Highlights Cement Oct2014

OCTOBER 2014
Thinking
beyond
EPC
Semen Indonesia
gains newest
OK mill
Worlds first
Postgraduate Cement
Plant Engineering Degree
HIGHLIGHTS CEMENT October 2014
LETTER FROM THE PRESIDENT
Strong partnerships
for a stronger future
Despite the cement market still being in a cyclical downturn, we
are on track at FLSmidth having the highest level of unannounced
orders for three years. We are seeing growth in opportunities in
countries including the Democratic Republic of Congo, Angola,
Nepal and Indonesia, which you can read about in this edition of
Highlights. Recently, we announced several important large orders,
including the supply of a complete equipment package for a
3,000 tpd greenfield plant in the Democratic Republic of the
Congo under the flagship of Lucky Cement Limited and the Rawji
Group (page 4). Another is the major modernisation project of
Holcims Ada plant in the US (page 5).
Product development and innovation are a hallmark of FLSmidths
contribution to the cement industry. Our most recent major release
is the new version of the OK Mill, which has been commissioned
at Semen Indonesias Tuban cement plant in Java, Indonesia. This
newest version of the OK Mill is a prime example of how FLSmidth
applies performance data and practical knowhow gained from
operations around the world. Close collaboration with cement
plants is an important element of FLSmidth research. Our research
partnership with Titan Cement (page 24) in conducting tests on
its OK Mill reflects our commitment to delivering solutions that
help meet our customers business challenges.
Contributing to local society is also central to the value we offer,
in particular training of local workforces. Our joint initiative with
the Helwan University in Egypt is an example of the long-term
efforts being made in overcoming the critical shortage of skills in
operating cement plants. Read about the FLSmidth sponsorship of
Helwan Universitys new post-graduate cement plant engineering
degree on page 8.
360 certainty solution: Design, Build and Operate
For cement plant owners and investors in todays demanding
business environment, we are continuing to see a greater need for
strong partnerships to add capacity and expand into new markets
from design and engineering to operation and maintenance.
FLSmidth continues to strengthen its offerings in all these areas.
Read more about FLSmidths Design, Build and Operate solution
on page 26.
Welcome to Highlights Cement.
Per Mejnert Kristensen
President, Cement Division
SCAN TO VIEW PER

MEJNERT KRISTENSEN
INTRODUCE THIS EDITION
OF eHIGHLIGHTS
cement.flsmidth.com
gives you more details and
additional articles
Editor-in-chief
Nadia Haagen Pedersen
Managing editor
Charlotte Lrke Backmann
Content editor
Kit Franklin Momme
Associate editors
Brenda Kaplan,
Bharathkumaar Soundararajan
Editorial board
Mark Brugan, Palle Erik Grydgaard,
Sten Stoltze, Martin Strouhal, Hari TR
Layout: Cross-Border Communications
2014 FLSmidth. All rights reserved.
Reproduction permitted quoting
Highlights as source.
All product names used herein are
trademarks of their respective owners.
Editorial office:
FLSmidth
Vigerslev All 77
DK-2500 Valby, Copenhagen, Denmark
Tel: +45 36 18 10 00
Fax: +45 35 45 44 27
Email: highlights@flsmidth.com
www.flsmidth.com/ehighlights
CONTENTS
Letter from the President
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MORE INFORMATION VIA YOUR SMARTPHONE
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GETSCANLIFE.COM
FRONT COVER: ILLUSTRATION OF FLSMIDTHS
NEWEST OK MILL, RECENTLY COMMISSIONED
AT SEMEN INDONESIAS TUBAN CEMENT PLANT
(SEE PAGE 6)
FEATURES
Worlds first Postgraduate Cement
NEW ORDERS
Plant Engineering Degree
New cement plant for the Democratic
Right first time
14
Thinking beyond EPC
26
SITE REPORTS
Republic of Congo
FLSmidth to modernise
Holcim US Ada plant
Clinkerisation project underway
INNOVATION
in Nepal
22
New graphite seal optimises kiln
Gas-insulated switchyard in India
32
performance
12
V8 process control system
18
PRODUCTS & SOLUTIONS
FLSmidth research delivers

silo-safe cement
Great teamwork and reliable

technology minimise plant disruption 36
The new ECS/ControlCenter
24
Semen Indonesia gains newest
Innovative fabric filter design
28
OK mill
FLSmidth STRIKE-BAR crusher
34
Delivering to customer needs
21
News in brief
38
Upcoming events
40
24
SCAN HERE FOR

PDF VERSION OF
THE HIGHLIGHTS
MAGAZINE
22
NEW ORDERS
CONTACT HUBERT SUINAT
HSU@FLSMIDTH.COM
Read more about new

orders on www.flsmidth.com/
announcements
New cement plant for

the Democratic
Republic of the Congo
DR Congos newest
greenfield cement plant
in more than 40 years
FROM L-R: MR. AHMED MASHKOOR,

MR. CARSTEN ZACHER GRAUGAARD,
MR. MUHAMMAD ALI TABBA, MR.
JOHANNES ENGELSBY HANSEN, MR.
HUBERT SUINAT
Rawji Group of the Democratic Republic of

the Congo. Together, they have formed a
joint venture, and the new entity, Nyumba
Ya Akiba sarl, will become one of the
countrys largest cement producers.
Lucky Cement is Pakistans largest producer
(7.75 million tpy) and a leading exporter of
high quality cement. Founded in 1993, the
company has developed to be the Pakistani
cement industrys trendsetter in terms of
business excellence, innovation and environmental performance. It is part of YBG,
which is among Pakistans leading business
houses with an unparalleled reputation for
professional management and strong
business ethics.
FLSmidth has been selected to supply a

complete package of equipment and engineering for a greenfield cement plant in
the Democratic Republic of the Congo.
The plant will be located in the province of
Bas-Congo, approximately 250 km west of
the capital Kinshasa. Worth EUR 68 million,
the contract includes all the engineering,
equipment and support for the construction
of the 3,000 tpd plant.
The equipment to be supplied includes

FLSmidth crushers, pyroprocessing equipment and vertical mills for raw meal, coal
and cement grinding all well-proven
machinery that is characterised by high
productivity, flexibility and energy efficiency.
DR Congos largest cement producer
The partners behind the project are Yunus
Brothers Group (YBG) of Pakistan under
the flagship of Lucky Cement Limited and
The Rawji Group includes companies involved

in commerce, industry and finance. Its history
goes back to 1910 when Mr Meraldi Rawji,
an Indian businessman, started trading
activities in the Congo. Today, the fourth
generation of the Rawji family is in charge
of the groups interests that range from
import and distribution of products and
equipment and manufacture of soaps,
edible oils and cosmetics to property and
banking services. With its extensive activities,
the group has in-depth knowledge of the
countrys social fabric and its economy.
Growth market
In addition to its enormous mineral resources, the Democratic Republic of the
CONTACT SCOTT ZOLOTSKY

SCOTT.ZOLOTSKY@FLSMIDTH.COM
Congo is characterised by growing stability

and a rapidly increasing population. There
is therefore an urgent need for cement for
the development of infrastructure and
housing. For the past 40 years, no new
cement plants have been constructed in
the Republic, therefore it is a very interesting market for FLSmidth, says Per Mejnert
Kristensen, President of FLSmidths Cement
Division.
The project
Nyumba Ya Akiba and the projects financiers highlight FLSmidths proven ability to
supply environmentally optimised and
energy-efficient equipment. They demanded
a solid technology provider with a proven
ability to deliver reliable products, particularly because of the challenging conditions
under which the plant will be installed and
operated.
The site of the new plant, Kinsua village
in Songololo territory of the Bas-Congo
province was selected because of the good
quality raw materials in its vicinity. The new
plant will provide much-needed cement for
housing construction and road building in
a rapidly growing region. DR Congo is
Africas second-largest country and there is
a significant gap between its current production capacity and demand for cement.
As the political climate is beginning to
stabilise, investments in the economy are
likely to take place. The new plant will also
be well placed for exports to neighbouring
countries.
FLSmidth is proud to have been chosen by
two highly professional and experienced
business partners to supply a state-of-theart cement plant in a region with vast
potential for growth.
FLSmidth selected as
supplier for Holcim (US)
Ada Oklahoma Plant
modernisation
project
FLSmidth has been selected to supply the

major equipment pieces needed as Holcim
looks to modernise its Ada Oklahoma
plant. The modernisation of the pyro process is expected to deliver lower emissions
of nearly all air pollutants while anticipating
an increase in the plants capacity.
The contract includes a dryer crusher, a
single-stage preheater with an ILC-calciner,
a dedusting cyclone, a ROTAX-2 kiln, a
kiln bypass system, a Duoflex kiln burner
and Cross-Bar cooler.
With the installation of two new FLSmidth

dust collectors, the project will significantly
improve the plants ability to reduce the
particulate emissions.
This contract further demonstrates
FLSmidths ability to help US cement
producers prepare for the upcoming
NESHAP regulations.
Semen Indonesia
gains newest
CONTACT KLAUS BGESKOV HANSEN

KBH@FLSMIDTH.COM
Amidst a buoyant cement

industry in Indonesia, South
East Asias largest cement
supplier, Semen Indonesia, is
continuing to raise the bar on
cement production capacity
and efficiency.
FLSmidths newest version of the OK mill has been commissioned

at Semen Indonesias Tuban cement plant in east Java as part of its
plans to use advanced, high-quality technology that delivers the
lowest possible energy consumption and the minimum possible
environmental impact.
OK mill
FLSmidths new OK mill, featuring an updated mechanical package

and structural design, will provide the required boost to Tubans
grinding capacity, helping to make the plant more effective and
energy-efficient.
Based on market data
This latest version has been developed using the performance
data from other FLSmidth OK mills as well as the practical knowhow and experience gained from working with them. Important
parameters included reducing maintenance requirements and
maintaining competitive pricing.
The update included reviewing and evaluating the complete mechanical package and structural design of the mill.
Of the many updates applied to the mill, the most significant
included optimising the grinding pressure needed for grinding
ordinary and high-Blaine cement. The grinding profile of the roller
and table enable a narrow wedge-shaped grinding area, without
compromising the peak pressure, which is the highest of any mill
in the market. The table profile ensures uniform bed thickness,
which eliminates the need for additional rollers or rolling scrapers
to remove material accumulated inside the dam ring.
The new OK mill includes the latest version of the ROKSH separator, which is an updated version of the standard OKS separator.
Requiring extremely low power, the ROKSH is a low-wear, highly
efficient separator and is one of the most durable top seals in
the market.
FLSmidths OK mill
FLSmidths OK mill is a vertical roller mill designed for cement
and slag grinding. It combines drying, grinding and separation
processes into just one unit and can provide savings of approximately 40 percent in power consumption compared with traditional ball mills. This latest version has been commissioned at
cement plants in Brazil, Indonesia and India, joining the more
than hundred FLSmidth OK mills in operation around the world.
FLUID DYNAMICS WAS

APPLIED TO ACHIEVE THE
AIRFLOW CONDITIONS
NECESSARY TO OPTIMISE
PERFORMANCE AND
REDUCE WEAR
Optimal airflow
Fluid dynamics played a vital role in the development of the new
OK mill. The airflow through the nozzle ring and inside the mill
was carefully analysed to ensure the right amount of material was
lifted into the separator. To minimise wear, it was also important
to know the air velocity required in the mill to optimise the load
on the guide vanes and rotor.
Increasing demands for cement
Indonesias economic growth in recent years, resulting in continuing
investments in infrastructure development, has had a significant
influence on the countrys cement production demands. As Indonesias leading cement supplier, PT Semen Indonesia has played a
major role in servicing the cement demands. The companys Tuban
plant is located in East Java and has a total output of 33,600 tpd.
Tubans four lines have all been supplied by FLSmidth. Tuban required
extra grinding capacity at two of its lines. Even though the plant
operates with many ball mills, it needed more effective and energyefficient mills. This was a key reason for the choice of an OK mill.
The OK mill was put into service in 2013 as an Ordinary Portland
Cement (OPC) finish grinder. The mill was fitted to grind clinker
from the older but updated production lines Tuban 1 & 2. However,
Tuban also needed to use it for Portland Pozzolana Cement (PPC)
finish grinding for cement containing trass, a volcanic tuff that is
harder than the normal Pozzolane and has a higher level of moist
content. The upgrade project started in 2010, and the new OK
mill 42-4 with a capacity of 250-300 tph, began operations in
October 2013.
Beating performance requirements
Klaus Bgeskov, Project Manager at FLSmidth, explains how some
of the installation and commissioning challenges were tackled:
We often face challenges in space limitations when installing
new equipment. It was no different at Tuban Cement as the OK
mill had to be squeezed between two existing mills. We solved it
by modifying the mills design to fit the plants layout.
Klaus Bgeskov explains that the OK 42-4 mill was guaranteed
to 250 tph OPC according to ASTM C-150 Type 1 (Standard
Specification for Portland Cement). But when the PGT certificate
was signed, the mill was running 253tph at a Blaine value of
3559cm2/g, he says, adding, The total power consumption
goals for the main motor, separator and fan motor were 26.8
kWh/t, and we achieved a figure of 24kWh/t.
WE OFTEN FACE
CHALLENGES IN SPACE
LIMITATIONS WHEN
INSTALLING NEW
EQUIPMENT. IT WAS NO
DIFFERENT AT TUBAN
CEMENT PLANT AS THE
OK MILL HAD TO BE
SQUEEZED BETWEEN
TWO EXISTING MILLS.
Klaus Bgeskov,
Project Manager at FLSmidth
FEATURES
CONTACT CRISTINA HOLMARK
CRHO@FLSMIDTH.COM
Worlds
first
Postgraduate Cement Plant
Engineering Degree
FLSmidth and Helwan

University in Egypt
launch new education
programme, paving
the way for a cement
plant career
Operating and maintaining cement plants requires a high level of

competence, and a critical shortage of skills in some local regions
has made it difficult to operate plants at maximum efficiency.
One of those regions was Egypt, where FLSmidth has had difficulty
employing qualified engineers with the right experience and skillset.
This is a key reason behind FLSmidths drive for a postgraduate
cement engineering diploma degree programme in Egypt. Launched
in February 2014, the degree has been put together in partnership
with Helwan University.
Cristina Holmark, General Manager of Global FLSmidth Institute,
has led FLSmidths development of the degree. She explains,
The idea was to create a graduate level degree that could bridge
the educational and qualification gap for engineers and prepare
them adequately for a potential career in the cement industry.
We also saw it as a good opportunity to play a very positive role
in the local community as well as nurture loyalty among FLSmidth
Group employees.
The degree is a combination of academic theory and practical
experience, which is designed to equip cement plant engineers
with the knowledge and hands-on experience required for
cement plant operation and maintenance. It makes effective use
of different learning styles to stimulate and motivate students.
Cristina Holmark elaborates, Students are exposed to lectures
with professors from Helwan University, group work and plant
visits. The plants involved are Ramliya and Wadi el Nile where
students will be exposed to our high safety standards and
on-the-job challenges.
Successful knowledge transfer
The diploma degree is part of an extensive education programme
that started in late 2009 with the search for an academic partner.
Cristina Holmark says, We looked into and spoke with several
universities in Egypt and the choice fell on Helwan University relatively quickly. Apart from being located close to cement plants,
Helwan University showed the most interest and demonstrated
high commitment. The university is a large public university with
around 100,000 students and 21 faculties, so we are very pleased
to be partnering with Helwan.
Less than a year after an agreement was reached, the first phase
of the programme was launched by the FLSmidth Helwan Cement
Institute. This involved a pilot project of two semesters that was an
essential part of developing a workable, sustainable educational
programme resulting in the diploma degree.
We wanted to create this degree according to established
academic processes, explains Cristina. This involved extensive
train-the-trainer programmes, including formal training sessions
in Denmark and Egypt as well as peer-to-peer training.
During the pilot project, FLSmidth Group engineers did the student
lectures, while the universitys professors observed and learned.
We feel this process has equipped the professors well, so they
would be able to teach the course material independently following
the pilot project.
And the pilot project was quite a success. Of its 33 graduates,
11 have been employed at three different plants operated and
maintained by FLSmidth and others have found employment in
related industries.
A world-first for the cement industry
Meanwhile, during the pilot project, extensive preparation was taking
place for the full implementation of the cement diploma degree.
This involved obtaining approval from Egypts Higher Counsel of
Ministry of Education, a process that took one year. With the
ministrys blessing, the degree was sanctioned allowing 16 students
to begin their new educational venture in February 2014. >>
The Helwan Postgraduate Cement

Engineering Diploma Degree
This is a diploma degree course offered by Egypts Helwan
University and created in partnership with FLSmidth.
The degree is taught by the Universitys staff and provides
three semesters of academic teach and a practical project
supplemented by short cement-specific courses.
Sixteen students from different Egyptian cement companies
are enrolled in the programme for 2014 and 2015.
10
WORLDS FIRST
POSTGRADUATE CEMENT PLANT
ENGINEERING DEGREE
STUDENTS AFTER A
DAY OF CLASS ROOM
LECTURES OUTSIDE OF
THE TRAINING CENTRE
Cristina Holmark emphasises that the programme is now owned

by Helwan University, following the success of the pilot project
and handover process: FLSmidths role in the future is to help
with marketing and promotion as well as training the professors.
We will provide any necessary support, but it is the universitys
programme now.
WERE NOT JUST

OPERATING A PLANT, WE
ARE SUPPORTING THE
COMMUNITY AND
WORKING ACTIVELY
WITHIN IT. TRANSFERRING
KNOWLEDGE IS A
FUNDAMENTAL PART
OF THIS.
We are very happy that the goal we set out to achieve in 2009
has come to fruition. Helwan is now the first university in the
world to offer a degree like this, so we are proud to be behind it,
she adds.
Professor Yasser Sakr, Helwan University President, sees many
benefits for the university, claiming, This degree provides an
attractive value proposition for the university. Our partnership with
FLSmidth has enabled us to prepare an innovative curriculum and
a commercially viable offering to the private sector, and it has meant
we have developed state-of-the-art facilities for our students.
Cristina Holmark,
General Manager of Global FLSmidth Institute
PROMOTIONAL LAUNCH OF
THE POSTGRADUATE CEMENT
ENGINEERING DIPLOMA
DEGREE, OFFERED BY HELWAN
UNIVERSITY, CAIRO, EGYPT IN
COOPERATION WITH
FLSMIDTH, COPENHAGEN,
DENMARK
Professor Sakr is also convinced that it provides significant benefits

to students: The degree will provide the students with marketable
skills and almost certainly a stepping stone to employment. The
international environment offered through the collaboration with
FLSmidth is very valuable, in particular.
Bonding with the local community
The cooperation between Helwan University and FLSmidth is a
public-private partnerships in Egypt. It is expected to benefit the
industry, the tertiary education system, local society in general,
and FLSmidths profile in Egypt. Indeed, Denmarks Ministry of
Foreign Affairs has identified this as a role-model example of CSR,
and the Danish governmental aid organisation, DANIDA, has
supported the project under its Innovative Partnership Development (IPD) Programme.
Cristina Holmark is convinced the programme has strengthened
FLSmidth Groups ties to the local community by playing an active
POSTGRADUATE
STUDENTS ON FIRST
SEMESTER
role in raising the education and skill levels of cement plant engineers: We want the partnership to make a long-term difference
for the community. It is a sign of our commitment to the country
and the plants that we operate and maintain for our customers.
Initiating and developing local programmes such as these is the
FLSmidth Institutes core business. Other similar projects currently
underway internationally include an energy efficiency training
programme in Vietnam and a vocational programme for unemployed youths in India.
For FLSmidth as a whole, its important to realise that were not
just operating a plant, we are supporting the community and
working actively within it. Transferring knowledge is a fundamental
part of this, asserts Cristina Holmark. I believe we have 33 graduates and 16 current students on the FLSmidth Helwan Cement
Institute programme who can attest to that.
11
12
INNOVATION
CONTACT MORTEN HANSEN
MOH@FLSMIDTH.COM
CONTACT NAVEEN SEELAM
NKS-IN@FLSMIDTH.COM
New
graphite seal
optimises kiln
performance
Designed for fast installation
on any kiln, FLSmidths new
kiln graphite seal reduces ID
fan power consumption
Energy efficiency and low maintenance is essential to optimal

kiln performance. The new FLSmidth kiln graphite seal reduces
the need for maintenance and optimises the operation pressure
stability by preventing false air entering the system.
FLSmidth provides a highly effective kiln seal that utilises carbon
graphite. The seal, which fits any kiln, uses a staggered
arrangement of overlapping graphite blocks [1] held in place
by a wire rope system to ensure an efficient seal against the
outer air casing [3]. The arrangement allows the graphite
blocks to move independently with the radial movement of
the kiln without the graphite blocks getting stuck or damaged.
The locking plates [4] on the rear flange [2] is a key design
feature that prevents false air from entering the kiln system.
The inlet seal air casing is designed to handle back spillage,
directing it to the hopper for collecting in the bin.
Trial assembly of the modular frames and thorough inspection
of geometrical tolerances of the flanges in the workshop
ensures the highest product quality standards.
EACH MODULE IS
DESIGNED TO BE
PRE-ASSEMBLED BEFORE
INSTALLATION
SCAN TO VIEW
PRODUCT SITE ON
FLSMIDTH.COM
Designed for predictable, low maintenance

A visual inspection can reveal whether maintenance is required.
When it is necessary, the wire rope system and modular frame
enables quick replacement of the graphite blocks, while specially shaped distance spacers [5] prevent the need to dismount
the flanges.
The wire rope system is comprised of counterweights and
independent rope systems covering each row of graphite
blocks. The ropes grip the graphite blocks tightly in place while
also allowing for movement caused by kiln runout, ovality and
expansion. This design allows for radial movement of up to
+/-50mm and axial movement of approximately 300-400 mm.
The need for spare parts is limited, as the graphite blocks and
wire ropes are interchangeable between the inlet and outlet
seals. Furthermore, the graphite blocks self-lubricating properties significantly reduce the wear of the sealing components.
Typically, the expected wear on the graphite blocks is 5-8 mm
per year, resulting in a long lifetime.
The wire rope is designed to run for a full production campaign,
but as an added preventative measure, the seals locking system
will hold the graphite blocks in place in the unlikely event of

wire failure.
Fast, cost-effective installation on all kilns
The new graphite seal can be fitted on any type and size of kiln
not just FLSmidth kilns. The graphite seal modular concept
is designed to fit to the existing casing and cooling mantle
without the need for modifications.
Installation of the graphite seal typically takes seven to ten
days. A large amount of pre-assembly can take place before
installation. This is made possible by the seals modular design.
FLSmidths inlet and outlet graphite seal has been retrofitted
on a non-FLSmidth kiln at NCC Egypt.
Inlet and outlet seals
Two types of kiln graphite seals are available. The kiln inlet seal
is designed to provide the interface between the kiln and preheater and the kiln outlet seal interfaces the kiln and the cooler.
Both seals are designed to help maintain optimal kiln operating
conditions and to minimise the loss of expensive energy.
VISUAL INSPECTION OF THE SEALING DURING

OPERATION IS EASY. WE HAVE EASY ACCESS TO
GRAPHITE SEAL BLOCKS AND WE CAN CHANGE
THESE WITHOUT COOLING DOWN THE KILN
COMPLETELY IF NECESSARY. THAT IS A HUGE
ADVANTAGE. FURTHERMORE, ANY BACK
SPILLAGE FROM THE INLET IS EFFECTIVELY
HANDLED AND LEAD TO THE GROUND.
Technical Project Manager, NCC Egypt
13
14
Right
FEATURES
first time
CONTACT SIMON LINDBERG

SLIN@FLSMIDTH.COM
Production underway
at FCKS cement plant
in Angola
Paul Dreyer looks back at the commissioning

of the new Angolan cement production
plant Fabrica de Cimento Do Kwanza-Sul S.A.
(FCKS) with satisfaction. It was a difficult
project with many obstacles, but despite
the difficulties, we managed to commission
the cement plant in the best possible way,
says the FCKS technical administrator.
From the crushers to the raw mill to the
kiln and packaging plant, we managed to
commission, start up and conduct successful
performance tests the first try every time.
Nothing failed; all key equipment behaved
as it should. I have not experienced this
before and it was beyond our expectations.
The commissioning was all the more impressive considering the plants unique
challenges. FCKS is located in a remote area
near the town of Sumbe in the Kwanza Sul
province, about 300 km south of Angolas
capital, Luanda. Even though Angola has
vast mineral resources and a fast-growing
economy, its cement industry is underdeveloped and the country possesses very limited
specialist cement expertise. As one of
Angolas newest and most modern cement
plants, FCKS represents a significant step in
the development of the countrys growing
cement industry. That is why it was important to work with a reputable, experienced
partner. This is how we saw FLSmidth,
says Paul Dreyer.
To complete the plant FCKS entered into an
EPC contract with ETA Star International
from Dubai. FLSmidth supplied all the design
and all mechanical, electrical and automation equipment for the cement plant.
Knowledge transfer for

sustainable operations
FCKS has chosen to continue its close
relationship with FLSmidth Group through
an operation and maintenance (O&M) contract over the next five years. The contract
sees NLSupervision part of the FLSmidth
Group employing all the necessary plant
operators and maintenance personnel. It
also includes sourcing and inventory control
of spare parts and lubricants. The plant is run
by the local recruitment and training divison
with local personnel under the supervision
of key NLSupervision staff backed by the
knowledge center of FLSmidth Group.
Paul Dreyer explains the reasons for outsourcing O&M: Since the level of expertise and
resources in the cement industry in Angola is
still very limited, and because FCKS is relatively
new to the cement industry, it makes sense
to be assisted by people who are highly
experienced in cement plant operations. >>
15
16
RIGHT
FIRST TIME
It brings us a lot of benefits for FLSmidth

Group to operate and maintain the plant,
not just because we have FLSmidth equipment, but also because they can easily
source spare parts and provide the right
technical support.
All equipment knowledge and many of the
supervisors involved with the plants construction and commissioning have now moved
into the O&M team. Simon Lindberg, Project
Manager says, This will bring valuable
experience and knowledge to the O&M
team, which ensures the plant can continue
full production during the transition period
from commissioning to handover to O&M.
But Paul Dreyer observes that even the most
experienced O&M teams can run into challenges, particularly in a developing nation
such as Angola. There are hiccups with any
new plant and it has taken time for the

operations and maintenance team to find
its feet, but the issues are being ironed out
and we can see improvements daily. One key
issue was the need for a huge expatriate
workforce in the beginning. As a foreign
company in Angola, it takes time and is
not easy to recruit the right workforce and
then build and manage a cohesive team.
He adds: My experience with FLSmidth is
that they do not walk away from or try to
hide a problem. In the event that an equipment problem arises, they take responsibility
for rectifying it. This is a strong quality and
is obviously part of the FLSmidth culture.
In addition to operating the plant, the transfer
of knowledge in efficient and cost-effective
production methods to the local workforce
is an equally important part of the O&M
agreement and a central reason for FCKS

continuing to working with FLSmidth. In
collaboration with the Angolan educational
authorities, NLSupervision is setting up
a training centre where courses will be
offered in mechanical, electrical, process
and safety skills.
Paul Dreyer says, FLSmidths training
division is very strong and we want to
benefit from that as much as possible so we
can become sufficiently skilled in cement
plant operations. The ability to train our
nationals is just as important as the production goals.
The training centre will be operated by NLS
Supervision, Angola, and helps to qualify
local workers not only for the cement plant
at Sumbe, but also more generally for the
industrial environment of any state-of-the-art,
modern plant. This involvement in the

local community is a significant contribution to the development of the Angolan
nation and is an example of both FCKS
and FLSmidth Groups commitment to
Corporate Social Responsibility.
Close teamwork
When the agreement for the 4,200 tpa plant
was signed in 2008, FLSmidths project
scope was the engineering, and the design
and supply of all mechanical, electrical and
automation equipment. All the machinery,
from crushers to kiln and mill to packers,
including automated control systems, were
designed and supplied by FLSmidth to ETA
Star International LLC of Dubai, who was
responsible for the plants construction.
The reputation and quality of FLSmidths
equipment was a key factor in FCKS deci-
sion, explains Paul Dreyer, emphasising

the specialist skills FLSmidth brought to the
project. Simon Lindberg, Project Manager
discusses the challenges of working in a
remote location: The site is located about
30km away from the nearest large town,
Sumbe, in an area with no existing facilities. There were many different parties
involved and everyone lived in a compound
just beside the plant. It was essential that
the different teams could function well
together and to help make this happen,
recreational facilities, an organised office
and a camp area was established.
It was a complex project lasting from 2009
to 2013. Completing the plant successfully
required a lot of hard work, dedication
and good communication by all parties.
We managed to overcome the challenges
through numerous design meetings, close
IT BRINGS US A LOT OF
BENEFITS FOR FLSMIDTH GROUP
TO OPERATE AND MAINTAIN THE
PLANT, NOT JUST BECAUSE WE
HAVE FLSMIDTH EQUIPMENT,
BUT ALSO BECAUSE THEY CAN
EASILY SOURCE SPARE PARTS
AND PROVIDE THE RIGHT
TECHNICAL SUPPORT.
Paul Dreyer,
Technical Administrator, FCKS
cooperation, and the expertise and experience of many solution-oriented people,

working together as a team. We felt like we
were one big family that had been through
a lot together, says Simon Lindberg.
Paul Dreyer believes the contribution
from the FLSmidth team was a key factor:
The coorporation with FLSmidth and
ETA played a huge role in the success of
the commissioning and start-up of the
plant, during which everything went to
schedule.
A foothold for future growth
FCKS aims to achieve 1.1 million tpa clinker in the first year and then lift this to
1.3 million tpa during the second year,
maintaining this production level over the
plants lifetime. Paul Dreyer concludes, Of
course, we are looking to expand business
in the long term and we have plans for a
second line, but for now our main focus is
to get the plant to full capacity and, with
the help of FLSmidth, truly make our mark
in the Angolan cement market.
17
18
INNOVATION
The new
ECS/ControlCenter V8 process control system

FLSmidth recently released the
brand new ECS/ControlCenter V8
process control system for the
cement and minerals industries.
It is now even better than before
more intuitive and simpler to
use thanks to a new, modern and
user-friendly design.
Trend-setter for modern users

In line with current trends, the latest release of the ECS/ControlCenter software is developed with focus on usability and making
things easy to do. This marks a departure from many years of traditional engineering of the system through technical tools.
The intention is to make everyday tasks easier to do not only
for operators, but also for the system maintenance engineers by
simplifying the most common tasks so that deep technical knowledge is not required. This will allow the users to focus on solving
their tasks, rather than figuring out how to work the system.
CONTACT JAN SCHILLING

JSCH@FLSMIDTH.COM
The perfect fit

The ECS/ControlCenter solution is tailor-made for the cement and
minerals industries. It offers the best combination of high-quality
standards combined with the necessary flexibility to adapt to
ever-changing conditions on the plant.
Based on FLSmidths more than 25 years of experience in automating large production plants, all our control system solutions come
with knowledge built-in. Learning from previous projects, gathering experience and listening to feedback has enabled FLSmidth to
make a control system that fits perfectly to customers needs.
As always, the ECS/ControlCenter software delivers the reliability,

scalability and user-friendliness production plants need to be operated effectively.
Beauty is in the details
The previous version of the ECS/ControlCenter software was already
a very strong solution. So what makes the new version even better?
By carefully inspecting every part of the system, FLSmidth has
identified missing features and identified opportunities for incremental improvements.
Through a unique combination of programming skills, experience
in developing control system software, engineering and commissioning expertise and a very close relationship with customers,
FLSmidth has been able to develop a new modern version of the
control system launched more than 25 years ago.
The platform
Through five years of development including two years of site
testing to ensure high quality utilising the latest technologies and
new effective programming paradigms, this is a product prepared
for the future.
The system is built for better integration between different products
on large installations, while at the same time avoiding annoying
constraints and version dependencies. Combined with a strong
server-client foundation, the new solutions will be perfect for
implementation in a virtual environment such as VMware.
Product details
For operators, the system will seem much more intuitive and complete, with all functionality contained in one common portal,
rather than a selection of tools. The new system is much more
user-focused and provides a simplified operator environment with
easy login and a personalised user environment. >>
FLSMIDTHS ECS/
CONTROLCENTER V8
SOFTWARE HAS JUST
BEEN RELEASED
19
20
THE NEW
ECS/CONTROLCENTER V8
PROCESS CONTROL SYSTEM
For example, each operator can choose a specific role such as

mill operator, which will present only information relevant to
the mill areas. This will improve focus on what really matters,
without the confusion and potential information overload from
areas handled by the other operators.
The system will also be available in a simplified version for touch
control, for example for machine control out on the plant floor.
This provides a uniform look and feel across the systems. Linking
these decentralised control systems with an overall process control
system requires minimum engineering and will provide easy access
to all parts of the system directly from the central control room.
THE ECS/CONTROLCENTER SOFTWARE

OFFERS A MODERN, USER-FRIENDLY
ENVIRONMENT FOR OPERATORS.
The ECS/ControlCenter solution still comes with built-in highperformance communication drivers for Siemens, Rockwell and
Schneider process controllers (PLCs) as well as OPC to allow for
flexible hardware selection, while retaining the same user interface.
PLC programming is still required, but utilising the ECS/ACESYS
function block library will encapsulate most of the complexity,
leaving mostly interlocking to the programmer. It also provides
DCS-like functionality and advanced faceplates with direct access
to detailed diagnostics.
Whats next?
The development of FLSmidths products never stops. The next release
of the ECS/ControlCenter software and the supporting ECS/ACESYS
library is planned for spring 2015 and will include improved focus
on functional safety and full alarm management based on the ISA
18.2 standard. FLSmidth is continuously working on making its
products even better for the benefit of customers.
Delivering
to customer needs
My Home Industries (MHIL) is a joint

venture between My Home Group
and CRH plc, an Irish building materials
conglomerate with 3,500 locations
spread across 33 countries.
From three manufacturing units located in
Melacheruvu in the Nalgonda district of
Andhra Pradesh, MHIL produces 3.3 million
tons of cement per annum. Another unit,
Sree Jayajothi Cement SJCL, in the Kurnool
district of Andhra Pradesh produces 3.2
million tons per annum. To meet increasing
demand for cement in domestic and international markets, MHIL has also set up
a cement grinding unit at Mulkapalli in
Visakhapatnam district of Andhra Pradesh
with a capacity of 2.0 million tons of
cement per annum.
FLSmidth won an order for the modernisation of MHILs Line II pyroprocessing unit,
which consists of a six-stage ILC PH tower
and a CIS-CFG cooler. This plant was supplied, constructed and commissioned by
FLSmidth in 2002. After analysing MHILs
requirements, FLSmidth provided a cost and
time-efficient solution to meet MHILs
upgrade objectives. Major objectives of this
upgrade were increased clinker production
and technology upgrades to reduce power

and fuel consumption. FLSmidths intention
is to provide effective, engineered systems
to meet customer requirements by using
the best quality products.
MHIL already had an SF Cross-Bar cooler
2 X 4 in its Line I. MHIL had been very
satisfied with the SF Cross-Bar coolers
performance over the last five years and
wanted to use the best in cooling technology at its Line II upgrade. FLSmidth
engineered a system by modifying the
cyclones 1, 2 and 4 with new preheater
fans, new Cross-Bar 10X37 cooler and a
new modular frame heavy-duty roller
breaker (HRB). The system also included
the new RABH & RABH fan, modifications
to the bag house and kiln main drive.
The project was completed in three phases.
Phase I included a new Cross-Bar cooler
with new HRB. Phase II includes a new
RABH and RABH fan, and Phase III includes
The conditions before and after modification

Guaranteed values

Before
after Phase III
Parameters
modification modification
Clinker production,
MTPD
2472 2750
Savings in specific fuel
consumption , Kcal/Kgcl
Nil
20
Clinker temperature at
kiln discharge, degrees
134 + Ambient 65 + Ambient
Achieved
after Phase I
modification
cyclone, calciner and kiln drive modification

along with a new preheater fan.
The Phase I modification has been in operation since January 2014 and the customer
is satisfied with all the major benefits that
the upgrade has delivered:
Clinker production at 2550 TPD
10-12 Kcal/Kgcl savings in fuel
consumption
Cooler maintenance shutdowns decreased drastically since the upgrade
No major spare parts changed during
this period
No HRB maintenance shutdown in last
eight months
Mechanical HRB motor power drawn is
less compared to the conventional
crusher.
Phase II is expected to be completed by
December 2014 and Phase III before the
middle of 2015. MHIL is satisfied with the
Phase I modification and placed two more
orders with FLSmidth in 2013 for the Jayajothi unit (new Cross-Bar cooler with HRB
and PH modification) and two orders in
2014 for Line I (coal mill and PH modification).
2550
10-12
64 + Ambient
CONTACT ANILKUMAR MUKUNDAN

CM.ANILKUMAR@FLSMIDTH.COM
21
22
SITE REPORT
Clinkerisation
project underway in Nepal
Project timeline
Signing of the contract
Effective date of contract
Completion of engineering
Supply of major equipment
Expected commissioning
With the increasing

need for dams, bridges,
housing projects and
other infrastructure
generating more
construction projects,
the demand for cement
in Nepal is growing
year on year. Cement
manufacturers are
looking to build new
plants in order to
expand cement
production capacity.
7 June 2012
15 October 2012
30 December 2013
6 May 2014
December 2014
In a move that reflects this demand, the

Saurabh Group has awarded the Sarbottam
Cement Plants clinkerisation project in
Nepal to FLSmidth. This is the first full-scope
supply of equipment to be undertaken by
FLSmidth in Nepal. The 1200 tpd cement
plant will be located about 50 km from
Lumbini, the birthplace of Buddha.
FLSmidth scope of supply
The project supply includes everything from
the crusher and mills to pyroprocessing,
electrical systems and automation.
FLSmidths scope of supply:
Limestone crusher (Impact 480 KW)
Limestone stacker (luffing) & bridge
reclaimer, material handling equipment
Raw mill grinding ATOX 30 & 32.5 RAR
air separator
Raw mill & coal mill bag house &
cooler ESP
FRF silo (16 X 28m)

Preheater: 5-stage single string ILC
Rotary kiln (3.15 X 47m)
Clinker cooler: FLSmidth Cross-Bar
Cooler 6 X 29 with clinker breaker
Coal mill TIRAX ball mill (TM30 X 4.5
+ 2.30) with air separator RTKM 17.5
Electrical, automation & instrumentation
items (from 33 KW incomer to control
system complete design and supply)
Progress at site
Mechanical installations are in progress and
the major installations, including limestone
crusher, kiln, cooler, preheater and raw mill
are nearing completion. This is closely
followed by installation of the electrical
and automation equipment.
Being the largest producer of cement in
Nepal, we awarded our new project
CONTACT MANOJ MANDHANA

MANOJ.MANDHANA@FLSMIDTH.COM
Sarbottam Cement Pvt. Ltd. to FLSmidth.

As our dream cement plant is being built
now, we could see that FLSmidths team is
fulfilling their commitment of lowest thermal
and electrical energy consumption, and
also honouring the trust that we placed in
them through their meticulous planning,
effort and cooperation, says Mr. Bishnu
Prasad Neupane, Managing Director of
Sarbottam Cement.
Trial runs of equipment are expected to be
performed in October 2014.
This project was planned in such a way
that there were no hurdles at site for want
of drawing or materials, which relieved us
of stress and saved our time in follow-up
activities with the supplier, adds Mr. Bimal
Kumar Sawarthia, Finance Director of
Sarbottam Cement.
Saurabh Group
The Saurabh Group was established
in 1964 by well-known business man
Mr. Lila Ram Neupane initially as a
trading agency and a fleet of bus
services. After coming to Nepal from
Myanmar, the group diversified its
activities when the founders son,
Mr. Bishnu Prasad Neupane, joined
the group in 1986. The group is now
mainly involved in the production of
cement, steel, tea, spun yarn, PP
Woven fabrics, calcium carbonates
and other products.
Several firsts in Nepal

In addition to the fact that Sarbottam
Cement is the first project for which equipment is supplied by FLSmidth in Nepal,
Sarbottam Cement plant provides the first
ATOX mill (VRM) at a cement plant in
Nepal. In addition, it is the first ECS, IMCC
and intelligent network system to be installed in Nepal as well.
Sarbottam Cement Plant has also ordered
a 70 tph OK 25-0 vertical roller mill for
cement grinding, and packing plants from
FLSmidth. The plants objective will be to
produce 1,500 tons of OPC & PPC cement
per day.
KILN DURING
ERECTION
23
24
INNOVATION
CONTACT JESPER HAVN ERIKSEN
JEHE@FLSMIDTH.COM
FLSmidth
research
delivers silo-safe
cement
A current project examines how to

avoid lumps and blockages in silos
with vertical mill cement.
Lumps and blockages in cement silos have long been an issue at

some cement plants. In the 1970s, FLSmidth conducted research
on ball mills and cement storage that revealed the cause to be an
unfortunate combination of insufficient gypsum dehydration in
the mill, high silo storage temperature and lengthy storage time.
When stored at high temperatures, the gypsum continues to
dehydrate. The water released from the gypsum prehydrates the
cement in the silo, and lumps begin to form.
In more recent developments, some plants have begun to report
issues in silos storing cement produced in vertical mills. Similar to
the past, these issues are the result of a combination of factors
such as lower degree of gypsum dehydration or high rates of
water injection such that the moisture content of the cement
stored in silos is increased.
Real-world research
Close collaboration with cement plants is an important element of
FLSmidth research. It ensures that the complexities of industrial
operations are considered from the outset and that the research
can be applied in practice. Titan Cement is a valuable collaboration
partner in this project. The FLSmidth Research and Process departments were therefore pleased to be invited to carry out tests at
Titan Zlatna Panega in Bulgaria. The plant produces OPC cement
with 4% limestone and max. 3.5% gypsum using an OK Mill 30-4.
The OK Mill field tests were performed over several weeks. Complete quality analyses were performed on cement product samples
taken with the mill in operation with different process conditions.
The mill outlet temperature was varied from 75 to 120 degrees
Celsius and water injection was varied from zero to approximately
2.3 percent (mass) of the total production in the mill.
Mill temperature tests
Within the temperature range of the tests, the effects on gypsum
dehydration and prehydration were clear.
Low mill outlet temperature
Cement produced at low mill temperatures (app. 75-80 degrees
Celsius) had a relatively low level of gypsum dehydration compared to typical mill cement. However, as the cement temperature is low, the gypsum in the silo does not dehydrate. Thus
making the cement silo-safe. This supports the conventional
rule-of-thumb that cement temperatures below 70 degrees
Celsius are silo-safe for longer periods of time (weeks).
At low mill temperature excessive water injection should be avoided.
Vertical Roller Mill (VRM) cement produced with low mill outlet
temperature should not be stored in a silo together with high
temperature cement (>70 degree Celsius).
High mill outlet temperature
Cement produced at high outlet temperatures (>110 degrees
Celsius) had significantly dehydrated gypsum. As a result, high
temperatures in the silo do not cause problems.
High mill temperature can produce cement with gypsum dehydration similar to ball mill cement, but water injection must be
low to medium.
The graph illustrating the water content from gypsum in cement
shows the impact of different VRM operating conditions evaluated
in the study on gypsum dehydration.
Water injection tests
The impact of water injection is explained below.
In general water injected on the mill table acts as a grinding aid to
increase production and lower power consumption. Water also helps
reduce mill vibrations, especially with dusty clinker. Ideally, in this
case it is better to study and improve the factors impacting clinker
granulometry rather than use increased water injection rates.
WATER CONTENT FROM

GYPSUM IN CEMENT AS
FUNCTION OF MILL OUTLET
TEMPERATURE AND WATER
INJECTION
Effect of temperature and water

injection on gypsum dehydration
HIGH WATER INJECTION
MEDIUM WATER INJECTION
LOW WATER INJECTION
0.7
Water from gypsum %
The field tests were a critical part of a study that also included laboratory tests and special analyses. The results showed that the cement
storage stability can be controlled by adjusting the OK Mill temperature and water injection (if water is used). Optimum mill operation
depends on specific plant conditions and constraints, including
clinker temperature, availability of hot gas, climatic conditions,
quality of the feed materials (clinker composition, amount of additive
materials such as gypsum, limestone, slag and their water content),
legislative requirements, and storage time in the cement silo.
0.6
0.5
0.4
0.3
0.2
0.1
0
60
70
80
90
100
110
120
130
Mill outlet temperature (C)
If water injection rates are maintained within recommended safe

ranges, silo-safe cement with good quality can be produced.
High water injection can cause prehydration, especially at low
mill temperatures, resulting in lower cement strength and an
increase in the total water fed to the cement silo
Excessively high water injection rates may be problematic even
at high temperatures and should be avoided.
OK mill operation with no or minimal water injection is best for
producing silo-safe cement
Conclusion
Overall, the study confirms that it is possible for an OK Mill to
produce cement of similar quality to a ball mill and to match the
gypsum dehydration and behaviour in the cement silo. This can be
achieved by ensuring that the proper operating parameters are
used. The plant tests also show that it is possible to produce silo-safe cement over a range of operating parameters that can be
varied according to specific site conditions.
Ongoing research
The results of this study demonstrate the versatility of the OK mill.
Further research is also being conducted to study the effects of
temperature and water injection on power consumption, cement
quality and storage stability. Activities include accelerated storage
testing of cements at the FLSmidth laboratories as well as additional field studies to investigate especially sensitive cements with
high contents of aluminate, gypsum and alkalis, as well as blended cements with very wet additives. If your plant is interested in
participating in additional studies, please contact us.
25
26
FEATURES
Thinking beyond
EPC
How a full-service partner can
help safeguard investments in
cement plants.
For cement plant owners and investors in todays demanding

business environment, strong partners are a necessity to provide
the elements and conditions for efficiently designing and building
cement plants - adding capacity and expanding to new markets.
Entering into an EPC contract is one way to minimise risk and
streamline the process by providing a single source for the delivery
of the plant.
But an EPC contract alone may not be enough to ensure that the
plants long-term business goals are met. Owners and investors
also need assurances that the ongoing operations and maintenance (O&M) of the plant will support the market potential: What
happens after production is underway? How will it be staffed and
run? How will the plants performance goals be monitorised and
optimised?
FLSmidths Design, Build,

Operate Solution
FLSmidth provides a unique 360 certainty solution for the
cement plant lifecycle, covering everything from initial raw
material investigation and Engineering, Procurement and
Construction (EPC) through to ongoing operation and maintenance services.
Our combined EPC and O&M solution is a unique offering
managed by some of the most experienced engineers in the
business alongside locally recruited staff who are trained and
integrated into our expert teams.
With 130 years of specialist know-how, FLSmidth can guarantee
a fully sustainable and efficient model that will grow the plant
and profits long after operations begin.
Design, build and then operate

The return on investments in a cement plant are achieved through
maximising future cement sales. It is therefore vital that investors
know how the cement plant will operate over the full extent of its
lifetime and have certainty that it can deliver to its full potential.
Planning for the long-term operating potential at the same time
as preparing the EPC contract will reduce the investment risk,
shorten payback time and maximise the return on investment.
The key is to bring an O&M strategy into the EPC planning from
the outset. This will deliver assurances from the very beginning
that the plant will run smoothly and deliver the expected return
over the full lifetime of the plant.
A strategic approach to O&M requires extensive operational expertise
and planning, but contributes significantly to a plants bottom
line. An effective O&M strategy includes several elements, such as:
CONTACT SAMIR IDRIS

SAI@FLSMIDTH.COM
CONTACT ANDERS BECH
AB@FLSMIDTH.COM
Risk sharing, in particular, should be carefully planned. Typically, the

plant owner is responsible for fundamental supply issues, such as
power, water, fuel and raw materials as well as capital investments in
machinery and property. The full-service provider helps define specifications and make recommendations where and when necessary.
The key is for the owner to be able to transfer the risk and complexities of the operations to a single partner who is responsible
for engineering, procurement, construction, and operating and
maintaining the facility according to best-in-class standards. This
leaves the plant owner to focus on building the business and the
marketing and selling of the cement.
FLSmidth
Design, build
& operate
Implementing and ensuring health, safety and environmental

practices in accordance with international standards
Having clear performance goals associated with the performance of the plant staff
Ensuring sufficient technical expertise is available to run and
maintain the plant
Ensuring strong organisational and technical training capabilities
Securing that the supply chain and organisation is in place to
deliver original spare parts
Implementing IT systems for optimising plant management
and maintenance
One-source partner
Forming a full plant lifecycle strategy may seem a complex task before
construction begins. That is why it is important to work with a partner
who can assist you to plan for the future and navigate every step of
the process. A single-source supplier should have the capabilities to
provide full life-cycle support, from initial raw material investigation
through construction and commissioning to ongoing day-to-day
performance. They need to know how to put together a complex
industrial project, manage suppliers and contractors, build new organisation and ensure the operational organisation runs efficiently.
Opening doors to financing

Financing for a cement plant is challenging, and a complete design,
build and operations strategy can make a significant difference to the
financing terms. Early on, banks require risk assessments and certainty
that production goals and cash flow targets will be met. However, this
can only be predicted with reasonable accuracy if the daily operations
have been planned in detail from the outset. Thorough strategic planning demonstrates to financial institutions how long-term revenues
will be generated and tailor-made solutions guide the investor through
the entire process covering all financial institutions requirements to
facilitate the credit needed with the right repayment strategy in place.
In addition, having the right partner gives the financial institution the
best guarantee that the plant will be a successful investment.
Sustainable, profitable operations
With an end-to-end solution covering design, build and operations,
cement plant owners can put their business goals into action, guaranteeing the most efficient and sustainable model to develop the
business and achieve the bottom-line results demanded over the
lifetime of the investment. By guaranteeing the plant is operated
and maintained according to the highest standards, the plant delivers a lower total cost of ownership and ensures that the asset maintains the highest possible value throughout the plant lifetime.
PLANNING FOR THE

LONG-TERM OPERATING
POTENTIAL AT THE SAME
TIME AS PREPARING THE
EPC CONTRACT WILL
REDUCE THE INVESTMENT
RISK, SHORTEN PAYBACK
TIME AND MAXIMISE THE
RETURN ON INVESTMENT.
27
28
INNOVATION
FLSmidth introduces two
new DuoClean filters
FLSmidth has recently introduced two new,
revolutionary DuoClean filter types the
DuoClean DC2 and the DuoClean
DC8. Continuing FLSmidths objective of
providing cost-efficient and effective filter
solutions, the new DuoClean filters meet
the strictest emission requirements, while
reducing upfront costs. They feature an
innovative octagonal shape and a compact,
modular design.
Lars Gamborg, FLSmidths Global Product
Manager for Fabric Filters, explains that
FLSmidth set out to design a fabric filter
that performed exceptionally, but at a
lower cost of investment. Based on this
vision, we developed a compact filter that
is simple to manufacture, transport and
assemble, while also delivering low operational costs, high performance and low
emission. With the new, compact DuoClean
filters, which are based on modules, we
focused on manufacturability and constructability, and this enabled us to create
filters that minimise environmental footprint
to an even greater degree.
CONTACT LARS GAMBORG

LARS.GAMBORG@FLSMIDTH.COM
Innovative
fabric filter design reduces

costs and cuts emissions
Further development of
proven technology
Already installed at more than 50 plants
worldwide, the DuoClean filter has a proven
design and technology concept. In creating
the two new filters, FLSmidth has further
developed the most important DuoClean
features, including the cleaning system,
gas distribution capabilities and the long-bag
technology. A close look at supply chain
and customer requirements revealed the
need to reduce engineering, manufacturing
and installation costs. To meet these needs,
the new filters feature a standardised,
modular design.
Advanced gas and dust
distribution screen
DuoCleans technology is characterised by
a dual-flow gas approach. Gas flows from
the bottom and side of the bags ensuring
low, uniform velocity over the entire bag
filtration area. This allows the use of longer
bags, which reduces the filter footprint.
To ensure gas is distributed evenly to the

hoppers and on the bags, individually
designed gas distribution screens are used
for each filter application.
Lighter filters reduce investment costs
The DuoClean DC2 and DC8s modular
design features eight identical panels assembled in an octagon. The filter uses simple
reinforcement profiles and requires fewer
components. Its near-round shape has a
self-reinforcing, strengthening effect, which,
together with the optimised casing and
hoppers, means it is significantly lighter than
comparable fabric filters. This leads to lower
capital expenditures (CAPEX) requirements,

as lighter filters are easier and more costeffective to fabricate, transport and assemble.
Easy transportation and installation
The octagonal shape also plays an important
role in simplifying transportation and installation. The filters steel components, transported in standardised containers, are
designed so the casing, the eight side-panels
and the hole-plate elements are a perfect
fit to the container. The container is packed
efficiently utilising the entire space, so fewer
containers are required. This helps to minimise transportation costs. >>
THESE 8 STEPS ILLUSTRATE A

DUOCLEAN DC2 FILTER TAKING SHAPE.
CONSTRUCTION AND INSTALLATION
CAN BE AS QUICK AS JUST FOUR WEEKS.
THE COMPONENTS ARRIVE ON-SITE IN
CONTAINERS. YOU ONLY NEED A
CRANE FOR THE FINAL MOVING OF
THE PRE-INSTALLED COMPONENTS TO
THE FINAL FILTER LOCATION; OTHERWISE
ALL CONSTRUCTION IS DONE AT
GROUND LEVEL.
1. PENDULAR SUPPORT
AND SUPPORT BEAMS
2. BOTTOM HOPPERS
3. INTERNAL BRACING
4. GAS DISTRIBUTION SCREENS
5. CASING AND DUCT
6. TUBE SHEETS
7. C
LEANING SYSTEM
AND ACCESS LIDS
8. WEATHER ENCLOSURE
29
30
TOP
ACCESS
The filter components are then typically

assembled at a dedicated area close to the
plant, and construction is completed onsite. This process reduces the demand for
scaffolding and crane capacity and means
construction takes place quickly, safely and
cost-effectively. The use of standardised,
prefabricated parts reduces the risk of
errors and optimises quality assurance.
Cleaning system increases bag lifetime
FLSmidths DuoClean filters ensure outstanding performance at a low operational
cost. Thanks to the unique gas distribution
and pre-separation of dust, the pulse jet
cleaning system operates with a minimal
number of cleaning cycles, resulting in low
compressed air consumption, less wear of
the bags and an increased bag lifetime.
The low pressure cleaning system (cleaning
pressure 2.0 bar), developed with extensive R&D, is also available to ensure efficient
cleaning and reduced stress of the long
bags. This means that the traditional
high-pressure compressor (6-7 bar) can
be replaced with a root blower, saving
investment and operational costs.
Smaller filters for smaller applications
FLSmidths DuoClean DC8 filter has been
designed to meet the needs of smaller
WALK-IN
PLENUM
WEATHER
ENCLOSURE
AS A TECHNOLOGY LEADER,
FLSMIDTH IS COMMITTED TO
DELIVERING EXCELLENT
SOLUTIONS FOR REDUCING
EMISSION LEVELS NOW AND
IN THE FUTURE. IT IS
DEFINITELY OUR OBJECTIVE TO
PROVIDE OUR CUSTOMERS
WITH A FUTURE-SAFE
INVESTMENT.
Lars Gamborg
Global Product Manager, Fabric filters
SCAN HERE TO
LEARN ABOUT MORE
SUCCESSFUL CASES
cement mill applications. Also featuring an

octagonal-shaped casing, The DuoClean DC8
is a compact, one-compartment filter for use
at a gas flow range of 45,000 to 150,000
Am3/h. With a small footprint and typical
bag length of six to eight metres, it is up to
40 percent lighter than conventional filters.
Significant R&D investments
The new filter types are the result of substantial R&D efforts by FLSmidth, in particular
using computational fluid dynamics (CFD)
to achieve optimal control of gas distribution
and the ideal dualflow split. The CFD results
demonstrated a well-distributed gas flow
with a significant amount of dust being
preseparated to the hopper. This delivers
uniform gas speed to the bags, reduces
compressed air usage and increases the
lifetime of the bags, all factors that help
reduce operating costs.
Lars Gamborg elaborates on FLSmidths

R&D efforts: We have invested extensively
in R&D to ensure that a well-proven technology is transformed into innovative filter
solutions responding to the needs of todays plants and industry trends. The testing was carried out at our R&D Centre
Dania, which is now the biggest in the
industry. Besides testing many prototypes,
the full-scale pilot filter allowed us to test
the 10m long bags in different operating
conditions.
As a technology leader, FLSmidth is committed to delivering excellent solutions for
reducing emission levels now and in the
future. It is definitely our objective to provide our customers with a future-safe
investment, concludes Lars Gamborg.
BMIC,
Egypt
At the BMIC cement plant in Egypt, all
emission targets have been met successfully with the DuoClean DC8 filter.
With a bag length of six metres, the
filter operates at a gas flow of 72,000
Am3/h and temperature of 140 C.
Askale Cement,
Gumushane, Turkey
The Askale Gusmushane plant in Turkey
selected the DuoClean DC2 filter for
the plants cement mill due to the filters
compact design and ability to handle
large gas flows. With an emission guarantee of 10 mg/Nm3, the filter has a
10-metre bag and operates at a gas
flow of 850,000 Am3/h and temperature of 95 C.
CEMEX, APO,
Philippines
At CEMEX APO in the Philippines, the
DuoClean DC2 filter is installed on the
plants cement mill. The eight-metre
bag provides an emission guarantee of
15 mg/Nm3 at a gas flow of 780,000
Am3/h and temperature of 100 C.
Lafarge Cement,
Rezina, Moldova
A nine-metre bag provides an emission
guarantee of 10 mg/Nm3 on the kiln/
raw mill at Lafarge, Rezina plant in
Moldova. The filter operates at a gas
flow of 630.000 Am3/h and temperature range of 100-250 C.
Performance test results show
an actual emission at
1.24
mg/Nm3
31
32
SITE REPORT
Indian cement
LONG VIEW
OF GIS
industrys first
gas-insulated switchyard
When there is a need for high

reliability and flexibility, low
lifecycle costs and maximum
environmental sustainability,
gas-insulated switchgear (GIS) is
the best choice over conventional
air-insulated switchgear (AIS).
Indias Reliance Cement chose a complete electrical and automation package from FLSmidth for its 10,000 tonnesper-day plant
at Maihar, Madhya Pradesh. Signed on an EPC basis, the contract
entailed complete engineering, procurement and commissioning
of the first GIS system to be installed at an Indian cement plant.
From the time of the equipments arrival at the site, it took only 17
days to install, test, assemble and charge up the switchgear. Managing risk was a key factor during the delivery and commissioning of
the GIS system in terms of equipment selection, engineering,
project execution and installation.
JOINTLY CONTRIBUTED BY
SUJITH VARGHESE GEORGE &
SUDEEP SAR
GIS CLOSE-UP
VIEW
CONTACT SUDEEP SAR

SUDEEP.SAR@FLSMIDTH.COM
Competitive sourcing
FLSmidth applied its in-depth understanding of the cement-making
process to select the equipment and components that would
ensure optimum performance. Extensive global knowledge of the
established electrical and automation OEM suppliers enabled the
cost-effective sourcing of equipment.
Dynamic engineering
The performance of any equipment supplied in a project depends
on how well it is engineered to match site requirements. FLSmidth
successfully met the challenges of bridging national, cultural and
linguistic gaps between supplier and end-user, whilst fulfilling the
customers expectations in terms of safety, acceptance, performance
and service.
The engineering started with concept drawing followed by 3D
modelling to mitigate any civil work issues. Complete testing of
the equipment took place at the suppliers workshops to prevent
unnecessary surprises at the site and save time in the execution
phase, where only resonance frequency testing was necessary.
Seamless execution
A well-structured organisation with dedicated managers for engineering, sourcing and logistics helped ensure efficient project
execution. The process involved obtaining all the necessary approvals
from customer consultants and electricity boards, securing the supply
of special or first-time equipment, and ensuring timely ordering,
inspection and delivery. All logistics were well-planned and deliveries
were tracked to ensure compliance with the agreed timelines.
Installation
The FLSmidth site engineers, the customers engineers and the
OEM engineers worked seamlessly together in identifying, installing
and commissioning the various equipment parts. Civil engineering
levels were verified against the approved drawings. After being
installed, the equipment was tested as recommended by the
OEM supplier.
About gas-insulated switchgear
The gas-insulated switchgear (GIS) in a substation is contained
in an earthed metal (aluminium) enclosure, which is filled with
high-insulation pressurised sulphur hexafluoride (SF6) gas as the
insulating and arc-extinguishing medium. The switchgear equipment includes a circuit breaker, disconnecting switch, voltage
transformer, current transformer, and surge/lightning arrester as
well as bushings and cable holders. GIS is compact, environmentally adaptable, safe and easy to operate and handle. It is reliable,
flexible and requires minimal maintenance. GIS rated voltages
range from 72.5 kV to 800 kV and rated short-circuit breaking
current ranges up to 63 kA.
Indian cement industrys second GIS solution
The best reward any company can expect for exceeding a
customers expectations is to receive another order from the same
customer. Reliance Cement awarded FLSmidth a second electrical
and automation EPC contract for the grinding unit in Kundanganj,
Uttar Pradesh, India. Following the same successful engineering,
procurement and commissioning model developed for the Maihar
Plant, the GIS for this new site is already in use.
33
34
INNOVATION
FLSmidth
STRIKE-BAR crusher
The EV hammer crusher has been
the preferred choice for raw material
crushing at cement plants for many years.
A billion tonnes of limestone has been
crushed by this grand old machine.
And now it is joined by a little brother.
The new crusher family member

The FLSmidth STRIKE-BAR crusher is the
newest member of the FLSmidth crusher
family and a perfect match to the EV
crusher. The STRIKE-BAR is a horizontal
impact crusher for raw material crushing
and, at first glance, it looks sturdy and
heavy duty and a bit similar to the EV.
The two machines certainly share some
familiar features, but the skin deceives and a
peek under the hood reveals the differences.
Crushing raw materials for cement presents
a number of challenges, and it is important
to select the right crusher for the job. Limestone comes in many forms and can exhibit
different physical properties that causes
varying degrees of wear of the machinery.
Other factors to consider include the required
reduction ratio and the size requirements
of the end product. This is where a broad
panel of crushers makes sense. At FLSmidths
in-house test facilities, the correct material
properties can be determined and the
appropriate crusher selected.
FLSMIDTH EV HAMMER
IMPACT CRUSHER
CONTACT HENRIK SRENSEN

HENS@FLSMIDTH.COM
The working principle

The main area of difference between the
STRIKE-BAR crusher and the EV is the
impact zone.
On traditional hammer crushers, the main
impact occurs between a pivoting hammer,
rock and a fixed breaker plate. The final
crushing occurs between hammer and
grate. The STRIKE-BAR crusher utilises the
similar high-speed impact, but the main
impact occurs between a fixed bar, rock
and flexible breaker plates.
In machinery operating at such high speeds
and impact forces, flexibility in the system is
a must and it is of course an integrated part
of both the STRIKE-BAR crusher and the EV.
The EV utilises the fixed grate for fine
crushing or grinding, making it suitable for
high reduction ratios and small output (such
as for a ball mill feed). The STRIKE-BAR
crusher utilises several flexible breaker
plates for crushing making it the right
choice for medium course output (for
example on vertical roller mills), easy wear
adjustment and more flexible output size.
FLSMIDTH STRIKE-BAR
CRUSHER
IN MACHINERY OPERATING
AT SUCH HIGH SPEEDS AND
IMPACT FORCES, FLEXIBILITY
IN THE SYSTEM IS A MUST
AND IT IS OF COURSE AN
INTEGRATED PART OF BOTH
THE STRIKE-BAR CRUSHER
AND THE EV.
Maintenance
The main crusher at a cement plant is the
first machine in the process. This crusher
processes heavy quarry boulders weighing
up to five tonnes each and reduces them to
mill-feed size. This kind of operation demands an extremely durable crusher. But no
machine can perform endlessly under such
circumstances; hence the crusher must be
flexible from the perspective of wear compensation, maintenance and replacement of
wear parts. It is important that crushers have
several inspection hatches for easy regular
inspection and to enable free access above

the rotor and breaker plates when major
overhauls are needed. This is just one of the
features that makes maintenance simpler
and more cost-effective. Others include
bolted-on wear segments, adjustable breaker
plates, minimal use of different spare parts
and chrome/manganese wear parts.
All of these challenges have been solved
in the design of the STRIKE-BAR crusher,
which is based on many years operational
experience gained from the EV crusher.
35
36
SITE REPORT
CONTACT PETER BROCKMANN
PEB-CH@FLSMIDTH.COM
UNCOVERED BREAK OF
AUXILIARY DRIVE TO
SHOW DESIGN - PRIOR
TO INSTALLATION OF
BREAK GUARD
Great teamwork
and reliable technology
minimise plant disruption
When plant equipment fails, replacement technology is not
the only answer. Teamwork plays a vital role in ensuring
operations get quickly back to normal.
Something was amiss at the Tahama Cement Plant in Saudi Arabia.
The gearbox installed on one of its mills had not been meeting
performance requirements, and when the gearbox failed, a quick
solution was needed to get the mill back into operation.
Meanwhile on another of Tahamas mills, an FLSmidth MAAG

gearbox had consistently been performing to expectations. So
when the decision had to be made for a replacement gearbox,
the choice fell on FLSmidth MAAG.
The Tahama Cement Plant is owned by Southern Province Cement
Company (SPCC), one of Saudi Arabias leading cement producers.
SPCC operates three cement plants with a total cement production
THE FOUNDATION OF THE PREVIOUS

GEARBOX WAS QUITE COMPLEX AND
NOT COMPATIBLE WITH THE FLSMIDTH
MAAG CPU. SO THE FIRST PART OF THE
PROJECT INVOLVED COMPLETELY
OVERHAULING AND RENEWING THE
FOUNDATION.
Peter Brockmann,
Field Service Engineer at FLSmidth MAAG
capacity of over 8.4 million tpy. The Tahama plant produces more
than 3.63 million tons of clinker a year. As of March 2015 the production will be even further increased to 5.45 million tons a year.
similar projects before. The key, especially when you have to work
at speed, is teamwork, which involves communicating and everyone
taking responsibility for specific tasks.
Peter Brockmann, Field Service Engineer at FLSmidth MAAG,

arrived at the Tahama plant soon after the gearbox failure. The old
gearbox had already been removed and Peter and his colleagues
could quickly get to work. The project consisted overall of two
parts. First, the foundation needed to be prepared. Then the gearbox could be installed, aligned and tested.
Preparing the foundation

The replacement of the foundation started with positioning and
roughly aligning the gear unit to the mill. This included the precise
control of the mill input flange and mounting the coupling connecting the mill to the gearbox.
Peter Brockmann explains the challenge of preparing the foundation:

The foundation of the previous gearbox was quite complex and
not compatible with the FLSmidth MAAG CPU. So the first part of
the project involved completely overhauling and renewing the
foundation.
SPCC was aware of this challenge, and it was one of the main
reasons FLSmidth MAAG had been chosen. Yet SPCC wanted
assurances that the new gearbox would meet its performance
requirements, as any potential malfunctions and resulting downtime
would be costly. This is where FLSmidth MAAGs professionalism
and expert knowledge of the particular demands of a cement mill
came to the fore. The installation engineers brought a professional
attitude and they knew it was important to work as a team with
the sites staff, especially as time was of the essence.
Peter Brockmann says, Our client wanted to know that we could
make everything work despite the challenges of the project. It was
important that the foundation was prepared properly so that the
gearbox would have optimal conditions. We were confident we
could deliver to SPCCs expectations as we brought many years
practical experience to the challenge and had completed many
With the gearbox fixed and grounded, the oil system and piping
could be installed. This was followed by testing the oil system
before the equipment was flushed. Then, as the last steps before
the final spin test and hot commissioning of the mill, the protection
interlocks were tested and the motor and gear unit were aligned.
Today, the mill is once again fully operational thanks to the FLSmidth
MAAG CPU and the quick response and professionalism of the
SPCC and FLSmidth MAAG teams.
37
38
NEWS IN BRIEF
Plant Service
Agreements
CONTACT JENS PETER KOCH

JPKO@FLSMIDTH.COM
CONTACT JACOB JRGENSEN
JACJ@FLSMIDTH.COM
Optimising cement plant operations

FLSmidth launches Service Agreement
Concept for on-site plant inspections,
remote support, assistance and training
a flexible service agreement concept that

gives plant managers everything they need
to effectively plan their maintenance.
Improvements in technology are increasing

the lifecycles of cement plant equipment. But
even the most reliable, advanced equipment
requires maintenance to optimise its performance. With a preventive maintenance
approach, cement plant owners can combat
the uncertainty of maintenance and avoid
unplanned stoppages. FLSmidth has launched
a flexible service concept based on the
principles of preventive maintenance that
aims to ensure maximum availability of the
plant while reducing the cost of maintenance.
Regular inspections for peace of mind

Central to the service concept are regular
onsite inspections, which aim to monitor
the equipment and reveal potential issues
before they arise. After each inspection, a
comprehensive report is produced, which
provides valuable insight into the plants
day-to-day operations. These reports are
particularly useful in the event of an unexpected failure between inspections. In such
cases, the service agreement will facilitate
that FLSmidth can provide instant technical
support in between inspections solving
issues based on the intimate knowledge
of the plant.
Jacob Jrgensen, Head of FLSmidths Service

Department in Denmark, says, Cement
plant owners are looking for high availability
in their operations. Stoppages are unavoidable to a certain point, but their effect on
production time can be minimised if they
are planned. This is why we have developed
FLSmidth has published a comprehensive

service catalogue, and everything contained
within the catalogue can be included within
the service agreement, explains Jacob
THE FLSMIDTH SERVICE

AGREEMENT CONCEPT IS A GOOD
MATCH TO OUR OWN
RELIABILITY-CENTRED
MAINTENANCE STRATEGY AND IT
CREATES INCREASED CONTINUITY
IN THE SERVICES DELIVERED AND
LOWERS THE COST OF THE
MAINTENANCE.
Mr. Amir Feroze,
General Manager, Maple Leaf Cements
Jrgensen. It applies to everything from

crushers, stackers and all types of mills
through to gear units, kilns and coolers.
It also covers a plants automation systems.
The agreement can mean extended warrantees to the equipment.
Jacob Jrgensen emphasises the importance
of training as part of the service agreement:
In addition to providing on-site assistance,
we offer training in the use of cement
plant equipment. This is valuable for plant
managers to ensure their personnel have
the right skills to operate the equipment.
Reduce the cost of maintenance
Maple Leaf Cement in Pakistan is one
plant that recognises the opportunity to
reduce the cost of maintenance through
a long-term approach to service. Mr. Amir
Feroze, Maple Leaf Cements General
Manager says, The FLSmidth Service
Agreement Concept is a good match to
our own reliability-centred maintenance
strategy and it creates increased continuity
in the services delivered and lowers the
cost of the maintenance.
FLSmidths service agreement covers everything from a one-time equipment inspection
to full flow sheet service agreements,
including continuous inspections and technical support. It provides several benefits.
As it is based on a fixed-price agreement,
costs are predictable for the duration of
the agreement. At the same time, maintenance budgets are reduced by eliminating
non-value-adding costs resulting in more
favorable pricing of the individual inspection. We estimate that plants can save
between 10 and 20 percent on maintenance by pre-scheduling inspections, says
Jacob Jrgensen, adding, There is also
less need for inventory as the inspections
lead to better spare part planning.
Successful
CONTACT MARK BLOWER

MARK.BLOWER@FLSMIDTH.COM
cooler upgrade
ABC INLET DURING

CONSTRUCTION
In May 2011, Holcim and FLSmidth

partnered to upgrade the existing
clinker cooler at Holcims Nobsa
plant in Colombia.
The existing air beam grate cooler was suffering from high maintenance costs and poor cooler efficiency. Several options were reviewed
for the upgrade of the cooler. After detailed review and analysis
Holcim chose a selective solution, upgrading the following key components of the cooler, while minimising capital costs for the upgrade:
New ABC (air blast controlled) fixed inlet with two new
undergrate fans
Compartmentalisation of the existing cooler, adding new
compartments, floor plates, and inter-compartment seals
New tube conveyor to transport the spillage material, replacing
the existing open-style drag chain
New pocket type grate plates for the entire cooler
Holcim and FLSmidth worked together closely on the upgrade,
incorporating Holcim design parameters into the final equipment
arrangement. Additionally, while both parties realised that all new
fans for the cooler would further improve results, only the fans for
the inlet were replaced, and the rest of the existing fans were
rearranged and re-used.
The equipment for the project was delivered in late 2011, but
a strong Colombian market postponed the plants planned shutdown for cooler upgrade and installation until October of 2012
when the cooler upgrade was installed during a scheduled maintenance stoppage. The shutdown, from flame-off to flame-on,
lasted 20 days.
FLSmidth has visited the plant twice since the installation, and the
cooler continues to perform well, with high reliability, limited
maintenance and good fuel consumption.
Performance testing
Guarantee description
Capacity
Fuel consumption savings
Clinker temperature
Guarantee
3,300 tpd
-20 kcal/kg
165C
Obtained
3,449 tpd
-50 kcal/kg
164 C
39
40
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paths
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Reliability-focused
OCTOBER 2013
performance
APRIL 2013
How will the

industry move ahead
in cooperation with the
Stay in touch through

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A source for good
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Cement
evolution of SCM
APRIL 2014
Avoid expensive
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Loan bundling
saves money
O&M Cement
reaches new heights
Automation
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Meet with us
The online edition eHighlights Cement - is enriched with videos,
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online platform is constantly updated with new content.
Highlights Cement also comes in an interactive tablet-friendly
version available for iPad. Download the app free in iTunes.
As a global player, FLSmidth regularly attends events and conferences all over the world. At these events, we present the full range
of our products and services and we offer the opportunity for a
no-obligation discussion about your cement plant requirements.
Here are some of the events where you can meet us in the coming year. Be sure to stop by and see us!
Upcoming events

DATE
EVENT
October 29-30, 2014
FLSmidth seminar Tehran, Iran
LOCATION
November 11-13, 2014 AUCBM
Marrakech, Morocco
November 12-13, 2014 CBI
New Delhi, India
April 21-25, 2015
AFCM
Hanoi, Vietnam
April 26-30, 2015
IEEE-IAS/PCA
Toronto, Canada
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OCTOBER 2014

HIGHLIGHTS CEMENT October 2014

LETTER FROM THE PRESIDENT

SCAN TO VIEW PER

HIGHLIGHTS CEMENT October 2014

Letter from the President

USE THESE QR CODES AS A QUICK WAY TO GET

Plant Engineering Degree

New cement plant for the Democratic

Right first time

Thinking beyond EPC

Clinkerisation project underway

New graphite seal optimises kiln

Gas-insulated switchyard in India

V8 process control system

PRODUCTS & SOLUTIONS

FLSmidth research delivers

Great teamwork and reliable

The new ECS/ControlCenter

Semen Indonesia gains newest

Innovative fabric filter design

FLSmidth STRIKE-BAR crusher

Delivering to customer needs

SCAN HERE FOR

HIGHLIGHTS CEMENT October 2014

Read more about new

New cement plant for

FROM L-R: MR. AHMED MASHKOOR,

Rawji Group of the Democratic Republic of

FLSmidth has been selected to supply a

The equipment to be supplied includes

The Rawji Group includes companies involved

HIGHLIGHTS CEMENT October 2014

CONTACT SCOTT ZOLOTSKY

Congo is characterised by growing stability

FLSmidth has been selected to supply the

With the installation of two new FLSmidth

HIGHLIGHTS CEMENT October 2014

PRODUCTS & SOLUTIONS

CONTACT KLAUS BGESKOV HANSEN

Amidst a buoyant cement

FLSmidths newest version of the OK mill has been commissioned

FLSmidths new OK mill, featuring an updated mechanical package

HIGHLIGHTS CEMENT October 2014

FLUID DYNAMICS WAS

HIGHLIGHTS CEMENT October 2014

FLSmidth and Helwan

HIGHLIGHTS CEMENT October 2014

Operating and maintaining cement plants requires a high level of

The Helwan Postgraduate Cement

HIGHLIGHTS CEMENT October 2014

Cristina Holmark emphasises that the programme is now owned

WERE NOT JUST

HIGHLIGHTS CEMENT October 2014

Professor Sakr is also convinced that it provides significant benefits

HIGHLIGHTS CEMENT October 2014

Energy efficiency and low maintenance is essential to optimal

HIGHLIGHTS CEMENT October 2014

Designed for predictable, low maintenance

will hold the graphite blocks in place in the unlikely event of

VISUAL INSPECTION OF THE SEALING DURING

HIGHLIGHTS CEMENT October 2014

HIGHLIGHTS CEMENT October 2014