers, and fully self-aligning roller supports.
Due to the sheer size of the kilns required at Ste. Genevieve and Tepeaca –
which are 6.6 metres (21.7 feet) in diam-
A wide spread of projects
The recent projects using FLSmidth
equipment in the Americas (see Table 1)
have a broad spread of production line
capacity, ranging from 2,540 to 12,000
metric tonnes per day. But in general,
the type of core equipment is similar at
all plants.
Figure 1: Modern two-support kiln
Table 1: New FLSmidth projects in the Americas for 2005-2006*
Company
Holcim (US) Inc.
CEMEX S.A.B. DE C.V.
Essroc Cement Corp.
Keystone Cement
Caribbean Cement Co.
GCC Rio Grande Inc.
Rinker Materials
Plant
Ste. Genevieve, Missouri, USA
Tepeaca, Mexico
Martinsburg, West Virginia, USA
Bath, Pennsylvania, USA
Rockfort, Jamaica
Pueblo, Colorado, USA
Brooksville, Florida, USA
* Not including two undisclosed projects totaling 8,570 tpd
12
Clinker production (tpd)
12,000
10,000
5,000
3,000
2,800
2,630
2,540
Figure 2: Recently installed MMC cooler in the United States.
eter and 93 metres (305 ft) in length –
three supports will be used. But the design will still take advantage of semirigid roller supports and tangential suspension-type attachment.
ILC or SLC-D Preheater System
In general, the low-NOx ILC (In-Line Calciner) preheater system from FLSmidth
has become the standard solution for
cement plants today. It is proven to have
the lowest NOx and CO emissions in the
industry and is suitable for burning both
traditional fossil fuels and many alternative fuels. All but two of the projects will
have this type of preheater system. Several of the low-NOx ILC preheaters will
also incorporate a high-temperature oxidation zone to make them even better
for burning petcoke and other alternative fuels. The preheater designs for the
large production systems at Ste.
Genevieve and Tepeaca are spectacular
in their own right and will incorporate
twin-string versions of the ILC system.
FLSmidth also offers the low-NOx
Separate-Line Calciner with Downdraft
pre-combustion chamber (SLC-D). This
type of preheater system will be supplied
to Keystone Bath, as well as an undisclosed plant, due to especially
largeamounts of liquid waste firing. The
SLC-D system can meet stringent residence time requirements for particular
waste fuels to achieve acceptable destruction and removal efficiencies.
Clinker cooler
The latest generation Cross-Bar™ cooler,
Figure 2, known as the Multi-Movable
Cross-Bar cooler (MMC), is being supplied to all the projects except Caribbean
Cement and Essroc Martinsburg. Due to
timing or prior arrangements, these
plants will use the Cross-Bar technology
in the original SFC design.
The success of the Cross-Bar cooler,
which has been on the market for 10
years, continues with the MMC design.
Customers particularly like the fact that
the MMC has fewer wear parts, longer
wear life, and horizontal construction.
Two retrofit coolers with MMC cassettes
are already in operation, and the GCC
Rio Grande Pueblo plant will become the
first full new MMC cooler to come on
line in the Americas.
13
The Americas’ next generation of plants
Figure 3: DUOFLEX burner in operation.
DUOFLEX burner
The very successful DUOFLEX burner,
Figure 3, will be supplied to all but one
of the projects. It is a modern, multichannel design that allows the firing of
multiple traditional and alternative fuels
while minimising NOx formation. The
DUOFLEX will not only be employed
as the main kiln burner, but also as
the calciner burner in the combustion
chambers of the SLC-D systems.
Secondary emission reduction
No other trend is more evident in today’s
projects than that of increasingly strict
emission requirements. Permit levels of
NOx, SO2, CO, and VOCs are some of
the lowest ever seen, and, in some cases, beyond the levels currently achievable by primary equipment and process
design. For example, NOx emission levels
as low as 380 mg/Nm3 at 10% O2 (1.6
lb/STcl) during the summer ozone season
will be required for Holcim Ste. Genevieve. Fortunately, effective and simple
methods exist for controlling the emissions but at a significant price of operational changes or handling and using
costly reagents.
SNCR (Selective Non-Catalytic Reduction) with the use of aqueous ammonia has become a popular and effective
technique for secondary NOx reduction
and will be installed from the outset in
many of the projects. Provisions for hydrated lime injection for SO2 reduction
are also included in many cases. To control CO or VOC emissions, two of the
plants will feature a material split to divert a portion of the incoming kiln feed
to a lower position in the preheater, or
even direct it to the calciner.
The milling solution
Raw grinding
Vertical roller mills for raw grinding have
been the industry standard for many
years, and FLSmidth recommends either
the FRM or ATOX design depending on
the application and specific requirements. Most of the projects will feature
the FRM mill, Figure 4, and the ATOX
raw mills being supplied at Holcim Ste.
Genevieve will be the first of their kind
in the US.
Rinker Brooksville is the sole exception to the vertical roller mill standard. It
will use a ball mill for raw grinding because the extreme characteristics of the
raw materials are not suitable for
smooth and reliable operation with a
vertical roller mill. In this unusual case, a
trade-off of using a less energy-efficient
technology is more practical.
Coal grinding
All plants with FLSmidth-supplied coal
mills will be vertical roller mills of the
14
ATOX design, Figure 5. Popular for many
years in other parts of the world, including Latin America, the ATOX coal mill
has finally entered the US market. Continuous improvement of the ATOX coal
mill has resulted in today’s compact construction together with high efficiency
and reliability.
Cement grinding
FLSmidth will use the OK vertical roller
mill, Figure 6, for all finish cement grinding. This type of mill has become the
market standard, and a total of 22 OK
mills will be in operation in the Americas
by the time this new group of projects is
commissioned.
The OK mill has better grinding efficiency than any other vertical roller mill
on the market. Many of the new plants
will incorporate a compact layout, using
cyclones and hot gas recycling to minimise the vented volume and emissions
to atmosphere.
.
Figure 4: FRM vertical roller mill for raw grinding.
Figure 5: ATOX vertical roller mill for coal grinding.
Figure 6: OK vertical roller mill for cement grinding.
15
The preferred supplier for 125 years
Ever since its creation 125 years
ago, FLSmidth has been characterised by innovative thinking and
a desire to find the best possible
technological solutions. Today,
more than 650 of the 6,500 people who make up the company’s
workforce are directly involved in
developing the technology of the
future.
1890
Poul Larsen, a mechanical engineer
Alexander Foss, a civil engineer of
innovative and practically-minded
and a gifted organiser with strong
great vision and political commit-
machine designer, opened his ‘Tech-
business acumen, joined the firm in
ment, entered the firm in October
nical Bureau’ on 2 January 1882.
July 1884.
1885.
1893
1898
The Shofer continuous working
Far better at crushing hard clinker than the previous technology, FLSmidth’s
In the USA, the oil-fired rotary kiln for
shaft kiln manufactured Portland
tube mill signalled the start of a whole new era in cement production.
burning cement had been developed to
and other cements and lime.
save labour costs. In Europe, FLSmidth
The fuel consumed in a Shofer kiln
introduced the coal-fired rotary kiln,
was only a third of that used in an
constructing two 18 m long kilns at
ordinary kiln.
the Aalborg Portland cement plant.
1960
1964
1980
1992
Preheating of particles suspended in
The United States holds great historical signifi-
The ATOX vertical mill com-
FLSmidth contracts to build the
hot kiln gases was invented by
cance for FLSmidth as the source of the rotary
bines the grinding, separa-
world’s first 10,000 tpd kiln at
FLSmidth back in 1933 but did not
kiln technology that was a cornerstone of the
tion and drying processes
Siam City Cement Company in
come into general use before 1960
company’s international success. The Dundee
into a single unit.
Thailand. The same year Siam
when it proved a better and cheaper
Cement Co. plant is home to the world’s largest
Cement Co. orders a similar kiln
solution compared to the long and
rotary kiln measuring 7.6 x 6.4 x 6.9 x 232 m.
for their Khao Wong plant also
energy-intensive wet kilns.
16
Frederik Læssøe Smidth, an
in Thailand.
From the start, FLSmidth focused on the technical and
scientific aspects of cement production.
1900
1922
1925
The Kominor mill was specially developed for heavy
The UNAX satellite cooler,
The famous Symetro gear together with
grinding. It was later ousted by the tube mill.
which reduced dust problems,
the Unidan tube mill became the preferred
was constructed as an integral
installation for cement grinding.
part of the kiln.
1998
2001
2007
The first SF Cross-Bar cooler based on
The HOTDISC is used to burn
The cement plant at Ste. Genevieve, Missouri, will hold
the concept of fixed grates, separates
large items of waste and the hot
the world’s single biggest production line with a capacity
clinker conveying through cross-bars
combustion gases are utilised in
of four million tpy, corresponding to 12,000 tpd.
and air flow control through mechanical
the calcining process.
flow regulators.
17
D.G. Khan upgrades cooler
The Pakistani cement producer,
D.G. Khan Cement Co. Ltd. and
FLSmidth have worked closely
for more than twenty years. The
upgrade project for the cooler
serving kiln no. 2 at the D.G.
Khan plant is the latest example
of their long-standing relationship. With the contract signed in
January, commissioning of the
upgraded cooler is expected to
take place in the spring of 2008.
After lengthy discussions about extra
cooling capacity, the final contract was
signed. The talks were based on current
operational data, notably the clinker
temperature, and D.G. Khan eventually
opted for a major cooler expansion solution including two Multi-Movable CrossBar cooler (MMC) cassettes. Instead of a
traditional clinker crusher, D.G. Khan
chose a Heavy-duty Roll Breaker (HRB),
consisting of two crushing rolls and several transport rolls.
A second upgrade for the cooler
Some years ago, FLSmidth upgraded
D.G. Khan’s kiln no. 2 from 3,300 tpd to
4,000 tpd, carrying out a minor modification of the existing Coolax cooler. This
time the cooler is being upgraded with
MMC cassettes, which are similar to the
modules of an SF Cross-Bar cooler, but
without the supporting frame.
The major difference is the way the
drive mechanism is constructed and
works in the MMC cooler. Each cassette
has two built-in drives and cross-bars
above the grate line, but not all cassettes
have a hydraulic cylinder. And all the
cross-bars are moveable and reciprocate,
which improves conveying efficiency.
The MMC cooler can be installed horizontally and the drives can have individual stroke lengths and speeds to match
the operation of the clinker belt conveyor.
The first of many?
D.G. Khan is the first plant in Pakistan to
be upgraded with MMC cassettes and
an HRB. FLSmidth’s Customer Services
Projects department hopes to upgrade
several similar production lines using
the same concept in Pakistan in the near
future.
D.G.Khan Cement Co. has recently ordered a cooler upgrade
including the new Multi-Movable Cross-Bar (MMC) cooler
cassettes and the Heavy-duty Roll Breaker (HRB). This type of
upgrade is the first in Pakistan.
18
Delivering world’s largest-capacity
DOCKSIDER
FLSmidth’s Pneumatic Transport Department (FLS-PT) has been awarded a contract with Eastern Portland Cement
Company to supply a new ship unloader
for their Florida terminal, Port Manatee.
The ship unloader is a gantry-mounted DOCKSIDER type. Since the customer’s berth is shared by other port
tenants, the gantry is supplied with
steerable rubber-tyre wheelsets for
movement to a parking position away
from the dock.
With a design capacity of 700 metric
tonnes per hour, this ship unloader will
be the largest-capacity DOCKSIDER in
the world. The vacuum system includes
our newest design vacuum arm capable
of unloading 45,000 DWT bulk vessels.
The pressure system includes three
FLSmidth SAHARA dry screw compressors and conveys cement through a 22inch diameter pipeline nearly 1,500 feet
to storage.
In addition, FLS-PT has entered into
an agreement with Borton LC of
Hutchinson, Kansas to supply the distribution, reclaim and loadout equipment
for the two new storage silos. FLS-PT will
also supply equipment to the customer’s
general contractor for modifications and
improvements to the four existing silos.
The Eastern Portland ship unloader will be similar to the Hawaiian Cement
unloader shown here
The Eastern Portland Port Manatee Terminal
Correction
In our November 2006 edition of Highlights the picture of the
Faraz Firouzkuh Cement Company (FFCC) plant on page 21 was
mistakenly referred to as being the Fars Firuzkuh cement plant.
The editors regret this mistake as we know the justifiable pride
that Faraz Firouzkuh Cement Company takes in the successful
commissioning of their new line.
19
KOCH strengthens FLSmidth Group
FFE Minerals, the minerals
processing arm of FLSmidth, recently acquired the German and
Austrian divisions of KOCH Transporttechnik. An exciting addition
to the FLSmidth Group, KOCH
is a dominant global force in
materials handling systems and
the clear market leader in pipe
conveyors.
KOCH designs, manufactures and services a broad range of mechanical transport systems and equipment used in
minerals processing and cement production around the globe. KOCH Austria
currently supplies pipe conveyors for the
world's largest cement production line in
St. Genevieve, USA – which was designed
and is currently being constructed by
FLSmidth.
Global reputation combined with
local presence
Uniting KOCH's expertise in conveying
equipment application, design and engineering with FFE Minerals' direct presence in 11 countries will help establish a
powerful market position for the company. FFE Minerals is also creating a new
Materials Handling Technology Centre to
be headed by Heinz Känel. Currently the
General Manager of FLSmidth-owned
MVT, he also has 18 years’ previous experience in working with KOCH.
World's longest pipe conveyor
One of KOCH Germany’s biggest projects is the construction of the world's
longest pipe conveyor for Cementos
Lima in Peru. With a total length of
8.2 km, the finished pipe conveyor will
be able to handle up to 690 t/h of
cement (upper strand) and 515 t/h of
coal (lower strand).
The Cementos Lima pipe conveyor
will transport materials between the
20
cement plant in Atoconga and the port
in Conchán, without transfer stations.
The upper strand of the conveyor will
carry cement and clinker from the plant
to the ship loading facility, while the
lower strand will convey coal and limestone, as well as other materials such as
iron ore, iron pellets and gypsum. To
avoid material spillage from the lower
strand, the belt will be turned at either
end, allowing the same side of the belt
to carry material in both directions.
Superior to the belt conveyor
Between the plant and the ship loading
pier, the conveying line passes through a
twisting 6.5 km tunnel, taking it under a
network of busy roads. The pipe conveyor is ideal for this. Far superior to conventional belt conveyor technology, it
can follow horizontal and vertical curves
with a minimal radius which allows optimum integration into the tunnel. The
pipe conveyor also eliminates dust emissions and material spillage, improving
ventilation and minimising the need for
tunnel maintenance.
In addition to the transport system,
KOCH is also supplying various storage
facilities for clinker and cement. The system is due to start in 2007.
Recently acquired KOCH Transporttechnik is
supplying the world’s longest pipe conveyor in
Peru to carry bulk materials between the cement
plant and the port.
A large section of Cementos Lima’s pipe
conveyor runs underground. The enclosed
transport system is easy to service even in
the tunnel.
The 8.2 km long pipe conveyor is a dust-free and efficient transport system and is easily configured to follow sharp vertical and horizontal curves.
FLSmidth opens new workshop in China
On 9 January 2007, FLSmidth inaugurated its brand new manufacturing plant in
the port of Qingdao in China’s Shandong
province. The workshop covers an area of
12,000 square metres and replaces the
old facilities which had become too small.
The workshop is already busy producing
various types of FLSmidth machinery and
machine components, notably for
Duoflex burners, SF Cross-Bar and MMC
coolers, pneumatic transport equipment
and Pfister weighfeeders.
The workshop was designed, built
and installed in accordance with schedule. It took only thirteen months from the
project was approved by FLSmidth and
the local government officials to the manufacturing plant was officially opened
and production was up and running.
21
Airtech fabric filter technology
– the optimal choice for today’s
cement industry
The requirements for process
filtration equipment are changing in the cement industry. With
kiln and mill capacity increasing
– and emissions decreasing –
environmental equipment must
become larger in size. Consequently, fabric filter technology,
in particular large fabric filters,
is gaining in popularity.
Giving customers a crucial
advantage
Already a leading supplier of bag filters
to the cement industry, FLSmidth Airtech
is continuously developing products
which offer customers a technological
edge and reduce operating costs.
Our fabric filters are designed to deliver:
• Low emissions
• Low differential pressure
• Low compressed air consumption
rates
• Long filter bag lifetime
To meet these goals, the filter products
are fitted with special gas distribution
features that ensure a low pressure drop
across the filter media and a long life.
The technology also utilises low cleaning
pressure techniques to optimise the
cleaning process.
Our pulse jet products:
Application
Products available
Kiln/Cooler/Bypass
FabriClean or PulseClean
Cement/Coal Mill
DuoClean or UniClean
Nuisance application
CE filter
The product range above, first launched
ten years ago, has been applied in more
than 150 process filters across an array
of applications. And thanks to ongoing
improvement efforts, FabriClean, PulseClean and UniClean are now established
as market leaders. Customers have been
particularly impressed with the gas and
dust distribution and low pressure cleaning features which have delivered remarkable results.
As well as new filters, FLSmidth
Airtech also offers an electrostatic precipitator (ESP) conversion, with the
proven fabric filter technology built into
the ESP. Such a conversion can ensure
lower future emissions if capacity increases or emission levels change. Our
reference list currently includes more
than 30 conversions and hybrid filters (a
combined ESP and fabric filter, usually in
the same casing).
The main benefit of hybrid filters is
the synergy between the filter technologies (pre-separation and charging of the
dust), which enables either a higher A/C
ratio or smaller pressure drops. Documented results of this synergy have
shown reductions in the cleaning cycle
by a factor of 30-50. Our work with hybrid filters in kiln and cement applications has delivered some impressive results. For instance, we have seen cement
mill filters operating at a pressure drop
of 50 mm Wg, and an emission rate of
In the DuoClean filter the gas is exposed to the filter bags
from the bottom of the bags - like the UniClean - and as
a new feature also to the side of the filter bags. This new
approach of distributing the gas and dust makes it possible
to use long bags (6 – 8 m).
22
1.5 mg/Nm3. What’s more, the bags’
lifetime is more than four years.
Working to increase bag
lifetimes
Bags for FLSmidth Airtech fabric filters
are supplied by Advanced Filtration Technology (AFT) – a US-based bag production company fully owned by FLSmidth.
The main factors for long filter bag lifetime, besides gas and dust distribution,
are bag material selection, bag and cage
design, and compliance with standard
operating and maintenance philosophy.
The very close working relationship
between FLSmidth and AFT has also
helped generate additional knowledge
about how to achieve longer lifetimes
for the filter bags. Specifically, this collaboration has resulted in improved mechanical design and cleaning cycle parameters. Achieving longer and longer
bag lifetimes is a continuous process,
and, together with AFT, we are committed to making further progress in the
years ahead.
The optimum choice
Our products are ideal for medium to
large filter applications in the cement
industry. The standard design has a filter
capacity exceeding 1,500,000 m3/hr
in one filter casing. We have delivered
solutions that include several filters,
reach with capacities in the range of
1-1,500,000 m3/hr, all of which are
operating successfully.
This filter is designed for venting of large cement kilns.
Always at the forefront of technological
advances, FLSmidth was the first company to apply long bag filter tech-nology
for kiln venting. And recently, FLSmidth
Airtech was selected to supply long bag
filter technology to the world’s largest
cement production line – Ste. Genevieve
in the USA (12,000 tpd).
New product hits the market
FLS Airtech recently launched a new
filter type – DuoClean – targeted at
cement mill applications. Increases in
cement mill capacity have pushed the
UniClean filter into a very long and slim
filter, which is not the most economical
shape for a large fabric filter. A more
economical filter with long filter bags
(up to 8 m) is being launched as the optimal solution for very large cement mill
circuits. The DuoClean filter is also
equipped with a state-of-the-art gas and
dust distribution system which secures a
very long bag life. The main benefits of
this filter are its significantly lower capital cost and greatly reduced footprint.
Filter bags (P84) after 8 years in operation. There is no mechanical damage on the surface such as rips, cracks or holes.
Well agglomerating dust layer.
23
Sanghi Cement production
at historic 10,500 tpd
During November 2006, Sanghi
Cement Plant’s C2 string was
commissioned, and within a
week of its operation it touched
a historic high of 10,500 tpd, beyond the guaranteed production
level of 9,000 tpd.
The plant is located in the Kutch district
in the State of Gujarat, on the northwest
border of India. The State of Gujarat has
the longest coastline among all states in
India and has a long tradition of maritime trade.
The original Sanghi cement plant
was conceptualised in 1994-95 for a capacity of 7,500 tpd with two preheater
towers. However, after combating with
innumerable bottlenecks, including environmental clearances, the work on this
project commenced much later. At this
stage, the plant was redesigned to produce 9,000 tpd with three preheater
strings. However, when commissioned in
the month of March 2002 the plant was
rated for an output of 7,500 tpd with
only two preheater towers.
The clinker grinding plant is located
approximately 12 km away from the
clinkerisation plant, on the shores of the
Arabian Sea. This plant is self-sufficient
with electricity and water, having its own
power generating sets and desalination
facility to cover its service water requirements.
Third preheater string
now on stream
Now with the commissioning of the
third preheater tower the plant has been
optimised at an output level of 10,000
tpd against the guaranteed 9,000 tpd.
It is India’s largest capacity plant with a
single kiln and one of its most modern
100% lignite fired plants.
It has been a rich experience for
FLSmidth’s specialist team to commission
a single kiln with a three-string six-stage
preheater and calciner (one ILC and two
SLC strings). Additionally, arriving at a
capacity of more than 10,000 tpd once
again testifies to FLSmidth’s world-leading technology and project capability
when it comes to very large kiln systems.
Major equipment includes:
• FRM-59.480 vertical mill for limestone grinding,
capacity 670 tph, baghouse for dedusting
• Two FRM-26.30D vertical mills for lignite grinding
• Three-support kiln dia. 5.6 m x length 84 m with
CIS MFR cooler built by Fuller in 1995
• Six stage preheater with precalciner
• Alkali bypass
With Sanghi Cement Plant’s third preheater string (the tower to the right)
now on stream, the plant is producing 10,500 tonnes per day.
24
A cost-effective shortcut
to dry conversion
The rising price of fuel is a growing burden on wet or semi-wet
plants because of the heat it
takes to dry the raw slurry. As a
result, cement producers are
looking at ways to reduce heat
consumption. A hammer mill drier downstream of the converted
cyclone preheater kiln could be
the answer.
Several cement plants still use a wet or
semi-wet process. One way to reduce
heat consumption is to convert the entire production line to the more fuel-efficient dry process. But, this is often a major project involving many elements, including raw material preparation, raw
grinding, shortening the kiln and changing the cooler.
Partial conversion of
the wet plant
Converting the plant to the semi-dry
process is a much simpler and more
cost-effective alternative, particularly if
the raw materials have a high natural
moisture content. The wet preparation
of the slurry is retained, and the wetprocess kiln converted into a cyclone
preheater kiln system. This solution is
cheaper than an all-out dry conversion,
and entails drying the moist raw materials in a separate hammer mill drier before they enter the kiln system.
The hammer mill drier
is the core
The principal machine involved in the
semi-wet concept is the hammer mill drier. This machine is specially designed to
disagglomerate and dry – in one operation – sticky, non-abrasive raw materials
such as chalk, clay, slurry filter cake or
simply slurry. The drier easily copes with
a moisture content in excess of 30 percent.
An apron feeder, a self-cleaning rotary sluice or slurry spray nozzles feed
the materials into the hammer mill drier.
Hot preheater exit gases with an inlet
temperature of up to 750oC continuously sweep the hammer mill drier. After
passing the hammers, most of the material is disagglomerated to a suitable
fineness, and is then swept away by
the air. Final drying takes place in the
riser duct, and the raw meal is then
separated in a cyclone.
The hammer and the rotor are designed to effectively disagglomerate the
feed and ensure heat is transferred from
the gases to the material. To improve
drying efficiency, a static or dynamic separator may be installed in the riser duct.
The purpose of the separator is to return
the large lumps or coarse grains to the
hammers for further pulverisation, enabling more moisture to evaporate.
Reliable and low cost operation
The fineness of the feed must always
match the requirements of the burning
process. The hammer mill drier merely
serves to disagglomerate the wet sticky
materials – and only to some extent
grinds the materials.
An extremely reliable machine, the
hammer mill drier has low maintenance
costs. Because the machine is an integral
part of the kiln system, operational reliability is very important. So far, FLSmidth
has designed hammer mill driers that
meet the requirements of kilns producing up to 4,000 tonnes per day. If the kiln
system consists of two preheater strings,
two driers may operate in parallel.
The hammer mill dryer disagglomerates and dries
sticky, non-abrasive materials in one operation.
25
Contestants give kiln simulator
the thumbs-up
Last year, FLSmidth launched
Beat the Autopilot, a kiln simulation competition designed to
demonstrate the complexity in
process control and optimisation. More than just competitive
fun, the simulator is a great
learning tool to help operators
improve their knowledge and
reaction times.
The completion was a web-based simulation of an ILC kiln process where the
number of measurements and control handles was reduced significantly for the sake of simplicity.
Also, in order to reflect the process
interaction in the shortest available time, the speed of the
simulation was accelerated by a factor of
20. In this way
the players were
able to interact
with the simulator and observe
the process response to their own actions over 100 minutes in just
five minutes.
26
Highly responsive
Within days of its launch, dozens of
competitors from around the world had
signed up for Beat the Autopilot, pitting
their wits against each other in a bid to
get closest to the optimum process performance target. Feedback has been extremely positive, with participants full of
praise for its realism and attention to detail. One of the early front-runners was
Adrian Oarga, a Plant Operator at Holcim Romania. He says: “The simulator
does an excellent job of reproducing a real kiln, and it responded
to every change I made. For example, when I reduce the fuel
in the burning zone, oxygen
levels at the back end increase
and the NOx decreases
which is what happens in a real
kiln.”
Close to reality
Randy Walters also enjoyed Beat the
Autopilot’s realism. And as a Control
Supervisor operating a four-year-old
3,500 tonne per day 5-stage FLSmidth
preheater low NOx kiln, a 400 tonne per
hour vertical raw mill, a vertical coal mill
and a 150 tonne per hour OK mill for Salt
River Materials Group, he should know.
He said: “It’s pretty close to the real thing.
I like that it shows that making too many
moves will put the kiln in a cycle that can
result in out of spec. clinker or emissions
that aren’t within range.”
Asked what functions would have
enhanced the simulator’s accuracy,
Randy Walters opted for kiln speed and
secondary air temperature. But overall,
he felt the simulator was a very good
learning tool. “It can really increase the
knowledge and improve the reaction
times that are needed to operate newer
kilns,” he concluded.
“Our idea with this web competition
was to demonstrate the process control
complexity,” says Hassan Yazdi, FLSmidth
Automation Product Manager. “Changing one parameter for process control,
main fuel for example, influences several
process parameters. Some of these are
desired changes, some are not. This is
due to interactions inside the process.
That is why a tight control of the process
for best utilisation of power and fuel requires a computer-based expert system,
an autopilot in other words.”
As the players could play as many
times as they liked, their performances
have steadily improved. This shows that
a safe environment, where operators
can conduct “trial and error” exercises
will certainly prevent unnecessary waste
production, process shut downs and
overhead production costs.
“This web-based process simulation
has also proven the potential for remote
operator training in the cement industry,” concludes Hassan Yazdi.
New literature
FLSmidth’s 125th anniversary book
To order copies of FLSmidth’s 125th
anniversary book, please contact Marketing
[email protected]
Since the last issue of Highlights, FLSmidth has issued
the following new brochures. Order your own copy
from FLSmidth’s Marketing Department at
[email protected] or download a PDF file from our
website, www.flsmidth.com
Air Blast Controlled inlet
– ABC inlet
Describes the new cooler
inlet which makes snowmen
a thing of the past.
FLSmidth O & M – the
total service concept
FLSmidth is widening its scope of
service to cement producers by
introducing complete Operating
and Maintenance contracts.
FLSmidth terminal
solutions
A complete range of ship
unloading and loading facilities is offered by FLSmidth.
Our capabilities
All the materials handling
systems and equipment
compiled in one brochure.
Addresses worldwide
An up-to-date list of
FLSmidth Group
companies and offices
around the globe.
27
Take the e-highway to
FLSmidth spare parts
Every time we build a cement
plant or deliver machinery and
equipment, we make a commitment to provide any additional
parts our customers might need
to operate and maintain their
plant or equipment. This has
been our promise for the last
125 years and one we will uphold well into the future.
A standard cement plant contains more
than a million different parts - the majority of which are non-standard - and
FLSmidth can offer replacements for all
of them. For the machines we sell, we
can supply everything from the smallest
screw to the largest rotating gear component. It’s essential that the customer
receives the right parts with the correct
28
specifications every time, so we accurately identify the correct parts when
handling orders for replacements. It is
equally important that we receive the
right information to process orders
swiftly and efficiently.
The key to correctly identifying spare
parts is maintaining a detailed and upto-date record of the machinery supplied, including each of its components.
Which is why every contract for
FLSmidth machinery includes a comprehensive catalogue of spare parts for the
plant or installation in question. Traditionally, these catalogues have been
presented as paper copies. However,
we are introducing an additional ‘eCatalogue’ to new contracts which can
be accessed via the FLSmidth Customer
Services website.
Vasavadatta Cement
chooses FLSmidth pyroprocessing
technology
e-Catalogue saves time and effort
The e-Catalogue is a dynamic and userfriendly tool for searching for spare parts
information. An online resource, the eCatalogue for the particular plant is updated when FLSmidth Customer Services
is informed about subsequent changes
or adjustments at the customer’s plant
and also when FLSmidth and the customer agree on technological improvements to equipment or components.
This means that customers no longer
need to update their own spares documentation. And to eliminate errors, both
the customer and supplier use the same
information.
An improvement on its hard copy
counterpart, the e-Catalogue is simple
to work with and precisely identifies
spare parts by part number. Customer
inquiries sent via e-Catalogue will automatically track all the information needed to identify the individual parts. This
information is sent to the customer and
forwarded to FLSmidth Customer Services for swift processing, saving time
and effort for both parties involved.
In December 2006, FLSmidth
commissioned a 3,800 tonnes
per day pyroprocessing system
for Vasavadatta Cement, a
member of B.K. Birla Group’s
Kesoram Industries Ltd. A
leading cement manufacturer,
B.K. Birla operates two clinkerisation lines in the southern
Indian state of Karnataka.
In June 2004, FLSmidth India was invited
to bid for a third line at the existing site
at Sedam. While the proposal was being
evaluated, key representatives from
Vasavadatta Cement visited FLSmidthsupplied cement plants in India, China
and Europe.
The Vasavadatta representatives
were impressed by the efficiency of the
FLSmidth plants they visited. This, and
FLSmidth’s prompt response to the bid,
meant Vasavadatta Cement selected
FLSmidth’s most advanced pyroprocessing technology.
First Rotax in India
Vasavadatta Cement is using the first
Rotax kiln in India, a 6-stage ILC preheater (with provision for future incorporation of a HOTDISC) and an SF CrossBar cooler. The plant also includes a baghouse designed for 800,000 m3/hr at
2400° C. The baghouse complies with
stringent emission standards and comes
with an on-line maintenance facility. The
baghouse uses specially treated fibreglass bags, and has an overhead outlet
manifold that was designed specifically
to customer layout requirements.
The kiln firing and kiln feed systems
are provided with Pfister rotor scales
(sourced from Pfister Germany/Pfister’s
licensee in India).
With plant operation stabilised,
clinker production now stands at 4,200
tonnes per day with free lime well below
1.5 percent as guaranteed.
Vasavadatta Cement’s new line 3 contains the
best of FLSmidth pyroprocessing technology,
including the first Rotax kiln in India.
e-Catalogues available for
all recent and new contracts
The e-Catalogue will be provided with
new contracts as a supplement to the
traditional hardcopy catalogues. e-Catalogues are also available for all equipment contracts dated from 2000 and we
are working to introduce e-catalogues
for all equipment contracts entered into
between 1995 and 2000.
We believe that electronic documentation is the way forward and we
expect to further develop and expand
our e-Catalogue platform to continue to
make it even easier to do business with
FLSmidth.
29
Sebryakovcement sets the ball
rolling in Russia
On a cold winter’s day in January 2005,
the contract for a ball mill installation at
JSC Sebryakovcement in Russia became
effective. In addition to the 120 tph
UMS 46x14 mill, the contract included a
SEPAX separator, a MAAG CPU gear unit
and FLSmidth Automation control
equipment. The contract was preceded
by several rounds of tendering and
negotiations.
What made the order particularly interesting was the fact that it came from
Russia, and so was a sign of growing
activity in this potentially huge market.
JSC Sebryakovcement was among the
very first to team up with FLSmidth in
the expansion and modernisation of the
Russian cement industry.
Now, two years later, cement consumption in Russia has rocketed above
the magic 50 million tpy mark, and the
Sebryakovcement ball mill is working all
out. The plant has achieved, and at
30
times exceeded, the guaranteed
throughput of 120 tph of standard OPC
ground to a fineness of 3,200 blaine,
which makes this mill the largest installed in Russia. By January 2007, the
parties involved in the project were able
to celebrate a job well done with the final handing over of the grinding plant.
Getting the job done
JSC Sebryakovcement is about three
hours’ drive northeast of Volgograd,
which is a fairly remote place even by
Russian standards. As a result, the project had to be planned and organised in
minute detail and the customer was
keen to ensure good working conditions
at the site. FLSmidth’s staff were accommodated at a nearby hotel owned by
JSC Sebryakovcement and participated
in all stages of the project, from openbox inspection, supervision of mechanical and electrical installation to final
commissioning. FLSmidth Automation
and MAAG Gear specialists also took
part in the process.
FLSmidth used its global organisation to design the plant and have the
machinery manufactured. It is hoped
that the Sebryakovcement mill will serve
as a reference project that both the customer and FLSmidth can be proud of
– and inspire other cement producers in
Russia.
12 December 2006 saw the achievement of the guaranteed production level: the mill ran for 68 hours at 90 percent charge – with only two stoppages
lasting a total of one hour. Since then
the ball mill has just kept on rolling.
Sebryakovcement’s new UMS cement mill is producing 120 tph of standard OPC. The successful commissioning and final handing over was celebrated in
January this year.
The UMS mill was delivered by barge and then by truck to the Sebryakovcement plant, 300 km northwest of Volgograd.
Can you travel next Wednesday? Continued from back page > > >
According to Niels, FLSmidth’s performance in implementing these projects was
recognised at ministerial level, and this
fact contributed to the company and its
partner Orascom subsequently winning
three major projects in Algeria: M’Sila,
CIBA White and CIBA Grey.
Human understanding, project
management and technology
must interact
Almost 50 years after his first assignment abroad, Niels is still on the go, cigar in mouth. His favourite destination is
Titan in Greece, back where it all started.
Twelve kilns have been bought by Titan
from FLSmidth, and Niels has many old
friends in high-ranking positions among
Titan’s staff who continue to draw on his
and FLSmidth’s expertise. This is how it
should be in an industry based on longterm relationships. It takes time to learn
how to install and maintain a cement
plant.
As Niels sees it, training is the alpha and
omega. Both FLSmidth and its customers
should be willing to spend time and resources on training selected candidates.
He himself has had the pleasure of guiding several young FLSmidth engineers
and a large number of customer
trainees. He has taught them the art of
combining human understanding, project management and technology so that
they are able to install, commission, optimise and maintain a production line.
“Once you’ve learnt how to combine
these aspects, there’s no limit to how far
you can get,” Niels concludes.
Niels Munk Jensen (front row, left) as
a machinist’s apprentice in 1958.
Niels Munk Jensen at the same
spot in 2007.
31
Can you travel next Wednesday?
The year is 1970 and Niels Munk
Jensen is busy painting his flat in
Denmark when the phone rings.
On the other end of the line is
Mr P.A. Knudsen, FLSmidth’s
renowned Vice President of
Sales. An important kiln installation job is underway in Greece
and there is a vacancy for a bright
young engineer.
On the job:
>
>
>
>
>
>
Niels did not hesitate. He had been waiting for such a call for a year while working in the Layout Department. Since his
youth, Niels had heard his father tell
stories about the exciting adventures of
an FLSmidth engineer working overseas.
So after leaving school at the age of
17, Niels was determined to work
abroad. In 1958 he embarked on
the classic career path
of an engineer:
a machinist’s apprenticeship at the
FLSmidth machinery works, followed by
a BSc in mechanical engineering and
then military service and officer’s training
in the Air Force. He had acquired craftsmanship, engineering expertise and
leadership training, in that order.
Niels left for Greece the following
Wednesday and has been travelling ever
since, with the occasional assignment
back at headquarters in Denmark, enabling the children to stay in touch with
their Danish heritage.
Nihil sine labore
– nothing without work
Thirty years of travel have taken Niels
and his family to
many countries:
Greece, Algeria, Poland,
Chile, Holland,
Belgium, Mexico, Turkey,
Egypt, Portugal and France. Major projects tend to last between one and three
years and Niels lists the Mediterranean
countries of Greece, Turkey and Algeria
as his favourite stop-offs.
Niels lets his work and spare time
blend to such an extent that he builds
replica antique monuments at all major
sites where he works. On these Greekinspired statues he inscribes his motto
“Nothing without work” in Latin, Arabic
and runes, serving as an inspiration for
visitors and a lasting testament to a job
well done.
His passion for international relations
is as strong as ever. As he says, “If you
can build strong human relations at a
construction site, the technical side is a
piece of cake.”
Niels left his mark on the camp facilities of major turnkey projects in the
somewhat turbulent Algeria during the
1980s (Ain Touta) and 90s (Tebessa). Despite the political uncertainty, everyday
life had to go on. At Tebessa, the situation became so insecure that most foreigners left the country, though FLSmidth
remained at the construction site. However, it soon became necessary to abandon the beautiful camp, including the
large swimming pool designed by Niels.
While in involuntary exile in Spain, Niels
designed a new high-security camp
which the customer then built at the
plant site in just two months. A self-contained community complete with restaurant, bar, lounge, chicken yard, park and
green houses, the camp and a host of
communal activities helped to keep spirits high in a tough environment.
The cement project was completed
to the customer’s full satisfaction and
the Final Acceptance Certificate was obtained on time and without lengthy discussions, despite bureaucratic hurdles.
< < < Continues on previous page
32

Highlight_1_2007

Transcription

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