Displaying items by tag: Maintenance
Vostokcement employees attend FLSmidth workshop
16 April 2020Russia: Denmark-based FLSmidth has held an equipment installation and maintenance workshop for Vostokcement employees at Vostokcement subsidiary Spasskcement’s 3.2Mt/yr integrated plant in Primorsky Krai. Employees of Spasskcement, Teploozerskcement and Yakutcement were in attendance, along with employees of Vostokcement partner company Betonych JSC. The workshop focussed on the use of FLSmidth equipment in material handling equipment monitoring and breakdown response, including kiln shell repair optimisation, vibration diagnostics and flaw detection and pneumatic conveying applications.
Teploozersky cement completes kiln maintenance
03 April 2020Russia: VostokCement subsidiary Teploozersky Cement has reported the successful completion of scheduled maintenance work on the rotary kiln at its 0.8Mt/yr integrated Teploozersky cement plant in Birobidzhan Oblast. Esmerk Russian News has reported that the work consisted of adjusting furnace units’ positions replacing worn sections of the lining.
Dalmia closes 26.5Mt/yr of production capacity overnight
27 March 2020India: Dalmia Bharat has suspended operations across its entire integrated cement production apparatus, equalling 26.5Mt/yr capacity, as of 26 March 2020. The move is a response to a government ordnance of 25 March 2020 imposing a 21-day lockdown on the whole of India due to the coronavirus. The company will implement the closure ‘until further notice,’ according to Mint News.
Dalmia Bharat CEO and managing director Mahendra Singhi said, “While cement production is continuous in nature and the plants have requisite permission from both the state and the central governments to operate with minimum employees during the lockdown, Dalmia Bharat will only carry out mandatory activities required for safety and security of the plants in the larger interest of its staff.”
Coronavirus had claimed 13 lives in India on 27 March 2020.
Anhui Conch uses coronavirus closure for maintenance
11 February 2020China: Anhui Conch’s subsidiary China Cement Plant Company (CCPC) has made the best of the downtime necessitated by the coronavirus outbreak by carrying out necessary maintenance work on its integrated plant’s third line, including the installation of a new vertical roller mill. Anhui Conch says CCPC is undertaking the work with the greatest degree of care for the ‘prevention and control of new coronavirus cases.’
Malaysia: Cahya Mata Sarawak (CMS) has responded positively to the government’s announcement that it will be subdividing its annual contracts for road maintenance between new concessionaries besides CMS’s 51% subsidiary PPES Works in 2020. “Competition in any market naturally breads competitive efficiency. This can only be good for the public and road users,” said CMS Group Managing Director Isaac Lugun. “We maintain the lion’s share,” he added.
Siguaney cement plant re-enters production
26 November 2019Cuba: Following 18 months of reduced operations in which time maintenance and repairs on its grey cement kilns were carried out, Corporacion Cementos Cubanos’ 0.7Mt/yr Siguaney plant is once more fully operational across its four wet lines. Esmerk has reported that the company hopes to re-open its white cement kiln at the nearest possible date.
Infrastructure for a developed world
14 August 2019One of the summer news stories in the UK has been the drama surrounding the near-failure of dam near Whaley Bridge in Derbyshire. Concrete slabs on an overflow spillway fell away after a period of heavy rain leading to fears that the dam could fail inundating the area. Around 1500 local residents were evacuated for about a week as a precaution until the reservoir’s water level could be pumped down low enough for inspection.
No one was hurt in the incident but it has raised questions about the maintenance and renewal of infrastructure and how this fits with changing weather patterns caused by anthropogenic climate change. A sadder example of this is the collapse of the Morandi Bridge in Genoa, Italy in August 2018 that killed 43 people. This was later blamed on decaying steel rods in the structure. There have been similar debates in the US with President Donald Trump’s on-going attempts to push through a US$2tn infrastructure bill to repair the country’s structures. Although, predictably, it is floundering on the question of who is actually going to pay for it all.
In the UK, for example, cement production hit a high of over 15Mt in the late 1980s before declining to a low of 7.6Mt in 2009 and eventually climbing to above 9Mt/yr since 2015. A big cause of that decline was the 2008 financial crash and the subsequent government austerity policies. Yet, even with this taken into account, production was at around 11Mt/yr in the 2000s. How much, if any, of this production capacity gap of at least 4Mt between the late 1980s and the 2000s might be needed to maintain the country’s infrastructure? Southern Mediterranean countries like Spain and Italy offer even starker examples. Italy’s cement production fell to 19.3Mt in 2017 from nearly 40Mt in 2001. Spain’s production hit a high of around 50Mt/yr in 2007 with apparent production (local consumption and exports) falling to around 20Mt in 2018. Much of these declines are due to loss of export markets but the same basic questions remain about how much capacity will be required in the future to maintain and repair existing structures in developed nations. This could be imported but the usual constraints about moving heavy building materials around inland mean than at least some of this cement will need to manufactured locally.
The International Energy Agency (IEA) estimated in 2010 that the world would need 50Bnt of cement between 2015 and 2030. The global cement industry was already producing around 3.5Bnt/yr in 2015 according to the Global Cement Directory 2015 giving it overcapacity even then towards the estimated target. Global production capacity is just under 4Bnt/yr today. Estimates for the cost of global infrastructure requirements in this period range from US$1Tnr/yr to US$6Tnr/yr. The majority of this will go towards new infrastructure in developing countries but a minority portion will be required for maintenance. One study by the Brookings Institution and the Global Commission on the Economy and Climate estimated that developed countries would need around US$2Tn/yr for their infrastructure bills.
A study by management consultants McKinsey & Company in late 2017 reckoned that there was a worldwide US$55Tn spending gap between then and 2035 for infrastructure spending. It estimated that countries like the UK, Germany and the US needed to increase their annual spending on infrastructure as a percentage of gross domestic product (GDP) by 0.5%. Although Italy only needed to improve by 0.2%. Looking at the change in infrastructure investment rates suggests that the European Union (EU) actually started to improve its investment from 2013 to 2015 by 0.2% but that the US did not.
All of this goes to show that the show is definitely not over for building materials producers in developed countries. These industries may be mature but they should not be complacent. Roads need patching up, bridges need replacing and all sorts of other infrastructure projects are required even in places that have them already.
The race to digitise the cement industry
10 July 2019The big announcement from LafargeHolcim this week was the launch of its Industry 4.0 plan known as ‘Plants of Tomorrow.’ The scheme hopes to use automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies across the company’s entire production process. Operational efficiency gains of 15 - 20% are promised.
There wasn’t much detail beyond the use of the Siggenthal integrated cement plant in Switzerland as the ‘lighthouse’ of the scheme, where around 30 proof-of-concept technology ideas will be tested. One technology it did flesh out a little was its long-running Technical Information System (TIS). This follows the work between Holcim and the power and automation product supplier ABB. LafargeHolcim says that over 80% of its plants around the world use the TIS to provide data transparency at plant, country, regional and global level. It added that some country operations have more than a decade of historic technical data available. This last point is pertinent as the data could potentially be used to support the training of any machine learning algorithms the company might want to invest in. The building materials company also mentioned its LH Maqer subsidiary. This startup incubator was launched at the end of 2018.
LafargeHolcim appears to be playing catch up here with Cemex, which has steadily been promoting its own Industry 4.0 developments in recent years. Emphasis on ‘promotion’ here as only yesterday, the day LafargeHolcim made its big reveal, Cemex happened to release information about a recent roundtable in France that it participated in on digitisation and productivity in the construction sector.
Notably in March 2019, the Mexican multinational struck a deal with Petuum to implement its Industrial AI Autopilot software products for autonomous cement plant operations at its plants around the world in March 2019. Readers can find out more about Petuum’s work with Cemex in the June 2019 issue of Global Cement Magazine. In late 2017 Cemex too set up a division, Cemex Ventures, to engage with startups, universities and other organisations. Cemex has also been building its digital customer integration platform Cemex Go since around the same time.
One interpretation of Industry 4.0 is as a German-industrial approach to the so-called fourth or digital revolution pushed by Anglophone software companies. The idea of taking as much data from a production process, such as making cement, is enticing but the prospect of actually doing something useful with this tsunami of information is daunting. Typically algorithm techniques or predictive maintenance seem so far to focus on discrete parts of a process such as a finish grinding mill or final product logistics networks. Companies like Germany’s Inform focus on the latter for example and, incidentally, it celebrated its 50th anniversary this week.
If automated systems start making apparently nonsensical yet useful decisions across the whole raw materials, production and supply chains, then Industry 4.0 will reach its full potential. This moment, if it comes, will be analogous to the time IBM’s computer Deep Blue managed to beat chess grandmaster Garry Kasparov in the late 1990s. What’s more likely are automated systems that can perform consistently outside the human operator comfort zone edging up against hard physical process constraints.
Meanwhile, what will be interesting to watch here is whether LafargeHolcim will be able to leverage any advantage over Cemex by having more cement plants to pull data from. Before LafargeHolcim started selling off its south-east Asian subsidiaries it had more than three times as many cement plants as Cemex. If data really is more valuable than oil these days then starting late in the industrial digital arms race may not be as deleterious as one might first think.
Switzerland: LafargeHolcim has launched a four-year industrial automation plan called ‘Plants of Tomorrow.’ It includes Industry 4.0 concepts such as automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies for its entire production process. The plan is expected to show 15 – 20% operational efficiency gains. It also claims that the initiative is, “one of the largest roll-outs of Industry 4.0 technologies in the building materials industry.”
“Transforming the way we produce cement is one of the focus areas of our digitalisation strategy and the ‘Plants of Tomorrow’ initiative will turn Industry 4.0 into reality at our plants. These innovative solutions make cement production safer, more efficient and environmentally fit,” said Solomon Baumgartner Aviles, Global Head Cement Manufacturing.
The building materials company is presently working on more than 30 pilot projects covering all regions where the company is active. The company’s integrated cement plant at Siggenthal in Switzerland will be a trial site where the integration of all relevant modules will be tested.
One examples of where LafargeHolcim has started the plan include a partnership with Swiss start-up Flyability to use drones to increase the frequency of inspections at plants while simultaneously reducing cost and increasing safety for employees by inspecting confined spaces. The concept is being rolled out to several markets, including Switzerland, France, Germany, the UK, the US, Canada, India and Russia. It is also using a subsidiary, Maqer, to identify technology startups with promising technology. It aims to harness the potential of this through new partnership models with both manufacturing and software companies.
LafargeHolcim has already launched technology to track performance centrally and allocated resources to support the plant network in real time. More than 80% of LafargeHolcim’s cement plants are already connected to its Technical Information System that provides data transparency at plant, country, regional and global level. Some country operations have more than a decade of historic technical data available. Other systems allow the remote control of certain parts of the operations through online condition monitoring systems. Since its implementation in 2006, this system has saved over Euro70m and an additional 3Mt of cement sold through fewer breakdowns.
Egypt: ASEC Engineering has renewed its technical management contract with Misr Beni Suef Cement until the end of 2023. ASEC originally worked on the first production line at the plant in 2001. It maintenance contract was renewed in 2007 with the addition of a new production line. The cement plant has a production capacity of 3.1Mt/yr.