Displaying items by tag: Mill

Pakistan: Gharibwal Cement has started commercial operation of a 250t/hr vertical cement mill for grinding cement. It says it is the single largest cement grinding mill in the country. The cement producer operates a 2.1Mt/yr integrated plant at Ismailwal in Chakwal.

There is lots to mull over for the cement industry from last week’s Global Slag Conference that took place in Prague.

One striking map from Michael Connolly, TMS International, showed the status of slag and steel products in the US. It was a multi-coloured patchwork of different regulatory statuses from approval to be used as a product to regulatory exclusion. This won’t come as a surprise to many readers but even within one country the way slag can be used legally varies.

As this column reported last year after the Euroslag Conference, the European Union can be presented in a similar way. The irony here is that increased use of slag and other secondary cementitious materials (SCM) is exactly the kind of change the cement and concrete industries need to make to decrease their carbon emissions. Constant quibbles over whether slag is a product or a waste undermine this. Happily then that Connolly was able to report progress in the US as lobbying by industry and the US National Slag Association have led to more states legally accepting slag as a product.

However, cement producers have other concerns in addition to environmental ones when it comes to slag usage as Doug Haynes from Smithers Apex explained. Haynes, a former UK steel industry worker turned consultant, spoke around a market report on the future of ferrous slag. His take on Basic Oxygen Furnace (BOF) slag was that despite fuel savings, decreased CO₂ emissions and the benefits of embodied iron when it is used as a raw material for clinker production, it is in the interests of cement producers for slag to be a waste because they then get it for free or at a reduced rate. It’s a similar story to the use of waste-derived fuels powering cement plant kilns where producers want lower fuel costs but waste collectors want value for their product. Unsurprisingly, Haynes wanted cement producers to accept the value embodied in BOF slag.

Charles Zeynel of ZAG International, an SCM trader, then laid out the situation where global SCM supplies are remaining static but cement demand is growing. Coal-fired power station closures are reducing supplies of fly ash, another SCM, placing pressure on existing granulated blast furnace slag (GBS) slag supplies. The message was very much in a slag trader’s favour but instructive nethertheless. If slag is in demand then the price will rise. Anecdotally, the increased number of cement producers at the conference seemed to indicate increased interest of the cement industry in the product.

Lots more speakers followed on topics such as slag beneficiation, grinding advances and new innovations. On grinding, one surprise that popped up was that Spain’s Cemengal has sold a Plug & Grind Vertical mill to CRH Tarmac’s cement plant at Dunbar in Scotland. It is the first such sale of this product in Europe. The last speaker, Jürgen Haunstetter of the German Aerospace Centre, stuck out particularly with his presentation on using slag as a thermal energy storage medium in a concentrated solar power (CSP) plant. This may not seem connected to the cement industry but it is along similar lines to Italcementi’s project at the Aït Baha cement plant in Morocco, which uses a CSP process that can be used with the plant’s waste heat recovery unit.

The Global Slag Conference will return in April 2019 in Aachen, Germany.

Read the full review of the 13th Global Slag Conference 2018

Pakistan: Kohat Cement has started commercial operation of a 105t/hr cement mill at its plant. The cement producer operates a single integrated plant at Kohat-Rawalpindi. It is also upgrading the site with a new 7800t/day production line.

UK: Spain’s Cemengal is supplying a 0.5Mt/yr Plug & Grind Vertical mill to Tarmac’s Dunbar cement plant. Work started in April 2018 and the project is expected to be completed by July 2019. The unit follows the Plug & Grind product line’s modular format and it includes a FLSmidth OK Mill 37.3. The mill will be used to grind clinker at the cement plant although the subsidiary of CRH may also use the mill to grind slag. The order is Cemengal’s first Plug & Grind Vertical in Europe.

Nigeria: Germany’s Gebr. Pfeiffer has struck a deal to sell a MVR 6000 R-4 mill for raw material grinding and a MPS 3350 BK mill for processing coal for kiln firing for Dangote Cement’s new plant at Okpella in Edo State. The mill order is the first for Gebr. Pfeiffer from the Nigerian cement producer. The order was placed by the China’s Sinoma International Engineering.

The MVR mill featuring a total drive power of 4000kW will be grinding 550t/hr of cement raw material to a fineness of 10% R 90µm. The MPS 3350 BK with a drive power of 1100kW is designed for a throughput rate of 50 - 70t/hr and will grind Nigerian coal, imported coal and/or pet coke, to a fineness of 12% R 90µm. Gebr. Pfeiffer’s own staff will supervise erection and commissioning.

Nigeria: Dangote Cement will use two vertical roller mills (VRM) from Germany’s Loesche for a new production line at its Obajana plant in Kogi State. The order comprises a six-roller mill for raw cement meal with a capacity of 580t/hr, the largest roller mill for raw material in the Loesche range, and a three-roller mill with a modular design featuring a drive power range of 1000kW for grinding hard coal and lignite with a throughput of up to 70t/hr.

The scope of delivery also includes a LDC classifier for the raw cement mill and a LSKS ZD classifier for the coal mill, which is characterised by individually adjustable grain size separation. The raw material mill is equipped with metal-matrix-compound (MMX) technology. The two mill gear units are equipped with state monitoring and remote access for remote monitoring. Loesche is also contributing to the design and planning of the entire plant as well as the engineering for the electrical measurement, control and regulation technology and complete automation. The delivery date is scheduled for the third quarter of 2018.

The contract partner for this project is China’s Sinoma International Engineering, which has previously installed a seven clinker and cement raw meal VRMs for the Obajana plant. The site has a cement production capacity of over 12Mt/yr and it is the largest cement plant in Sub-Saharan Africa.

India: Wonder Cement has ordered two vertical mills from Germany’s Gebr. Pfeiffer for its Nardana plant in Rajasthan. The order includes a MVR 6000 C-6 mill for grinding slag cement and a MPS 3070 BK mill for grinding fuel. Delivery is scheduled for early 2019 and mid-2019 respectively.

The MVR mill will feature a total drive power of 5820kW. Mixed cements will be be ground to a fineness of up to 5% R 45µm. The grinding plant will be designed to process granulated blast-furnace slag with a target fineness of approximately 4500 cm²/g Blaine and blast-furnace cements with different proportions of granulated blast-furnace slag, fly ash and gypsum and different product fineness degree. Wonder Cement has requested the option to grind relatively hot clinker in the mill while at the same time being able to reduce the cement temperature, and alternatively to use cold clinker from stockpiles.

The core components such as the tension system and the grinding rollers will come from Gebr. Pfeiffer in Germany. The grinding bowl and the gearboxes for the mill and classifier will also be delivered from Europe. Gebr. Pfeiffer’s subsidiary, Gebr. Pfeiffer India, will provide the housing parts, the foundation parts and supports of the rollers as well as almost the entire high-efficiency classifier type SLS 5600 BC. Gebr. Pfeiffer India scope of supply will incorporate most of the equipment to complete the grinding plant including the plant fan.

The MPS mill will grind petcoke with a capacity of 40t/hr to a product fineness of 2% R 90µm. It will come with a SLS BK classifier, allowing both coal and petcoke to be ground in the mill, dried with process gases and then classified in the integrated classifier. Due to the high abrasiveness of Indian coal, the mill will be designed with appropriate wear protection.

Most components of the coal mill will be supplied by Gebr. Pfeiffer India. The housing and foundation parts, the grinding bowl and a large part of the power-transmitting parts will be manufactured in India. Setting up the new MPS mill is planned to coincide with the commissioning of the entire kin line.

Poland: LafargeHolcim has celebrated investing over Euro95m at its Kujawy cement plant since 2008. As part of the Pomeranian Special Economic Zone, the plant has had a number of upgrades over the last decade and has created over 60 jobs.

Projects at the site have included spending Euro24m on environmental improvements such as installing new filters, building a new clinker silo and four cement silos, and converting the plant to process alternative fuels. Euro56m has been invested on production upgrades including a new cement grinding mill, a new calciner and new constant monitoring systems. Euro18m has been spent on two bulk loading terminals, a new weighbridge and self-loading systems and a new laboratory.

Indonesia: Semen Grobogan has ordered two MVR 5000 C-4 mills for cement grinding and one MVR 5000 R-4 for raw material grinding from Germany’s Gebr. Pfeiffer. The package also includes an MPS 3350 BK mill for grinding lignite. The mills will be set up at Grobogan cement plant near Semarang in Central Java.

The cement mills, each featuring a drive power of 4000kW, will be capable of grinding 190t/hr of Ordinary Portland Cement at 3600 Blaine or PPC at 4000 Blaine. In addition, the mills will be suitable for grinding blast-furnace cements. The MVR 5000 R-4 with a drive power of 4300kW is guaranteed to achieve a capacity of 500t/hr of raw meal ground to a fineness of 12% R 90µm. The lignite to be processed has a high feed moisture (37%), which is typical for Indonesia. The inherent moisture content in the lignite is 14%. The MPS 3350 BK with a drive power of 800kW will dry the material to a surface moisture content of 1% while at the same time grinding it at 50t/hr to a fineness of 15-25 % R 90µm. The order also includes a spare parts package for two-year operation.

The order was placed by the Chinese general contractor Nanjing Kisen. Commissioning of the mills is scheduled for the first half of 2019.

Honduras: Cementos del Norte has spent US$29m on upgrades for its Rio Bijao cement plant in Choloma. The project includes increasing the unit’s capacity for production, storage capacity and alternative fuels, according to the La Prensa newspaper. The cement producer is installing a new cement grinding mill at the site. This will enable it to raise its cement prouction capacity to 2.5Mt/yr from 1.5Mt/yr.