World Cement February 2022

February 2022

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CONTENTS 03 Comment 05 News REGIONAL REPORT: INDIA 10 Innovation In India Neeraj Akhoury, Holcim in India, outlines Ambuja Cement and ACC Ltd’s sustainable development ambitions for the Indian cement sector.

CONVEYORS & BUCKET ELEVATORS 17 As Good As New BEUMER describes how a cement plant was assisted in the modernisation of its bucket elevators.

LOADING, UNLOADING, DISPATCH & LOGISTICS 21 Mindful Of Maintenance Austin Anderson, Vortex Global, discusses the importance of choosing a carefully designed dry bulk handling system in order to prevent wear, extend service life and limit maintenance and downtime.

27 Delving Into Dust Control WAMGROUP considers the most effective technologies for controlling dust emissions produced during the loading, unloading and storing of cement.

39 The Perks Of Plastic Frank Goris, Arodo, considers the advantages of plastic over paper cement packaging and explains how the material could contribute towards CO2 emissions reduction in the industry.

43 Packaging Progress Sigrid Eder-Ince, Starlinger, describes the economical and ecological advantages of woven polypropylene cement sacks and discusses the shift towards this type of packaging in Côte d’Ivoire.

SILOS & CLEAN-OUT 47 Counting On Cannons Brad Pronschinske, Martin Engineering, explains how air cannon technologies can effectively prevent material build up in the preheater, whilst maintaining workplace safety and minimising unscheduled downtime.

BURNERS 52 Satellite Success Reinhard Ringdorfer, Unitherm Cemcon, explains how the development of new satellite burner systems has allowed cement plants to push the limits of AF utilisation.

GRINDING & MILLING Q&A

31 Going Beyond The Gate Matthew Furry, PSCL, explains how self-contained monitoring and control systems can solve the logistical challenges posed by the need to source materials, such as fly-ash, from reclamation projects.

56 World Cement Grinding Q&A World Cement invited industry leaders to share their thoughts on a range of grinding and milling-related topics.

BAGGING & PACKING

Contributions come from: FIVES FCB, Gebr. Pfeiffer, and thyssenkrupp Industrial Solutions.

WORLD CEMENT

35 It’s In The Bag Graham Rawlings, Concetti, details the installation of a fully automatic bag filling system as part of a planned switch to greener, more environmentally friendly packaging materials.

February 2022

February 2022

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Applicable only to USA and Canada: WORLD CEMENT (ISSN No: 0263-6050, USPS No: 020-996) is published monthly by Palladian Publications, GBR and is distributed in the USA by Asendia USA, 17B S Middlesex Ave, Monroe NJ 08831.

Periodicals postage paid New Brunswick, NJ and additional mailing offices. POSTMASTER: send address changes to World Cement, 701C Ashland Ave, Folcroft PA 19032 Copyright © Palladian Publications Ltd 2022. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner.

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February 2022 World Cement

DAVID BIZLEY, EDITOR

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n 04 February, China will be hosting the 2022 Winter Olympics.

When making its bid for the games, the Chinese Organising Committee promised to deliver a “green, inclusive, open and clean” games. On top of that, organisers also promised that this would be the first “carbon neutral games” and that they would be delivered using 100% renewable energy.

To meet these lofty goals, the Organising Committee said it would work to limit the impact of preparations by prioritising the protection of native species, reducing greenhouse gas emissions, and cutting back on resources used.

In terms of utilising renewable energy, official figures certainly appear to show that the goal has been achieved. The new wind and solar projects constructed over the last six years will be enough to provide 100% of the energy needed for the games and 10% of Beijing’s total energy consumption. That’s no mean feat when considering that Beijing has a population comfortably over 21 million people. Indeed, Beijing Daily reported that the Zhangbei Rouzhi Project can deliver approximately 14.1 billion kilowatt-hours of clean energy, saving 4.9 million tpy of coal, and eliminating 12.8 million tpy of CO2 emissions.

There have been challenges, and criticism, however. Development of Alpine ski runs through the Yanqing district’s Songshan nature reserve caused controversy when it was announced that some 20 000 trees would need to be removed. The Beijing Olympics Committee did pledge to transplant the trees (and some 81 hectares of topsoil) to another nearby location, and the Beijing Forestry University reported that more than 90% of the trees survived the move, but concerns remain. Dr Carmen de Jong, Professor of Hydrology at the University of Strasbourg, told the BBC that the removal of topsoil could greatly increase the risk of erosion, landslides, water pollution, and harm to animal habitats.

This Winter Games will also be the first to rely almost entirely on artificial snow – created in an energy intensive process that required an estimated 49 million gallons of water. This news gains added poignancy when taken in context with a recent report from researchers at Loughborough University, which warned that: “Of the 20 venues used for the Winter Games since Chamonix in 1924, scientists think that by 2050 only 10 will have the […] natural snowfall levels to host an event.”

Perhaps the lesson that can be learned from the preparations for the 2022 Winter Olympics is that climate issues can’t be avoided and that interacting with the natural world in an environmentally friendly and sustainable manner can be complicated. Thankfully for the cement industry, there are a whole host of innovative technologies and processes that can be applied to reduce (and ultimately avoid) harm to the environment.

To learn more about these, and to hear from experts across the cement industry, be sure to join us on 16 – 17 March for World Cement’s EnviroTech 2022. Free registration is available here: www.worldcement.com/envirotech2022 3

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NEWS HeidelbergCement expands sustainable concrete portfolio in Germany

HeidelbergCement’s German subsidiary Heidelberger Beton is now offering a broad portfolio of sustainable concretes under the EcoCrete brand. Depending on the application, EcoCrete offers between 30 and 66% CO2 reduction per cubic metre of concrete compared to the reference value of the industry. This reduction is achieved on a strictly technical basis and without compensation measures. In addition, EcoCrete is available in resource-saving types with at least 10% of recycled content. Part of the EcoCrete concept is the 100% use of green electricity, the use of recycled water, and the complete recyclability of the concrete in the case of subsequent deconstruction.

“Expanding local, sustainable product portfolios is a key element of HeidelbergCement’s climate strategy,” said Dr. Dominik von Achten, Chairman of the Managing Board of HeidelbergCement. “The launch of EcoCrete in the German market is representative of the ambitious CO2 roadmaps we are implementing at all levels of the company and in all Group countries”.

Dr. Nicola Kimm, Chief Sustainability Officer and member of the Managing Board of HeidelbergCement said, “We are committed to regionally produced, CO2-optimised building materials that push the limits of what is technically feasible today in terms of sustainability. Our cements and concretes are also being continuously developed to reduce the ecological footprint even further in the future – over the entire life cycle”.

A significant part of HeidelbergCement’s research and development activities focuses on minimising energy use and CO2 emissions through products and process improvements.

The company has set itself the goal of reducing its CO2 emissions by 30% by 2025 compared with the reference year 1990 and achieving climate neutrality by 2050 at the latest. HeidelbergCement is heavily invovled in the development and application of innovative technologies for carbon capture and utilisation.

With its increasing involvement in concrete recycling, the company also contributes to the circular economy.

Febuary 2022 World Cement

A TEC commissions ReduDust Bypass Dust Treatment System

Using alternative fuels or Cl-containing raw materials typically requires a Cl-bypass system to control the Cl-loop in the pyroprocess. This leads to the production of bypass dust, which contains various types of salts.

To re-use the dust in cement manufacturing, Ssangyong Cement Ind. Co. Ltd. with its plant in Donghae, Korea, has teamed up with A TEC Production and Services GmbH from Austria to install A TEC’s innovative ReduDust® process in their plant. The process will recover salts from the dust and produce bypass dust free of these components, which can be re-used and does not need to be deposited anymore.

The ReduDust plant for Donghae has a bypass dust treatment capacity of 35 000 tpy and was commissioned in Q2/2021.

The scope of supply for this order by A TEC includes the engineering services and selected equipment supply including the required supervision and optimisation services.

Ssangyong Cement Ind. Co. Ltd. is one of the leading manufacturers of high-quality cement in Korea. The plant at Donhae has several state-of-the-art kiln lines, operating with significant alternative fuel rates. In the plant, the A TEC Rocket Mill™ is also in operation to produce high quality solid alternative fuel for the kilns. By using the ReduDust bypass dust treatment system, the plant has realised a novel waste-free Cl-bypass dust concept.

Currently, large amounts of bypass dust are produced by cement clinker production systems, especially using alternative fuels as an intermediate product. As this dust is highly loaded with chlorine and alkaline compounds, the utilisation of the dust in the cement mills is limited. Furthermore the disposal of this dust is quite expensive, as due to the high chlorine content it is often categorised as hazardous waste. The A TEC bypass dust treatment process (ReduDust) solves this problem as the contaminated bypass dust is used as a resource for the production of pure NaCl and KCl salts.

The residual dust is free of these undesired components and can be recycled completely in cement production without enrichment of the undesired components.

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NEWS DIARY ENVIROTECH 2022 THE GATEWAY TO GREEN CEMENT

16 – 17 March, 2022 www.worldcement.com/ envirotech2022

IEEE-IAS/PCA Cement Industry Technical Conference 01 – 05 May, 2022 Las Vegas, USA www.cementconference.org

08 – 09 June, 2022 www.worldcement.com/ optimisation2022

Hillhead 2022 21 – 23 June, 2022 Derbyshire, UK www.hillhead.com

SOLIDS & RECYCLINGTECHNIK Dortmund 22 – 23 June, 2022 Dortmund, Germany www.solids-dortmund.de 6

Not only can the costs of disposal be saved, but the lost amount of material from the bypass system can also be recovered effectively.

Modern suspension preheater kilns frequently face substantial problems of coating caused by dust deposition in kiln riser ducts, meal pipes, ducts and cyclones due to excessive contents of chlorine (Cl) in the kiln system. A TEC’s bypass REDUCHLOR® consists of a take-off chamber above the kiln inlet, specifically designed for each installation and a specially designed quenching chamber where the Cl condensates and adheres to the fine dust particles. After this condensation process, the Cl-enriched material is collected in a filter.

CEMEX USA holds ‘Safety Week’

CEMEX USA started the new year by hosting Safety Week 2022, the company’s annual initiative intended to get all employees laser-focused on the company’s core value, ‘Health & Safety’.

Safety Week 2022 began at all CEMEX USA plants and facilities on Monday 10 January with safety activities and messages delivered by local leadership to all employees aimed at refocusing them on safety for the new year. Employees attended socially distanced or virtual meetings that followed the company’s ‘Behaviours That Save Lives’ guidelines that encourage vaccination, the identification and reporting of symptoms, personal hygiene and physical distancing, all designed to stop the spread of COVID-19. Throughout the week, employees also participated in exercises that encouraged them to use important safety tools like hazard recognition, hazard control and risk assessment while emphasising accountability aimed at preventing unsafe behaviour.

“Safety is a team effort, and at CEMEX, we encourage our employees to contribute and build on our strong safety culture by looking for opportunities to improve the health and safety for everyone each day,” said CEMEX USA President Jaime Muguiro. “We strive to work together and utilise our company’s health & safety management system tools to identify and mitigate hazards, so we all can go home safe to our families every day.”

During Safety Week, employees across CEMEX USA operations were encouraged to reflect on their safety performance in 2021, examine their actions and seek opportunities to improve. They were encouraged to make use of CEMEX’s safety tools including ‘Take 5’ assessments, which aim to get them to stop, think and act when approaching jobsites, guidelines that can be utilised to help mitigate hazards. Meetings throughout the event also focused on strengthening a culture of personal accountability to identify and prevent any unsafe behaviours.

“Our employees are empowered to take action when it comes to safety, and they are encouraged to follow these well-established tools and guidelines in an ongoing effort to create an injury-free workplace,” said Alan MacVicar, CEMEX USA Vice President of Health & Safety.

“Safety is a core value at CEMEX, and we expect each of our employees to become safety leaders and hold each other accountable to prevent injuries and create a sustainable, injury-free environment.”

World Cement February 2022

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NEWS Since 2016, CEMEX USA has hosted Safety Week each January to promote a renewed commitment to safety throughout the new year.

Fitch Ratings raises the credit outlook of Cementos Argos to ‘Positive’

Argos, a Grupo Argos cement company, has received an upgrade in its credit rating outlook, going from ‘Stable’ to ‘Positive’ according to Fitch Ratings, an international credit rating agency.

The Positive Outlook granted

by Fitch Ratings reflects the excellent performance of Cementos Argos and the expectation that the generation of operating cash flows will continue with a growth trend in the following years, a trend that has been benefited by the operational efficiency strategies that the company has launched.

It should be noted that among the reasons for the positive rating of Argos, its competitive position stands out by consolidating itself as one of the main producers of cement and concrete in Colombia, the United States and Central America and the Caribbean, which is reflected in the increase in volumes of shipped material.

Likewise, the company increased its EBITDA margin and reduced debt thanks to the strategic divestments it has carried out and its operational efficiencies programmes.

The strategy implemented by Argos to protect the cash flow from the impacts of the pandemic generated favourable financial results and allowed the company to maintain the employment of 100% of its employees and continue creating value for the community through different social investment projects.

MPA merges with British Precast

Britain’s concrete producers have joined forces in one association to represent the industry and accelerate its journey to beyond net zero carbon emissions.

British Precast, whose members include manufacturers of concrete masonry, paving slabs, structural sections and drainage systems, has merged with the Mineral Products Association (MPA) which represents all the UK’s cement makers, over 90% of aggregates producers and more than 70% of ready-mixed concrete suppliers.

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The merger gives the British concrete industry a single voice, with the sector’s advocacy vehicle – UK Concrete – driving forward a common agenda to set the record straight about concrete’s role in sustainable construction and address the challenges of climate change.

The UK concrete and cement industry has already reduced absolute carbon emissions by 53% since 1990 – faster than any other sector of the economy – and the merger will unite the sector behind its ambitious ‘Roadmap to Beyond Net Zero’ by 2050.

Concrete is the only structural material whose raw ingredients are sourced from within the UK and, over the whole life of a building, concrete outperforms the alternatives economically and environmentally.

Nigel Jackson CEO of Mineral Products Association said: “This is a landmark moment in the evolution of the UK concrete industry which is already a global leader in terms of decarbonisation, recycling and biodiversity enhancement. Now more than ever the concrete industry must work hand-in-glove to promote the essential role this amazing and under-appreciated material plays in our economy and our quality of life. Mitigating the industry’s environmental impacts whilst delivering solutions that help people to adapt to climate change is an important balance to be struck. With the entire sector united and pulling in the same direction we are better able to achieve our shared goals.”

Alan Smith, who retires as President of British Precast, said: “British Precast has been affiliated with the Mineral Products Association for the past decade and the successful relationship we have built has given our members the confidence to fully support this merger. Coming together enables the industry to operate more strategically, rejuvenating our determination to rise to the challenges of climate change and emphasise the importance of our industry in climate adaptation.”

Two new MPA product groups have been formed as a result of the merger – MPA Precast and MPA Masonry. Along with existing MPA product groups, especially The Concrete Centre and BRMCA, the combined trade association has a vast breadth and wealth of concrete expertise.

World Cement February 2022

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Neeraj Akhoury, Holcim in India, outlines Ambuja Cement and ACC Ltd’s sustainable development ambitions for the Indian cement sector.

B

uilding progress for people and the planet is a core ambition for Holcim; the company plans to lead in the development of innovative and sustainable building solutions. Driven by this purpose, the company’s sustainability framework integrates green products and solutions into the circular economy, the built environment, digitalisation and the capture and utilisation of carbon. The company’s overall approach aims to advance society and uplift communities.

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Holcim has set itself ambitious 2030 climate targets that are validated by the Science-Based Targets initiative (SBTi). The company is also looking beyond 2030, to support the development of the cement industry’s first climate targets for a net zero future, keeping global warming below 1.5˚C.

Advances in India

Holcim’s entities in India, Ambuja Cements and ACC Ltd., have built their own sustainable development ambitions based around global standards, and are aligned with Holcim’s sustainability strategy.

With sustainability at the heart of Holcim’s business strategy, the company aspires to set new standards in sustainable construction. The goal is to transform the way the cement industry works and encourage the whole construction sector to play its part in addressing the planet’s biggest issues.

These sustainability goals will also help customers reduce CO2 emissions released from buildings and infrastructure throughout their

An abandoned mine at an ACC plant now serves as a water reservoir.

Bubble Barrier technology.

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entire life-cycle via a portfolio of sustainable products and services. These products and solutions include green concrete and green cement and many other low carbon solutions, such as Airium insulation and Firestone building products, which are designed to make buildings greener and more efficient. Holcim has sustainability KPIs in place and consistently reviews how strategy implementation can be improved.

India is still at a nascent stage in its technology adoption, but a shift has been witnessed in recent times with ACC and Ambuja Cement helping to lead innovation and sustainable practices in the country. Some examples include: ff Low carbon solutions: ACC has launched global green concrete range: ECOPact. ff Circular Economy initiatives: Bubble Barrier Technology): A pilot project led

by Holcim and Geocycle India has used breakthrough ‘bubble barrier’ technology to remove plastic from rivers. It is soon to be implemented in other cities in India. � Driving digitalisation: Both ACC and Ambuja Cements are focusing on digitalisation and technology to increase plant efficiency through initiatives like ‘Plants Of Tomorrow’ and ‘TAC’. � Biofuel usage: Ambuja Cements has pioneered the usage of bio-diesel for sea transportation in India. � Green Building Centres: ACC is generating self-employment through its 100 GBCs across the nation, encouraging entrepreneurial effort through its green building centres initiative.

Even in the midst of the COVID-19 pandemic, ACC has continued to focus on bringing low carbon products to India, as well as developing and launching a local low carbon range. ACC launched ECOPact, a green range of concretes.

Similarly, Ambuja Cement launched Ambuja Kawach during the pandemic, a high quality water-repellent cement brand, endorsed with a ‘Solar Impulse Efficient Solution’ label, recognising the company’s commitment to protecting the environment in a profitable way.

Driving digitalisation to make businesses smarter was a key focus during the pandemic. Both companies demonstrated strong commitment to enhancing business efficiencies by leveraging digitalisation.

World Cement February 2022

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Cleaning up construction

The scope for creating a more sustainable construction sector is immense and the use of environment-friendly building materials is one important part of it. The centrepiece of the sustainability initiatives in these sectors is largely driven by the idea of a circular economy, based on the 3 Rs: reduce, reuse, and recycle.

The opportunities are numerous provided that a framework is put in place: ff Building codes for green, efficient buildings are essential. ff The availability of green products and solutions designed from customer perspectives to help them reduce their CO2 footprints is another opportunity that should not be missed. f f Upcycling of construction waste is a huge opportunity. This is especially important for concrete which has a 100% circularity. It can be used in a very effective manner as has been done in many Western countries. It performs well with regard to the lifecycle of a building, and at the end of a building’s lifecycle, it can be recycled again, which is a great example of circularity.

ACC and Ambuja Cement pride themselves on being responsible and sustainable, and believe these qualities have formed the foundations of their businesses. The companies are committed to making a tangible difference in the areas of carbon footprint reduction, circular economy, protection of natural resources and the welfare of communities.

Aligned with the ‘net zero’ ambition of parent company Holcim, ACC and Ambuja Cement have taken several initiatives and increased their focus on the reduction of CO 2 emissions in India. In the year 2020, the companies reduced their specific CO 2 emissions to 493 kg/t of cementitious material, comparing well with global benchmarks.

The companies’ sustainability development plans for 2030 are ambitious, with impressive targets earmarked. The aim is currently to reduce CO 2 to 463 kg CO2/t cement. One initiative is the construction of a waste heat recovery systems (WHR) in three locations by 2022 that would generate 54 MW to support power requirements in plants.

Priorites

Ambuja and ACC have undertaken initiatives which focus on four priority areas, namely climate and energy, the circular economy, the environment, and people and community. These initiatives include: 14

ff Reducing the clinker factor of cement through the incremental use of alternative materials like fly ash, slag, and waste gypsum. ff Improving energy efficiency (thermal and electrical) and process technology. ff Increasing the use of waste heat recovery and renewable energy. ff Optimisation of fuel composition, along with the use of waste as alternative fuel.

These initiatives helped operations avoid the release of ~6.5 million t of CO2 into the environment during 2020. Three out of four pillars of the Sustainable Action Ambition 2030 from ACC and Ambuja Cement contribute to protect natural capital.

ACC and Ambuja Cement are also aligned to the Science Based Targets initiative (SBTi), and are gearing up to follow in the footsteps of parent company Holcim, which has signed a net-zero pledge with SBTi. At ACC, green concrete brand ECOPact is sold at a range of low carbon levels, from 30% to 100% less carbon emissions compared to standard (CEM I) concrete.

Similarly at Ambuja, the company’s research and innovation team works continuously on introducing products which are innovative in nature but also responsible and sustainable.

In 2020 Ambuja Cement participated in a project on Natural Capital Accounting and Valuation of Ecosystem Services-Business Accounting Pilot Case (NCAVES) with UN Statistics Division (UNSD), supported by the European Union.

By 2030, the company’s target is to reduce its specific CO 2 emissions to 400 kg/t of cementitious material, whilst also hoping to be five times water positive by 2030. The company plans to use 30 million t of waste to promote the circular economy.

Ambuja has optimised its process for use of low-grade limestone and waste derived alternative fuels. The result is ~90% of production being comprised of PPC and composite cement and ~32% of the raw materials being derived from alternative sources.

Working with water

11 million t of plastic enters the oceans every year, making it one of the biggest threats society faces. If this trend continues unabated, there will be more plastic than fish in the oceans by 2050. Most of the plastic in the ocean gets there by way of rivers.

Geocycle India, the in-house waste management arm of Ambuja and ACC, has come forward with an initiative to World Cement February 2022

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clean up the Yamuna River. ‘Bubble barrier’ technology channels plastic waste towards the banks of rivers, where it can be picked up for further treatment. The Geocycle bubble barrier is established in Agra city, and the process is to be replicated in other cities on the banks of the Yamuna River.

Fresh water is critical for sustaining healthy communities and natural ecosystems. During the year, Ambuja continued its efforts to

conserve water and improve its water harvesting capacities. The company complies with stringent environmental regulations to ensure that its activities, in particular raw material quarrying, do not endanger local water bodies and groundwater.

During the year, various efforts were made for strengthening water conservation and harvesting to closely monitor water consumption, augmenting water harvesting structures in communities and optimising processes.

Sustainability innovations Some of Holcim’s key innovations in sustainability include: An offer of low carbon materials: From the ECOPact global green concrete range to the global ECOPLANET green cement range, Holcim offers low carbon building materials, with minimum 30% CO2 reduction compared to conventional products.

Energy efficient buildings: The company is making buildings more energy efficient from foundation to rooftop through its Airium insulating foams and Firestone Building products.

Driving a circular economy: Holcim’s ‘Circular Explorer’ is leading a circular economy journey to preserve the oceans. This is a renewably powered catamaran, recovering and recycling waste from rivers and bays, which is later recycled or is co-incinerated in an environmentally friendly way in the company’s cement plants.

Circular by design: Striatus bridge, a 3D concrete bridge, stands solely through compression without reinforcement, using concrete at its best with minimal material use for maximum strength. This demonstrates the versatility of concrete.

Driving digitalisation: Holcim’s ‘Plant of Tomorrow’ initiative is making the business smarter with automated data driven solutions, robotics, artificial intelligence, predictive processes and maintenance. By digitally connecting the company’s manufacturing processes with its sales, sourcing and logistics, Holcim is improving its operational efficiency and CO2 footprint.

Thriving with people and communities: With 3D concrete printing, the company is increasing access to affordable and greener housing and schools in Africa.

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Green fingers

During the year, Ambuja and ACC continued efforts to conserve nature and preserve biodiversity. Their initiatives focused on the conservation of particular floral/faunal groups at some plant locations under the ‘B-Buzz’ project. As part of the B-Buzz programme, while one unit worked towards improving avian biodiversity by creating a fruit garden, two units developed a herbal garden (‘Aushadi Udyan’) at their locations.

Some of the companies’ sites have also initiated their ‘B-Buzz’ with a butterfly garden within their own premises.

About the author

Mr. Neeraj Akhoury has over 28 years of experience in the steel and cement industries. He has worked in leadership roles in India and other emerging markets. He began his career with Tata Steel in 1993 and joined the Holcim Group in 1999. He was a member of the Executive Committee of Lafarge India, heading Corporate Affairs followed by Sales. In 2011, he moved to Nigeria as CEO & Managing Director of Lafarge AshakaCem PLC. Thereafter, he was appointed as Strategy & Business Development Director for Middle East & Africa at the Lafarge headquarters in Paris. He was also CEO of Lafarge Surma Cement Limited and Country representative of Holcim Bangladesh.

Mr. Akhoury was appointed as Managing Director & CEO of ACC Limited in February 2017. In February 2020, he took over as CEO India, Holcim, Managing Director & CEO, Ambuja Cements Limited and Non-Executive Director, ACC Limited.

Mr. Akhoury has a degree in Economics and MBA from the University of Liverpool, General Management from XLRI, Jamshedpur, and an alumnus of Harvard Business School.

World Cement February 2022

BEUMER describes how a cement plant was assisted in the modernisation of its bucket elevators.

as good as new O

utdated technologies often lead to increased maintenance, and this can rapidly become expensive. A cement plant owner faced this problem with their bucket elevators. An analysis carried out by BEUMER Customer Support made clear that it was not necessary to replace the whole system, but only components. Service experts were able

to modernise the bucket elevators and make them more efficient.

Three bucket elevators were causing problems for a cement company based in Erwitte, North Rhine-Westphalia, near Soest, Germany. In 2014, the manufacturer also established a plant in Duisburg. The company produces blast furnace cement, using a central chain bucket elevator as

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a circulation bucket elevator for the vertical mill and two belt bucket elevators for the silo feeding.

The central chain bucket elevator on the vertical mill had been unusually loud since installation and there was also an immense chain vibration of more than 200 mm. Although the original supplier made several improvements, a high level of wear and tear was evident after only a short running time. The plant was having to service its systems more and more frequently. Of course, this was expensive, with the cost of frequent downtime and spare parts quickly adding up.

One important item is the belt clamping connection. On all steel cord belts, the rubber is removed from the ends of the steel cords.

The ends of the steel cords are divided into individual strands in the U-shaped part of the belt clamping connection, twisted and cast with white metal.

Frequent downtimes and high costs

Due to the frequent downtime of the vertical mill circulation bucket elevator, BEUMER Group was contacted in 2018. The system supplier not only supplies bucket elevators and modernises them if necessary, but also optimises existing systems of other suppliers. In cases like this, operators of cement plants are often faced with the question of whether a completely new plant or a possible conversion would be the more economical and targeted measure. Modernisation can often be worthwhile; BEUMER’s customer support helps customers to fulfil future performance and technology requirements in a cost-efficient way in the context of modernisations and modifications.

Typical customer challenges include performance improvements, adaptations to modified process parameters, new materials, optimisation of availability and extension of the maintenance cycles, designs that are easy to maintain, as well as reduced noise levels. In addition, all new developments with regard to Industry 4.0, such as belt monitoring or continuous temperature monitoring, are included in the modifications.

BEUMER Group offers everything from technical dimensioning to assembly on site. Only having the one contact also reduces organisational and coordination expenses.

Profitability and especially availability play a crucial role for customers, because modifications are often an interesting alternative to new constructions. In the case of modernisation measures, as many components and structures as possible are kept – in many cases, the steel structure is also kept. This alone reduces material costs by approximately 25% compared to a new construction. In the case of the customer in Germany, the bucket elevator head, the chimneys, the drive unit and the bucket elevator boot could be reused. In addition, the assembly effort for a project like this is lower, and so the downtime is usually much shorter. This leads to a faster return on investment compared to a new construction.

Heavy duty for coarse-grained material No material can penetrate between belt and bucket.

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The central chain bucket elevator was retrofitted to a high-capacity belt bucket elevator type HD

World Cement February 2022

(heavy duty). Belts with wire-free zones, to which the buckets are fastened, are used for this type of bucket elevator just as with all BEUMER belt bucket elevators. In the case of other products, the steel cords are often cut through when mounting the buckets. As a result, the steel cords are no longer covered, which can result in moisture penetration and, consequently, lead to corrosion and damaged supporting cords. Using the BEUMER systems, the tensile strength of the bucket elevator belt is maintained.

Another important factor is the belt clamping connection. The rubber of the steel cord ends is first removed on all BEUMER steel cord belts.

The technicians divide the ends into individual strands in the U-shaped part of the belt clamping connection, twist and cast it with white metal.

After casting, the junction is cured after a very short time and the belt is ready for use. The customer thus benefits from a substantial time advantage.

Going steady

In order to enable a steady running of the belt and to extend the service life in view of the abrasive material, the BEUMER team exchanged the existing segmented laggings of the drive pulley by specially adapted ones equipped with ceramic. These are crowned for a steady straight run. The design, which is easy to maintain, enables quick replacement of the single segments of the segmented lagging through the inspection hatches. Thus, it is no longer necessary to exchange the complete drive pulley.

The segmented laggings are rubberised, with

The Modern Way

bolted bulk material silos for all kinds of bulk solids simple and quick installation short delivery times comes with complete finish easy to relocate

Silos made to measure After casting, the junction is cured very quickly.

SILOBAU THORWESTEN GmbH Daimlerring 39, 59269 Beckum / Germany Phone: +49 2521 9333-0 info@thorwesten.com www.thorwesten.com

The buckets are mounted with forged segments and screws on the back side of the belt.

linings made of full ceramics or steel. The choice depends on the material conveyed.

The buckets are adapted to the crowned shape of the drive pulley and thus lie flat, which considerably increases the service life of the belt. Their shape allows for smoother running and therefore less noise generation. Depending on the intended use, the operator receives the buckets in the design that suits them best. They can, for example, have a rubber bottom or be made of high-quality steel. The BEUMER HD technology utilises a special bucket connection.

In order to prevent coarse-grained material from penetrating between bucket and belt, the bucket is provided with an elongated back plate, which can be mounted flush to the bucket elevator belt.

In addition, with the HD technology, the buckets are mounted firmly to the back of the belt with forged segments and screws.

Keeping everything running

To avoid caking, the take-up pulley is designed as cage-type foot pulley and is provided with a double deflection cone. For this order, the screwed and hardened version of the cage-type foot pulley has been used.

In order to achieve and maintain correct tensioning of the belt, BEUMER mounted an external parallel take-up device without product contact in Duisburg, which ensures that the take-up pulley is limited to parallel movement. The tension bearing is designed as an inner bearing in a completely encapsulated construction. The bearing housings are filled with oil.

A part of the HD technology is the cage-type foot pulley which is easy to maintain. The bars are hardened due to the abrasive material conveyed and screwed into the cage-type foot pulley to enable a rapid replacement. The take-up pulley is equipped with a double deflection cone, which reliably prevents damage to the belt caused by jammed bulk materials.

Following up

The parallel take-up device ensures that the take-up pulley is limited to parallel movement.

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This modification enabled the customer to increase the availability of their vertical mill circulation bucket elevator and to be more competitive in the long term. Compared to a new investment, the plant could reduce its costs and operate faster. The noise level of the bucket elevator in operation had also changed, with the customer claiming it was smoother running than their previous chain bucket elevator.

The company was enthusiastic about the retrofitting and therefore commissioned BEUMER Group to optimise the conveying capacity of other two bucket elevators. The operator had also previously complained about continuous off-tracking, buckets hitting the shaft casing and difficult maintenance conditions. The customer additionally wanted to further increase the throughput of the mill. In 2020, the system supplier’s customer support team also solved this problem.

World Cement February 2022

Mindful of Maintenance

Austin Anderson, Vortex Global, discusses the importance of choosing a carefully designed dry bulk handling system in order to prevent wear, extend service life and limit maintenance and downtime.

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he maintenance of dry bulk handling systems can be a timely, costly, and messy endeavour. When designing the dry bulk solid handling components used in these systems, many principles must be considered to address wear and abrasion to limit maintenance, decrease production downtime, and extend a product’s service life.

The implementation of components that can be maintained and repaired in-line provides many benefits to the consumer. For example: � It is more cost-effective to replace parts rather than the entire valve. � Money and time can be saved by reducing downtime. � No special equipment is required.

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Slide gates

Slide gates are ideal for controlling dry bulk materials such as fly ash and potash in gravity flow and dilute or dense phase pneumatic conveying applications. Since slide gates are used to handle a wide range of materials around the world, manufacturers of slide gates have been tasked with developing methods to extend the service life of these valves.

A well-manufactured slide gate should be strategically designed to allow for in-line maintenance and to help reduce the amount of downtime that facilities must face to carry out repairs when needed. Slide gates can be designed for high cycle environments, not only to prolong service life but to limit the amount of maintenance needed. The most effective way to limit maintenance requirements is to implement strategies and features to limit wear.

Bonnet seals are important for hindering material migration into the bonnet area.

Otherwise, gate actuation issues, as well as dusting into the atmosphere, can occur.

In the production of cement, high silica concentrations pose many environmental and occupational health hazards.

In applications where abrasive materials are being handled, wear-compensating bonnet seals can be constructed from hard polymer and compressed rubber backing. As the polymer experiences frictional wear from multiple actuations over time, the compressed rubber load seals continuously force the polymer seal against the sliding blade.

This ensures a consistent seal with limited maintenance intervention, even as the hard polymer seals experience wear over time.

Bonnet seals will lose their compression load after many cycles and, therefore, must be replaced. The Vortex Titan Slide Gate is designed so that the bonnet seals can be easily replaced while the gate remains in-line. Using simple tools, the slot covers can be removed,

and new bonnet seals can be driven into the milled access slots, as the worn bonnet seals are simultaneously ejected out the other side of the gate.

Titan’s Slide Gate is also equipped with replaceable abrasion-resistant liners at the gate’s inlet. The purpose of abrasion-resistant liners is to protect the gate’s inlet, blade, rollers and side seals from abrasive wear caused by the material flow stream. For added durability, the gate’s rollers are constructed using hardened steel rather than the industry-standard polymer rollers.

The rollers are also cam-adjustable for in-line maintenance.

Diverter valves

Diverter valves are commonly used to converge two (or more) lines of cement mixing material into one. They can also be used to separate one line of material into several. Often used to handle heavy-duty materials, diverters must be designed to address the abrasive nature of these materials. By addressing these concerns when sourcing a diverter, downtime and maintenance can be kept to a minimum.

Many bucket diverters and flap diverters are designed with thin elastomer seals adhered to the blade’s perimeter. These seals are constantly exposed to the material flow stream.

Because most diverter designs do not provide the necessary protection for the internal seals, they often erode or tear away in service, deeming them ineffective.

Bucket seals constructed from a full sheet of thick rubber, sandwiched between the bucket blade and a metal plate can extend service life. Diverters can be designed so that the leading edge of the blade enters a recessed area, to protect the seals from the material flow stream. Because of these considerations, the diverter provides a positive seal across the opposite leg(s). This prevents material leakage, cross-contamination, and dusting past the blade, into the opposite leg(s).

Equipping diverters with replaceable abrasion-resistant liners throughout can also address concerns of handling abrasive materials. The purpose of abrasion-resistant liners is to protect the diverter’s material contact areas and other internal mechanisms from wear caused by the material flow stream. Liners can be constructed from Cam-adjustable rollers provide ease of maintenance. durable metal materials,

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World Cement February 2022

including 400 Brinell Hardness Number (BHN) abrasion-resistant steel and chromium carbide. For return-on-investment purposes, abrasion-resistant liners are critical because they are the difference between heavy-duty materials abrading upon replaceable parts, or full diverter replacement because materials have abraded holes through the body of the valve.

In applications where cross-contamination is not a concern, diverters such as the Vortex Aggregate Diverter can be equipped with rock box liners – also known as honeycomb liners – along the bucket blade and outlet chutes. The rock box design allows abrasive, dry materials to accumulate in gridded areas so that as materials flow through the diverter, particles abrade upon themselves, rather than abrading upon the diverter’s material contact areas.

Many diverters are not designed to be maintained while in-line. Instead, the entire diverter must be removed from service, which results in significant downtime and expensive diverter rebuilding or replacement. The Vortex Aggregate Diverter, Pivoting Chute Diverter and Titan Lined Diverter are all designed with a removable access panel, which allows interior inspection and/or maintenance to be performed while the valve remains in-line. These diverters are also designed with wetted parts that can be removed and replaced through the removable access panel. This accelerates the maintenance process and prolongs a diverter’s service life.

Loading spouts

Loading spouts provide fast and steady material flow during the loading of dry bulk solid materials such as cement in open and/or enclosed loading into trucks, railcars, or stockpiles. When equipped with proper components, a loading system can be designed to capture fugitive dust, prevent material waste and ensure plant and environmental safety. Like slide gates and diverter valves, loading systems are under an immense amount of pressure by the materials they handle.

Most loading spouts have a two- or three-cable design. Should one cable of a two- or three-cable spout break from wear or premature trucker pull away, it is inoperable until a repair is made.

Vortex Global’s four-cable lifting design provides stability and more lifting torque compared with some standard loading spouts. Should one cable on the Vortex four-cable spout break, the spout is still operational while waiting for repairs.

All Vortex spouts are equipped with a CNC-machined pulley. To eliminate cable

SOME THINK THAT WASTE IS WORTHLESS. WE THINK DIFFERENT. beumer.com

Removable access panels for in-line inspection and maintenance.

Loading spouts are designed with spiral cable guides to assist with lifting cable and/or outer sleeve maintenance and replacement.

fraying, a loading spout can be equipped with an additional CNC-machined three-piece pulley with rounded edges and precision cable grooves. This design prevents cable failure and other costly downtime for cable repair.

Many traditional spouts utilise eyebolts to guide the sleeve support rings during spout extension/retraction. The primary disadvantage to eyebolts is their maintainability. If either the lifting cables or the outer sleeve must be replaced, eyebolts must either be removed from the sleeve or physically distorted (opened) to free the sleeve from the lifting cables.

To resolve this maintainability issue, a spout can incorporate four spiral-shaped cable guides along the circumference of each outer support ring. The primary advantage of spiral guides over eyebolts is that the lifting cables and/or the outer sleeve can be removed without having to manipulate the spiral guides. The lifting cables can be extracted from the spiral guides while the guides remain connected to the sleeve support rings.

Loading positioners are used in conjunction with standard volume loading spouts to facilitate and speed up the loading of open or enclosed trucks and railcars at loadout stations. Internally vented spout positioners allow for dust control during the loading process. While the hopper and spout remain attached to the positioner, hopper seal replacement can be easily performed to limit downtime.

Spout filtration systems are engineered to capture the fugitive dust emitted from the spouts and deposit it back into the material flow during the loading process, eliminating material loss.

These filtration systems are more cost-effective than central dust collection systems and offer in-line maintenance features. Magnehelic® pressure gauges provide differential pressure readings. When high differential pressure is indicated, filter cartridge maintenance or replacement is needed. Filtration systems that feature hinged panels secured by a handled, stationary clamping mechanism help accelerate the inspection and maintenance processes, and allow interior access without tools.

Case study: Handling sand and cement

A cement mix packager sourced a Vortex Multiport Diverter comprised of three, two-way Vortex Titan Lined Diverters in their system. This unique multiport arrangement allows material to be delivered from a single source to any of four destinations – one destination at a time. The diverter outlets are 14 in. (356 mm).

Vortex Loading Spout, Aero Bin-Bottom and Filtration System to assist at a cement terminal.

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Features Two Vortex Titan Lined Diverters are connected by fabricated chutes to create a four-way World Cement February 2022

multiport diverter. The diverters and the chutes are manufactured with replaceable, abrasion resistant, interior steel liners (400 BHN) to address the abrasive qualities of the materials being handled by the customer. These features are designed to extend the service life of the diverter.

Each diverter contains an exterior access port that allows inspection or maintenance of the diverter without having to remove it from service, while limiting downtime. Unlike alternative flap diverters, the Vortex Titan Lined Diverter features a removable access panel that can be removed using simple tools.

In abrasive applications, this is an especially beneficial feature to be able to replace blades or liners quickly and easily without having to take the valve out of service to return it to the manufacturer for maintenance.

Case study: Handling cement-based mortar mix

Four Vortex Titan Slide Gates were sourced by a cement manufacturer to handle cement-based mortar mix in their process. These gates feature 10 in. (254 mm) round outlets. The gates will be utilised to convey the mortar mix to a bagging operation once it has been blended.

Features The Vortex Titan Slide Gate is designed to handle abrasive materials in gravity-fed applications. To combat wear, the gates contain abrasion resistant steel blades and liners.

Replaceable bonnet seals make in-line maintenance possible. Because of the fineness of the product handled, the gates were manufactured with a special polymer end seal.

Over time, if the gate starts to leak dust, a new end seal can be tapped into the end slot, ejecting the old seal out the other end without having to take the valve out of service.

Round-to-square inlet flanges and square-to-round outlet transitions were installed to match the shape of the customer’s conveying line.

Case study: Developing a dust-free loading system

Following complaints from neighbouring businesses regarding dust exposure, a cement terminal contacted Vortex to assist in developing a dust-free loading system.

Features This loading system utilises three products from the Vortex line of loading solutions – a Vortex Loading Spout with a vertical travel distance of 14 in. (355 mm), a

Vortex Titan Slide Gate to handle cement-based mortar mix.

Vortex In-Line Filtration System and a Vortex Aero Bin-Bottom. The telescoping loading spout features a self-sealing discharge cone that contains dust when the spout is inactive.

The aero bin-bottom requires less head room and offers a cost-effective discharge of material at a much smaller angle of repose.

The in-line filtration system traps dust created during loading and re-introduces it back into the load. Panels are hinged and secured by a handled, stationary clamping mechanism to accelerate the inspection and maintenance processes, and for interior access without tools.

Conclusion

When designing a system for the handling of dry bulk solid materials, maintenance will be inevitable over the course of the system’s lifetime. Sourcing products that are designed to address abrasion/wear concerns, require little maintenance, and can be maintained while in-line without having to disrupt operations can save valuable time and money.

About the author

Vortex Titan Lined Multiport Diverter handling sand and cement.

Now in his third year with the company, Austin Anderson is the Content Marketing Manager for Vortex Global. He has created numerous case studies and written articles for a range of global publications sharing the successes Vortex products have experienced.

DELVING INTO DUST CONTROL WAMGROUP considers the most effective technologies for controlling dust emissions produced during the loading, unloading and storing of cement.

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he potential for dust emissions occurs throughout the cement-production process, from the quarry, to the preparation and handling of the raw feed, the handling and storage of clinker, and the feeding, milling, conveying, bagging and loading of cement. These emissions pose challenges both for the health and safety of workers and surrounding populations, as well as the environment.1 The release of coarse particles (>10 µm), for example, can be a source of conflict between a cement plant or loading/unloading facility and local communities. Serious incidents have the potential to endanger a company’s social licence to operate, and risk a response from local regulators. It can also adversely impact agricultural productivity in nearby areas with a number of studies showing cement dust adversely affecting plant growth, soils and groundwater.2 Fine particles (<10 µm, PM10) create health concerns due to their respirable nature.

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These particles, for example, can penetrate deep into the respiratory system, while PM2.5 particles (<2.5 µm) may enter the lungs, significantly increasing the risk of lung damage and disease. The size of these very small particles (for reference, particles <50 µm are invisible to the naked eye) also allows them to linger when airborne and travel on air currents for long periods of time.

Controlling dust also brings safety benefits in terms of improving visibility, for example, during ship loading or unloading, allowing operators to better see into ship holds. And of course, cement dust is designed to harden on contact with water: this may be its essential

BELLOJET ZA loading bellows for efficient, dust-free loading of dry, dusty bulk solids into tankers.

ZX loading bellows ensure efficient, dust-controlled discharge of dry, dusty bulk solids into ships, barges and railway wagons at rates of up to 550 m3/hr.

ZQ loading bellows for dust-free loading of barges and ships up to 1800 m3/hr.

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role in concrete, but it can be a nuisance should sufficient quantities of fugitive cement dust harden in areas where it may damage equipment or negatively impact the environment.

Controlling dust when loading

How to eliminate – or at least reduce – the release of dust is therefore a vital consideration at any facility that handles cement. Loading (and unloading) cement poses particular challenges – whether to truck, ship/barge or train. These operations must not only be dust free, but carried out quickly and efficiently in order to meet delivery schedules and site safety requirements.

The loading spout in particular is integral to the loading operation – and to limiting dust release. The BELLOJET ZA loading spout from Modena-based WAMGROUP Division, TOREX, for example, offers dust-controlled loading of cement into tankers at rates up to 250 m3/hr. The spout itself is provided with an inner tapered cone to control the flow of material, while outer double bellows are used for dust removal. A SINT-engineered-polymer-coated cone at the lower end then provides a sealed connection to the tanker.

During filling of the tanker, a polymer coating on the outlet cone acts as a dust seal. At the same time, a filter fan continuously sucks air through the outer bellows and into integrated filter cartridges, which feature nanofibre filter elements that are unique to TOREX loading spouts. The spout also lowers automatically with the tanker as it fills. This eliminates the risk of any gap arising between the tanker hatch and spout outlet cone, and therefore of any subsequent dust escape.

Dust release is a particular risk as the loading cycle comes to its end. This risk is mitigated by careful co-ordination of processes. For example, the BELLOJET ZA features a level monitor that automatically closes the silo valve when the maximum material level is reached inside the tanker, preventing overfilling. The loading spout remains attached, however, for a short period (about 10 seconds) after the valve is closed to allow the filter to remove any remaining dust.

An automatic pulse-jet cleaning cycle then kicks in to clean the nanofibre filter cartridges of dust, ensuring collection efficiency is maintained. The collected dust falls back through the gap between the outer and inner chute into the tanker.

When it comes to ship loading, the ZX loading spout is available for capacities up to 550 m3/hr, while the ZQ loading spout is available for high-capacity ship and stockpile loading up to 1800 m3/hr.

With a design similar to that of the BELLOJET ZA, the ZX also features inner tapered cones to contain the flow of material, while outer bellows provide dust removal. Both the ZX and ZQ also feature a specially-designed skirt around the bottom that limits dust release during loading operations. The ZQ can World Cement February 2022

also be connected to a central dust collector onsite via a lateral flanged spigot in the upper head.

Between loading operations, low-profile slide gate valves represent an efficient and economical solution to intercepting dry powdery materials, such as cement. VIB valves in particular offer a reliable and long-lasting dust-free seal, manufactured from a highly abrasion-resistant SINT engineering polymer, and can quickly and easily be integrated into any process due to their lightweight design and compatibility with WAM and CEMA flanges. Standard installation for cement applications would comprise a manual valve on the silo outlet, with a pneumatic or electrical valve installed directly underneath.

Taking care of the silo

Premium powder, premium packed From automatic bag filling machine to stretch hooder: our customized packaging solutions make sure your

What has been loaded must, of course, also be unloaded – and for cement, this often involves transfer back into a silo. The process of filling a silo is, however, another point at which the risk of dust release is high, not to mention the potential risk of damage to the silo and its accessories.

TOREX’s KCS silo safety system can help to mitigate these risks. It consists of a central electronic monitoring and control panel, which manages a series of silos and components including: ff Silo power panel ff Silo pipe connection ff Pinch valve ff Tanker coupling to the filling pipe ff Maximum level indicator ff Differential pressure switch or electronic pressure meter ff Pressure gauge for the venting filter ff Pressure relief valve ff Alarm

powders maintain their high quality.

Dust emissions and silo damage are more likely during silo filling because of the risk of overfilling or excess pressurisation. The KCS silo safety system helps to avoid that risk by monitoring the internal pressure and fill level of each silo. It also monitors the venting filters (which can be supplied by TOREX’s sister division, WAM AIR), automatically starting and stopping cleaning, as well as warning when a filter may need attention. Meanwhile, the ability to monitor up to 32 silos simultaneously helps to eliminate the risk that an operator may accidentally try to fill a silo that is already full.

Finally: a 100% waterproof packaging

Catching dust

Tens of thousands of SILOTOP venting filters have been installed worldwide since their launch in 1998.

Containing vertically-mounted filter elements, they prevent the release of dust to the atmosphere in the event that venting is required. Dust is separated from the airflow by special POLYPLEAT nanofibre filter elements, and then drops back into the silo, after an integrated automatic air pulse-jet cleaning system, which is located inside the weather protection cover,

Thanks to the AROVAC® technology you can opt for bags that are 100% waterproof and completely sealed.

This offers you maximum protection and carefree transportation of your product, even when stored outside for longer periods.

has removed it from the filter elements. This not only avoids the nuisance release of dust, but also any loss of valuable product.

The POLYPLEAT nanofibre filter medium offers high filtration efficiency of even the smallest particles. It also traps particles on the surface of the nanofibre, rather than deep inside the filter medium, making it easier to clean with lower compressed air pressures.

VIB low profile slide valve features SINT engineering polymer for high abrasion resistance and live-loaded seals, which ensure extended durability and wear resistance, providing dust-tight sealing across the entire valve surface.

In addition to its SILOTOP venting filters, WAMGROUP dust collection solutions include WAMFLO flanged round dust collectors and WAMAIR flanged polygonal dust collectors.

Available for both venting and suction applications, WAMAIR polygonal collectors separate dust from the airflow either with pocket-type or POLYPLEAT filter elements. Dust-laden air enters the filter casing either from a top inlet flange, with heavier particles being pre-separated as the air descends, or through a bottom flange, which can be either fixed on a PT-type WAM AIR hopper or on the device to be dedusted (silo, belt conveyor, bucket elevator, chain conveyor, etc.).

WAMFLO dust collectors, meanwhile, come inside a cylindrical casing with flanged bottom ring, and can feature either bag-type, cartridge-type or high-efficiency POLYPLEAT filter elements. The dust collectors are available for venting, suction or vacuum applications, and can be installed on top of equipment that requires dedusting, including silos, belt conveyors, bucket elevators, and chain conveyors. They are also available as stand-alone units fixed on standard WAM AIR hoppers.

All dust collectors manufactured by the WAM AIR Division come with a standard stainless-steel casing.

Moving up the hierarchy of control

The KCS silo safety system prevents both overfilling and excess pressurisation, avoiding damage to the silo, venting filter and other accessories. It also reduces the risk of dust emission into the atmosphere.

Dust is an inevitable consequence of the loading, unloading and storage of cement. There is no way to eliminate it; the best solutions therefore aim to isolate people from the hazard through the use of engineering controls, some of which have been mentioned in this article. These offer significantly greater protection to people than simply providing PPE or reducing the time people are allowed to work in risky environments.

They also offer environmental protection and protection for local communities around sites that handle cement.

With the focus on sustainability (both environmental and social) growing, governments, the media, NGOs and the wider public are also becoming more aware of the health and ecological risks posed by industrial processes. Cement in particular has been in the crossfire as a large emitter of carbon and other pollutants. Adopting high-performance engineered solutions to issues such as dust is therefore taking on a wider business imperative – one that is only likely to become more urgent in the coming years.

References

WAMAIR and WAMFLO dust collectors feature POLYPLEAT nanofibre filter elements for increased collection efficiency and easy cleaning. Pictured: WAMFLO cylindrical dust collectors.

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1. MISHRA, S. & SIDDIQUI, N.A., ‘A review on environmental and health impact of cement manufacturing emissions’, International Journal of Geology, Agriculture and Environmental Sciences vol. 2, issue 3 (June 2014), pp. 26 – 31 (p. 29).

2. SUTHAR, L., KANSARA, P., GUPTA, R. & GOSWAMI, G., ‘Pollution due to cement dust’, International Journal of Engineering Research & Technology (IJERT) ETRASCT – 2014 vol. 2, issue 3, pp. 17 – 21 (p. 19 – 20).

World Cement February 2022

GOING BEYOND THE GATE

Matthew Furry, PSCL, explains how self-contained monitoring and control systems can solve the logistical challenges posed by the need to source materials, such as fly-ash, from reclamation projects.

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ement’s journey begins with materials quarried or reclaimed, moving to a plant for processing. Often cement stock is transferred to a terminal before reaching its destination at a batch plant to become the binder in concrete. In understanding the complete journey of cement from constituents to construction, PSCL saw the benefits of solving the next series of challenges by going beyond the gate.

New sources

In addition to traditional quarries, and with pressure from environmental stakeholders and demand for

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cement and concrete only growing, alternative materials like fly ash for CO2-emissions-reduced green concrete can also be sourced from reclamation projects. Addressing the greater logistical challenges of these locations – increased numbers of shipments, carriers, trucks, transactions, paperwork and information – is at the forefront of managing the supply of new raw material sources.

These remote sites often have no power or networking infrastructure, and the useful material to be extracted can be had in a few months or even weeks. With a just-in-time model for material delivery, it is not economically or physically feasible to schedule and implement running power to every point on the site, to install computers and controls, or acquire and house personnel there to run them. Plus, many sites – like former power plants and other government-controlled areas – require security monitoring for all personnel on site. With time pressures to consider and the need for a full suite of data services, there was nothing on the market that would meet the needs of these off-the-grid sites.

At the core of each system is the Tag Interface Module (TIM), a rugged standalone unit built to US military spec. (MIL-STD-810G), meaning it can stand up to the toughest environments, weather, and human-created mishaps.

Able to be set up on its own sturdy tripod or mounted to a pole on site, the TIM runs on 110 VAC or its own internal battery. Connect it to the gate, scale and other controls, power it up, and the configuration is downloaded automatically from the cloud. With no onsite setup required, thousands of dollars in hardware and software configuration and their associated labour costs can be avoided. Should a TIM require replacement, the old unit can simply be swapped out for a new one. The site’s unique configuration is automatically downloaded into the new TIM, allowing operations to resume quickly.

Defining processes

Unlike swiping RFID cards or entering data on a kiosk, FR8Works and CDM Edge are designed for reduced interaction and contactless operation for several reasons. The first is time management.

Keeping a driver in the truck by removing manual A new solution steps reduces their time on site and keeps Using an array of wireless technology, PSCL transactions moving. They are onsite and then developed FR8Works and CDM Edge as self they are back out on the road moving materials contained monitoring and control systems. more quickly. On a busy site where trucks may Waypoints are configured and downloaded from the be queued to load, their wait times (and potential cloud and each site’s unique hardware configuration frustration) are significantly reduced. Automation is delivered. Real-time status and progress is here reduces the overall time to complete moving of available to all parties involved in the operation – all material on the site. owners, brokers, carriers and receivers.

Along with time efficiency, eliminating manual entry methods mitigates human error and the potential for identity and load fraud.

Sites without infrastructure often have a security guard to control access to the site, manually recording data on their clipboard. The paperwork is sent, at some point, to the head office where it is reconciled. The data is assessed with hindsight and error tracking is, at best, hampered.

Drivers interacting with loaders can introduce errors. By keeping them in their trucks and automating interactions with site devices, the system eliminates errors and provides real-time GPS systems require a transmitter and cellular data plan for data of all activities. Potential each truck and only track that truck’s location. The GPS satellite mistakes are avoided before determines position, and the truck’s transmitter constantly updates they can happen. the service provider with location data. FR8Works or CDM Edge require only one data plan per site, reducing connections and Personalisation cost. They control or monitor materials, gates, scales, traffic lights Each driver and truck is and more, as well as each truck and driver. They are cheaper and assigned their own TAG, a quicker to install with real-time data every step of the way for each Bluetooth 5 beacon with an component in the supply chain.

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World Cement February 2022

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~80 m (260 ft) range. The system’s controls and monitoring are triggered by a TAG’s proximity to the TIM. Differentiating a driver and their truck provides the necessary oversight for permissions of personnel on sensitive sites requiring security clearances with each site access logged to the system to comply with security requirements. While a carrier may be approved, a certain driver working for that carrier may not be. It also enables assessment of a driver’s performance separately from the material they deliver.

Now the labour of a security guard is no longer required, and the site is accessible 24 hours a day – delivering longer business hours with better security at a lower cost. As the truck approaches the gate, the TAGs are read by the TIM and – assuming the driver and their truck have been given site access in the cloud app – the gate will automatically open, eliminating the need for the driver to get out of the truck or open a window to swipe a card or enter a code. At the same time, the event is logged in the system for authorised users to view. If a driver not configured on the system must be granted access, the site operator can open the gate from the control suite.

Scalable systems

Depending on how many processes require monitoring, multiple TIMs can be deployed. For example, if a site has multiple material piles, it would be important to know a truck is loading up the material intended. A TIM at each pile triggers a visual indicator, confirming that the truck is at the right location. As the truck is loaded, the driver remains in his truck. Site safety is increased by reducing or eliminating contact between drivers, site machinery, material loading and unloading, and personnel.

Moving onto the scale, the system already knows what the truck is carrying and weighs the load without needing the driver to get out of the truck.

Product accuracy and its weight is assured. By the time the exit gate opens and the truck hits the highway once more, the data is already in the cloud for users accessing the web app as well as being sent to the truck’s destination for site personnel to be ready for the next step in the process. This is complete supply chain monitoring. Information in real-time is available to all parties involved when they need it.

Even larger sites will still only need one cellular data plan when incorporating the mesh network option. A mesh network links all devices into a single Wi-Fi network without the need for a router or switch. With the mesh antenna required on one TIM only, it networks all TIMs on site in a 20 km radius.

Extending the concept

With FR8Works and CDM Edge being process and device agnostic – the system will accommodate whatever systems the operator wishes to monitor and control – they can manage existing and 34

future processes for the cement industry and related resource handling and transfer industries.

Beyond FR8Works raw material reclamation sites, CDM Edge cement plants and terminals can monitor silos to address contamination concerns and stock levels via the Silo Sentry Module using data generated for the Bill of Lading (BOL). With all information checked in real-time, the driver knows they are loading or unloading the right material in the right place. Silo monitoring is only the first addition to CDM Edge. More will be added as PSCL and its clients identify other areas for process automation.

Clear reporting

The web app is set up with same attention to permissions and what each person in the process chain needs to know at any given time. Brokers, carriers, end users and customers share common information but need to focus on their specific areas. The thousands of verified transactions generated every month are available to stakeholder systems via the Customer Link Module. The resulting increased speed and accuracy of information comes with reduced labour and cost savings. By making the process automatic and transparent there is no longer any guesswork around data.

In addition to FR8Works and CDM Edge’s ability to build links to physical processes is PSCL’s ability to integrate with business administration processes.

Raw material transactions can be pushed to an ERP system via the CDM Suite. This allows operators to know where their people and materials are, how they’re affecting the books, and gives the ability to confidently bill at each stage.

Summary

New situations challenge established processes and perceptions. Being able to see what may appear to be limitations at the outset as an opportunity for operators to move themselves and their customers forward is the attitude that PSCL brings to its projects. By addressing the remote areas where the demand for new materials for cement are coming from, FR8Works and CDM Edge have been launched as solutions that can enhance the entire materials handling process for the cement industry. Going beyond the gate has highlighted new directions to improve the processes used and new ways to bring them to support customers.

About the author

Matthew Furry is the President of PSCL. His career in software and automation started at Process Solutions in 1996. Matthew has held a number of positions within the company, and learned the business from the ground up. He also had the opportunity to gain experience working with similar tools in other industries around the world.

World Cement February 2022

IT’S B IN THE BAG!

Graham Rawlings, Concetti, details the installation of a fully automatic bag filling system as part of a planned switch to greener, more environmentally friendly packaging materials. ritish manufacturer of heat resistant castable refractories, Capital Refractories, has recently installed an automatic bag filling system as part of a planned switch to greener, more environmentally friendly packaging materials, coupled with a drive to reduce manual handling and provide improved working conditions for staff.

With a wide range of dense and highly abrasive cement-like materials for furnace lining and repair, Capital looked for a system which not only provided flexibility but offered reliability. After a careful selection process, the company opted for a complete line supplied by Concetti SpA of Bastia Umbra, Italy, comprised of a gravimetric dosing system, bag filling using continuous reels of gusseted tubular PE film and a robotic palletiser for automatic pallet stacking.

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Line output is up to 440 x 25 kg bags per hour.

The investment involved a switch from conventional paper valve bags with inner PE liners, which generally require disposal by landfill, to heavy gauge PE film, an easily recyclable single (mono) material, which is a major environmental benefit.

In addition, PE film allows the use of bright multi-colour printing to display Capital Refractories’ new corporate logo and branding.

The Concetti filling line also allows for the use of unperforated PE film, creating a hermetically sealed finished pack. This extends shelf life and further reduces waste by preventing moisture from impacting product quality if stored for prolonged periods at the user’s site.

The compact, highly integrated line is controlled from a single position, allowing the operator to choose from a series of programmes depending

Robotic palletiser for automatic pallet stacking.

on product type. The selected programme automatically sets various parameters for dosing, filling and pallet stacking patterns. A feature of all Concetti systems is the absence of any spanner or manual adjustments between product changes.

Capital Refractories emphasised the need to ensure pallets were stacked wherever possible without perimeter overhang to avoid potential damage when loading ISO shipping containers serving vital overseas export markets. After initial tests, Concetti suggested reel width and gusset dimensions to provide the best finished pack sizes.

Product dosing

The Concetti system is supplied with bulk product from a small loading hopper equipped with level switches and interlocked removable covers for inspection and cleaning. Material is dosed using a belt fed net weigher fitted with programme controlled, motorised bed depth regulator and a heavy-duty high wear resistant polyurethane belt. Again, interlocked inspection covers allow cleaning as required.

A variable speed drive, with programmable settings, provides additional control over both main and fine feed rates for different product grain sizes and types.

Concetti’s MNET/N scale uses high accuracy precision strain gauge load cells and a weighing controller compliant with European Directive 2014/32/EC (MID). For consistent accuracy, the unit features an auto zero facility, over/under weight checking and, to maintain high levels of accuracy, constantly monitors and corrects for changes in bulk density and material characteristics.

Weights that fall out of tolerance initiate an alarm and stop the system.

Product is discharged from the weigh hopper via a chute into the bag filling machine. Impact surfaces on the belt feeder, weigher and discharge chute are fitted with replaceable plates manufactured using special wear resistant steel to combat abrasion.

Bag filling and sealing

Horizontal Form Fil Seal (FFS) machine ‘Continua’.

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Bags are produced using a continuous reel of tubular gusseted PE film in a horizontal form fill seal (FFS) machine. Horizontal machines offer a significant advantage in fine powder applications where seal contamination can weaken bag security. The use of tubular film eliminates the need for the long and frequently troublesome vertical seals required when using flat film FFS systems.

The Continua 600 is a heavy-duty four station machine designed for use in harsh and aggressive construction industry applications, World Cement February 2022

and has been used effectively with dry concrete duty heat-sealing jaws close the bag, providing a pre-mixes and pure cement as well as sand and strong, secure, hermetically sealed pack containing gravel. well compacted product and minimal air, ideal for Inside the enclosure, bags are transferred palletising. through four stages of forming, filling, sealing and At the final station, the seal is cooled to ensure seal cooling by a smooth motorised reciprocating maximum strength prior to release. action.

Film reels of up to 1200 mm in diameter are Conveying, flattening and printing loaded into place using a power-assisted lift.

Filled bags are conveyed to the palletiser via a bag A motorised drive unwinds the reel and feeds film flattener and an ink jet coder along a series of belt into the machine. Bags of the correct length are cut conveyors. The coder applies two lines of print to WorldCementAd_Feb_2022.01insert.pdf 1 1/4/22 12:10 PM according to registration marks printed on the film the gusseted side of the bags. and the bottom is heat sealed to form the bag.

A precision encoder is provided to monitor the forming process and, if necessary, allow the bag length to be set by the programme.

After forming, the empty bag is transferred to a stainless-steel filling spout fitted with special dust control clamps and replaceable internal wear resistant plates.

The mouth of the bag is opened by suction cups during the transfer cycle.

Discharge of the net weigher occurs when the bag is confirmed on the filling spout. After filling, a bottom vibration system ensures the contents are rapidly settled and compacted, Martin Engineering’s Foundations™ Education which is another Seminars bridge the theoretical with the advantage of horizontal practical—providing the facility-customized FFS systems. training required to maximize the efficiency of Filled bags are your specific operation. Reducing the losses transferred to the top associated with injuries, component failures, seal station fitted with fugitive material, and unplanned downtime an optional vacuum ensures both productivity and profitability. arrangement which evacuates excess air Seminars first include inspection and analysis before closure, further of the design and function of your bulk solids compacting the product. handling system, then equip your team with An air blast system the real-world information they will need to opens and cleans the identify, understand, anticipate, and resolve internal film surface your particular conveying problems. to avoid any potential contamination of the Because when you learn why, you know how. seal area, which might otherwise impair final seal strength.

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A device for verifying that bags are properly closed is located immediately after the motorised flattener unit which provides the final shaping of the bag to ensure the pallets are stacked neatly and uniformly. The flattener height is again programme controlled and set automatically by a servo motor according to the product handled and the pack size.

Palletising

Automatic palletising is accomplished by a Fanuc M410 robot integrated by Concetti and equipped with a Concetti designed bag pick-up tool.

The robot provides reliable operations combined with flexibility and easy housekeeping.

Finished coded bags arrive at the bag pick-up point on a roller conveyor with programme-controlled guides set automatically by a servo motor, to centre bags consistently regardless of the filled width.

An automatic pallet dispenser with manual length and width adjustment and centring guides dispatches empty pallets by powered roller conveyor from the stack to the palletiser as required. The stack builds according to the pattern and the number of layers set in the selected programme.

Loaded pallets are evacuated by powered roller to the unloading position.

Fence type mesh guarding with interlocked access doors or photo-electric light curtains protect the

installation from unauthorised access, all of which complies with the European Machinery Directive 2006/42/CE.

Dust management

Extraction points are fitted at various points to link with the client’s dust collection system, entraining any fine dust that might otherwise escape, ensuring the area around the line is maintained in safe and clean conditions.

Controls

Siemens PLCs control the system and operator interface uses Siemens widescreen touch panels. All machine status displays, buttons, alarm messages and parameters editing are in the English language or graphical form.

A network connects the filling machine and the palletiser, enabling the line to operate as an integrated whole rather that two independent machines.

Selecting a filling programme automatically sets the weighing controller and the appropriate palletiser programme.

This feature, along with Concetti’s long-standing belief in removing as many manual adjustments as possible, helps to eliminate potential operator set-up errors.

Factory acceptance testing

Every Concetti line, even the largest, are fully wired, assembled and tested in Italy with the client’s product and film, before shipment to site. This also includes all fence guarding and safety systems.

Factory acceptance testing is an opportunity to reveal any unforeseen issues and for the client to witness the system operating as it is intended to work when installed.

Moreover, site reassembly and commissioning time is significantly reduced.

Service support

Compact complete bag packaging line.

The system is supplied with comprehensive documentation. A modem connection allows factory-based English-speaking technicians to rapidly check and advise on the system status in case of any issues. Local service support is also available from the nearby city of Nottingham.

Concetti carries most spare parts in stock ready for same day shipment and overnight delivery to the customer’s site.

The line can be seen under factory acceptance testing at Concetti’s modern 16 000 m2 plant close to the historic city of Assisi in Umbria.

About the author

Stable and safe pallets for shipment.

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Graham Rawlings has enjoyed a long career with several manufacturers, in both process control and bag filling systems, and was Concetti’s sales representative in the UK. He now provides support for Concetti’s world-wide marketing activities.

World Cement February 2022

THE PERKS OF PLASTIC

T

he cement industry is facing an enormous environmental challenge, and it is widely acknowledged that the CO2 emissions it is responsible for must be drastically reduced. Every avenue is being explored in an effort to curb these emissions.

However, the potential advantages of using

Frank Goris, Arodo, considers the advantages of plastic over paper cement packaging and explains how the material could contribute towards CO2 emissions reduction in the industry.

plastic packaging are generally overlooked.

The benefits are probably greater than initially expected.

The aim of becoming CO2 neutral by 2050 can only be achieved if the cement industry cuts its CO2 emissions by three quarters by 2050 compared to 2017 levels, according to

39

calculations by research firm McKinsey.1 By that time, cement production must be less energy intensive. And there are gains to be made by switching to green energy. Using alternatives to the raw material clinker can also save CO2, not to mention other alternative building materials that can reduce the use of cement, such as CLT (Cross Laminated Timber).

Despite this, more than half of CO2 savings will have to come from new technologies, McKinsey argues. As examples, the agency mentions carbon capture, use and storage (CCUS), carbon-cured concrete and 3D printing. But the most promising new technologies are not expected to bear fruit for several years.

Nevertheless, cement producers will soon be able to take a step forward by packaging their products differently. Paper bags are still the industry standard, although plastic offers a more environmentally friendly alternative. This may sound strange, especially at a time when plastic is a symbol of global pollution – ‘plastic soup’ certainly comes to mind. But a more nuanced

view is needed here, and the benefits of plastic packaging should be explored.

Substantial product loss

Much less fossil energy is required for the production of paper bags, and paper bags consist of a much smaller proportion of fossil raw materials than plastic bags do. Also, more green energy is used to produce paper bags. As a result, the CO2 footprint of paper cement packaging is smaller than that of plastic packaging. However, this only considers the production of the packaging material.

The entire lifecycle of the packaging paints a completely different picture. It then becomes apparent that plastic packaging could be better for the environment. The missing factor here is product loss. Moisture renders a substantial proportion of the cement produced unusable.

Environmental consultants at BASF have calculated that this affects as much as 10% of the cement stored outdoors.2 This is due to the fact that 11% of paper bags become damaged between delivery to the dealer and use on the building site.

Plastic bags examined

In order to prevent damage due to moisture, British Blue Circle (Lafarge) approached Belgian company Arodo over 20 years ago with the request to supply plastic packaging instead of paper. Arodo supplies technology for both paper as well as plastic bags.

Advantages of plastic

Product loss of 10% is experienced using cement packed in paper bags.

Hermetically sealed bags shielded against water/moisture ingress.

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Arodo discovered that plastic bags have a number of important advantages over paper bags: � Protection: Plastic provides better protection for cement than paper.

Oxygen and moisture are not able to penetrate a fully sealed bag, which allows the cement to be stored for longer and improves its usability. � Storage: Plastic packaging makes it possible to store cement both indoors as well as outdoors. � Waste: Plastic packaging results in less leakage (and less dust) than its paper counterpart.

World Cement February 2022

� Recycling: Plastic is easier to recycle than paper packaging. Paper cement bags contain an inner poly liner that needs to be collected separately. ff This often does not happen and the bags end up in the general waste or – incorrectly – with used paper. To a large extent, plastic packaging can also be made out of recycled materials. ff Printing: It is easier to print on plastic than on paper. ff Price: Plastic is cheaper to produce than paper.

The challenge: Fully automated packaging

The properties of plastic offer a number of advantages. But the packaging process still poses one major challenge, as fully automated packaging with plastic is not a simple technological undertaking. This can be clearly seen by looking at the valve fillers in cement plants used when filling paper bags. The product is first blown into a bag using compressed air, after which the bag is made round to ensure that as much product as possible fits inside with the air. Then the bag is flattened, allowing the air to escape through the many holes in the bag – which creates dust – and the bags can be stacked on top of each other on a pallet.

Sealed plastic bags cannot be filled in the same way. If the bags are flattened, the air in the product/mixture is unable to escape due to the air bubbles that form in the bags. For this reason, Arodo examined the technologies that would be necessary to pack cement in plastic. ff Hermetically sealed bags: Arodo was the first manufacturer to develop a machine that could fill standard (hermetically sealed) PE bags. AROVAC® technology makes it possible to remove excess air from a bag before it is sealed. Vacuum technology is used to achieve this end. ff Water-resistant labyrinth bags: At a later point, Arodo developed machines that could fill another type of plastic bag – the labyrinth bag, also known as the ‘venting bag’. This bag is designed to allow air to gradually escape through a labyrinth. It is difficult for water to penetrate into the bag. Filled labyrinth bags should be as compact as possible when they are stacked on a pallet, because that is when the air escapes from the bags. If the bags contain too much air, the pallet will become unstable. To prevent this, the product should contain as little air as possible when the labyrinth bags are being sealed. In addition, removing the air should not be a lengthy process. The Arodo machine is designed to ensure a good balance between stability and speed.

Different packaging technologies are required depending on the type of plastic bag used.

The differences can be seen not only in pallet stability, but also in the cleanliness of the bag (dust tightness) and of course in the price of the bag.

Price depends on plastic quantity

The price of a cement bag is very much dependent on the quantity of plastic used. The less the bag weighs, the cheaper it is. Arodo welcomes the challenge of reducing the use of plastic as much as possible, also with a view to sustainability. Through applying AROVAC technology, a smaller amount of plastic is used in the hermetically sealed bag.

Saving CO2 by using plastic

Previous studies have shown that the production of a paper bag causes CO2 emissions of 71 g, while a plastic bag causes 192 g of emissions – 2.5 times as much. If we know how much cement is produced globally and what this costs in terms of CO2 emissions, the amount of product loss can be calculated, and this can be seen to make a plastic bag the better choice.

An article on the website of Imperial College London3 discussing a study by Paul Fennell4 states that 3.5 billion t of cement are produced globally each year and that each ton is responsible for 622 kg of CO2 emissions.

This means that one kilogram of cement is responsible for 622 g of CO2 emissions. Much of that cement is packaged in bags. Since a standard bag holds 25 kg of cement, a bag of cement is responsible for 15 550 g of emissions.

The difference in CO2 emissions between the production of paper versus plastic bags is 121 g in favour of paper. This is offset by a ‘loss’ of 1555 grams of CO2 emitted during the production of cement that was ultimately lost.

Of course, product loss can also be prevented in other ways, such as by storing the product in dry rooms. Arodo has therefore calculated when a paper bag might be the better choice over plastic in terms of reducing CO2 emissions. The break-even point is (121/15 550 =) 0.78%. This is far below the 10% product loss calculated in the current market where paper bags are mainly used.

This calculation is based on Portland cement.

In practice, many other types of cement are sold with slightly lower CO2 emissions and a slightly higher break-even point. On the other hand, plastic bags are usually made of up to 80% recycled materials. This would likely lower the break-even point again. If in future the amount of plastic used to make cement could be lowered further, the benefits of using plastic bags over paper bags will only increase.

Cement packaging: Making the right choice

More and more producers in the cement industry are already opting for plastic instead of paper packaging. In order to decide whether plastic packaging is the right choice, it is advised that cement producers seek advice from an expert first, as the type of bag and the filling technology needs to be well matched to the product. Bag suppliers and the developers of filling machines could be asked about the options. From sustainability to shelf-life and presentation, every element is important and can play a decisive role in achieving a successful end result.

Sources

1. ‘Laying the foundation for zero carbon cement’ – https://www.mckinsey.com/industries/chemicals/ourinsights/laying-the-foundation-for-zero-carbon-cement 2. BASF research – galco.ie/products/cement 3. ‘Best ways to cut carbon emissions from the cement industry explored’ – www.imperial.ac.uk/news/221654/ best-ways-carbon-emissions-fromcement 4. FENNEL, P. S., DAVIS, S. J. CO2 emissions of paper and plastic cement packaging compared. & MOHAMMED, A., ‘Decarbonising Paper Plastic* cement production’, Joule, May 2021.

Packaging emissions 71 g CO2 per bag 192 g CO2 per bag Difference between paper and plastic packaging Cement production emissions Break-even point (% of product loss where plastic packaging results in lower net CO2 emissions than paper

192 – 71 = 121 g CO2 per bag 622 g CO2 per kg cement 15 550 g CO2 per 25 kg cement 0.78% (far below the product loss of 10% when using paper packaging)

packaging) *It is unclear what percentage of recycled plastic was assumed here.

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About the author

Frank Goris, Technical and Commercial Manager at Arodo, has more than 25 years of experience in management positions at Arodo and has helped pioneer many innovative packaging solutions. Frank and his sales team translate the customers’ questions into the best possible solutions.

World Cement February 2022

PACKAGING PROGRESS Sigrid Eder-Ince, Starlinger, describes the economical and ecological advantages of woven polypropylene cement sacks and discusses the shift towards this type of packaging in Côte d’Ivoire.

A

lthough the COVID-19 pandemic has affected the economy of the West-African states, investments in the cement sector continue.

Côte d’Ivoire’s economic growth rate has been among the highest in the world in the past years, with GDP growth reaching 7% in 2018 and 6.5%

in 2019.1 The government’s focus on housing and infrastructure construction during the past decade contributed significantly to the strong development of the cement sector, which is currently producing a surplus that by far exceeds the current consumption of roughly 5 billion tpy.2 Still, industry players such as Dangote and Sinivoire are

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expanding production and have announced new plant construction projects.3 In line with this development, suppliers to the cement industry are scaling up production.

To keep up with increasing demand for woven polypropylene cement sacks, plastic packaging producer Plastica Sarl. installed its second woven PP sack conversion line. Plastica produces block bottom valve sacks made of woven polypropylene (PP), an alternative to the still dominant paper cement sacks. These sacks, marketed under the brand name AD*STAR, currently account for a market share of 25% in Côte d’Ivoire. They are economical, production is less resource intensive, and they offer protection especially for moisture-sensitive bulk goods such as cement.

“Looking at the GDP growth of Ivory Coast in the past years and the government’s big development projects, the country was clearly having a boom in the infrastructure sector, which resulted in a significant growth of the cement industry”, says Abbas Baddredine, General Manager of Plastica Sarl. Based in Abidjan, Plastica was founded in 1999 and produces woven PP sacks for various applications as well as PE films and sacks and injection moulded household and garden products.

Besides supplying sacks to cement producers, the company caters to the cotton, agro-alimentary and agro-industrial sector and wholesalers.

Plastica decided to start the production of AD*STAR sacks in 2018, after noticing a trend

shift from traditional paper sacks to PP sacks in other parts of Africa and around the world.

As one of the biggest plastic processors in the region, Plastica decided to take the initiative in Côte d’Ivoire and its neighbouring countries.

The company met with almost all major cement manufacturers and discussed the benefits of the sacks. Although still relatively new in the field of PP raffia sack production, Plastica took the decision to install its first woven block bottom sack production line in 2018 and became the first supplier of AD*STAR cement sacks to Ivorian cement manufacturers.

Plastica supported its customers in the transition period from paper to woven PP sacks and helped provide solutions for any emerging problems. The changeover to the new sacks offered financial benefits to customers, but also reduced typical problems observed during cement transportation and storage, such as sack rupture or premature hardening of the cement due to moisture. The company supplies AD*STAR sacks to national cement producers such as Cimivoire and Ivory Diamond Cement. Around 25% of AD*STAR sacks produced in Côte d’Ivoire are exported to neighbouring countries such as Burkina Faso, where the companies Cimfaso and Cimasso use them.

Due to rising demand, Plastica decided to expand production capacities and installed the second Starlinger conversion line for AD*STAR sacks in December 2021. It has a production output of up to 120 block bottom sacks per minute, increasing the company’s production capacity to a total of 80 million AD*STAR sacks per year. Plans are being made to install a third line this year.

Benefits of woven polypropylene sacks

Woven polypropylene cement sacks.

The woven PP tape fabric is produced in endless tubes on circular looms.

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The block bottom valve sacks, developed and patented by Austrian woven plastic packaging machinery manufacturer Starlinger & Co GmbH., are made of coated polypropylene tape fabric and are produced in a special hot air sealing process. No glue or other adhesives are used, which makes them a mono-material packaging solution that can be recycled easily. The sacks offer the following advantages: ff They are suitable for automated filling and palletising. ff They are brick-shaped and strong for improved stacking and occupy less floor space in storage facilities. ff They are high strength, even when exposed to moisture. ff The likelihood of spillage or leaking is reduced due to the polypropylene coating. ff The sacks offer adjustable air permeability due to optional micro-perforation, which keeps dust formation to a minimum and World Cement February 2022

ADVANCED PROCESS CONTROL INNOVATIVE MEASUREMENTS

WE MEASURE PRECISELY AND CONTROL INTELLIGENT ADVANCED PROCESS CONTROL

INNOVATIVE MEASUREMENTS

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Truck loading is possible as well as direct feed via belt conveyor to raw material silo. The InterHop impresses with a flexible design.

It is a tailor-made solution developed according to the client’s requirements.

Contact us: The InterCem professionals will also find the right solution for your requirement.

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protects against moisture (equating to a longer shelf life). ff They are tamper and theft-proof. ff Sack production is fully automated. ff The sacks have an attractive design for improved brand promotion.

Environmentally friendly cement packaging

The AD*STAR sacks are economical in the use of raw material, have a low breakage rate, help to reduce CO2, and can be either recycled or reused for other purposes. These ecological advantages also turn into economic benefits for the cement producer. The special characteristics of the polypropylene tape fabric ensure high strength and durability while significantly less raw material is used in the production process.

As a result of the material characteristics and the special production process, the empty weight of an average AD*STAR sack holding 50 kg cement can be as low as 65 g. In comparison, a same-sized two-layer paper sack weighs about 140 g, and a PE film sack weighs around 150 g – both are almost double the weight of a woven

Quality control of the cement sacks before stacking.

polypropylene sack. The lighter the sack (while offering equal strength and protection), the less raw material input is required. This not only keeps sack production costs low, but the economical use of raw material also helps to reduce the carbon footprint.

The low breakage rate of AD*STAR sacks has both environmental and economic effects. Compared to paper sacks, the risk of contaminating soil and water with cement is almost zero. Secondly, there is savings potential for cement producers as breakage rates in the life cycle of paper sacks (filling, conveying, palletising, stacking, loading, transporting, unloading, etc.) are about 4 to 5%, whereas only 1% of woven polypropylene sacks are damaged in the course of their life-cycle.

Another big issue is CO2 emissions. The cement industry is responsible for about 7% of total global CO2 emissions.4 By reducing bag breakage rates, millions of tons of CO2 emitted during cement production could be saved additionally each year.

Conclusion

Cement sacks made of woven polypropylene fabric provide an economically and ecologically sound alternative to kraft paper sacks and are gaining market share in Côte d’Ivoire. Ivorian Packaging provider Plastica Sarl sees great potential for more growth within the country and for export and is expanding its production of the environmentally friendly cement packaging solution. Besides being a raw-material saving and lightweight type of cement sack, woven polypropylene sacks provide protection of cement and limit waste due to their low breakage rate, helping to reduce the carbon footprint of the world’s cement industry.

References 1 – 3. BELL, P., FERNANDES, J., Côte d’Ivoire. The Global Cement Report – 14th Edition (p. 103 – 104).

Tradeship Publications Ltd., 2021.

4. GCCA Global Cement and Concrete Association.

(2021) GLOBAL CEMENT AND CONCRETE INDUSTRY ANNOUNCES ROADMAP TO ACHIEVE GROUNDBREAKING ‘NET ZERO’ CO2 EMISSIONS BY 2050. Available at: https://gccassociation.org/news/ global-cement-and-concrete-industry-announces-roadmapto-achieve-groundbreaking-net-zero-co2-emissionsby-2050/.

About the author From right to left: Raiss Ghaith, Production Director Plastica, the Starlinger installation engineers, Lucas Dorfwirth and Lukas Sattler, Patel Nikunj, Technical Director Plastica, and the Plastica team in front of the new AD*STAR conversion line.

46

Sigrid Eder-Ince holds a Master’s degree in Translation Science and started working as a technical translator in the machinery industry in 2005. Since 2010, she has handled the PR activities of Starlinger & Co GmbH and writes technical articles and press releases on plastic packaging and plastics recycling technology.

World Cement February 2022

Counting on cannons Brad Pronschinske, Martin Engineering, explains how air cannon technologies can effectively prevent material build up in the preheater, whilst maintaining workplace safety and minimising unscheduled downtime.

I

n cement plant preheaters, intense heat courses upwards through the system, raising the temperature of the meal to ensure it does not cool the kiln when it arrives. Material fed into the preheater has a temperature as high as 200˚F (93˚C) but within seconds, it enters the kiln heated to 1500˚F (815˚C).1 This saves on energy consumption, reduces the calcining time and promotes plant efficiency.

However, no matter how many stages the preheater has, as the material flows through each stage, it can quickly adhere to the coarse refractory, build up and clog. This slows or stops the flow and leads to expensive downtime.

Many operators mitigate clogs by implementing regular cleaning schedules, assigning workers with water lances extended through access holes.

A worker ascends the tower and dons a suit of high-heat personal protective equipment (PPE).

Lancing the material with high-pressure water clears the blockage, and the workers restore proper flow.

Unfortunately, this procedure is always done while the preheater is still in operation, causing a tremendous

amount of heat and some molten material to blow back. The PPE, the heat and the safety issues make preheater cleaning one of the most unpleasant jobs in a cement plant.

To improve safety and increase efficiency, virtually all cement plants in the USA have air cannons installed on the preheaters. Over the years, Martin Engineering has worked to improve the technology to the point where both installation and maintenance can be performed safely without a shutdown or exposure to intense heat.

Preheater flow

Preheater towers, in some form, have been in operation since the 1920s. Today’s designs can have as many as six stages in towers up to 12 stories (120 ft/35 m) tall. The mix flows down a chute to a splash box, proceeds to the airflow of the riser duct where it gets heated, and progresses to the next stage, and the procedure happens all over again.

One of the biggest contributors to material buildup is high heat and material velocity.2 As material

47

New cannon designs are more compact and have dramatically increased in power and efficiency.

The material flows through this stage several times within seconds, leading to the kiln.

gets hotter, it gets stickier, clinging to the sides of the flow chutes and splash box, as well as in the riser duct. If left unchecked, clogs can form quickly, stopping the material flow, which leads to unscheduled downtime and lost production. Large buildups can even completely block the outlet of the cyclone.

Whenever operators open the access door, this lowers operating temperatures. Cold water also reduces temperature, and injecting water into the hot tower creates steam, which can result in a dangerous steam ‘explosion.’ A better alternative is a series of low-pressure air cannons – a technology originally developed and patented by Martin Engineering in the 1970s. Early cannon designs were engineered to use very high pressures – some as high as 34 474 kPa (5000 PSI) – which were expensive to operate and introduced safety issues. But today’s low-pressure ‘air blasters’ are fed by compressed air (or some other inert gas), delivering a powerful surge through a specially designed high-heat nozzle to clear a specified area.

Air cannon nozzles are strategically positioned in the tower, riser duct or cyclone. As adhered material is dislodged, it returns to the flow, with the pressurised shot facilitating the flow and enhancing efficiency.

In the past, operators have been concerned with valve maintenance that required tank removal and nozzle replacement, which could only be performed during scheduled shutdowns that involved a system cooldown. Back then, most cement plants used their annual scheduled shutdown to maintain or clean nozzles. This often required the removal and replacement of refractory, where any disruption can lead to cracking. But over the last decade, these issues have been addressed by new technologies, including retractable nozzles that can be installed and serviced during production.

Many designers proactively include the mountings for air cannons in new designs, so that future retrofit can be done without vessel entry or extended downtime. New technology has even been developed for installing air cannons in high-temperature applications without a processing shutdown, allowing specially-trained technicians to mount the units on furnaces, preheaters, clinker coolers and in other high-temperature locations while production continues uninterrupted.

Controlling the flow

A series of air cannons can be programmed to deliver precisely-timed operation for maximum benefit.

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When employing flow aids such as air cannons, it is critical that the flow aid is properly sized and mounted. Nozzle location is critical, and the new designs allow nozzle installation from outside the structure, so they can be precisely located to deliver the necessary performance.

The best practice is to use flow aids as a preventative solution to be controlled by timers or sensors to avoid material buildup, rather than waiting World Cement February 2022

until material accumulates and restricts the flow.

Using flow aid devices in a preventive mode improves safety and saves energy, since flow aids can be programmed to run only as needed to control buildup and clogging.

How air cannons work

The basic components of the air cannon include an air reservoir, fast-acting valve with a trigger mechanism and a nozzle to distribute the air in the desired pattern to most effectively clear the accumulation.

Often installed in a series and precisely sequenced for maximum effect, the network can be timed to best suit individual process conditions or material characteristics. The air blasts help break down material accumulations and clear blocked pathways, allowing solids and/or gases to resume normal flow.

In order to customise the air cannon installation to the service environment, specific air blast characteristics can be achieved by manipulating the operating pressure, tank volume, valve design and nozzle shape.

Tanks and valves

To facilitate maintenance without a process shutdown, air reservoirs with volumes typically ranging from 35 l up to 150 l are now outfitted with a rear-facing valve that can be removed without

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dismounting the tank. Today’s fast-acting valves can release the tank volume in a fraction of a second, creating a high-magnitude force at the exit nozzle which is installed through the wall of the vessel or duct. The new designs feature a hybrid valve concept that provides more force, uses less air and simplifies maintenance in challenging applications with limited budgets.

Positive-firing valves that respond to an air pressure surge delivered by a solenoid have also made air cannons safer. Unlike negative pressure-firing designs, a cannon equipped with this type of valve will not discharge accidentally in response to a drop in pressure, so an air supply failure or broken line cannot trigger it suddenly. The high-speed valve design is mounted on a smaller air reservoir, delivering higher discharge forces than less efficient valves on larger tanks. The new generation of valves produces about twice the blast force output of previous designs, saving energy by using about half the compressed air volume.

Nozzles and service

Another innovation has been the patented Y-shaped assembly that allows the nozzle to be maintained or replaced without removing the tank or disrupting the refractory. The system allows specially-trained technicians to mount the units on furnaces, preheaters, clinker coolers and in

other high-temperature locations while production continues uninterrupted. It dramatically reduces downtime associated with traditional approaches to installation, service and replacement, which require that high-heat processes be halted to allow core drilling and mounting of the cannons.

Avoiding unplanned shutdowns is key to a plant’s profitability. Any shutdown other than scheduled maintenance is production time that cannot be recovered. Once that production time is lost, it cannot be made up again. With the core drilling option and Y-pipe, installation and maintenance can be done during normal production.

The nozzle is the component that takes the stored energy in the form of compressed air and directs it to do work, so it has a dramatic effect on the performance of any air cannon. The application dictates the type of performance needed, including the shape of the air blast, length of the plume, etc.

A primary goal in every application is to use the stored energy as efficiently as possible.

The new series of retractable air cannon nozzles has been developed specifically for high-temperature applications, extending into the material stream only during the firing cycle to protect the nozzles from extreme temperatures and abrasion. These ‘smart’ nozzles allow the cannon and nozzle to be installed independently, so the nozzle can be accessed for inspection or service during production, without stopping the process or removing the cannon. The new design solves two common industry problems: effectively dislodging accumulations in hard-to-reach areas without shutdown or manual labour, while significantly extending nozzle life. Further, the units can be serviced from outside the vessel without disturbing the refractory, reducing potential damage while minimising service time and risk of injury.

Case study – Indian cement plant

Drilling for a new air cannon on an operating preheater by a trained specialist.

Retractable nozzles are only exposed to the material stream for the split second it takes to deliver the shot.

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A cement facility in Northern India, producing 3.25 mtpy, was experiencing clogging issues in the feed pipe of its preheater tower. Production demands prohibited managers from allocating system downtime to fully clear the duct. To mitigate clogs and avoid unscheduled stoppages, the plant implemented a manual cleaning schedule while the tower was in operation. The procedure used an air lance through an access hatch, which can result in extreme heat exposure, blowback, and potential contact with molten debris. This also pulled resources away from other essential tasks in the plant. The extra labour increased the cost of operation, so managers sought a solution that allowed them to address the problem without a shutdown.

Technicians from Martin Engineering India were invited to examine the issue, and they decided to install two air cannons at the clogging point. Buildup is common in preheater towers and can take up to 10 days of downtime for cooling, cleaning and reheating. By using a Martin® Core Gate, holes were carefully drilled through the refractory during operation, then the air cannon assemblies were installed. Using 70 l Martin Typhoon Air Cannons connected to the plant’s compressed air system and jet nozzles designed for high-temperature environments, each unit delivers a powerful shot of air that dislodges adhered material. The cannons were set to fire automatically at predefined intervals.

The drilling and installation required just two hours.

With the ability to service and maintain the valve and nozzle without removing the tank or assembly, a permanent solution was provided that significantly reduced maintenance labour, while improving safety.

World Cement February 2022

Moreover, dislodging adhered material before it accumulates means the problem area no longer requires manual cleaning. The cement facility was pleased with the outcome of the project, and managers are now working with Martin Engineering India to install air cannon solutions in other parts of the tower and throughout the plant.

Conclusion

Flow through the preheater tower takes only seconds, but a clog can cause hours or days of downtime that can not be made up, resulting in significant losses. Prevention and maintenance can be a gruelling task that leads to increased labour costs. Thanks to new air cannon technologies, the lost production, reduced revenue, workplace safety implications and employee morale issues can be efficiently minimised.

After calculating the costs saved by avoiding downtime, this technology pays for itself quickly.

The savings are compounded by reduced maintenance, improved safety, lower labour costs and greater production efficiency. Given the current production volumes and costs, a typical manufacturing operation can avoid paying up to US$600 000/day by preventing downtime and cleanout labour, not including the potential safety implications and expenses.

WORLD CEMENT

References 1. FREDLAKE. J., and SPAITS.T., ‘Preheater tower best safety practices’, 2016 IEEE-IAS/PCA Cement Industry Technical Conference, 2016, pp. 1 – 7, https://ieeexplore. ieee.org/document/7742670 2. GUTZWILLER. L. , BANYAY H. D., and COHEN. S. M., ‘Cement plant preheater fan build-up control’, in IEEE Transactions on Industry Applications, vol. 27, no. 3, pp.

425 – 430, May – June 1991, https://ieeexplore.ieee.org/ abstract/document/81822

About the author

As Global Product Manager of Martin Engineering’s Flow Aid Division, Brad Pronschinske is responsible for the development and management of the company’s air cannon products and vibration systems, used to improve bulk material handling in applications around the world.

Brad joined Martin Engineering in 1998 as an Air Cannon Product Specialist and served as Air Cannon Product Manager from 2000 to 2005. He became Global Product Manager for Air Cannons in 2005 before assuming his current role in 2008.

Brad holds three US and international patents on air cannon models, with two additional patents on nozzles for air cannon systems. He also holds a B.S. in Electronics Engineering from Hamilton Technical College in Davenport, Iowa.

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SATELLITE SUCCESS T

he usage of alternative fuels in liquid and solid form is an integral part of every cement process. Initially the cement kiln was used as an incinerator. Since landfilling was no longer allowed, other methods of waste disposal had to be found. The cement kiln with its high temperatures was a perfect candidate, and cement plants were paid to dispose of the waste.

Over the years the incentive has changed, but alternative fuels are still used in the kiln and calciner to a high extent. Since secondary fuels are nowadays considered CO2 neutral, the use of these fuels reduces production costs and helps cement producers to decarbonise their production.

52

Reinhard Ringdorfer, Unitherm Cemcon, explains how the development of new satellite burner systems has allowed cement plants to push the limits of AF utilisation.

Ever since cement plants started using alternative fuels, Unitherm has been a disruptive pioneer in the market, introducing new technologies to push the limits of AF utilisation.

While liquid secondary fuels are rather easy to burn with the right equipment, solid secondary fuels haven proven more difficult. In 2001, with the introduction of the Pneumo-Swirl (PS), the first attempt was made to influence the flight behaviour of the fuel particles. This device, located at the exit of the solid secondary fuel channel causes the fuel particles to a swirl and mixes them with the primary fuel (Figure 1).

In 2007 the PS was supported by the Pneumo-Injector (PI), which gave the operator the ability to accelerate the particle exit velocity

and therefore affect the throwing length of the particles. Bigger particles especially could be thrown farther into the kiln, avoiding reducing conditions in the sintering zone.

Both devices were used in numerous burners, ensuring a successful operation with the combustion of solid secondary fuels.

The latest development was the introduction of the Pneumo-Deflector© in 2011 (patent no. E 2 633 235 B1). Solid secondary fuel particles can be deflected above the kiln axis via bores in the outlet nozzle of the fuel, the required air is supplied by the primary air fan and the intensity can be adjusted via valve. Since then, this innovative solution has been further optimised using CFD and has proven to be most

successful, enabling the operator to increase the amount of secondary fuel of the same quality while maintaining a high clinker quality. Figure 2 shows the CFD simulation of solid secondary fuel firing with and without Pneumo-Deflector (parameters 200 mbar PD air pressure, injection velocity of particles 30 m/s).

Where to fire secondary fuels

Generally there are three parameters for classifying solid secondary fuels to determine where they can be utilised in the cement process (Figure 3): � Particle size � Moisture content � Ratio of 3D to 2D particles

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Depending on the available residence time where the material is brought in, the fuel has to be prepared accordingly.

The highest residence time is available at pre-calciner combustion, where bulky material is burned until it can be fed into the calciner.

Modern calciners, with or without a combustion chamber, usually have a residence time of up to 10 sec., which allows the firing of bigger particles with high 3D content.

When it comes to firing in the rotary kiln, the particles have to be much finer and have a lower moisture content due to the low residence time.

While the implementation of technologies, such as Pneumo-Swirl, -Injector and -Deflector had a positive influence on the combustion, there is still room for improvement.

Satellite burners Figure 1. The Pneumo-Swirl (PS) was first introduced in 2001, followed by the Pneumo-Injector (PI) and Pneumo-Deflector.

on

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Figure 2. Alternative fuel trajectories inside a rotary kiln.

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particle size commercial main burner PNEUMO-DEFLECTOR© - main burner UNISAT - satellite burner combustion via precalciner

Figure 3. Generally, there are three parameters used to classify solid secondary fuels: particle size, moisture content, and ratio of 3D to 2D particles.

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Several years ago Unitherm resurrected the concept of the satellite burner to increase the amount of solid secondary fuel fired in the kiln.

Initially invented in the 1980s as a simple static pipe, Unitherm was among the first to adapt this technology to the new millennium.

The operation of the UNISAT satellite burner brings the following advantages: ff The material is introduced in a high temperature area above the main burner, ideal for drying and the release of the volatile matter. ff Unlike injection of the fuel inside the kiln burner, the oxygen content above the main burner is at the highest level, allowing an ignition of the volatile matter. ff Usually the injection point of the satellite burner is a certain distance above and behind the main burner nozzle. This increases the residence time of the particles and allows for complete combustion. ff Since the secondary fuel channel is located outside, the main burner can be designed with a smaller diameter and less weight. ff Mixing of the secondary fuel with the primary fuel reduces the risk of a double flame formation.

To achieve the optimum combustion with a satellite burner, there are two important factors to be considered.

Firstly, the satellite burner has to be designed as an actual burner, not just a pipe. The Unitherm satellite burner consists of a solid secondary fuel channel surrounded by a cooling air channel with a heat resistant air nozzle. Adjustment possibilities in every direction are necessary to adjust the burner for optimum mixing of the material into the main flame. Therefore, Unitherm supplies the satellite burner with a separate burner trolley for axial, vertical and horizontal adjustment.

To ensure the efficient mixing of the secondary fuel into the main flame, the satellite burner has to be paired with a high momentum burner with strong mixing capabilities. Typically, Unitherm satellite burners are delivered together with World Cement February 2022

the M.A.S. burner. Due to the unique primary air system with strong primary air jets with high momentum, the burner is well suited for the use with a satellite burner.

If these conditions are not met, the set-up with the satellite burner will not operate efficiently.

All satellite burners are tailor-made solutions, fitting exactly to the existing kiln and main burner.

During the engineering phase all relevant data for the design of the satellite burner is collected. The final design and the positioning of the burner is then determined using the know-how gained from previous installations as well as the operational experience of commissioning engineers.

Case study – Austria

The plant in question is using an M.A.S. burner delivered in 2003. The burner is designed for the firing of coal, fluff and natural gas for start-up with a thermal capacity of 40 MW. Solid secondary fuels have been used at a high percentage for many years through the main burner. The goal of the satellite burner installation in 2020 was the optimisation of the operation in terms of ignition behaviour of the particles and process stability.

Due to the lack of space above the main burner, the satellite burner had to be installed on a monorail beside the main burner, roughly at the 2 O’clock position (Figure 4).

Result: due to the pre-drying, the material ignites earlier and the operation is more stable.

The burner is currently operating at >90% substitution rate.

Case study – Hungary

The goal of the project was to increase the substitution rate at the main burner.

The existing burner, an M.A.S. burner has been operation for more than 10 years, operating on petcoke, heavy fuel oil, liquid and solid secondary fuels.

During the modernisation project, the 50 MW main burner was upgraded to the latest nozzle head, the M.A.S.DT system. For the secondary fuel firing, a satellite burner DN 150 was installed (Figure 5).

February 2022 World Cement

After successful commissioning, the burner is now operating with solid secondary fuels through both the main burner and satellite burner. The main burner is fired with approximately 2.5 tph of industrial plastic and a maximum of 1.5 tph of petcoke, while the satellite burner uses between 4 and 5 tph of fine RDF. With a substitution rate of 83% the client is fully satisfied with this successful project.

Conclusion

While the combustion of solid secondary fuel through the main burner works well with the latest generation of primary air injection and Pneumo-Deflector, the advantages of the satellite burner technology are obvious when it comes to increasing the total amount or reducing the quality (particle size, moisture content, 3D/2D ratio) of the solid secondary fuel.

Looking at the references and the latest orders, there is a clear tendency in the direction of the UNISAT satellite burner technology. The numbers of orders for a satellite burner have been constantly increasing over the last years and account for approximately 70% of the orders involving solid secondary fuel firing.

Figure 4. The satellite burner was installed on a monorail beside the main burner.

Figure 5. For the secondary fuel firing, a satellite burner DN 150 was installed.

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WORLD CEMENT GRINDING Q&A 56

World Cement invited industry leaders to share their thoughts on a range of grinding and milling-related topics.

Contributions come from: FIVES FCB, Gebr. Pfeiffer, and thyssenkrupp Industrial Solutions.

1) In our increasingly climate-conscious world, emissions reduction remains a key goal for the cement industry. What steps can be taken to reduce the environmental impact of cement grinding operations?

FIVES FCB As well the consideration of production costs and carbon footprints, one key issue is energy consumption. For reference, the grinding process represents a significant part of a cement plant’s electrical demand, in the range of 50 – 70% of the total integrated plant’s needs. Therefore, limiting grinding power demand is a major industry focus.

The end-product evolution is another key issue to address, with respect to the expansion of the cement additives range and cement/ clinker ratio, as well as the emergence of ultra-fine products in the cement industry. It appears then that the solutions are to be found in versatile technologies, with low-energy consumption, and the capability to adapt to a wide range of raw materials, which come with their own constraints such as grain size variation, moisture content, grindability, etc.

The FCB Horomill ® grinding system can help provide a solution to these challenges, offering low energy consumption and high flexibility and end-product quality for an optimised cement/clinker ratio.

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Gebr. Pfeiffer Sustainability is one of the most important challenges facing cement production, which is responsible for 8% of global carbon emissions – the dependence on fossil fuels must be reduced.

In the area of material comminution, we are constantly optimising our systems to save raw materials and energy, and thus reduce emissions.

Especially in the recent past, we have been able to increase the already high power density of our MVR mills by a further 10% and also drastically reduce the water requirement and pressure losses in the overall system, to name just a few examples.

And we are determined to continue on this path of constant improvement.

On the way to achieving climate neutrality for cement plants, there are many pieces of the mosaic that only together form a complete pattern.

This starts with low-CO2 raw materials, alternative fuels, kilns with carbon capture technology, reduction of clinker content, energy-efficient grinding, and many other aspects, such as transport of the cements.

The cement grinding process will be further optimised and become significantly more environmentally friendly. The trend toward using clinker substitutes will also continue. Taking all these aspects into account, mill designers must ensure that energy-saving comminution is possible and is further improved. thyssenkrupp Industrial Solutions Cement producers can apply the following measures in order to reduce the environmental impact of their cement grinding plants: ff Reduction of the clinker factor by shifting the production towards cement types with the maximum possible proportions of constituents.

By increasing the amount of fly ash, limestone, pozzolana or granulated blast-furnace slag in the final cement product, the clinker factor and consequently the required heat consumption per ton of cement as well as all emissions (CO2, NOx, SO2, TOC, etc.) caused by the clinker burning process are significantly reduced. ff Along with the increasing demand for low clinker cements or high early strength cement types, the installation of the polysius® booster mill is a highly energy-efficient solution for achieving the necessary cement quality even at existing cement grinding plants. It is a horizontal agitated bead mill based on a modular and very compact design, which is advantageous for very fine grinding of cementitious materials or constituents. As the polysius booster mill releases a very high energy density, it is well suited for the production of high-performance cements or shifting the portfolio to lower clinker cement 58

types and simultaneously for reducing the emissions. ff Depending on the specific customer needs, the cement grinding plant installation comprising a high-pressure grinding roll polycom® or a vertical roller mill quadropol® in conjunction with a sepol® separator technology offers the lowest specific power consumption. These best available grinding technologies not only help the cement industry to save OPEX costs, but also to reduce its emissions, especially the CO2 footprint and the exhaust gases originating from the hot gas generator of the cement grinding plant.

2) What factors need to be considered when grinding Supplementary Cementitious Materials (SCMs)?

Gebr. Pfeiffer In general, the regional availability of supplementary cementitious materials plays a role, but also the reactivity of these alternative materials.

Depending on the reactivity of the SCM, the product fineness might be increased to a higher level.

The cement producer also has to weigh up whether the product is better ground together or separately. Some SCMs benefit from separate grinding, others from co- or inter-grinding. If the SCM needs to be ground to a fineness higher than clinker, separate grinding is more appropriate.

Using SCMs can also drastically raise the material feed moisture. If drying is required, a heat source must be available. And their granulometry also has an influence on comminution. In addition, the wear protection of the mills must also be designed according to the materials used to keep the abrasiveness under control.

The flexible MVR mills are successfully in use worldwide for all the variants described, operators can thus also react quickly if material sources change. Contrary to a ball mill system, the MVR mill is flexible for all grain size variations and moisture contents in feed material as well as coarser or very fine product finenesses. Our vertical mills run successfully with inter-grinding or separate grinding, they process raw materials with more than 20% feed moisture and CEM I to a fineness of at least 5500 cm²/g (acc. to Blaine). thyssenkrupp Industrial Solutions Worldwide, the use of SCMs, such as fly ash, ground granulated blast-furnace slag, pozzolana, silica fume or calcium carbonate fines, as additives to all kind of cements is growing due to its contribution to a more environmentally-friendly and sustainable manufacturing process. In addition, the SCMs, which are added to the clinker, have an World Cement February 2022

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influence on the final cement quality characterised by product fineness, early and final compressive strength, concrete setting time, water demand or workability.

The process design of the cement grinding plant needs to be adapted to the given raw material properties of the different SCMs: For instance, dry fly ash – where a certain part is already smaller than the target fineness – will be fed directly to the separator to avoid unstable mill operation. On the other hand, wet fly ash leads to a significant increase of the hot gas requirement for drying.

Due to the higher abrasiveness and jet wear of pozzolana, the protection concept of the mills has to be more wear resistant. And in the case of granulated blast furnace slag addition, the enrichment of metal particles in the grinding circuit has to be avoided.

In addition to considering the raw material properties of SCMs for a reliable and efficient cement grinding plant design, the additional installation of the polysius booster mill as a very fine grinder can help to lower the clinker content significantly while keeping previous – especially early – strength values of concrete. These results were achieved at a first industrial reference plant and from many trials in our small-scale pilot plant.

At other trials, ultra-fine cements were produced achieving comparable cement qualities at lower fineness values.

3) How has the ongoing trend of digitalisation impacted grinding and milling systems?

FIVES FCB As a grinding equipment and plants supplier, the main digital technologies we have developed are automation solutions allowing grinding plants to be operated in a fully automatic mode. This is highly recommended with regard to bed compression technologies as they are generally more dynamic and reactive systems, which require more close and accurate control than a conventional ball mill. Fully automated systems allow for the management of raw material quality variations and a large range of finish products, in a very smooth and safe way. In addition, automation relieves operators of the increasingly high responsibility of daily operations and allows them to focus on more valuable tasks.

Another field of development in the remote services, aimed at supporting customers in their daily operations, is predictive maintenance and troubleshooting. This kind of development has shown its relevance during the pandemic.

Gebr. Pfeiffer Artificial intelligence will revolutionise the efficiency of cement plants.

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Digitalisation impacts mill usability as well as process efficiency and therefore sustainability. One thing that drives us is developing a machine that essentially runs and optimises itself. This includes artificial intelligence that enables the machine to learn by itself to maintain its performance, which optimises plant operation and saves resources.

We have been following the Industry 4.0 trend since it became a feature of our sector. We offer several digital products, one of them is GPlink which saves sensor data for data analysis and enables 24/7 access to data from mobile devices around the world. When transmitted to the company’s service team, a solid basis for support and rapid, targeted assistance is given. GPlink forms the basis for all other digital products.

The modular GPpro is the logical continuation of digitalisation. GPpro enables, for example, an advanced maintenance system, with maintenance according to actual need and not according to fixed intervals. The system also includes additional sensors and offers modules for data analysis, reports, optimisation with the help of artificial intelligence (AI), and many other resource-saving improvements such as dynamic water injection.

The topic of AI is particularly exciting because the benefits are clear. A skilled human operator can certainly set several operating parameters and overlook the interaction of these. With the help of artificial intelligence, any number of parameters can be examined and the ideal setting values for individual application can be determined. We see enormous potential here and the first results with an industrial mill have been very promising.

Digitisation is progressing and we are following this path. There is a lot of movement in this area and Gebr. Pfeiffer attaches great importance to this topic. thyssenkrupp Industrial Solutions Generally, improved digitalisation concepts allow for both the protection of the mechanical components and sub-equipment of the mills and the optimisation of the complete process of the grinding plant, with respect to availability, efficiency and reduction of maintenance time. So far, the ongoing trend of digitalisation has had less of an impact on the comminution process itself, and the mechanical configuration of the grinding system remained mainly the same, but the location of the sensor technology and the processing of operating data are getting more and more important.

Advanced Mill Control assists the mill operator by achieving, for instance, higher average throughputs over a longer period of time. The active system automatically increases values until the defined or maximum rate is achieved. For this holistic approach, the reliability of these basic values is crucial. As current systems actively intervene in the grinding process, a lower vibration level is, for World Cement February 2022

example, achieved and the number of potential mill stoppages (downtimes) resulting from a shaky mode of operation, are reduced to a minimum.

Thus, the functional condition of the grinding system is maximised. The future of maintenance strategies will be based on such developments taking the impact of OPEX more into consideration.

The current development within the digitalisation of milling systems is still limited, but the objective for the future is a self-learning system, using AI (Artificial Intelligence) for process, cost, and product quality optimisation.

4) What role do modular grinding plants have to play? What advantages do they offer over conventional systems?

FIVES FCB Besides a quick installation set-up and corresponding savings at the erection stage, and provided that they can achieve the expected production performances, modular grinding systems allow quick access to some markets.

This implies that time has been taken in the design process to ensure the grinding system effectively meets these new market requirements, yet this is in general, contradictory with the standardisation

of the modular concept. In this regard, the FCB FLAG™ Station has been designed for flexibility in terms of raw material types (particle size, moisture content, etc.) and finish products’ variety (recipe, fineness, etc.) Therefore, this not only allows quick market access but also still allows adapting to market changes in the long term.

Gebr. Pfeiffer Their distinct modularity means they have fewer options than a conventional grinding plant, but these systems offer the same efficiency, sustainability and reliability, plus additional benefits.

Systems like our ready2grind therefore offer new possibilities in some areas.

We developed this product range very early on in response to market demand. After the financial crisis of the late 2000s, there was a realisation that there was severe clinker overcapacity across our industry. At the same time, there were still several markets with relatively poor infrastructure that were natural homes for small grinding plants. Now these too have moved to larger capacities to save on capital expenditure as much as possible, albeit in a lower ‘capacity window’.

Our ready2grind grinding plants, which are available in various sizes, are designed for remote areas or when cement production needs to be

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very close to the cement consumer, even if the infrastructure is challenging. There needs to be a high degree of prefabrication built in at the design stage so that they can be installed relatively quickly.

Using the ready2grind range, we have attracted clients that are not traditional cement producers but rather traders and construction firms. For them, the speed with which the project can be completed is often very important. This is another driver towards a modular, pre-fabricated approach. A further advantage of these systems is that the containerised plant components can be transported and installed more easily. Our almost 20 references demonstrate that we have also implemented our customers’ requirements well in the field of modular systems. thyssenkrupp Industrial Solutions Modular grinding plants (MGP) are following the market demand to offer cement customers as well as new entrants a pre-engineered solution off-the-shelf, which results in a significantly lower EPC price and delivery time. Commonly, MGPs with a capacity of up to 500 000 tpy are deployed at greenfield or brownfield projects, where cement markets are calling for fast installations, (semi-) mobile solutions or for closing white spots.

Compared to conventional tailor-made grinding systems there are several advantages: MGPs are based on a strip-down concept, which focuses on the core needs of the operation with optimised costs and reduced engineering.

They are fully standardised and incorporate pre-engineered equipment, plant layout as well as procurement packages, and the erection sequences maximise the use of pre-assembled content. Because of all these criteria the modular plants offer a very competitive solution in respect of a low EPC price, short delivery time, easy installation and low maintenance. As a consequence, MGPs are allowing customers and even newcomers a fast entry into cement markets. In addition to the low CAPEX with shorter payback periods, the modular concept bears low technical and financial risks for customers. Last but not least, modularisation also facilitates the dismantling and re-erection of the grinding plant elsewhere if commercial or market conditions change.

A very important advantage for customers is that the polysius modular grinding plant is uncompromised in the quality and reliability of all equipment and that it is focused to provide maximum performance from the plant, producing a superior cement quality. This is ensured by providing equipment like the mill, gearbox, separator, process bag filter, weighing and dosing, packing system as well as all electrical components from European brand manufacturers.

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5) What approaches can be taken to reduce maintenance costs and maximise the reliability of VRMS and other milling systems?

Gebr. Pfeiffer A first sensible step is to establish service contracts and audits with the mill supplier, because no one knows their machines better than they do. In this way, the systems can be inspected by experienced engineers at regular intervals and individual recommendations can be made in a report.

Further reduction of maintenance costs can be achieved by using artificial intelligence as a component of GPpro. This involves general process stabilisation, even with less experienced personnel in the control room, which leads to an increase in running times. Furthermore, initiatives such as increasing the throughput rate, reducing energy consumption or even reducing mechanical load cycles can be prioritised, among others. But GPpro offers much more because maintenance is based on individual predictions. In addition to extended running times, the required spare parts can also be requested in a more targeted manner.

Upgrading older equipment can also increase throughput rates and reduce dust emissions and energy consumption. Extensive multi-phase 3D CFD simulations additionally reduce energy consumption, pressure losses, and jet wear, and increase mill efficiency even more.

All this and the big data from the field are important foundations for our continuous improvement process, which is reflected in ongoing design optimisations. This deep learning extends maintenance intervals.

Proper maintenance work by the operator themselves also extends the maintenance intervals and thus the technical availability. For this purpose, we offer on-site support as well as tutorials, digital maintenance information on the spotand, of course, remote control and individual personal training. thyssenkrupp Industrial Solutions The process, product and plant design of polysius grinding plants is a holistic approach, which, right from the beginning, focuses on customer views with regard to CAPEX & OPEX efforts including smart plant layout, maintenance and OSH aspects, after sales-services and digitalised solutions. Thus, VRM quadropol or HGPR polycom as well as any other polysius milling system is designed as a high-efficient and low-maintenance grinding plant for trouble free operation with enhanced reliability.

The high content of preassembled components, a reduction in mechanical parts and sensor technology inside the mill, exceptional damping World Cement February 2022

characteristics resulting in lowest possible mill vibration levels and operational continuity are the most important aspects of reducing maintenance costs and ensuring the highest possible reliability of any milling system. Most important is the reduction in mechanical and hydraulic components, which decreases the probability of failures. All these different aspects are covered by the philosophy of the quadropol concept and it is also valid for the polycom design.

During their daily work, plant operators are strongly influencing the maintenance costs and reliability of the milling system, too. They can opt to follow a strategy that focuses on cement sales with a resulting plant availability, or to strive for a performance-based strategy, which primarily focuses on high plant availability in connection with the designed plant capacity values. In any case, increased numbers of training courses for plant staff is a beneficial step that pays off quickly. The polysius service team can train and support customer operating and maintenance personnel to continuously improve the required downtime for maintenance works and the replacement of spare parts. This includes a predictive planning for assembly and logistics, too. Other measures include the installation of a more stable IT-infrastructure and the use of a higher degree of polysius digitalisation products and services for remote support of plant operators.

6) What advances do you see on the horizon for grinding & milling technology?

FIVES FCB For some years, cement producers have been facing climate change challenges increasing the complexity of their installations so that they can be set-up and operated in a sustainable manner. Suppliers are adapting and complying with these challenging requirements, developing flexible solutions with high levels of energy efficiency, emission control and product quality.

In addition to the limitation of the environmental impact in terms of emissions, this evolution should positively help reduce the use of natural resources by their substitution with by-products or recycled materials.

Gebr. Pfeiffer There are three areas: sustainability, efficiency and digitalisation. These are inextricably linked.

Sustainability has rightly come to the fore as our customers need to improve their environmental performance and energy consumption, finding a balance between ecological, social and economic needs. Efficiency is important both for sustainability and for the reduction of overall February 2022 World Cement

operating and production costs. Digitalisation is advancing and will have a major impact on the efficient operation of cement plants and grinding systems. The algorithms used in our digital products are developed and programmed by our own staff, so new knowledge from the field flows directly into the software. This is how our customers benefit from the best possible digital solution.

Cements will also be ground even finer in some cases in the coming years and the trend toward using clinker substitutes will also continue. Our mission is to continue to efficiently and reliably process all materials used in the cement industry, especially looking ahead to all materials used in the future. Only in this way can we continue to provide our customers with a competitive advantage. thyssenkrupp Industrial Solutions The raw material and clinker grinding technology will still play an important role for the cement industry in the future. The mechanical crushing and grinding of raw materials, clinker and cementitious materials used for the concrete industry are and will be, a major process step in any cement works worldwide. The mechanical comminution process cannot be substituted by other technologies.

However, with the EU Emission Trading System’s allowed CO2 emissions being reduced, the CO2 credits have to rise further and with increased speed (mid December 2021 the CO2 price was around €82/t).

As sustainability became strategic in the cement industry and most global cement players pledged to reduce CO2 emissions to ~500 kg CO2/t (of cement) by 2030 and set their goal to offer a carbon-neutral concrete by 2050 at the latest, there will be huge impact especially on the design and performance of cement grinding plants.

The trend towards grinding systems, like the VRM quadropol or the HPGR polycom, offering the lowest possible specific power consumption per ton clinker or cement [kWh/t] will continue to grow. In order to ensure the utmost grinding efficiency combined with the highest possible reliability, the digitalisation of grinding and milling systems will soon become essential. Also, the trend for using and grinding more SCMs and to replace the clinker portion in the cement products to a maximum content will further accelerate in order to meet the green goals in the cement industry. Here, the polysius booster mill for very fine grinding of cementitious materials is already an available solution for achieving the necessary cement quality and partially also for compensating for loss of capacity due to higher product fineness.

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AD INDE X 4B Components www.go4b.com/usa ABC www.abc.org.uk Arodo www.arodo.com Axians IAS www.axians-ias.com BEUMER Group www.beumergroup.com CICSA www.cicsa.com Claudius Peters www.claudiuspeters.com Concetti S.p.A. www.concetti.com DALOG www.dalog.net EUREKA Machines www.eureka-machines.com HEKO www.heko.com IEEE-IAS/PCA Cement Conference www.cementconference.org

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Unitherm Cemcon www.unitherm.at

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Vortex Global www.vortexglobal.com

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