Cemtech 2011 DubaiNotes on Presentations

Agarwal, Nomura

Presentation most useful for a general picture of the world cement markets today. Contains a prediction for -3% cement volumes in Egypt for 2011.Folliet, IFC

Included for only one reason, the page on the conditions for an IFC loan. Reference made to a specific biomass usage of the jatropha plant family. Have we considered this for cultivation at locations where we have suitable land available? What cement company has done this?Karkun, Holtec

A rather strange presentation trying to decide if a company should build a plant in North West India for export to the West India coastal region and East Africa or build 2 plants, one in India, one in East Africa. Conclusion is for 2 plants. Included only because it shows:- Theoretical future demand patterns in Africa - It highlights the vulnerability of the West India coastal region to imported clinker and cement. High ($110/t) prices and availability of fly ash and slag are the key elements.

Bodo, ASEC

Included for ASEC activities interest and given by ex-ITC manager. Interesting as is very honest on the problems during constructionSubramaniam, Kuwait Cement

Kuwait plant new line based on site with no raw materials except sand. Overall reads as a catalogue of disasters, with all of the reasons to build the extension being removed. The jetty for the additional raw materials import was not built, the local petcoke for the new line is not available and there is no availability of additional power until 2013! Technically interesting for use of large CKP vertical (Hindustani Glass supplier) pregrinder for cement milling giving 40% increase in output at 3200blaine and use of single string preheater for 5500+tpd (but 150m tower height)Bossi, Sinai White

2 large white kilns in Egypt, one with a grate cooler and quenching clinker in the kiln and one with specifically built quench system. Both kilns apparently with virtually same fuel consumption.

Bodo, ASEC

Included for ASEC activities interest and given by ex-ITC manager. Interesting as is very honest on the problems during construction.$253m for a 1.6Mtpa cement plant not including the 42.5MW power plant. The power plant supplied on an O&M contract by company called Global EnergyPottier, FCB

Some points of interest are:- Project times- High bypass required for Beni Suef- Bypass dust cooling and nodulisation at Beni SuefStrohmeyer, Loesche

Technical presentation which is not very clear on details. Concentrates on a project to build a 250tph cement mill in India. A very long delivery time on equipment (18 months) but Ok for construction.Guarantees of 250tph and 30.75kWh/t @ 4000blaine for a PPC with only 60% clinker, 5% gypsum and 35% dry fly ash which is received at 2500blaine. Actual was 253tph and 25.6kWh/t @ 3920blaine. No water used to stabilise mill operation

Hose, Aumund

Included for showing the equipment used on the Holcim plant of 12000tpd at St Genevieve in the USA. Using the Centrex feeder for fgd extractionBoarder, Cement Consultancy

Working as consultant to the Egyptian government on use of waste fuels in cement and has visited Quattamia.Interesting facts and figures on the availability of waste fuels in Egypt. However some of the financial figures are dubious as the gas price seems low and the oil price high. Claimed rice straw collection is (or was) now organised in Egypt.2 wastes are already used in Egypt, pharmaceutical wastes by Lafarge and some others use oil wastes. Cemex using biomass at Assuit.

Seemann, KHD

Presentation concentrated on the various arrangements of the fully integral roller press system for raw materials and cement. The KHD Comflex system comprises roller press, V separator and 3 gen Sepmaster dynamic separator. A single press arrangement seems to be limited to approx. 180tph depending on blaine required.The presentation itself was poor on technical performance, but in separate discussion the following was given:The grinding effectiveness of the roller press is similar or slightly more effective than the vertical millThe advantage for the Comflex lies in the much lower pressure drop in the air system, reducing the kWh/t for the main fan to less than half of that for the vsm. An overall 18kWh/t for OPC of 2900blaine was stated, but for a clinker grindability which was poorly defined. The 2 doubts which still remain are the life of the rollers and the quality of the product cement. Roller life appears to have been an area of considerable advance over the recent years and 18000hrs was offered. Quality of the cement was not discussed in sufficient detail.Overall, a system which merits further consideration where minimum power consumption is a major consideration.

Marx, ABB

3 main themes included. First was expert systems for mills, kilns etc. which remain the fuzzy logic systems of 20 years ago. The second was the Organic Rankine waste heat to power recovery system. This has previously been offered to the steel industry but now is offered for the cement industry. One of the first is being installed at Untervaz and is available for inspection.Lastly was the Spectraflow infra red cross belt analyser. More expensive than the neutron activation systems but a much lower cost to maintain, with only commonly available bulb changes and no permitting issues. Tuncay, HC Trading

Included only for general interest in Heidelbergs trading activitiesOehme, Claudius Peters

Packing plants and ultrasonic valve sealing

McDougall, Castolin Eutectic

Possibly the most interesting practical technical presentation of all. The nano based welding material DO*390N appears to offer a significant step forward in terms of wear protection. A life of up to 7 times those obtained by the next best Eutectic material has been achieved. It can be applied to any metallic base with the correct heat treatment and can be sprayed or welded on cooler plates, screws, scrapers, crushers etc.Do we have any experience with this material? Please let us know.Rajendran, Chemtrols

A gas conditioning system in the top stage of a preheater. Of the same design as we have in Sitapuram. An alternative to the conditioning tower which appears to work satisfactorily.