World’s largest

2007 November

Highlights

Highlights Editor: Anders Klinkby Godiksen (responsible under Danish law) Brenda Kaplan V. Ragini Shah Henrik Vinther Charlotte Pinson Production: Gunnar Andreasen Translations: Martin Bojesen 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 Cementing industry relations World’s largest ATOX mill on stream

3 12

Alternative fuels – tomorrow’s standard 14 Upgrades for Italian cement industry

16

Growing into the future

18

QCX/Robolab sales still buoyant

21

FLSmidth Institute expands programme 22 … and opens in India

23

Up the Mississippi

24

D.G.Khan inaugurates plant

28

Quality control for Grasim Industries

29

Acquisition fuels Minerals growth

30

And the diploma goes to…

33

FLSmidth adopts new internet media

34

Facilitating FK pump maintenance

35

Support from A-Z

36

The right price

Cementing industry relations on four continents

“Can I help you?” says the shop assistant. Mr Thomsen is in the local do-ityourself store. He wants a light bulb, and he wants the cheapest they’ve got. The wise shop assistant immediately offers him a low-energy bulb – it’s seven times the price of the cheapest bulb, but lasts much longer and uses far less electricity. “This is the one you need,” he tells Mr Thomsen. “It’s the cheapest, because with electricity prices as they are, you’ll recover your initial investment within a year or two.” In the cement and minerals industries, investors often face a similar situation. When assessing the viability of a project, it’s essential to compare the initial cost and operating costs. Today, operating costs and production availability deserve more attention than ever when selecting equipment. As we see it at FLSmidth, balancing operating expenses (OPEX) and capital expenditures (CAPEX) to find the total cost of ownership results in the best price in the long term. In our industries, it can be costly to economise. Design, maintain and operate are our keywords in serving the cement and minerals industries. The market demands these services, and we are well placed to provide them thanks to our years of expertise in cement combined with the experience from similar ongoing contracts in minerals. FLSmidth’s recent acquisition of GL&V (Dorr-Oliver Eimco and Krebs Engineers) is another historic step forward, resulting in an unparalleled product portfolio for the minerals processing industries. Lean process management is now fully implemented in Global Engineering, enabling us to meet the demand for plant projects, which appears to be reaching an unprecedented level again this year. Our three major project centres in Denmark, the USA and India are busier than ever, and yet we are still well prepared to take on more orders. Our 125th anniversary year has so far proved exceptionally successful, and we are ready, both strategically and organisationally, to serve our industries for many more years to come.

The spring and summer months have seen a continuation of the global investment boom in the cement industry. FLSmidth continues to play an active role in providing complete technology solutions to the world’s emerging and leading cement producers. On the following pages we give a summary of the major orders received over the past six months, from customers in Russia, Qatar, Saudi Arabia, Syria, Sudan, Colombia, Spain and India Breakthrough on the Russian market Russia’s largest cement producer, Eurocement Group, has awarded FLSmidth a contract to build a 6,000 tpd line in the Voronesh district, 600 km southeast of Moscow. This is FLSmidth’s first major project in Russia and for Eurocement Group, which accounts for one third of the

I wish you pleasant reading of Highlights. J. Huno Rasmussen CEO, FLSmidth

MMC solution for existing Volga cooler 37 KilnLoq total passes 100

38

Finnsementti adopts ECS/CEMulator

40

Celebrating 125 years around globe

42

A long history in China

43

On the job

44

Front cover: The world’s largest single production line (12,000 tpd) is making good progress (see page 24) at Ste. Genevieve in the USA. In China, the world’s largest ATOX mill for raw material grinding has successfully come on stream at Zhonglian Luhong Cement Qingzhou Co. (see page 11). And the recent acquisition of GL&V’s Process Division (see page 30) has made FLSmidth the world’s leading supplier of Minerals technology, as it already is in Cement.

Celebrating the contract between Eurocement and FLSmidth for a new 6,000 tpd line. Seated left to right: Per M. Kristensen, Vice President, FLSmidth and M.A.Skorohod, President of Eurocement.

Russian cement industry’s total output. As part of the contract, FLSmidth will supply: • A crushing plant • MVT raw material stores • Two hammer dryer crushers • Raw meal silos • An ILC three-support kiln with two-string preheater • An SF Cross-Bar Cooler • Two UMS cement mills • A sand mill • FLSmidth MAAG gears • Four cement silos • Pfister dosing equipment • Ventomatic packing and bulk loading systems • FLSmidth Airtech air pollution control systems • An FLSmidth Automation quality process and control system • A complete electrical equipment package

• Supervision of erection and commissioning • Training of plant personnel The new FLSmidth line will replace Eurocement’s existing Podgorensky facility. In addition to expanding capacity, the line will optimise energy efficiency and help Eurocement improve its environmental protection practices. Eurocement Group owns 13 plants across Russia, two in Ukraine and one in Uzbekistan. Eurocement is planning to invest heavily in innovative cement technologies in the coming years – and the FLSmidth contract marks a clear step in that direction. FLSmidth is looking forward to resuming its close relationship with Russian cement producers, which began with the first plant project 100 years ago.

Lay­out: Blue Business A/S · ISSN 0909-8992 

Highlights November 2007



Highlights November 2007



Cementing industry relations on four continents

A first in Qatar Gulf Cement Company, a relative newcomer in the industry, is building a complete 5,000 tpd cement plant west of Doha, Qatar’s capital. FLSmidth has signed a comprehensive contract with Gulf Cement, its first with the company and its first major project in Qatar. FLSmidth and its subsidiary companies will provide all the equipment needed for the new plant, including: • A crushing plant • Raw material stores • An ATOX raw mill

• A raw meal silo • A complete ILC three-support kiln with preheater • An SF Cross-Bar cooler • Two OK cement mills • Cement silos • Filters • Dosing equipment • Packing lines • A quality and process control system

The equipment supplies are backed by a complete range of services for the project: • Supervision • Commissioning support • Training • Spare parts The cement plant is scheduled to be commissioned by mid 2009.

3-D view of Gulf Cement Company’s coming 5,000 tpd greenfield plant near Doha, Qatar.

Saudi Arabia’s Eastern Province opts for FLSmidth fabric filters FLSmidth Airtech has signed a contract with Eastern Province Cement Company Ltd. (EPCC) to supply four large fabric filter installations. “This major order confirms FLSmidth Airtech’s leading market position in fabric filters for cement plants,” says Ole Boegh, General Manager for Sales, Operation & Services, FLSmidth. By installing modern fabric filters to de-dust the kiln and bypass gases, the project aims to reduce the dust emission from the two existing cement lines to less than 15 mg/Nm3. The filter installations will consist of two FabriClean® and two RetroClean® filters including ducts, supports, dust transport systems, fans, motors, MCC.

EPCC is a Saudi-owned company with a cement plant in Al Khursaniyah, near the Khursaniyah oil fields close to the Dammam-Kuwait and Jubail-Abu Hadriah Highways. Over the past few years, FLSmidth Airtech has supplied a large number of fabric filters to cement plants in Saudi Arabia and elsewhere in the Middle East. This recent contract confirms the company’s ability to meet the demands of the industry – for both new fabric filters and upgrades of existing installations.

The Quba Mosque just outside Medina, Saudi Arabia, is the first Islamic mosque ever built.

FLSmidth Airtech has signed a contract with Eastern Province to supply four large fabric filters for the Al Khursaniyah cement plant. Pictured l – r: Mr Ali Al-Qahtani, Deputy General Manager, Eastern Province Cement Co.; Mr. Syed Basheer Shafee, Plant Manager, Eastern Province Cement Co.; Mr Ole Bøegh, General Manager, FLSmidth Airtech; Mr Steffen Houlberg, Project Manager, FLSmidth Airtech; Mr Ahsen Hussein, Area Sales Manager, FLSmidth Airtech; and Mr. Kurt Christensen, General Manager, Al-Cem Aps.

The city of Doha, Qatar’s capital.



Highlights November 2007



Highlights November 2007



Cementing industry relations on four continents

The Middle East’s No. 1 cement producer invests in Syria Egyptian-based Orascom Construction Industries (OCI) is building a new 7,500 tpd plant through its 75 percent-owned subsidiary, Syrian Cement Company. The greenfield plant will be located close to Syria’s border with Turkey, some 500 kilometres north of Damascus. The project will be carried out in cooperation with FLSmidth and OCI. FLSmidth will supply the machinery and equipment, and OCI’s construction division will handle the construction work. FLSmidth’s scope of supplies comprises: • A crushing plant and stacker/ reclaimer systems • An ATOX 55 raw mill and a raw meal silo • A complete ILC three-support kiln with a two-string preheater

• An SF Cross-Bar cooler • Two OK cement mills and cement silos • A complete electrical equipment package • Electrostatic precipitators and fabric filters • A complete quality and process control system • A Ventomatic cement packing system • Pfister dosing equipment • MAAG gear units The Syrian plant will comply with stringent NOx, SOx and dust emission standards, and the vertical cement grinding mill will ensure high energy efficiency. OCI is a long-standing partner of FLSmidth, and the companies have worked together on successful projects in Algeria, Nigeria, United Arab Emirates, Pakistan and Libya. OCI’s Cement Group

is the largest producer in the Middle East with a current capacity of 21 million tonnes per year (tpy). The new Syrian plant will be commissioned in mid-2009. Along with the other OCI projects currently in progress, it will help the OCI Group reach its total capacity goal of 39 million tonnes within the next couple of years.

The old citadel in Aleppo, Syria.

Proven partnership behind new plant in Sudan FLSmidth is maintaining its strong relationship with the Egyptian-based ASEC Group. ASEC’s wholly-owned Aresco company is building a new cement plant for Al Takamol Cement Company in Sudan, and the FLSmidth Group of companies is providing a complete package of engineering and machinery supplies. The 4,500 tpd cement production line will be built at Atbara in northern Sudan, some 200 kilometres north of the capital, Khartoum. Commissioning

is scheduled for 2009 and FLSmidth‘s comprehensive range of equipment for the new project includes: • An EV 200 x 200 limestone/clay crusher, 1060 tonnes per hour (tph) • Raw material stores • An ATOX 40 raw mill, 355 tph, including a MAAG gear unit • A CF silo, 18 m in diameter x 49 m tall • A five-stage ILC preheater/calciner • A rotary kiln, 4.75 in diameter x 49 m long • A 4 x 5 SF Cross-Bar clinker cooler

• Two 46 x 15.5 UMS cement mills, 120 tph, including MAAG gear units • Three Ventomatic packing lines Over the past decade, FLSmidth has successfully worked with Aresco on other projects in the region, notably one white and two grey production lines on the Sinai Peninsula and a greenfield project in southern Egypt.

Customer and FLSmidth representatives study the site and raw materials for OCI’s new greenfield plant in northern Syria.



Highlights November 2007



Highlights November 2007



Cementing industry relations on four continents

Leading Latin American producer signs up for 5,000+ tpd line Cementos Argos S.A. has awarded FLSmidth a contract for a new 5,250 tpd line in addition to other aftermarket services and support. Located in Cartagena, Colombia, the plant will support both the local Colombian market and strengthen Argos’s position as the fifth largest cement producer in Latin America and an exporter to 27 countries. Much of the success for winning this contract is due to FLSmidth’s ability to provide technology and services that will minimise the total cost of ownership throughout the plant’s life. FLSmidth will supply engineering services, project management, training, and commissioning, as well as all major machines and auxiliary equipment, including: • Primary and secondary ABON sizers for 2,500 tph • 5 kilometres of MVT-designed overland conveyors from quarry to plant • MVT stackers & reclaimers for limestone, chert, puzzolana, gypsum, and coal • An FRM 48/315 raw mill with central feed

Celebrating the laying of the foundation stone for Cementos Argos’s new 5,250 tpd facility in Cartagena, Colombia.

• A CF 18 m x 47 homogenisation blend silo • An ILC 5–stage preheater with low NOx In Line Calciner • A ROTAX-2 (5.25 x 62) two pier kiln • A Multi-Movable Cross-Bar cooler (MMC 467/14 x 87) with electromechanical roll breaker • Complete air pollution control (APC) systems: main kiln/mill/cooler vent baghouses • Two 37,000 tonne clinker storages and discharge control equipment • An ATOX 25 coal mill • Two OK 33-4 vertical mills for finished cement grinding • Two 10,000 tonne cement storage silos and discharge control equipment • FLSmidth Automation plant control system plus a complete automated sampling and QCX/RoboLab quality laboratory and gas sampling package. Fuel efficiency and strict emission standards will be achieved with a pyro process system design that includes the latest generation MMC cooler, DUOFLEX kiln burner, and ILC preheater with low NOx and CO calciner. Two OK vertical roller mills have helped make this solution the

Cementos Molins has contracted FLSmidth to supply another production line at its Barcelona-based plant. Seated l – r: Thøger K. Christiansen, General Manager, FLSmidth Spain; Erik Birch, Vice President, FLSmidth; Juan Molins Amat, Managing Director Grupo Cementos Molins; Enrique de Bobes General Manager Grupo Cementos Molins.

The new production line is due to be commissioned during the second half of 2009. It will be the plant’s sixth line and is expected to replace the capacity of production lines 3, 4 and 5 – all supplied by FLSmidth between 1962 to 1972. One of the World Heritage fortresses in Cartagena.

market standard for finish cement grinding. The efficient design will minimise power consumption and the high moisture content in the raw materials will be mitigated by using a centre feed in the FRM mill. Key considerations in the selection process included FLSmidth’s attention to safety and ability to train staff and support installation and operation. The project will use resources from FLSmidth’s US headquarters and local satellite offices in Latin America. Project centres in both Denmark and India will also assist. Operation is scheduled for 2009.

Celebrating the contract, which includes all major equipment and services for the new line, seated l-r: Christian Jepsen, FLSmidth, and Jose Alberto Velez, President, Cementos Argos. Standing l-r: Kevin Chabin, Joseph McKay and Mark Brugan, FLSmidth; Luis Fernando Vergara, Victor M. Lizarralde, and Fernando Montoya, Cementos Argos.

Long-standing Spanish relationship pays off FLSmidth has won a contract from Cementos Molins to supply equipment for a new 4,100 tpd production line. The production line will be the fourth supplied by FLSmidth to Cementos Molins’ plant near Barcelona in Spain. Based on state-of-the-art environmental technology that complies with the European Union’s stringent emission standards, the production line will include a calciner characterised by low NOx and CO emissions.

For the new project, FLSmidth and its Group companies are to supply: • An ATOX 47.5 raw mill • An 18 m CF raw meal silo • A complete 4.75 x 56 m ILC two-support kiln with preheater • An 11 x 85 Multi Movable Cross-Bar cooler • A MAAG mill gear • FLSmidth Airtech filters • Pfister dosing equipment • Supervision services

Cemex chooses FLSmidth main equipment for greenfield plant in Spain Cemex, one of the world’s leading cement producers, is a major player in the Spanish market. In 2006, the Group invited bids for a new greenfield plant in Spain, and FLSmidth was chosen to provide the main equipment. Located in the town of Andorra, Teruel province, a typical Aragonian rural environment with olive and almond groves, the new plant will get electricity from a nearby power plant. Cemex and FLSmidth signed the contract in December 2006. The scope of supplies is an ATOX 40 raw mill, a Rotax 4.15 x 49 m kiln and a 2 x 5F SF Cross-bar cooler. March 2007 saw the signing of an additional contract for an OK 33-4 grinding mill, which will be the first OK vertical cement mill in Spain. The contracts reflect the long-standing relationship between Cemex and FLSmidth. Known as a strong supplier for major projects, the contract underlines that FLSmidth is also competitive in package solutions for equipment supplies.

Three existing lines at Molins are to be replaced by a new modern line.



Highlights November 2007



Highlights November 2007



Cementing industry relations on four continents

Growing Indian economy triggers spate of projects India’s economy grew nearly 10% in 2006 and the growth rate for 2007 is expected to be around the same level. As a result, infrastructure development is accelerating and cement producers are experiencing a boom in demand. They are all busy preparing new projects, and the industry expects to add 40 million tonnes per year (tpy) of new capacity this year. This will increase the present installed capacity of 158 million tpy by 26%. It is estimated that the industry’s total capacity might rise to 300 million tpy by year 2010. In the first six months of 2007, FLSmidth’s Indian project centre signed four major contracts as shown in the table on the next page.

Customer

Chettinad Cement

Vasavadatta Cement

Raghuram Cement

Location

Ariyalur, Tamilnadu

Sedam, Karnataka

Kadapa, Andhra Pradesh

Kadapa, Andhra Pradesh

Capacity

4,000 tpd

3,800 tpd

4,500 tpd

4,500 tpd

Core equipment: Raw mill

ATOX 42.5, 350 tph

Coal mill

ATOX 22.5, 33 tph

Blending silo

Inverted Cone, 22 m x 41 m

FRF 16 m x 45 m

Inverted Cone, 22 m x 40 m

Kiln

4.15 m x 64 m

ROTAX-2, 4.55 m x 56 m

4.35 m x 67 m

4.35 m x 67 m

Preheater

5-stage ILC, 8 m x 8.2 m

6-stage ILC 7.8 m x 8 m

6-stage ILC, 8.5 m x 8.8 m

6-stage ILC, 8.5 m x 8.8 m

Calciner

ILC LowNOx, 6.9 m x 37.5 m

ILC LowNOx, 7.2 m x 33 m

ILC LowNOx, 7.5 m x 39.5 m

ILC LowNOx, 7.5 m x 39.5 m

Cooler

SF Cross-Bar, 3 x 5

SF Cross-Bar, 3 x 6

SF Cross-Bar 4 x 5

SF Cross-Bar 4 x 5

Burner

DUOFLEX

DUOFLEX

DUOFLEX

DUOFLEX

Highlights November 2007

Inverted Cone, 18 m x 40 m

History

FLSmidth/Fuller supplied first plant Two existing Polysius lines.

KHD supplied first line,



in 1989, L&T-FLS second plant in

upgraded by FLSmidth in



2004. This is plant 3.



Third line by FLSmidth



commissioned in 2006.

2002. In 2006 FLSmidth

This is repeat order for line 4.

supplied new 3,800 tpd pyro



system, blending silo and



stacker/reclaimers

Raghuram Cement’s greenfield plant in Andhra Pradesh is to include an FLSmidth pyroprocessing system.

Vasavadatta Cement in India’s Karnataka province has ordered major equipment for its new line 4.

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Dalmia Cement



Highlights November 2007

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World’s largest ATOX mill successfully onstream As cement kilns continue to grow in size, so do mills. FLSmidth’s largest raw grinding mill to date, an ATOX 57.5, was commissioned at the start of this year – and performance guarantees were reached shortly after. Ordered by Zhonglian Luhong Cement Qingzhou Co. for its new 6,000 tonnes per day (tpd) plant, the mill has a 5356 kW

main drive, a MAAG gear and a 57.5 RAR-LVT separator. The mill’s capacity of 460 tonnes per hour (tph) reflects the grindability of the fairly hard limestone mill feed. The plant is the first of several 6,000 tpd cement clinker production lines that China Building Material (Group) Corporation plans to build in Qingzhou in the Shandong province.

10.8 metres

Layout of the grinding system Based on the commonly used three-fan system (preheater fan + raw mill fan + electrostatic precipitator fan), the grinding system at Qingzhou uses cyclones to dedust the mill vent gas. This reduces the operating suction, and usually limits the gas volume of the precipitator. The raw materials (limestone, sandstone, iron ore and fly ash) are fed into the mill from proportioning bins. Feeding devices under the bins extract the materials according to a preset ratio and a belt conveyor carries the materials to the mill. The average moisture content of the raw materials entering the mill is 2.5 - 3.2 percent, with a maximum of 6 percent. The fly ash does not enter the grinding process but is mixed into the raw meal that leaves the mill.

The excellent drying capacity means the mills are well suited to raw materials with high moisture content, as well as highly abrasive or very sticky materials. Some of the mills grind very dry raw materials with a moisture content of less than one percent, while others grind very wet raw materials with a moisture content up to 20 percent. The grindability of the mill feed varies widely, from less than 3 kWh/t to more than 11 kWh/t. And ATOX mills can be designed specifically to produce a raw meal of a suitable fineness for the kiln operation in question. The ATOX is also extremely compact compared to other vertical mills. It produces very little noise which allows for outdoor installation, like the one at Qingzhou.

Highly versatile ATOX mill FLSmidth’s ATOX mills successfully grind raw materials that vary greatly in terms of grindability, drying requirements and abrasion. The mills combine grinding, separation and drying into a single unit. 26.2 metres

The world’s largest ATOX raw mill at Zhonglian Luhong Cement Qingzhou Co. in China will grind 460 tonnes of hard limestone per hour.

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Highlights November 2007

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Alternative fuels: Today’s alternative – tomorrow’s standard

A wide range of waste materials are used to fuel cement kilns. FLSmidth offers complete solutions and all the necessary technology for handling and firing alternative fuel.

On 1 May this year, FLSmidth set up a group dedicated wholly to establishing the use of alternative fuels in the cement and minerals industries. The FLSmidth Alternative Fuels group brings together specialists from many disciplines, consolidating focus in this increasingly important field. For over a decade, FLSmidth and the FLSmidth Group have developed products that are market leaders in the simple, effective and reliable use of alternative fuels in the cement industry. These include: • The HOTDISC combustion device • The DUOFLEX kiln burner • Pfister rotor weighfeeders • FLSmidth Automation’s multi-fuel controller • KOCH conveying systems • Silo extraction systems. Generally, the industry’s use of alternative fuels has become more established and accepted. Cement and minerals producers are now seeking suppliers who can offer a complete range of equipment and services related to alternative fuels. It was this development that prompted FLSmidth to create the Alternative Fuels group. In addition to supplying market-leading machinery, FLSmidth now offers to take responsibility for complete alternative fuel projects, including all accompanying technical services. All needs covered by one group There is a wide range of disciplines involved in successfully replacing fossil fuels with alternative fuels. The role of specialists should not be underestimated, and combining their different areas

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Highlights November 2007

Lars Skaarup Jensen, head of FLSmidth’s newly established Alternative Fuels group, introduces the Company’s new initiative at Cemtech in Prague in September 2007.

of expertise is the best way of successfully leveraging the potential benefits of using alternative fuels. Problems frequently encountered when firing alternative fuels are reduced clinker production capacity, higher emission values and inadequate availability of the fuel handling equipment. But all these difficulties can be successfully addressed. The connection between handling equipment and the fuel process is often ignored. A solid understanding of both aspects is necessary – and this is best dealt with at the earliest possible design stage. The fuel of the future? Over the past century, the cement industry has used a variety of fuels for pyroprocessing. Oil has largely been replaced by coal, which in turn has partly been replaced by petcoke (and natural gas). In the coming decades, alternative fuels made from waste generated by society are likely to be a major energy source.

Driving the industry forward FLSmidth’s investments in alternative fuel technology have proved fruitful. We have greatly improved our fundamental understanding of the differences between burning fossil fuels and alternative fuels, particularly through our research collaboration with combustion experts from the Technical University of Denmark. Products and services based on market-leading technological developments will continuously be launched. Moving forward, FLSmidth will accelerate its research and development into alternative fuels. This will ensure that our customers have access to industryleading technology and make alternative fuel usage by the cement and minerals industries even more attractive.



Highlights November 2007

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Upgrades important for the Italian cement industry Italy doesn’t just produce good football players, it also has some major players in the cement market who have been around for many years. In 2004 FLSmidth approached the Italian market with a minor upgrades concept. Now, it’s one of the world’s best markets for upgrade projects. Highlights visited the beautiful medieval town of Gubbio, in the Umbrian region of Italy, to interview managers at both Barbetti I.C. and Colacem. Situated on the slopes of the Monte Ingino on the outskirts of Gubbio, both companies have recently ordered FLSmidth upgrades – and we wanted to learn more about their views on environmental issues and FLSmidth services in general. We talked to Alessandro Agostinelli, the Technical Manager at Barbetti. From Colacem, we spoke to Pier Federico Baldinucci, Manager of Engineering, and Nando Tinti, Project Manager.

Barbetti FLSmidth has a long-standing relationship with Barbetti. Back in 1982, FLSmidth installed a 1,500 tonnes per day (tpd) pyroprocessing line at the Gubbio plant. In 2000, the plant was upgraded to 4,000 tpd in only 72 days. Now production has been boosted to 4,600 tpd. The success of this project spurred Barbetti’s decision to work with FLSmidth again. We have since collaborated on various projects, including a new separator for the existing ATOX mill. In November 2006, FLSmidth strengthened its relationship with Barbetti, winning a contract for a 100 tonnes per hour cement grinding plant. Colacem Colacem’s collaboration with FLSmidth started in 2002 when it ordered a new grate cooler for its plant in Tunisia. This newly developed technology ideally suited Colacem’s plant. As Colacem was one of the first plants to introduce the

new type of cooler, there were some teething problems – more than Colacem actually expected. However, FLSmidth quickly solved the problems and its personnel remained at the site until the cooler was up and running. Since then, there have been no problems with the cooler and the plant is producing at maximum capacity. Colacem was impressed with the way FLSmidth handled the initial problems, so the company decided to work with FLSmidth on various other upgrade projects. These include a bypass system in the town of Sesto Campano, and most recently, a project in Caravate in northern Italy, which involved enlargement of the calciner and installation of a tertiary air duct. FLSmidth’s low NOx technology was considered the best solution for this upgrade.

Colacem’s plant is beautifully situated in Umbria, the green heart of Italy.

Talking about the environment Environmental protection is important to both Barbetti and Colacem. Barbetti has installed an FLSmidth low NOx calciner to reduce emissions. The new ATOX mill, tower and filters supplied by FLSmidth have also had a positive impact on the environment. According to Mr Agostinelli, Italian cement producers are keen to protect the environment. Energy is now becoming very expensive so there is a great deal of interest in reducing energy consumption. However, partly because NOx limits differ greatly from one Italian region to another, Italian cement producers don’t have a common approach to environmental issues. Colacem is also actively involved in minimising the environmental impact of its facilities. At Caravate for example, the plant is very close to the town and the local community has a great interest in how the plant affects the environment. Messrs Tinti and Baldinucci explain that the plant has changed from electrostatic precipitators (ESP) to hybrid filters (ESP and bag filter together), and the pyro system is being upgraded to reduce NOx emissions. Barbetti and Colacem both agree that the Italian cement market will remain stable for at least four or five years, but is unlikely to grow. Meanwhile, higher environmental standards will continue to necessitate upgrades, revamping and new products, so there will be a lot of activity in the Italian cement industry in the future.

High quality and strong relations In general, both companies value working with FLSmidth. They consider good personal relations to be very important. The service provided by FLSmidth is good, its proposals are clear and its support is supreme. The prices are a bit high, though, even though they realise

that FLSmidth quality is probably superior. “Price is balanced against the quality of the products and the good relationship with FLSmidth – and then FLSmidth often wins,” they say.

Barbetti, also situated in Umbria, has worked with FLSmidth on several upgrade projects over the past few years.

Back in 2003, FLSmidth found a gap in the services provided to customers. The company was selling major projects and spare parts, but had no specialists to take care of the upgrades market. Now there are four Customer Services Projects (CSP) departments in FLSmidth. They keep on expanding to keep up with all the orders coming in.

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Highlights November 2007

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Growing into the future Pretoria Portland Cement Company Ltd (PPC) has launched an ambitious capacity expansion plan for its southern African operations. This includes a new 3,300 tonnes per day (tpd) clinker line at PPC’s existing Dwaalboom cement factory originally supplied by FLSmidth. The project is entitled “Batsweledi” – a Sotho word meaning “growing into the future”. Founded in 1892, PPC is currently South Africa’s leading cement producer. It has eight cement factories in South Africa, Zimbabwe and Botswana. Incidentally, FLSmidth’s relationship with PPC goes back to the first supply of a mill in 1906. A booming economy Greg Thomas, the Construction Manager for the Dwaalboom Expansion Project, has been in the cement business for 27 years, but has never before experienced such a growing need for cement. “The demand in South Africa has grown significantly. The soccer World Cup in 2010, booming housing construction, and increasing public sector infrastructure investment have boosted

cement consumption by 50% over the last 4 years from 9.6 million tonnes per annum in 2002 to 14.3 million tonnes per annum at the end of 2006. Cement sales are forecast to rise to in excess of 15.5 million tonnes in 2007. Room for further expansion To cope with the increased demand, PPC has embarked on an upgrade and expansion programme, which will increase capacity of its South African operations from the existing around 6.0 million tonnes per year to 7.5 million tonnes by mid 2009. They have recommissioned their Jupiter plant, but they will soon need additional capacity. PPC faced two options when deciding to expand Dwaalboom: either upgrade the existing line or build an additional one. The existing line was

based on SLC technology from 1984 so it made sense to build a new line based on modern technology while keeping the old line producing during the peak sales cycle. The new line is planned for future expansion and there is space for more additional lines on the present site. The quarry facilities and stacker/reclaimer system were originally built for double capacity, so no expansion of this part of the Dwaalboom plant was needed. PPC will increase the grinding capacity at Hercules which is where the biggest market is and where fly ash is readily available. The clinker from Dwaalboom will be transported by rail to the Hercules plant’s grinding facilities near Pretoria and also to the recommissioned Jupiter plant in Johannesburg.

The new line is planned to be commissioned as from April next year. In addition to serving the South African market, PPC exports to other African countries. Protecting the environment PPC is committed to reducing the environmental impact of its operations. They have implemented a risk management system which is certified to the ISO 9002 and ISO 14001 standards for quality and environmental management, respectively. The state-of-the-art technology that will be installed at Dwaalboom will reduce greenhouse gas emissions and lower the fuel (coal) consumption per tonne of production.

FLSmidth is supplying • An ATOX 37.5 raw mill • A Pfister kiln feed system • A 6-stage preheater and ILC calciner with an option for subsequent installation of a HOTDISC • A ROTAX-2 4.55 x 54 m rotary kiln • A DUOFLEX kiln burner for coal • An MMC 11 x 73 Multi-Movable Cross-Bar cooler with Heavy-duty Roll Breaker • An ATOX 20 coal mill • FLSmidth Airtech fabric filter and electrostatic precipitator • An FLSmidth Automation CEMulator for training the PPC staff

Pretoria Portland Cement Company is expanding its Dwaalboom plant with a new 3,300 tpd clinker line.

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Growing into the future

QCX/RoboLab sales still buoyant

Scarce water supplies The impressive 115 metre tall preheater tower made of concrete is a landmark and will probably be of high marketing value for PPC and FLSmidth. The preheater system has six stages instead of five, which enables lowering the gas temperature. This saves water for cooling. The limited water reserves in this part of the country, particularly in the summer, also ruled out a conditioning tower.

There were significant orders for QCX/RoboLab in the first half of 2007, continuing its strong market performance from 2006. This positive trend shows the industry remains confident in the automated sample preparation and analysis solution.

Movable Cross-Bar (MMC) cooler with roller breaker. The project also marks the first collaboration between FLSmidth and its sister company FLSmidth Minerals in carrying out a project. FLSmidth’s contract with PPC includes design, equipment supplies and supervision. FLSmidth Minerals’ role is to erect and commission the equipment and manage the fabrication and installation of the preheater steel structure.

The industry ordered 18 QCX/RoboLab systems and around 50 QCX systems in 2006. These impressively high numbers confirmed FLSmidth Automation’s QCX line as market leaders.

Several firsts for South Africa Dwaalboom will be the first site in South Africa to install FLSmidth’s new Multi-

FLSmidth is responsible for the pyroprocessing system at Dwaalboom’s new line, which includes a spectacular 115-metre high preheater.

Both new and retrofit projects The QCX/RoboLab system is robotics based and, of the 18 sold last year, 13 were new projects that included complete packages of automated sampling, sample handling and sample preparation equipment as well as analysers. The sampling and preparation equipment for all these projects is supplied by Pfaff AQS. The remaining five orders were retrofit projects, which included software upgrades to the latest Windows version of the QCX software. Saudi Arabia tops the list for new projects with five systems orders, includ-

ing one double RoboLab cell for the gigantic Hofuf plant. Russia and Kazakhstan are significant newcomers to the automated laboratory systems market. Meanwhile, Spain dominated the retrofit market with three software upgrade projects, two of which included additional automated combustion analysis. QCX Product Manager Steen Tokkesdal Pedersen says: “We see a clear trend towards adding on the more complex preparation and analysis tasks. For example, among the projects sold in 2006 and the first half of 2007, eight included automated fusion and four included automated combustion analysis. In the early days of robotics automation, we and other suppliers typically automated the simpler tasks such as powder sample preparation. Now, customers are considering the automation potential of all tasks in their 24/7 production laboratories.” New orders in US and India The first half of 2007 saw a couple of important entries to the sales list. One is the QCX/RoboLab for Holcim’s St. Genevieve project in Missouri, USA. It will produce 12,000 tonnes of clinker each

day, making it the world’s largest single production line. Another important milestone is India’s first QCX/RoboLab system, ordered by Sagar Cement Ltd. Director S. Sreekanth Reddy of Sagar Cement Ltd. comments: “We are looking for the best achievable quality in our lab operations to facilitate high product quality. QCX/RoboLab will bring us this, and the flexible robotics concept allows us to add more automation in the future. Another important reason for choosing QCX/RoboLab is FLSmidth Automation’s strong presence in India. Their skilled personnel from Chennai make us confident that we will be well looked after with fast local service.” Market acceptance grows FLSmidth Automation expects sales of QCX/RoboLabs and other QCX products to rise in Russia and surrounding countries, and particularly in India. The growing acceptance of laboratory automation is a clear sign that improved sampling quality and lab procedures are ranked highly in these countries – possibly more highly than potential labour costs.

The QCX/Robolab system, here at Cementos Portland Valderrivas’ Alcala Plant in Seville, Spain, is a well-proven and popular automation solution for sampling, sample handling, sample preparation and sample analysis.

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Expanded 2008 programme for FLSmidth Institute

2008 promises to be a bumper year for FLSmidth Institute. As well as an increased training schedule, there are courses planned in Spanish and a comprehensive e-learning programme. Next year, there are so many training courses and seminars that we’ve had to divide our calendar up into two sections. And there are separate application forms depending on whether you want to enrol in a training course or a seminar. Pull the calendar out and put it on your wall, so you know exactly what’s coming up when. Seminars in Spanish back – and better than ever Due to popular demand, FLSmidth Institute will run a week-long set of seminars

in Spanish in Madrid in October 2008. FLSmidth Institute has not held any seminars in Spanish since 2003, but many Spanish-speaking plant employees have asked for a repeat. “Of course, we’re not content to rest on our laurels at FLSmidth, so the new seminars are better, more extensive and more flexible than before,” says Cristina Holmark, International Seminar Manager. This year, the seminars will feature two educational lines, running concurrently: maintenance and production. Moreover, a new arrangement of subjects on the Spanish production seminar makes it possible to select from the following options: three days focusing on grinding with a plant visit (module 1); four days focusing on kiln and cooler systems with a plant visit; or both modules over six days. The greater range of topics and booking flexibility should allow participants to concentrate on exactly what they want to learn. The Spanish maintenance seminar, however, will be a week long session. The seminars are aimed at people with one year of experience or more, but of course all process and maintenance staff will find them relevant. You can find more information on the content and issues covered at

www.flsmidthinstitute.com. And you can sign up by e-mailing Cristina Holmark at [email protected] Extended e-learning activities With a new intranet-based e-learning management system on its way in 2008, FLSmidth Institute plans to step up internal training programmes for FLSmidth employees. Accessible from anywhere in the world, the new system will help to raise our employees’ skills and knowledge. As Carsten Storgaard, e-learning manager explains, “This will have a great knock-on effect for our customers, because the better and quicker we are, the faster their installations are up and running.” There will be a number of elements to the new system, including online simulations where engineers can, for example, run through all the documentation for the total installation of a cement plant. The simulations can be configured to suit specific installations, taking into account the varying equipment on a site. “Part of the beauty of the e-learning platform is its flexibility,” says Carsten. “People have different learning styles and the e-learning programmes contain many elements, from text-based learning to 3D animation and video.”

Carsten continues, “One of our main goals is to include what we call the three Es: Engaging, Educational and Entertaining. We’ve followed these principles as much as possible, so the programmes are interactive and learner-centred, and they use tasks that are directly relevant to people’s everyday work situations. Everything is designed so trainees can relate to the information they are doing and see its relevance in their work”. Technical training will also be covered by the new e-learning platform. “E-learning is much faster and less expensive than classroom-based training, so there’s less time learning the processes and more time working with customers. Reducing time-to-competence can only be a good thing for everyone involved,” Carsten concludes.

FLSmidth Institute opens in India India is an expanding market and its cement and minerals industries are in great need of training and seminars. To meet the growing demand, FLSmidth Institute has now set up a unit in Chennai, India. FLSmidth Institute is an umbrella organisation covering all training, seminars and human resource services for FLSmidth Group customers. It consists of FLSmidth Institute Denmark, FLSmidth Institute US and now also FLSmidth Institute India

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At the International Maintenance Seminar, delegates meet various specialists from FLSmidth (left) and apply their knowledge at a cement plant (below).

– which will operate as part of Customer Services India. Working closely with the other FLSmidth Institutes, it will support the entire FLSmidth organisation including FLSmidth Minerals and all other divisions. FLSmidth Institute India will provide training and seminars both to the industry and within FLSmidth. Opened on 1 August, the new department is headed by Mr Shyamsundar Iyer, who will support FLSmidth Institute Denmark on a number of large training projects in the future.



Highlights November 2007

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Up the Mississippi to world’s largest clinker line Equipment supplies for the 12,000 tpd Holcim (US) Ste. Genevieve project are literally streaming into the construction site on the banks of the Mississippi. As Highlights visited the site in late June, the contours of Holcim’s new flagship plant in the US were rapidly taking shape.

How’re you doin? It’s seven o’clock in the morning. This friendly greeting in a strong southern accent stands in contrast to the tense and hectic mood at the specially built harbour, only 300 metres from the construction site. The last of the kiln tyres for the 6.6 m diameter and 93 m long kiln has just arrived from Korea and is being brought safely ashore. FLSmidth’s

site manager, Michael Olsen, is carefully following the landing operation. The people from Washington Group Alberici, whom Holcim (US) Inc. has chosen to do the construction work for the USD 905 m cement plant, have the situation fully under control. The tyre is landed safe and sound, before being carried on a special truck the last 100 metres to the site and unloaded next to the kiln

sections and an increasing amount of other FLSmidth equipment ready to be installed. “This project is simply great by all measures,” Michael comments. “Not just because of its size, but also because the people here are great to work with and have great equipment at their disposal.”

The Mississippi River plays a decisive role in the gigantic project. The waterway is the nation’s largest transport corridor, and the location of the plant – in Ste. Genevieve County, Missouri, halfway up the river – will enable Holcim (US) to serve cement customers from the U.S. Gulf of Mexico in the south to Minneapolis and Chicago in the north and in no less than 22 of the largest cities in the US. The Mississippi is also contributing to the actual construction project. The site has limited space for receiving goods, and only ready-made components arrive directly by barge. FLSmidth is supervising two pre-assembly sites down the River: In Memphis, Tennessee, 400 km downstream, the Atlas Company is assembling the kiln riser, the preheater and calciner including cyclones, the kiln hood and other FLSmidth supplies, and at Scott City, Missouri, some 125 km downstream, Delphi, a specialised contracting firm, is assembling the FLSmidth Airtech process filters. Three of the key players at the Ste. Genevieve site, l-r: Michael Olsen, site manager, FLSmidth; Phil Morony, construction manager, and Rudy Blum, project manager, both Holcim.

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The famous Mississippi River tugs are like taxis moving barges with goods up and down the River regardless of the strong currents. “They come and go like a Swiss clockwork based on Holcim’s and Washington Group’s master plan,” Ole Sørensen says. He is FLSmidth’s mechanical engineer at the Memphis pre-assembly site. “The secret is to be slightly ahead of schedule all the time and be ready when the tug arrives. So far, we’re making good progress here in Memphis. We reckon on being finished by June 2008.” Some of the machinery comes from China where FLSmidth’s own field inspectors visit the workshops regularly to check the quality. Before being shipped, all the equipment is trialassembled and inspected. Both Ole and the customer are fully satisfied with the marking and the quality of the supplies. At Scott City, all the Airtech filter components are being preassembled according to the same principles. To minimise the number of individual components to be unloaded at Ste. Genevieve even the top and bottom casings are welded together here on the river bank.



Highlights November 2007

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Up the Mississippi to world’s largest clinker line

An extraordinary project The size in itself makes the project something quite unique to all parties involved. The preparations have been extensive. In the mid 1990’s Swissbased Holcim Ltd. acquired the huge site which holds enough limestone for more than 100 years’ production. Holcim underwent a six-year review and permit process involving both federal and state regulatory agencies before the final go-ahead was received in 2005 and the subsequent planning of the project progressed very swiftly. Executing the world’s largest single clinker production (greenfield) line with the world’s largest cement producer as your partner requires exemplary planning. Together Holcim and FLSmidth have meticulously planned the engineering phase by identifying critical milestone deliverable dates affording Holcim the opportunity to get the full benefit of efficient erection planning. Recognising that the success of the project hinges upon open communication at all project team levels, FLSmidth has dedicated a core team of ten engineers from its US office to the project and is utilising the strengths of its other project centres in Denmark and India to

ensure that work is completed to support field erection needs. Holcim has assigned two experienced members of its staff, Project Manager Rudy Blum and Construction Manager Phil Morony, to oversee the project. Environmental concern, occupational safety and health and efficient planning have top priority at the site which at first glance resembles a bustling anthill of people, machinery and contractors. But it is all backed by a strong organisation. Highlights asked the two Holcim managers for their opinion on the project. Both Rudy Blum and Phil Morony as well as several of the team members have worked together in other projects around the world. So everyone knows each other and is conversant with the job. Why FLSmidth? Safety and reliability. A project of this magnitude leaves no room for experiments when selecting the technical solutions. All the process solutions are therefore well-proven and familiar to the project team. FLSmidth made the best proposal and has experience in building huge facilities. Moreover, FLSmidth has a large organisation in the USA capable of carrying out the engineering and project management for this large

plant. The resources of FLSmidth Inc. in Bethlehem, Pennsylvania, are of course being supplemented by the worldwide FLS organisation. The choice of technology is always a balance between several factors, notably the type of raw materials available and the characteristics of the site. For example, we chose to have several mills instead of one big one. But why then only one huge kiln? The answer is: It’s no big complication to have one large kiln. There is less maintenance and there are economies of scale. So at Ste. Genevieve this is the most suitable solution. But at other sites, the situation could be different. One hundred percent safety and environmental compliance In Ste. Genevieve County Holcim has acquired a 3,900 acre (16 square kilometre) site which is located in an environmentally sensitive area. Over 1,800 acres (7 square kilometres) are being preserved as a conservation area. The quarry will be mined in increments no larger than 200 acres (0.8 square kilometres) at any given time. As the quarrying is completed in one area, that portion of the quarry will be reclaimed and mining will continue in another portion of the quarry. Stormwater runoff is not discharged directly into

the River, but is cleared first in huge artificial ponds. Holcim considers these precautions not only a necessary additional cost, but also a natural commitment to ensuring the sustainability of the project, demonstrating both on a local and a global scale that such a gigantic plant can operate in an environmentally sound way, whilst creating jobs and prosperity for the local community within a radius of some 50 miles (80 kilometres). Holcim is equally committed to maintaining a maximum level of occupational health and safety. Safety courses, safety boots, badges, eye protection and helmets are all a natural part of the project. Any violation of the safety guidelines immediately results in sanctions – both personal and financial - for the contractors and their personnel at the site. The success criterion of the Ste. Genevieve project is of course that 12,000 tonnes or more of clinker will leave the kiln every day as from the agreed time in 2009. But until then it is also a definite goal that no serious personal accident occurs that might have been avoided by correct behaviour. So far Holcim has been successful in this respect. Our interview is over. Rudy Blum and Phil Morony need to go back to the harbour and attend a special safety award

session held by Washington Group, the main civil works contractor. The harbour team is being awarded for safe and correct landing of equipment. The master plan proves to be working. FLSmidth’s Site Manager, Michael Olsen, also attends the ceremony and promises those present many more tonnes of FLSmidth equipment to be tugged in via the Mississippi from all over the world, from Memphis and from Scott City over the coming months. The point is taken. We are all in the same boat until we can say: Job well-done. Everyone is making their contribution and helping to create industrial history here in the baking Missouri sun. “How’re you doin” acquires a new meaning when visiting Ste. Genevieve. FLSmidth scope of supply for the project: • FLSmidth Minerals gyratory crusher rated for 2000 tph limestone • Secondary crusher rated for 800 tph limestone • 65,000 tonne circular limestone store from MVT • Additives and correctives stacker / reclaimer units from MVT • 46,000 tonne circular coal/petcoke store from MVT

• Docksider barge vacuum unloader • Two ATOX 50.0 raw mills rated for 515 tph each • Two ATOX 27.5 solid fuel mills rated for up to 70 tph coal or 37 tph petcoke each • Equipment for two 15,000 tonne CF raw meal homogenisation silos • ILC 5-stage preheater with low NOx and low CO calciner • 6.6 metre diameter x 93 metre 3-support kiln with tangential tire suspension • DUOFLEX kiln burner • MMC 774/23 x 123 Multi-Movable Cross-Bar cooler with Heavy-duty Roll Breaker (HRB) • Pfister solid fuel and kiln feed dosing systems • Four OK 36-4 vertical roller mills for cement grinding rated for 165 tph cement at 3800 Blaine • Eight MAAG vertical roller mill main gear reducers • Equipment for eight inverted cone cement storage silos • FLSmidth Airtech process filters • FLSmidth Automation control system with QCX laboratory and sampling system.

Kiln tyres are a key component for a project of this magnitude. The tyres are cast in Korea, shipped to the US, tugged on barges up the Mississippi to the specially built site harbour where they are unloaded, ready for assembly onto the kiln.

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D.G. Khan inaugurates environment-friendly plant Pakistani Prime Minister Shaukat Aziz attended the inauguration of D.G. Khan Cement’s new Khaipur plant on 14 May. The Prime Minister, who laid the foundation stone back in April 2005, remarked that the commissioning of this modern plant had generated numerous jobs and created several associated industries. The Khaipur plant will supply both the national market and neighbouring Afghanistan. A greenfield production facility, the 1.3 square km site is located next to limestone and clay raw material deposits near Khaipur village, 38 km from Chakwal city in the district of Shakwal, Punjab.

Contributing to economic development The cement plant will contribute to the industrial economic development of a poor rural region. The increased cement production capacity will also help Pakistan maintain low cement prices. This is essential for developing infrastructure and affordable housing projects, as well as for reconstruction following the October 2005 earthquake. D.G. Khan Cement Company D.G. Khan Cement Company Limited (DGKCC) belongs to the Nishat Group, one of the leading and most diversified business groups in South East Asia. Assisted by FLSmidth, DGKCC is also optimising two existing lines, built in 1986 and 1998, raising the company’s

Attending the inauguration of D.G.Khan’s new environment-friendly production facility, r-l: Ole Bak, General Manager, FLSmidth; Jan De Kok, Head of EU delegation to Pakistan; Jehangir Tareen, Federal Minister of Industries; Shaukat Aziz, Pakistan’s Prime Minister; Lt Gen (Retd) Khalid Maqbool, Governor Punjab; Sardar Ghulam Abbas, Administrator, District Chakwal; Mr. Raza Mansha, Chief Executive Officer, D.G. Khan Cement.

total capacity from 5,500 tonnes per day (tpd) to 6,700 tpd. This will help make DGKCC the largest cement producer in Pakistan, with about 10 percent of the industry’s total production capacity. Environment-friendly production The production processes at DGKCC comply with the World Bank’s environmental standards. The company is certified to ISO 9002, as well as the ISO 14001 Environment Management System. It’s the only cement producer in Pakistan to have both certifications. Making Pakistan a major cement exporter At the inauguration ceremony, Prime Minister Aziz acknowledged the role the Nishat Group is playing in the country’s

development. He said that Pakistan was emerging as a major cement exporter to the neighbouring countries and the Middle East – and that this industrial growth will trickle down to the benefit of all layers of society. According to Chief Executive Officer Raza Mansha of DGKCC, who thanked the local authorities and suppliers in

making “a dream come true”, the Nishat Group will expand further over the next three years.

FLSmidth supplied: • A raw material store • ATOX coal and raw grinding mills • Two OK vertical cement grinding mills (the first in Pakistan) • A preheater and kiln, and the world’s hitherto largest SF Cross-Bar cooler • Four FLSmidth Airtech electrostatic precipitators • Six Ventomatic packing lines • Four MAAG gear units • An FLSmidth Automation quality control and laboratory system • Supervision of erection and commissioning, as well as staff training

FLSmidth’s contribution The contract between D.G. Khan Cement Co. Ltd. and FLSmidth for a new 6,700 tpd production line was signed in June 2004.

Quality control for Grasim Industries India’s Grasim Industries Limited (Cement Division) has once again selected FLSmidth Automation to supply a Quality Control by computer and X-ray (QCX) system. The system will manage laboratory information, and optimise raw mix and cement quality.

Celebrating the first bag of cement from D.G.Khan’s new Khaipur plant in Pakistan’s Punjab province, Ole Olsen, FLSmidth (left) and Dr Arif Bashir, General Manager, D.G.Khan, shake hands.

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Grasim Industries are leading cement producers in India and are expanding their production capacities. The quality control systems are for Grasim’s three upcoming plants: Grasim Cement at Kotputli; Aditya Cement, Line 2; and UltraTech Cement, Line 2 at Tadpatri, and for the existing Shree Digvijay plant.

The scope of the projects comprises: • Advanced raw mix control by QCX/ BlendExpert • Complete laboratory information management solution • Registration and storage of quality control data for two years • Specialised communication driver for X–ray equipment • QCX/Server and QCX/Client computers • Networking solution. In addition to these software solutions, FLSmidth Automation will supply: • XRF machines • XRD machines (not in Shree Digvijay) • PGNAA-based cross belt analysers (not in Shree Digvijay or Ultratech Cement in Tadipatri)

• Manual sample preparation equipment from Pfaff AQS • Fused bead preparation equipment (not in Shree Digvijay or Ultratech Cement in Tadipatri). All supplied software will be based on the Microsoft Windows 2003/XP platform. A regular supplier to Grasim Industries Limited (Cement Division) and UltraTech Cement Limited, FLSmidth Automation has previously provided high-level control solutions such as ECS/ProcessExpert, ACE/ECS Cement Plant Control and QCX Quality control solutions.



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New acquisition fuels rapid growth of FLSmidth Minerals Combining the strong engineering legacy of the Fuller Company and F.L.Smidth & Co., FFE Minerals had become the predominant supplier of crushing, grinding and pyroprocessing equipment to the mineral processing industry by the mid-late 90s.

FLSmidth Minerals has finalised the acquisition of GL&V Process, one of the world’s leading providers of separation technology for the metals and minerals industries. The acquisition includes the global businesses of DorrOliver Eimco, headquartered in Salt Lake City, Utah, and Krebs Engineers, headquartered in Tucson, Arizona.

Two major differences Despite many similarities, the cement industry and the minerals processing industries have two major differences: 1. Minerals processing entails larger equipment for crushing, materials handling systems (up to 12,000 tonnes per hour (tph)), and grinding mills.

Shared technologies in minerals and cement FLSmidth Minerals, formerly called FFE Minerals, and until recently the smaller sibling of the FLSmidth Group, has experienced rapid growth since beginning life as the Minerals Processing Divisions (MPD) of the Fuller Company and F.L.Smidth & Co. in 1991. With sales of USD 2bn projected for 2008, minerals will become similar in size to the cement side of FLSmidth’s business. Minerals has many things in common with the cement industry, including crushing, grinding, materials handling, pyroprocessing, plant engineering, automation and pollution control. The FLSmidth Group is the leading global supplier of most of the equipment based on these shared technologies.

Highlights November 2007

For example, a preferred grinding method in minerals is to wet process large (40 feet diameter) semi-autogenous grinding (SAG) mills with 30,000 hp wrap around motors. Primary gyratory crushers and materials handling systems range in size up to 12,000 tph. Already the leading supplier of such products, the company proceeded to fill the gaps in its portfolio with acquisitions, and today it has the most complete line of products for the minerals processing flow sheet.

The large capacity ABON sizer is particularly suited for crushing wet and sticky materials.

RAHCO mobile material handling system.

Heavy materials handling equipment In mining operations, materials handling systems account for a large part of capital expenditure – so two German companies were transferred to Minerals from other parts of the FLSmidth Group in order to grow that area of the business: • MVT – A well-known manufacturer of materials handling equipment • Möller – Renowned for its pneumatic conveying capabilities, and particularly prominent in the power industry and alumina processing Two new companies were recently acquired: KOCH, a large and wellknown materials handling company from Germany; and RAHCO, a US company with advanced technology in mobile materials handling systems. This now makes FLSmidth Minerals one of the largest materials handling companies in the world, booking over USD 200m in the first half of 2007.

MVT shiploader for coal.

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Large capacity crushers Some ores require a different type of crusher than the well-known FullerTraylor gyratory, so ABON Engineering was acquired in 1998 to provide a sizer capable of handling large quantities of coal, iron ore, bauxite and limestone for cement and lime plants. The ABON sizer is especially suitable for wet, sticky materials. Also during the late 90s, Vecor, a large South African producer of ball mills and other mining equipment including mineshaft hoists, was acquired which expanded business in Africa.

2. Minerals processing predominantly entails wet processing for the beneficiation of ores.

Agglomerator at copper ore processing plant.



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New acquisition fuels rapid growth of FLSmidth Minerals

Complementary activities make FLSmidth Group the market leader The three companies, FLSmidth Minerals, Dorr-Oliver Eimco and Krebs Engineers, complement each other both geographically and product-wise. FLSmidth Minerals is a market leader in pyro technologies and in crushing and grinding of minerals, while the GL&V Process companies are market leaders in downstream separation processes. Together, their products represent one complete process technology from the extraction of minerals through to the end product.

Excel heavy-duty cone crusher

In order to increase the crushing line for mining and aggregates, the Excel Crusher company was purchased in 2006. This brought the most modern heavy-duty cone crusher into the Group along with a manufacturing facility in Pekin, Illinois, enhancing FLSmidth’s ability to supply high-quality parts and components for crushers and other mining equipment. An 1100 hp cone crusher was recently commissioned in a copper mine in Peru.

Comminution •Crushers •Sizers •Mills

•Belt Conveyors

•Pipe Conveyors

Separation •Flotation •Thickeners •Filters • Cyclones & Pumps

Pyro •Kilns •Dryers •Fluid beds •Gas suspension

ABON

The competition took place in spring and the winners were invited to Copenhagen to try the real simulator and meet the FLSmidth people behind the campaign. The contestants with the highest scores were: Mr Kumar Tripathy Pasant Technical Vice President Shree Cement Ltd., India

Materials Handling •Feeders •Stackers/Reclaimers

Product

Mr Tony Valenzuela Control Room Operator Sr. Salt River Materials Group, USA

•Loading/Unloading

For more information about the campaign see: www.beat-the-autopilot.com

Parts & Service

F L S m i d t h Minerals

FLSmidth Automation’s Beat the Autopilot competition featured an online simulation that demonstrated the complexity of kiln process control and optimisation.

Mr Charles Randolph Walters Control Room Supervisor Salt River Materials Group, USA

Mineral Processing E x t ra c tion •At the face mining • I n - p i t crushing • M i n e Hoists

And the diploma goes to…

M öller

Vecor

Dorr-Oliver Eimco

Excel

MVT

Buffalo

Krebs

Rahco

KOCH

Award-winning campaign garners commercial interest This is the first time FLSmidth Automation has launched a campaign of this magnitude. The ECS/ProcessExpert platform is a complicated product and a very complicated simulation – and the online campaign ran for longer than expected. But General Sales Manager Peter Harrig Nielsen and Product Manager Hassan Yazdi of FLSmidth Automation were both very satisfied with the outcome. Approximately 3,000 operators at 780 cement plants in 128 countries were initially contacted. Almost 150 plants qualified for the online game, and 38 actively participated, benefiting from the advanced real-time training program. The campaign has received awards from the public relations communities in Denmark and the USA. And the simulation program has attracted a great deal of commercial interest – several cement companies are considering buying training programs and 14 systems have already been ordered.

Knowing that it’s less expensive to practise on a training server than an actual production line, FLSmidth Automation will make the simulation program available on its website later this year. This will help build interest in automated kiln process control among kiln operators around the world.

Mr Walters accepted the invitation to visit Denmark. However, the two other winners were unable to make the trip at this time.

Solid/liquid separation – the missing link But FLSmidth was still lacking capabilities in one area of minerals processing: the concentration of ores through a series of solid/liquid separation steps. So, on 10 August 2007, FLSmidth acquired the process division of GL&V, which included Dorr-Oliver Eimco, leaders in flotation, separation and filtration, and Krebs Engineers, the world’s leading suppliers of wet slurry cyclones.

Concentration of ores through a series of solid/liquid separation steps

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FLSmidth adopts new internet media

New design facilitates maintenance of FK pumps

Over the last two decades, the internet has transformed our communication habits. Among the hottest venues on today’s worldwide web are YouTube, the world’s most rapidly growing video-sharing website, and Second Life, an internet-based virtual world.

For some products, like cars, maintenance has become more difficult over time and requires special tools, but for the FullerKinyon (FK) pump it has never been easier.

The fact that it is no longer necessary to enter the bearing assembly during screw flight replacement is an additional advantage. In this way, any damage to the seal and bearings when removing the screw is eliminated.

Development of the pump dates back to 1919 and the pumping technology was a central element in the formation of Fuller Company in 1926 (Fuller was acquired by FLSmidth in 1990). Over the years, the pump has established itself as a dependable high-performance product, and new versions have been launched: • Type ‘H’ pump, developed in 1935, over 12,000 sold • Fuller-Kompact pump, developed in 1961, over 1,000 sold • Type ‘M’ pump, developed in 1976, over 2,000 sold

FK Pump The FK Pump is a reliable two-phase material injector for high capacity, long distance conveying. It is simple in design, with only one moving part – the screw, and it is designed to lower lifecycle cost and maximise run times. The pump is used for transporting materials from silo to silo and from the grinding mill to the silo as well as for loading and unloading ships, barges and railcars. The FK Pump is capable of handling a large flow of dry, free flowing, fluidisable materials over long distances. Conveying distances up to 1500 metres and capacities up to 600 tonnes per hour of standard Portland cement have been achieved.

FLSmidth is active on both sites and has been pleasantly surprised to see that our fairly conservative industry is embracing these new modes of online communication. As a case in point, FLSmidth recently uploaded a short 3D animation of a cement plant project to YouTube. Within a couple of months, it had been viewed more than 2,000 times. See it for yourself. Visit www.youtube.com and search for FLSmidth.

In Second Life, all the limitations of the physical world disappear. You can say goodbye to congested airports and highways, closed shops – and all time and space constraints. Just like a Star Trek character, you can swiftly teleport from one place to another. Soon, you realise that Second Life is no longer the preserve of teenagers and IT geeks. Rather, it’s a place to do business and discover new ways to communicate with a global audience. 3D engineering and online communication are opening up new possibilities, and this is merely the tip of the iceberg.

Visiting the FLSmidth Cement Theme Park is easy. The Second Life software is available at www.secondlife.com and is free to download and use. All you need to do is register and install the program. You’ll need a good computer, preferably with 512 MB RAM and a good graphics card. It may take some time to get used to moving about in your new avatar (your Second Life persona) in this virtual world – but you’ll get the hang of it. Once you’re ready, search for FLSmidth and teleport yourself to our virtual Theme Park. We hope you enjoy the ride!

FLSmidth Cement Theme Park: Open 24/7 FLSmidth has created a virtual 3D environment on the popular virtual reality site Second Life. Now, whenever you feel like it, you can walk through a 3D cement kiln, meet someone from FLSmidth, or watch the latest FLSmidth film in the cinema.

Easier maintenance of FK Pumps The latest conversion kit is based on the “M” type and features a 3-piece screw design. The 3-piece screw needs less time for replacement, as only the flight section has to be dismantled. Total replacement can be done in just four hours instead of up to 24 hours for a 1-piece screw.

New service centre in Europe FLSmidth is opening an additional service centre for customers in Europe, Middle East and North Africa. The centre includes a spare parts warehouse that

Kovako serves as the European Service Centre for the F-K pump for customers in Europe, the Middle East and North Africa.

will provide both emergency and nonemergency supplies. This will be the 11th FLSmidth Pneumatic Transport service centre and will be located at FLSmidth Kovako in the Netherlands, which already has specialist knowledge of the pump and can provide technical support and training. The service centre also offers an exchange program to replace worn pump screws.

Less disassembly during screw removal Lighter, more compact

FLSmidth is successfully embracing two new internet media: the Second Life virtual world (above) and the YouTube video-sharing website (left).

flight section

Seal and shaft bearing can be removed as a single unit, including the screw shaft

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Support from A-Z longer equipment downtime and lower production efficiency. The new Support A-Z strategy will help customer services address maintenance, upgrades and operational needs to improve the longterm performance of a plant.”

In October 2007, Vice President Kristian A. Gregersen and his global team of more than 650 staff launched a new strategy for FLSmidth Customer Services, Support from A-Z. Highlights met him on his return from presenting the strategy to colleagues in Denmark, India and the USA.

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FLSmidth is well-known for selling complete plant projects. Over the years, FLSmidth has accumulated extensive know-how, helping to make it the largest service organisation in the cement industry. Today, FLSmidth offers the most comprehensive range of products and services on the market. The new strategy, Support A-Z is all about taking a new approach to customer services. Vice President Kristian Gregersen is very upbeat after meeting management teams and employees to discuss the change of strategy. “The key to good service is really very simple: listen to your customers. What are their immediate challenges and their longterm goals? After all, there’s a reason why it’s called customer service. Cement plant projects are not just about buying machinery and equipment. The total cost of plant ownership (for example, over a twenty year period) has to be considered as well. Independent studies have proven that attempts to economise on the initial investment can have long-term negative effects such as

Old wine in new bottles? “The new strategy combines both the old and new. Services have always played an important role in our business; but now, we’re abandoning a very product-oriented attitude and adopting a more integrated approach. Maintain, Improve and Operate are the keywords of our redesigned Global Customer Services organisation.” Why “operate”? “We need to keep on top of the rapidly changing cement market as new players from other industries enter the scene. Outsourcing of the entire plant operation based on performance-pricing is leading to new forms of partnering. Not only when operating a plant, but also when it comes to spare parts, continuous upgrades and other services. This new form of partnership entails 24/7 joint responsibility for operating the plant and carrying out scheduled maintenance stoppages. For FLSmidth, the new concept offers a unique opportunity to develop our own resources at modern cement plants. How did you become involved in Customer Services? “I’ve worked at FLSmidth for 31 years and have spent most of my time outside

Denmark. To me, it’s all a question of dealing with people, whether performing field work in Indonesia, serving as a plant manager in Mexico or heading IT in the USA. Cement is in my blood, and I consider this new service concept a mission that will unite all my previous activities. I’m convinced that the aftermarket will come to play a far more important role in the industry than it does today. And it’s a great opportunity for an old cement hand like me to be able to influence the way in which things are developing, and to change the business focus from machinery and processes to customer services. And on top of all that, I’m supported by the best group of professionals in the industry – the global Customer Services team!”

What does a customer get if he asks for category Z service? “We’ve actually considered that too. Seen from my desk, the answer is quite simple: zero problems,” Kristian Gregersen concludes.

MMC solution for existing Volga cooler As the Ukrainian cement market continues to grow, Volyn Cement Plant, one of the largest cement plants in Ukraine, is having to put one of its kiln lines back into operation to meet demand. In the spring of 2007, Volyn Cement asked FLSmidth to help modernise a Russian-designed Volga cooler. Volyn Cement has an annual production of 1.4 million tonnes and the cooler is part of a kiln line already undergoing renovation. FLSmidth came up with a technical solution for the rebuild.

Reusing existing parts Although the second section of the clinker cooler is intact, the first section has been used for replacement parts for the other kiln lines. As a result, it needs to be rebuilt. FLSmidth chose a Multi-Movable Cross-Bar Cooler (MMC) solution consisting of a stationary inlet, a material conveying system (cross-bars), an air distribution plate with mechanical flow regulators (MFR) and a cassette design. Fits all types of coolers The material conveying system will present a challenge because the new

MMC system must fit into the existing cooler frame. The MMC cassettes are similar to the modules of an SF CrossBar cooler, but do not have the supporting frame – which makes them ideal for all types of coolers. Unlike the SF CrossBar cooler, all the MMC crossbars move and reciprocate, improving conveying efficiency. FLSmidth signed the contract with Volyn Cement in June. Located near the city of Rivne some 400 kilometres from Kiev, Volyn Cement plant has been a member of the German Dyckerhoff AG Group since 2000.



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KilnLoq total passes 100 June 2007 saw the 100th order for the completely redesigned kiln inlet analysis probe, which was first released for sale on 1 January 2004. Now, with four years’ site experience, the probe’s reputation is going from strength to strength. The KilnLoq gas analysis system is specially designed for the highest temperatures and dust loads in cement production. Typical applications are in the kiln inlet, the riser duct and the calciner. The KilnLoq probe is simple and easy to maintain; it is strong so it will not bend; and it is reliable, ensuring trouble-free operation and reliable analysis results. All this means that KilnLoq has revolutionised the design of gas analysis probes. The design is based on a single pipe extending through the entire probe, enabling cleaning without dismantling. The actual probe is much thicker than the old version, and uses a special

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type of steel to increase strength. A PLC monitors the system and the proactive control system keeps it up-and-running, as well as triggering an automatic purging procedure if the probe begins to clog. FLSmidth Airloq has applied for a patent for the concept. Success proven through experience In July 2003, Aalborg Portland installed the first KilnLoq probe on its coal- and waste-fuelled kiln 87. The new probe was continuously tested in operation, resulting in a few design and control system changes. Meanwhile, other KilnLoq probes were sold to customers in many countries, including Finland, Spain, Chile, Jamaica, Australia, Canada, the US, the United Arab Emirates, India and Thailand. The test installation at Aalborg Portland and the other probes around the world have shown that:

• The operating ratio is extremely high • The probes are hardly ever dismantled for maintenance • Preventive maintenance takes less than 30 minutes per week on average • The probe is easy to maintain • The investment in a KilnLoq analysis system has proved highly profitable with a ROI period of less than 200 days Great performance at Algeria’s Ain Touta plant From 1986 to 1991, the Algerian cement plant spent a lot of time on daily maintenance of its gas analysis system because of probe blocking, leakage, problems with the jet pump, water circuit, manual extraction, and other issues. In 1992, the system stopped completely. Eventually, the cement plant bought a new KilnLoq system, which was commissioned in May 2006, bringing immediate success.

FLSmidth Airloq recently undertook a satisfaction survey in which Belkhiri Mokhtar, Ain Touta’s chief electrical engineer, says: “I would like to congratulate all FLSmidth Airloq staff for designing the successful kiln inlet analyser, the KilnLoq.” The operators at Ain Touta only perform one or two weekly visual inspections of the probe and analyser system. Since being commissioned, the probe has never blocked, and the run factor has been almost 100 percent. The system is only stopped for short periods when cleaning or calibrating the probe. The experience in Algeria is typical of customers using the new KilnLoq probe system. Changing types of fuel require stable and reliable kiln gas analysis In recent years, most cement plants have started using different types of fuel, including cheap coal, household waste, old tires. These complicate gas measure-

ment in the kiln inlet - a process which is already challenging because of the approximately 1100 °C temperatures and a dust content of as much as 500 g/m3. These challenges have increased the problems of bent probes and clogging, resulting in considerable maintenance requirements. Sometimes, the probes had to be inspected several times a day. All of which illustrated the need for a new and improved probe. Nearly all greenfield cement plants are equipped with kiln inlet gas analysis – and plant operators agree that it provides important data to ensure efficient and stable kiln operation. But less than 25 percent of the analysers are in stable operation after one to three years in operation. When users were asked why they thought the equipment failed, most felt that the gas analysis equipment installed was: • Too complicated • Too weak • Too unreliable

The new KilnLoq probe has been designed to answer these problems. Answering the industry’s need Focusing on simplicity, strength and reliability, the new KilnLoq probe is designed to withstand and handle the most difficult cement production processes.

(Above) The KilnLoq analysis probe in action at Haiphong Cement Plant in Vietnam. (Below) The KilnLoq system is simple, strong and reliable. More than 100 probes have been ordered since 2004.



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ECS/CEMulator: a key to successful start-up for Finnsementti Of all the challenges facing cement producers, introducing new equipment is one of the most critical. Upgrading is essential, but the risk of shut-downs associated with many traditional operator training programmes can seriously impact plant safety, product quality and productivity. FLSmidth Automation’s ECS/CEMulator software provides operators with the true-to-life experience that creates confidence in the control room and stability in the kiln, as Finland’s largest cement producer has discovered. Introducing new equipment without introducing new problems Finnish cement producer, Finnsementti Oy, produces a total of more than 1.5 million tons per year at its Parainen and Lappeenranta plants. The Lappeenranta plant, which produces 490,000 tons of cement annually, needed a comprehensive training programme after the installation of a new five-stage, in-line calciner kiln. Previously, the plant had used two kiln lines without calciners, so the training programme had to introduce operators to completely new equipment and processes. Jarkko Riepponen, Proc-

ess Engineer at Finnsementti Oy, explains their training objectives. “We had two goals. First, all the operators needed to learn the main principles of how to run the new kiln before actual commissioning to ensure they would confidently be able to run the kiln once it was operational. Our second goal was to introduce new operators to the process once the kiln was up and running, using the ECS/CEMulator. We also wanted to use the ECS/CEMulator software to train new operators in our kiln process at Parainen, where we produce more than one million tons of cement a year. Obviously, we wanted to achieve these goals with as little plant downtime as possible,” says Riepponen. Comprehensive, three-part training Fifteen Lappeenranta plant personnel participated in the ECS/CEMulator training, which was divided into three phases. Training began with a general introduction, where operators learned about the main equipment and the new kiln process. This was followed by personal training sessions, where operators were instructed on using the tutorials and devising their own standard training sessions.

One of the key advantages of the ECS/ CEMulator software is that tutorials can be customised to meet the specific needs of a particular process environment. Lappeenranta’s customised training sessions covered main burner flame ignition, kiln heat-up, kiln start-up, production increases, a normal run with a variety of disturbances, and stopping the kiln. In the final training phase, operators directed their own training sessions using the tutorials. As part of the training, operators received detailed fact sheets with information regarding kiln operation. Every operator repeated each of the 20-30 minute tutorials five times. In total, each trainee spent about 15 hours using the self-conducted ECS/CEMulator tutorials. The immediate benefits of a hands-on approach Finnsementti was clear from the beginning that hands-on training was important. “We believe operators learn better by doing rather than just sitting and listening,” says Riepponen. “It was important to have hands-on training instead of lectures, so that the operators could feel more confident when it came to running the actual kiln and changing parameters in a real control room.” Being in control of the simulated environment encouraged trainees to take action and responsibility, ultimately creating a more valuable learning experience. “Because the ECS/CEMulator provides customised hands-on training, it allows operators to make decisions for themselves – which is not so common in traditional training situations,” Riepponen adds.

Using the ECS/CEMulator, operators at the Lappeenranta plant in Finland trained to run the plant’s new five-stage, in-line calciner kiln with skill and efficiency.

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Lappeenranta plant have been using the built-in features to design self conducted tutorials for specific process situation.

Realistic training leads to stable operation The ECS/CEMulator was just one part of the overall operator training for the new kiln – but it was essential for Finnsementti’s productivity and quality. “Without the ECS/CEMulator, operators would not have gained the skills they needed in the start-up phase,” Riepponen explains. “In such a realistic training environment, we were able to avoid unstable kiln operations, which can have negative effects on the clinker quality and the kiln production level – and can also result in unwanted kiln stoppages.” The operators’ feedback indicated that the ECS/CEMulator was easy to use. They reported that they were able to learn all the major aspects of running an in-line calciner – a significant achievement in a relatively short period of time. Yet the training sessions weren’t entirely obstacle-free. “Finnsementti doesn’t use an FLSmidth control system, which is what the ECS/CEMulator software is based on,” says Riepponen.

Still, Finnsementti sees the training as a significant improvement to its processes. “We’re pleased with the ECS/CEMulator. It’s a good way to teach personnel a completely new process in a safe, risk-free environment. Our primary goal – introducing the operators to the main principles of the new process operation – was achieved. And we plan to achieve the second goal – introducing new operators to the process once the kiln is up and running – when we use the ECS/CEMulator in further training.” Why ECS/CEMulator training works The ECS/CEMulator offers a realistic copy of a cement plant’s operating conditions. Unlike most cement process simulators, it has been developed on a fully functional control system platform – so users can experience a simulation of the complete set of functions and features of a modern control system. FLSmidth has combined decades of operational experience with theoretical

insight and the latest software technology to develop the groundbreaking ECS/ CEMulator training system. The simulator is unmatched in its ability to allow process operators and engineers to visualise numerous operation difficulties and test the boundaries of their process and control knowledge in a completely realistic, safe and risk-free environment. The results include: • improved performance for the individual operator • streamlined operation strategy among operators • steady, stable production • optimal control system utilisation.



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Celebrating 125 years with customers around the globe

A long history in China sets FLSmidth up for the future

Booming markets, busy schedules and an anniversary to celebrate – it can be difficult to fit everything in. But 125 years as the leading supplier to the world’s cement industry is an event not to be ignored. So FLSmidth took a road show to its customers to celebrate.

Since Deng Xiao Peng introduced the open door policy in the late 1970s, FLSmidth’s Chinese operations have gone from strength to strength. Today, the future looks bright.

In May, Chief Executive Officer Jørgen Huno Rasmussen and the rest of the executive management team travelled the world, presenting seminars which covered both regional and global issues. Seminars were held in Denmark, Egypt, India, Indonesia and the US. There were also special customer events in a number of countries, including South Africa and Mexico. The road show was designed to celebrate 125 years in cement with selected customers, while focusing on key issues in the industry. At each seminar the combination of technical issues, future studies, economics, history and celebrations formed an inspiring programme. The presentations can be downloaded from www.flsmidth.com.

long-standing personal relationships make an ideal cocktail when addressing the challenges of the global cement industry – and it’s always important to meet face to face. The world tour has strengthened relationships. And hopefully customers will have happy memories of the seminars, which will help maintain cooperation within the industry for many years to come.

In the 1980s and early 1990s, FLSmidth was by far the most important foreign supplier to the Chinese cement industry. Initially, we sold complete production lines, but due to the on-going knowledge transfer, the Chinese design institutes have learnt to handle more and more themselves. The economic crisis that affected Asia in 1997 led to a three-year blip, during which our sales to China came to a halt. But the establishment of a small-scale Wholly Foreign Owned Enterprise (WFOE) in 2000, combined with an extraordinary sales effort, saw us re-emerge as a local force in the Chinese cement industry. Impressive performance in recent years We think that our recent performance is so impressive that it’s worth showing some figures.

Strengthening relationships face to face This was the first time FLSmidth had arranged a programme like this, and the organisers were very excited as they set off on their world tour. Judging from the high attendance and positive feedback, the seminars were very well received. World-class technology and

• Our workshop in Qingdao has increased annual production more than 10 fold since 2003 • The number of FLSmidth employees has increased nearly four times in the same period • Our workshop began by supplying equipment to the local market. Today, nearly 70 per cent of turnover comes from sales to projects outside China. At present, we sell three products in China: The ATOX mill (only large sizes for raw material grinding), the DUOFLEX burner and the SF Cross-Bar cooler. ATOX mills The sale of ATOX mills has risen dramatically. Since 2001, we’ve sold 127 mills, and the ATOX 50 accounts for 90 per cent. China’s biggest cement producer, the Conch Group, has purchased 48 ATOX 50 mills. DUOFLEX burners The first product made in our Qingdao workshop, the DUOFLEX burner has recently passed the 100 mark for sales in China. In the last 2 - 3 years, more and

SF Cross-Bar coolers We also produce SF Cross-Bar cooler modules in China for sale on the local market. Although coolers made by Chinese design institutes are comparatively cheaper, demand for our coolers is growing. Interest has increased as customers are now more aware of the long-term benefits of reliability and high efficiency. We’ve now sold 14 SF CrossBar coolers in China, and believe that sales will increase as the coolers prove themselves in operation. Sourcing from China to improve global competitiveness Many companies source parts in China and FLSmidth is no exception. Several of our traditional sub-suppliers have started manufacturing in China, and many Chinese companies have improved the quality and reliability of their products. Together with lower costs, this gives us an opportunity to increase our global competitiveness without reducing our quality standards. In China, we are very confident that our sales performance and sourcing opportunities will further strengthen our offering to customers. The future looks bright, and it’s going to get brighter.

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SF Cross-Bar cooler sections being assembled at the Qingdao workshop (below). Visitors to the FLSmidth office in Beijing pass through this impressive entrance (right).

more export orders have been placed, and we have 40 burners in our pipeline.



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The perfect problem solver Liu Ming loves coming up with new ideas and finding practical solutions to on site problems. This is lucky, because since 2001, he’s taken part in more than 120 ATOX mill and SF Cross-Bar cooler installations for FLSmidth site service in China. On the job: Liu Ming’s work at FLSmidth has taken him to almost every big cement plant in China and everywhere he goes he searches for ways to improve the site, the equipment and ultimately, the end product. “I love being on site,” he says. “And I enjoy solving the complex problems that can arise at an installation. My goal is to make our products even better and this means identifying problems and suggesting improvements – both for our customers’ sites and our products.” Learning from the best After studying cement design and equipment at college, Liu Ming spent 10 years working as a site supervisor and consultant. The job took him to Brunei and Zimbabwe, but when he returned to China he realised that if he was to

learn everything he could about cement installations, he had to work with the best. FLSmidth was the obvious choice. “I wanted to compare what I knew with the methods at FLSmidth,” he says. “I knew I could bring some new ideas to the company, but I also wanted to learn from colleagues. Cement installations are very complex things and I need to keep researching into installation methods and technological know-how if I’m going to make a real difference to the customers I work with.” Breaking the language barrier When Liu Ming arrives on site, his first job is to check the drawings made by the Design Institute. He then inspects the site and discusses any issues with the parties concerned, before starting technical training for the site personnel. One potential problem he identified was manuals. Written in English, they can be quite difficult for Chinese workers to understand. Many have been translated but the Chinese isn’t always clear – so he began translating the key points himself. “There are

Mr Liu Ming is mechanical supervisor at FLSmidth Beijing.

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more than 100 ATOX mills in China,” he explains. “And it’s essential that the manuals are completely up to date.” Liu Ming intends to extend this work in training materials. He’s already written numerous articles on installation, maintenance and operation – all designed to help site personnel improve their working methods, increase their output and extend the life of the mills. Keeping our customers satisfied “I really enjoy working at FLSmidth. I work with Chinese, Danes, Germans and Americans,” says Liu Ming. “To keep doing well in China, FLSmidth must continue to keep up with China’s high speed development and satisfy customers’ needs for completing jobs on a tight schedule.“ Of course, there’s more to life than cement. Liu Ming is married and has a 20-year-old son who studies agriculture at university. “He’s going to be a farmer,” he says proudly.