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World BusinessCouncil orSustainableDevelopment

CementIndustrySuppliersForum

Dear readers,

In the global cement news in this October 2013 issue oGlobal Cement Magazine, the

spectre o cartels in the cement industry has reared its ugly head once again. In India

there are reports that cement prices have risen dramatically o late, increasing by 30% in

just a week in some areas at the end o September 2013. A major real-estate association

has claimed in no uncertain terms that this is the result o a cartel. Meanwhile, ve

producers are under investigation in Colombia aer the Superintendency o Industryand Commerce claimed that it had identied an alleged agreement to x prices and

divide up the market since 2010. Also, in anzania, the East Arica Cement Producers

Association (EACPA) has denied the existence o a cartel in that market in response to

similar accusations, claiming that there is erce competition in the sector.

Claims o cartels are relatively easy to grasp in subdued markets with oversupply like

India. However, the claims being tackled by the EACPA in anzania are dierent, taking

place in a country and region where cement demand is on the rise and one where

imports are a major actor in supply. Cement production in anzania almost doubled

rom 1.25Mt in 2004 to 2.4Mt in 2011. More projects are proposed, which will see the

countrys capacity increase. Further cement is sourced rom overseas rom cement

export hot-spots like the Middle East, China and Pakistan. Around 4.1Mt/yr came into

East Arica in 2012. rying to establish a ormal cartel in this sort o environment wouldrequire an impossible amount o work, requiring eort rom a very large number o

players rom several dierent countries. However, i external producers are exporting to

an East Arican market that has inherently high prices, the importers would only need

to undercut these producers by a small margin. Once again, this raises the possiblilty o

multi-player non-deliberate cement price infation. As always, inexplicably high prices

that look like a cartel are not necessarily indicative o deliberate price manipulation.

Actual collusion is notoriously hard to prove. Whatever the causes o the current claims

in India, Colombia and anzania, however, it is ultimately private and public contractors

and their customers, the public, that end up paying higher cement prices.

Elsewhere in this October 2013 issue, there are articles covering the global lime

industry, alternative uels, solar energy, expansion joints, pneumatic conveying and

bulk handling. Tere is also an in-depth review o the recent VDZ

Congress in Dsseldor, Germany and a look at the orthcoming

CMA Congress in Antalya, urkey.

We hope that you enjoy this issue oGlobal Cement Magazine!Dr Peter Edwards

Deputy Editor Global Cement Magazine

is printed on Forest Stewardship Council (FSC) certied

papers by Wyndeham Grange, a company with ISO

14001:2004 environmental certication.

CONFERENCE & EXHIBITION

This issues front cover...

Standard Industrie International: A French company

present all across the world, has been specialized or 35

years in bulk handling. Declogging, industrial vacuuming,

conveyor belt optimiation and on site interventions; the

motto o Standard Industrie International is to support the

bulk industry. This picture highlights its fagship product:

the AIRCHOC. This air cannon which contributed to the

success o Standard Industrie International, is presentedhere in its Wireless version. Remote control, no cable: so

many benets that enable eective and sae solving o

clogging problems.

See: www.standard-industrie.com

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Dirk Lechtenberg, MVW Lechtenberg&Partner

Alternativefuels- Whatabout theenvironment?

-Part1

14 globalcementMAGAZINE October2013

ALTERNATIVEFUELS

Alternativeuels arenow a frmly-established reality in well-developed cement industriesaround theworld and increasingamounts o alternativeuels arealso beingused in developing

economies.Here,MVW Lechtenberg& Partners Dirk Lechtenberguncovers a wealth oinormation regardingtheuseoalternativeuels in the German cement industry,especially withreerenceto therelatively unexplored negativeaspects otheir use.Alternativeuels may mean

lower CO2 emissions,avoidanceolandfll and decreased costs but they may also entail highernumbers otruck movements,higher dust emissions and higher specifc energy consumption pertonneocement. Part 2oDirk Lechtenbergs research will ollow in theNovember 2013issueo

GlobalCementMagazine.

When a cement plant announcestothepublicth at secondary uelsromwasteorbiomass willbeused, itsat this

stage(at thevery latest) that theques-

ti on i s pos ed a s to whether s uch

a l tern a ti ve uel s ha v ea n eg a-

ti v eor ha r mul i n uen ceon

the environment and the

immediateenvironsothe ce-

ment plant. Tepossibility that all

burningcan havea negativeeect on

theenvironment should beobviousto

everybody. In many casesthistopic

isdiscussed in an animated man-

nerasit has a very emotional

eect. It is, in many cases,

understandably aicted

with residents existential

concerns.

When a cement plant announcesa

new uel, theneighbouringvegetable

grower, orexample, isworried he

willno longerbeableto sellhis

vegetables. Residentsmay b e

concerned that alternativeuels

willlead to dust orodour pol-

lution. A classicexampleis the

burningotyres. Who hasnt seen the

picturesorisingblack cloudsosmoke ia

tyre storagedepot catchesre?

Ocourse each cement plant operatorswilltry to

considerthetopic oemissionsscientically. Ofen they

willtry, usingdata and gures, to proveto neighbours

and in theworst case, opponentsosuch coincineration,

that no such eectson mankind and theenvironment

need to beeared.

No eectsat all? Well, claimingthat therewillb eno

illeectswillsurely beincorrect. Also thecement plant

operatorofen hasno suitable and independent data

and actsat hisdisposal. Teuseoalternativeuelswill

alwayshavean inuenceon theoperationalbehaviour

oa cement plant and, asa result, on theimmediate en-

vironsothe plant. Tisbeginswith changed logistics

ortheuels to beutilised. Ipreviously a truckdelivered

20t ocoalto a cement plant with a caloricvalueo ~

500GJ, in uturemaybe30 truckswillberequired to de-

liverthesame caloricvalueo alternativeuels. Tese

aredirect consequencesand eectst hat willsurely be

elt by immediateneighboursoa cement plant.

For thema i n pa r t, the pos s ibl edi s pl ea s ur eothe

residentswillnot beocused on theimmediate eects

but on theindirect eects, such asaltered emissions

roma cement plant.

Forthe latter, every cement producerwillo course

immediately haveworldwide cement association sta-

tisticsor thoseo thec ement sustainability initiative

orsuch to hand (and presented usingnicephotos) in

orderto emphasisethe advantagesousingalternative

uelsto allpossible critics. Emissionsdata prognoses

arealso presented, especially regardingsaved ossil

CO2 emissions, in orderto illustratethe advantageso

theplantsintentions.

For ma n y deca des en v i ron menta l i sts ha v e been

strugglingworldwideto publiciseemissionsdata rom

industrialacilities, not only to pillory possibleenviron-

mentalcontaminatorsbut also to promoteawarenesso

responsiblebehaviouramongallindustrialacilities. Re-

member-20 or30 yearsago environmentalprotection

in industrialcomplexesin many countriesin Europe

orexample, wasstillbeinghandled asan aferthought.

Environmentalprotection wasa necessary evil.

Nowadaysthesituation ispresented somewhat di-

erently. Environmentalprotection and sustainability

are the slogansthat weencounter every day in indus-

trialcompany statements. Forsustainablecompanies

thereiseven an indexoitsown on theNew Yorkstock

exchange. Only sustainably-run companiesnowadays

havea chanceto attract new employees, to receivecom-

pany loansorto selltheirproducts. Everythingisgreen,

lightor sustainable.Teact that appearancesofen

deceiveis somethingthat wewitness moreand more

in theconsumerorood industry. Eggboxeswith pic-

tureso hensrunningaround in theopen. Who wants

to buy eggslaid by hensin cages? Lightbutter, which

ismerely rothed up with nitrogen and asa result no

longerweighs500gbut 340gand ishencelight.

CO2 emission penalty remains, deliveringmortarwith

CO2 ootprintso~190kg/t. Otherspecialist bindersare

available, (e.g. naturalhydrauliclime orNHL), which

aremanuactured romimpure limestoneto delivera

blend obelite, limestone, limeand alite. Tiscomposi-

tion isanalogousto 1:1:6 v/v cement mortarsasNHLs

contain thealite/belitecementitious species.4

Teircomposition precludesmanuacture in e-

cient gasred PFRkilnsrelyingon coalred verticalor

cement horizontalkilns. Limeco estimatesthat a stand-

ard 1:3 v/v NHL:sand mortarstillhasa CO 2 ootprint o

~150kg/t. NHLsareused solely asbindersor special-

ist restoration workand remain nichedueto slow and

unreliablesettingratescombined with poorworkability.

Howevertheirlowerlevelso alite/belitedelivermortars

with somevapourpermeability (porosity) and exibility

underload.

Tekey per orma n ceel ement oa l l commer ci a l

hydraulicbinders, cement orNHL, istheormation o

CSH. Techallenge, thereore, orLimeco wasto create

a sustainablebindertechnology, rich in CO2-absorbing

Ca(OH) 2 that delivered sucient CSHor structural

purposeswithout employingalite/belite.

o thisend, Limeco hasdeveloped a hydrauliclime

bindertechnology, which employshydrated limewith

a proprietary highly-activesilica additivethat ismade

romsand.5

Upon mixingLimeco binderwith aggregateand

water, it reactsquickly to ormCSH, leavingover80%

reeCa(OH)2 to adsorb atmosphericCO2. Tehigh lime

content afordsexcellent workability and therate oset

and 28 day strengthsarecomp arableto 1:1:6 mixesor

gypsumplasters.

Limeco hasworked with itssuppliersto accurately

determinetheCO 2 ootprint oitsproducts. Workin the

laboratory and eld showsthat Limeco bindersabsorb

ov er 75% oth eCO2 emitted duringtheirmanuacture

within 1 year(See Figure2), deliveringmortarswith

CO2 ootprintso~40kg/t omortar. Tiscomparesto

CO2 emissionso150-220kg/t orcementitiousbinders.

Tis isd emonstrated by pH indicatorstaining,

Ca(OH) 2 analysisand gravimetricassessment omortars

made with Limeco

products. Such

mortarsgain weight

ov er ti mea s CO2 is

absorbed. Sucient

reeCa(OH) 2 i s r e-

tained orautogenic

s el -h ea l in g ( See

Figure3). Recycling

th emor ta r s i s a l s o

simple.

By utilisinglimestoneand sand raw materialsand

processingthesewith themost ecient gasuelled plant

to delivera quicksettingand workableCO2-absorbing

limebinder technology, Limeco haslaunched a range

oruly Sustainable productswithin Europeunderits

trademark, HyperLime.

HyperLimehaslow bulkdensity and istypically used

as1:3 v/v HyperLime:aggregatemix(HyperLime~10%

w/w) so it iscompetitiveon cost. HyperLimebindersdo

not contain theknown carcinogens, crystallinesilica or

heavy metals. Current HyperLime2 and HyperLime3.5

productsareCE marked (EN459:2010) and HyperLime

5 willbelaunched shortly.

Limeco workswith internationallicenseesas su-

cient raw materialsare availableworldwideto make

over50Mt oHyperLime.

References

1.IPCC, IPCC FourthAssessmentReport2007(AR4),WorkingGroup

IIIReport Mitigation of Climate Change,Chapter7, 2007.

2.Knut O. Kjellsen et al., CO2 uptake during the concrete life cycle:Te

CO2 balance of concrete in alife cycle perspective,Norden NordicInnova-

tion Centre, December2005.

3.EntecUKLimited,EUEmissionsrading Scheme Phase II.Review of

new entrantsbenchmark Lime,Report orUKGovernment Depart-

ment orade and Industry,

Report Version 2, August 2006.

4. For example: http://www.

stastier.co.uk/nhl/ino/pds/

Hydraulicity_and_Properties_

o_NHL.pd, Setra Marketing

2006. Accessed 10 October2012.

Also see: www.c-e-s-a.r.

5.HyperLimewebsite,

www.hyperlimeco.com.

globalcementMAGAZINE October2013 29

LIME

Above-Figure2:Carbonation rateof

HyperLimemortars.

HyperLime2%(massgain)HyperLime2%(freelime)

HyperLime3.5%(massgain)HyperLime3.5%(freelime)

100

80

60

40

20

0

Carbonation(%)

0 50 100 150 200 250 300 350

Phenolphtalein stain

Ageof mortar(days)

Above-Figure3:HyperLimecarbonation.

Below:HyperLimeasmortarforbrick-laying.

Below left: HyperLimeasa render.

North African nations haveseen varying

amounts ofpolitical disruption in recent years,

with revolutions in Egypt,Libya and Tunisia anddisruption in Morocco and Algeria.Construction,and hence

cement production,has been a low priority as a result.In some

countries thecement industry is also battlinghigher fuel costs.

However,recent expansions may signal a brighter cement futureforAfricas north coast.

Peter Edwards, GlobalCementMagazine

NorthAfricancementfocus

GDP US$174.0bn

GDP/capita US$5400

Population 32.6m

Area 446,550km2

54 globalcementMAGAZINEOctober2013

Morocco -23.3Mt/yr

Next to th ev i ta l tr a der outes th a t pa s s th r oug htheStrait oGibraltar, Morocco hasdeveloped amixed economy based on exportsto itsEU neighbours

acrossthe Mediterranean. However, despiterelatively

dynamicmarkets and ranking13th out o54 Arican

nationsin termsoGDP/capita, Morocco isstillpoor

by internationalstandards, with high ood costsrepre-

sentinga particularburden.

Cement industry

Morocco has13 cement plantsand itstotal capac-

ity is22.8Mt/yr. Much oth e cemen t i n dus tr y i s

today owned by Laarge, Holcim, Italcementiand

Camargo Corra units. CimentosdeLAtlas(CIMA)

isthe only Moroccan-owned producer,

LaargeMaroc isMoroccos largest cement pro-

ducer, with our plants. Its largest plant, a 4.5Mt/yr

acility at Bouskoura, isalso Moroccoslargest. Other

plantsacquired by Laargeoverth eyears includethe

1.2Mt/yrMeknsplant (built in 1945), its2.5Mt/yr-

touan plant (2000) and its1Mt/yrangierplant (1954),

which giveit a totalMoroccan capacity o9.2Mt/yr.

Hol ci moper a tes th r ee

cement plantsin Morocco,

at Fes(1.9Mt/yr), Settat

(1.8Mt/yr) and Oujda (1.2Mt/yr), which giveit a total

capacity o4.9Mt/yr. TeSettat plant wasexpanded

rom0.9Mt/yr in 2012. Holcimalso operatesa grind-

ing, baggingand distribution centreat Nadorand a

baggingand distribution centrein Casablanca.

ItalcementiGroup operatesin Morocco through

Ci ments du Ma r oc. I t h a s th r eecemen t pl a n ts ,

which arelocated at Agadir At Baha (2.2Mt/yr),

Saf(1.0Mt/yr) and Marrakech (1.4Mt/yr), aswell as

a grindingcentrein Layoune(0.25Mt/yr), which is

expandableto 0.5Mt/yrin theuture. Integrated capac-

ity is4.6Mt/yr. Tebulk oItalcementisassets come

r omi ts 1999 pur ch a seo Mor occan g r oupAs ma r,

although it opened theAgadirAit Baha plant, built by

DenmarksFLSmidth, in 2010.

Te on l y Mor occa n pl a y er i n th e ma r ket i s

CimentsdeLAtlas(CIMA), launched by businessman

AnasSerioui in 2007. It commissioned Germanys

Polysiusto simultaneously construct two identicalce-

ment plantsin thenationally strategicregionso Ben

Ahmed and BeniMellal(both 1.6Mt/yr). CIMAaimsto becomea majorplayerin Morocco.

Tef n a l pl a y er i n th e ma r ket i s As men t de

mara (1.3Mt/yr), located in Ain Attigand owned

by Camargo Corra oBrazil. Te plant waspart o

a large-scaleasset swapbetween the plantsprevious

owner, PortugalsCimpor and Camargo Corra in

mid-2012.2

Current situation

Figure1 shows Moroccan cement production and

GDP/capita orthepast two decades. Aswith many

nationsthere isa strongcorrelatation between these

parameters, although Morocco hashistorically used

relatively littlecement compared to itsneighbours.

In 2011 thecountry hit consumption in excesso

500kg/capita/yr, consumingaround 16.1Mt, 11% up

on 2010.1 However, in 2012 consumption ellby 1.6%

to 15.9Mt/yr.1

16

14

12

10

86

4

2

0

2011

2009

2007

2005

2003

2001

1999

1997

1995

1993

Year

Cementpro

duction

(Mt)

0

5

1

15

2

25

3

35

2

6

1

12

1

16

1

3

1

4

1

5

1

6

1

7

1

8

1

9

2

0

2

1

2

2

2

3

2

4

2

5

2

6

2

7

2

8

2

9

2

1 0

2

1 1

2

1 2

3500

3000

2500

2000

1500

1000

500

0

GDP/cap

ita

(2012US$)

Below -Figure1: Cementproduction (red)andGDP/capita (green)forMorocco,1993 -2011/2012.

Above:Summary statisticsforMorocco in 2012.

M on th Mt %

Jan 1.18 -25.4

Feb 1.21 -10.7

Mar 1.23 -25.0

Apr 1.38 -2.6

May 1.41 -3.2

Jun 1.37 -2.5

Jul 1.17 -5.5

Aug 0.89 +9.22

Jan-Aug 9.4 -10.2

Below right-Table1:Monthly Moroccan cementconsumption statisticsfor2013in Mt,with %year-on-yearchangesrelativeto thesamemonth of 2012. 1

NORTHAFRICA

ELECTRICALENERGY


Hasan Delikanli, AdanaimentoSan. T.A..

AdanaCementsnew

499KWsolarpowerplant

In urkey, 62% o installed electricalcapac-ity comesromossil uelplants. In 2012 73%oth e power g en er ated i n th ecoun tr y ca me

rom these. Tereore, urkey hasto import

great amountso resourcesor power. Increasingthe

amount oinvestmentsin theeld orenewableen-

ergy isalso an important steporurkey to decrease

itsdepe ndenceon oreign resourcesand implement

sustainablepolicies.

Adana Cementsprimary mission issensitivity

towardssociety and theenvironment. In thisregard

i t h a s con ducted r es ea r ch towa r ds th eus eoth er e-

newableenergy sourcesand observed th at urkey has

great potentialorthe useosolar power. Accordingto

thegureso Ministry oEnergy, thepowergenerationcapacity ourkey romsolarenergy is:

Solarenergy potential: 380 billion kWh/yr

Averageannualsunshineduration: 2640hr Averagedaily sunshineduration: 7.2hr

Averageannualradiation pressure: 1.31kWh/m

Peakannualradiation pressure: 3.6kWh/m

Photovoltaicpowergeneration

Temost common method osolarpowergeneration is

thephotovoltaic method. Tisprocessuses thousands

os ol a r cel l s ma der oms emi - con ductor s th a t a r e

connected to createa solarpanel. In orderto usesemi-

conductormaterials, two typeso layers, typeN (-)

and typeP(+) layersareproduced via a processknownasdoping.

Light particles(photons) hit thetypeN layer, which

hasveelectrons in itsouteratomic orbit. Tiscauses

oneelectron to breakaway towardsthePlayer, whichhasjust ourelectronsin itsouteratomic orbit. Tis

i s th e ph otovol ta ice ect a n d pr ov i des a poten tia l

dierence(also reerred to asa voltage) acrossthe

solarpanel.

By placingwiresbetween theP and N layers, the

solarcell istransormed into a battery with positive

and negativepoles. Largequantitiesosolar cellsare

connected with each otherthrough parallelor se-

rialconnection and mounted on a surace. Tisnew

structureis called solarpanel, solarmodule orpho-

tovoltaicmodule.

Solarpanels aremanufactured in three

dierent structures: monocrystal, polycrystal

and thin-lm. Teefciency othe photovol-

taicsolarpower plants(SPP) diersbetween15-20% accordingto theefciency othe sys-

temand thelocation oinstallation.

Tecurrent generated with photovoltaicsys-

temis Direct Current (DC) and theoutpu t

voltageo each modu leis between 12-1000V.

Below:SolarradiationpressuremapforTurkey.Adana Cementislocatedin thecentral southernregion of Adana.

Global energy demand rises by 1.6%/yr,while

thepopulation increases by around 1%/yr.The

need or renewableenergy sources to satisy

this increasingdemand whileimplementingsustainableglobal environmental policies is

evident or all countries.To this end,Adana

Cement has recently completed theinstallationoa new photovoltaic solar power plant th at will

providesignifcant energy and CO2 savings in

thecomingyears.

1400 -1450kWh/m2

1450 -1500kWh/m2

1500 -1550kWh/m2

1550 -1600kWh/m2

1600 -1650kWh/m2

1650 -1700kWh/m2

1700 -1750kWh/m2

1750 -1800kWh/m2

1800 -2000kWh/m2

Above:Adana Cements499kWpsolarpowerplantbegan operationson 8 May 2013.

Adana Cement

4 globalcementMAGAZINE October 2013

CONTENTS

Global technology, trends & AFR

6 Diary dates

8 Maerz: Contracts and new plants

10 HyperLime: CO2-absorbing hydraulic lime

14 Alternative uels - What about the environment?- Part 1

19 Global cement industry eyes new diet

22 Adana Cements new 499KW solar power plant

24 Standard-Industrie: Success with theAIRCHOC air cannon

26 Expansion joints in the cement industry

28 Pneumatic conveying round-up

European cement

30 The View rom Brussels

31 European cement news

37 7th International VDZ Congress 2013 - Reviewed

45 12th TCMA International Technical Seminar &Exhibition - Floorplan

Cement in the Americas46 American cement news

Asian cement

48 Asian cement news

54 Aumund completes highest ever bucketelevator rebuild

Middle East and African cement

55 Middle East and Arican cement news

58 North Arican cement ocus

Regulars and comment

63 Global cement prices

64 Subscription orm or Global Cement Magazine

65 The Last Word

66 Advertiser Index & Forthcoming issue eatures

22

58

14Photovoltaicsolarpanels areconnected in seriesvia

inverters. Tegenerated DC voltageisconverted intoAC voltagein equalamplitude, requency and electri-

calanglewith thelinevoltage and transerred to a local

l i n eor th egr i d. Te output v ol ta geoth ei n v er ter i sgenerally 230V, 400Vor500V. Connectionsat higher

voltagesarealso possiblewith step-up transormers. I

thegenerated powerneeds to beused at dierent time

periods, it can bestored usingaccumulators.

499kWpsolarpowerplant at Adana Cement

Adana Cement, an Oyakenterprise, decided to estab-lish a photovoltaicsolarpower plant with an installed

capacity o499kWp (kilo-Watt peak) in accordance

with itsprinciplesoenvironmentalsensitivity, power

saving, and sustainableeciency.Tef rs t s ol a rpowerpl a n t to be a pproved by

EDA, urkeysnationalelectricaldistribution com-

pany, thebid ortheplant wasconducted in July 2012and theplant commenced operation on 8 May 2013.

Teacility isexpected to meet the42% otheelec-

tricenergy in thegeneral administrativeexpenses

othe Adana Cement plant and 82% othegeneraladministrativeelectricity expensesotheskenderun

grindingacility. Additionally, with theestablish-

men t o th epl a n t, 409,200kg/y roCO2 emissionswillbeaverted. Tisisequal to theamount oCO2

consumed by 409 treesin a year.

Project information

SolarPanels: A totalnumbero 2088 polycrystal

solarpanels wereused in theproject. Each panel

poweris 240Wp. Panelvoltageis30V at maximumpowerand themaximumcurrent is7.96A. Tepanels

weremanuactured in China by ZhejangUniversity

Sunny Energy.

Inverters:Teinvertersare used ortransormingthe

DC electricity signalgenerated by thepanelsinto AC

current to match therequency, amplitudeand phase

angleothe main electricalline. Tanksto thiseatureotheinverters, thereis no need oran additionalsyn-

chronisation circuit. Tereare30 inverterunitsused in

theplant and each othem hasa powero17kW.Teinverters, which weremanuactured in Ger-

many, communicatewith each other over an RS

interace. Inormation on allelements oplant opera-

tion can beobtained onlineby operators, includingthetotalgeneration othesystem. Each inverterhas our

groupso18 solarpanelsconnect ed to it.

Te eci en cy o th ei n v erter s i s 98% . O ther

summary inormation can

beseen in thetablebelow.

Grid connection

Tes y s temi s con n ected to

the Adana Cement plant

line, which operates at400V. Tegenerated power

wi l l be con s umed wi th i n

this distribution system.Tes y s temproducti on i s

monitored by EDAover

an automated metersystem

and can beseen online.

Returnoninvestment

Tereturn on investment isestimated as11 years.

References

Communiquon theGeneration oElectricity without License; Com-

muniquon theSolarPowerGeneration Facilities; Communiquon

theImplementation oRegulation on Generation oElectricity in the

Energy Market without License; www.euas.gov.tr-EAElectric-

ity Production SectorReport; www.enerji.gov.tr-R.o.. Ministry o

Energy; www.emo.org.tr- ChamberoElectricalEngineers; www.

teias.gov.tr; SolarElectricPowerAssociation (SEPA); SolarElectric

IndustriesAssociation (SEIA); www.iea.orgInternationalEnergy

Agency; Dnya Gazetesi(daily); 13 July 2012; www.spenerji.com.

tr-SPEnergy; www.technologyreview.com/spain/solar; www.solara-

cademy.com; www.sma.de.

ELECTRICALENERGY

Above:17kWSMA Inverter.

globalcementMAGAZINEOctober2013 27

Input(DC) Value

Max.DCpower(@ cos = 1) 17,410W

Max.inputvoltage 1000V

MPPvoltagerange/ratedinputvoltage 400-800V /600V

Min.inputvoltage/Startinputvoltage 150V /188V

Max.inputcurrentoutputA /inputB 33A/11A

Out put (AC) Value

Ratedoutputpower(@ 230V,50Hz) 17,000W

Nominal ACvoltage

3/N/PE, 220/380V

3/N/PE, 230/400V

3/N/PE, 240/415V

Ratedpowerrequency /ratedpowervoltage 50Hz /230V

Poweractoratratedoutputpower 1

Left: Invertereatures.

Left:Onlineautomated

readingsystem.

Farleft: Imageo of-linetestscreen

OM t/ yr 1 5 - 20 M t/ yr

0-10Mt/yr 20-40Mt/yr

10-15Mt/yr +40Mt/yr

1000km


GDP US$277.4bn

GDP/capita US$7600

Population 38.1m

Area 2,381,741km2

RedSea

SUDANCHADNI

GER

MALIM

AURITANIA

Mediterranean Sea

Atla

ntic

Ocean

LIBYA -9.7Mt/yr

1.Ahlia (Arab)CementCo.,1Mt/yr.

2.Ahlia (Arab)CementCo.,0.3Mt/yr.



5.TheLibyan CementCo.(Asamer),0.9Mt/yr.

6.TheLibyan CementCo.(Asamer),1.1Mt/yr.

7.TheLibyan CementCo.,(Asamer),1Mt/yr.

8.ArabUnion ContractingCo.,1.4Mt/yr.

EGYPT-43.7Mt/yr

1.Alexandria PortlandCementCo.(Titan),2.2Mt/yr.

2.Ameriyah CementCo.(Cimpor),2.4Mt/yr.

3.ASECCementCo.,1.5Mt/yr.

4.Cemex AssiutCement,4.8Mt/yr.

5.BeniSue CementCo.,(Titan),3.2Mt/yr.

6.LaargeCementEgypt.,10.6Mt/yr.

7.MisrEgyptCementCo.,1.4Mt/yr.

8.National CementCo.,3.8Mt/yr.



11.SinaiCementCo.,1.5Mt/yr(1 Whitekiln).

12.SuezCementCo.,1.4Mt/yr.

13.SuezCementCo.,2.4Mt/yr.

14.Tourah PortlandCementCo.,1.35Mt/yr.

15.Tourah PortlandCementCo.,1Mt/yr.

16.Tourah PortlandCementCo.,2.23Mt/yr.

17.SinaiCementCo.,0.41Mt/yr.18.Royal CementCo.,0.18Mt/yr(White).

Ain Salah

Western

Saha

raN

ALGERIA

TUNISIA

MOROCCO

EGYPTLIBYA

2

3

4

5 6

8

1RABAT

Casablanca 9 10

ALGIERS

26,34

12

Oran

13

14

TUNIS

1,2TRIPOLI

3

4,865,7

1

Alexandria

2,3,5,6, 8-18CAIRO

49

11

13

12

Between January 2013 and theend o August

2013 Morocco had consumed 9.4Mt/yro cement,

with Grand Casablanca and angier-touan con-

s umi n g th emos t.1 Teeight monthsto 1 September

2013 saw cement consumption down by 10.7%.

August 2013, saw a year-on-yearimprovement o

9.2%, possibly dueto Ramadan movingbackwards

relativeto theGregorian calendarinto July 2013.

Tedecrease in cement consumption mirrorsa de-

clinein economic growth in 2012. It islikely that this

hasbeen due, at least in part, to thecontinued slow-

down in Moroccosexport partnerslikeSp ain (17% o

exports) and France(21%) in southern Europe. Te

Moroccan economy grew by 3.2% in 2012 3 compared

to estimateso4.5%. GDP growth isnow orecast as

3.9% or2013, 5.6% or2014 and 5.9% or2015. 4

Algeria -21.9Mt/yr

h eP eopl es D emocr ati cRepubl i coAl g er i aendured a bloody separation romits ormercol on ia l r ul er Fr a n cei n th e 1950s a n d h a s s i n ce

been a relatively unstablenation. Most recently it

experienced politicaldisruption in 2011 ollowing

revolutionsin unisia and Libya. At present, thecoun-

try reliesto a great extent on itsoilrevenues, a resource

that thegovernment iskeen to exert controlover. Oil

provides95% oexport earningsorthecountry. Since

the2011 proteststhegovernment hasmade attemots

to generateadditionalrevenue streams.

At thestart o2013 it wasexpected that thegov-

ernment oAbdelaziz Boutefica would present a new

constitution in 2013, although electionsin 2014 may

bedivertingattention romthistask.

Below -Figure2: North Arica with integratedcementplants,major settlementsandneighbouringterritories/areaso water.Colour-codedby cementcapacity.

Above:Summary statisticsorAlgeria in 2012.

4

7

71 5 6 11

1013

124

2 98

3

4

5

151 2

6-89

12

1113

14

1016

17

7

1,92 8

6

3

4

5

3

1,2

4,8 5,7Benghazi

ALGERIA -21.9t/yr

1.EntreprisedeCimentsetD rivesdEch-Cheli(EDCE),2Mtyr.

2.ERCC,0.5Mt/yr.

3.ERCC,0.4Mt/yr.

4.ERCC,1M/yr.

5.GroupdeCimentsetDrivs, 1Mt/yr.

6.EntreprisedesCimentsetDr ivsEst,1.05Mt/yr.

7.EntreprisedesCimentsetDr ivsEst,0.8Mtyr.



10.SCTSocitdesCimentsdeTebessa, 1Mt/yr.

11.SocitdesCimentsdeBeniS a (SCIBS),1.6Mt/yr.

12.Laarge,2.5Mt/yr(White).

13.Laarge,5Mt/yr.

14.CementAlgeria Co SA,3.3Mt/yr.

15. Sonatrech,1Mt/yr.

16. SocitdeCimentsdeZahana (ASEC),1.2Mt/yr.

17. ASECCimentAlgerie,3.2Mt/yr.(Commissioningin 2015).

TUNISIA -12.2Mt/yr

1. CimentsArtifcielsTunisiens(COLACEM),1Mt/yr.

2. CimentsdeBizerte,0.84Mt/yr.

3. La CimenteriedeDjebel El Oust(Camargo Corra),1.2Mt/yr.

4. LesCimentsdOum El Klil,0.87Mt/yr.

5. SocitdesCimentsdeGabes (SECIL),1.0Mt/yr.

6. SocitdesCimentsdEnfda (88%CPV),1.4Mt/yr.

7. CarthageCement,2.3Mt/yr(Commissioningnow).

8. CimentdeMditerraneGasa, 3Mt/yr.

9. SocitTuniso-AndalousedeCimentBlanc(Molins),0.6Mt/yr.

MOROCCO-23.3Mt/yr

1.AsmentdeTmara (Cimpor),1.25Mtyr.

2.Cimentsdu Maroc(Italcementi),1.0Mt/yr.

3.LaargeMaroc,1.0Mt/yr.

4.LaargeMaroc,4.5M/yr.


6.Holcim Maroc,1.9Mt/yr.

7.Holcim Maroc,1.3Mtyr.


9.Holcim Maroc,1.8Mt/yr.



12.CimentsdeLAtlas(CIMAT),1.6Mt/yr.

13.CimentsdeLAtlas(CIMAT),1.6Mt/yr.

NORTHAFRICA

Swiss limekilnmanuacturer andThyssenKruppcompany

Maerz Oenbau AG is theworld leader in thefeldolimeplant engineering.

Herethecompanypresents its most recentlycompleted projects and

recent orders.

Recently-completed projects

Dongbei SpecialSteelGroup-China

SINOCHEMInternationalenderingCo. Ltd., asthe

buyerorDongbei SpecialSteelGroup Co., Ltd., based

in Dalian (Liaoning), China, placed an orderwith Maerz

orthec onstruction oa Maerz PFRkiln. TeR4S-type

kiln wasdesigned to produce600t/hr oburnt lime,

processinglimestonewith a gradingo40-80mm and

usingproducergaswith a caloricvalueo~6200kJ/m3

asuel.

At theend o2012 theindustrialproduction stage

wa s r ea ch ed a n d th econ tr a ctua l per or man cea n d

quality parameters, aslisted in able1, wereachieved.

Tecus tomer con r med th a t

th e con tra ctual per orma n ce

guaranteeswereullled and the

plant wasaccepted.

Xinjiang Zhongtai Miningand Metallurgy -China

aigangGroup InternationalradeCo., Ltd. asthe

buyerand Maerz OenbauAG asthe seller, signed a

contract ortheinstallation othreeMaerz PFRlime

kilnsorXinjiangZhongtaiMin-

ingand Metallurgy Co., Ltd.,based in Urumqi, China. Te

kilnswereeach to produce600t/

day oburnt limeusingcarbide

gasasuel.

In February 2013 thecon-

tractualguarantee test run was

carried out. Teperormanceand quality parametersas

shown in able2 wereachieved.

Chememan-Thailand

Chememan Co., Ltd., based in Bangkok, Tailand, en-

trusted Maerz with thesupply o engineering, materials

and equipment aswell astechnical assistanceorthe

installation oa second limekiln, a

Maerz PFRkiln at itsSaraburilime

plant. TerectangularE5-type kiln

wasto produce300t/day oburnt

limeusingpulverised coalasuel.

Tenew kiln plant wasrecently

commissioned and the industrial

production started shortly afer

start-upo thekiln. Duringthe contractualguarantee

test run theperormanceand quality parametersshown

in able3 wereachieved.

Guangxi LiuzhouIron&Steel-China

GuangxiLiuzhouIron & Steel (Group) Company, Liu-

zhou, China, which hasoperated ourMaerz PFR kilns

orseveralyears, earlierplaced an orderwith Maerz or

theconstruction oanother kiln at itsLiuzhouplant.

TeR4S-type kiln wasto produce600t/day oburnt

lime, processinglimestonewith a gradingo30-90mm

usingconvertergasasuel.

Afererection workwas completed in a very short

period, thenew Maerz Kiln No. 5 isnow in industrial

production. It hasachieved theperormanceand quality

parametersshown in able4.

RefractariosBsicos-Mexico

ReractariosBsicos oMexico placed an orderwith

Maerz orthe supply oengineering, license, know-

how, key equipment, erection servicesand technical

assistanceortheinstallation oa Maerz PFRlimeshaf

kiln at itsMitrasplant. Tenew R4S-typekiln wasto

produce600t/day oquicklimeusingnaturalgas asuel.

In February 2013 theindustrialproduction stagewas

reached and thecontractualguaranteetest run wascar-

ried out. Perormanceand quality parametersareshown

in able5.

Maerz OfenbauAG


LIME

Kiln capacity(t/day) 600

Heatconsumption (kCal/kg) 3750

Losson ignition (%) 300

Limestonesize(mm) 35-90


ResidualCO2-content(%) 1.7

Reactivityof lime(t60 valuein seconds) 45

Kiln capacity(t/day) >600


Limestonesize(mm) 19-64

Heatconsumption (kCal/kg) 200Mt/yracrosstheglobe.

High-calciumlimestonecan becalcined in ultra-

ecient gasred parallel-ow regenerative(PFR) kilnswithout decrepitation, unlikecement orotherimpure

limestonewherecoalorhorizontalkilnsmust beused.

PFRkilnsareupto 80% moreenergy-ecient compared

to otherkilns3 and willbecomemoreimportant astheenergy mixshifstoward shalegas. TeCO2 ootprint

orthistypeo Ca(OH)2 is~750kg/t. Most importantly,

however, istheability othehydrated limeto react withand sequesteratmosphericCO2, regeneratinglimestone,

which ormspart othelimecycle(SeeFigure1).

Hydrated limeisadded to cement mortarsto im-

proveworkability (i.e. 1:1:6 mix), howeverthecement

Below -Figure1: Thelimecycle.

CO2 emission penalty remains, deliveringmortarwith

CO2 ootprintso~190kg/t. Otherspecialist bindersare

available, (e.g. naturalhydrauliclime orNHL), which

aremanuactured romimpure limestoneto delivera

blend obelite, limestone, limeand alite. Tiscomposi-

tion isanalogousto 1:1:6 v/v cement mortarsasNHLs

contain thealite/belite cementitiousspecies. 4

Teircom position precludes manuacturein e-

cient gasred PFRkilnsrelyingon coalred verticalor

cement horizontalkilns. Limeco estimatesthat a stand-

ard 1:3 v/v NHL:sand mortarstillhasa CO 2 ootprint o

~150kg/t. NHLsareused solely asbindersor special-

ist restoration workand remain nichedueto slow and

unreliablesettingratescombined with poorworkability.

Howevertheirlower levelsoalite/belited elivermortars

with somevapourp ermeability (porosity) and exibility

underload.

Tekey per orma n ceel emen t oa l l commer cia l

hydraulicbinders, cement orNHL, istheormation o

CSH. Techallenge, thereore, orLimeco wasto create

a sustainablebindertechnology, rich in CO2-absorbing

Ca(OH)2 that delivered sucient CSHor structural

purposeswithout employingalite/belite.

o thisend, Limeco hasdeveloped a hydrauliclime

bindertechnology, which employshydrated limewith

a proprietary highly-activesilica additivethat ismade

romsand. 5

Upon mixingLimec o binderwith aggregateand

water, it reactsquickly to ormCSH, leavingover80%

reeCa(OH) 2 to adsorb atmosphericCO2. Tehigh lime

content afordsexcellent workability and therateo set

and 28 day strengthsarec omparableto 1:1:6 mixesor

gypsumplasters.

Limeco hasworked with itssuppliersto accurately

determinetheCO 2 ootprint oitsproducts. Workin the

laboratory and eld showsthat Limeco bindersabsorb

ov er 75% oth eCO2 emitted duringtheir manuacture

within 1 year(See Figure2), deliveringmortars with

CO2 ootprintso ~40kg/t omortar. Tiscompares toCO2 emissionso150-220kg/t orcementitiousbinders.

Ti s i s demon str a ted by pHi n di ca tor s ta i n in g ,

Ca(OH)2 analysisand gravimetricassessment omortars

ma dewi th L i meco

products. Such

mortarsgain weight

ov er ti mea s CO 2 is

absorbed. Sucient

reeCa(OH) 2 i s r e-

tained orautogenic

s el -h ea l i ng ( See

Figure3). Recycling

th emor ta r s i s a l s o

simple.

By utilisinglimestoneand sand raw materialsand

processingthesewith the most ecient gasuelled plant

to delivera quicksettingand workableCO 2-absorbing

limebinder technology, Limeco haslaunched a range

oruly Sustainable productswithin Europeunde rits


HyperLimehaslow bulkdensity and istypically used

as1:3 v/v HyperLime:aggregatemix(HyperLime ~10%

w/w) so it iscompetitiveon cost. HyperLimebinders do

not contain theknown carcinogens, crystallinesilica or

heavy metals. Current HyperLime2 and HyperLime3.5

productsare CE marked (EN459:2010) and HyperLime

5 willbelaunched shortly.

Limeco workswith internationallicenseesas su-

cient raw materialsare availableworldwide to makeover50Mt oHyperLime.

References

1.IPCC, IPCC FourthAssessmentReport2007(AR4),WorkingGroup

IIIReport Mitigation of Climate Change,Chapter7, 2007.

2.Knut O. Kjellsen et al., CO2 uptake during the concrete life cycle:Te

CO2 balance of concrete in alife cycle perspective, Norden NordicInnova-

tion Centre, December2005.

3.EntecUKLimited, EUEmissionsrading Scheme Phase II.Review of

new entrantsbenchmark Lime,Report orUKGovernment Depart-

ment oradeand Industry,

Report Version 2, August 2006.

4. For example: http://www.

stastier.co.uk/nhl/ino/pds/

Hydraulicity_and_Properties_

o_NHL.pd, Setra Marketing

2006. Accessed 10 October2012.

Also see: www.c-e-s-a.r.

5.HyperLimewebsite,

www.hyperlimeco.com.


LIME

Above-Figure2:Carbonation rateof

HyperLimemortars.

HyperLime2%(massgain)HyperLime2%(freelime)

HyperLime3.5%(massgain)HyperLime3.5%(freelime)

100

80

60

40

20

0

Carbonation(%)

0 50 100 150 200 250 300 350


Ageof mortar(days)

Above-Figure3:HyperLimecarbonation.

Below:HyperLimeasmortarforbrick-laying.

Below left:HyperLimeasa render.

8

10

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Hurricane

SystemClinker Cooler

Gas Flow

Material Flow

Cooler

BurnerRotary Kiln

Flash Furnace

Burner

Ciclone

Preheater Ciclone Tower

Condioning

Tower

Stack

Cooler

Exaust

Coal

MillGrinding

of pet coke

Stack

Stack

ENERGY RECOVERY FROM THE CYCLONE PREHEATER TOWER

www.advancedcyclonesystems.com [email protected] Tel: +351 225 322 097 Fax: +351 225 322 096

Centro de Empresas NET Edifcio PROMONET Rua de Salazares, n 842 4149-002 Porto, Portugal

Hurricane high efficiency cyclone system to clean exhaust gases

Problem:

To be able to use the hot exhaust gases from the preheang tower to

grind Pet Coke in the Coal Mill without compromising its quality (ash

content limit) and therefore, the reselling value.

This is a common problem in cement plants, namely for an ACSs

Hungarian customer.

Advanced Cyclone Systems, S.A. (ACS) is a

company exclusively dedicated to the

development and supply of the most

efficient cyclone systems worldwide.

ACS mission is to achieve total parcle

capture exclusively with cyclone systems

through connuous investment in Innova-

on and R & D.

Hurricane and ReCyclone systems contra-

dict the general thinking that cyclones are

inefficient powder collectors. These

cyclone systems can replace bag filters in

many demanding operang processes.

Applicaons include Pre-Heater andClinker

cooler exaust air dedusng.

www.advancedcyclonesystems.com

Mission: Leading gas-solid separaon with cyclones,

avoiding filter maintenance costs

Soluon:

To design the most efficient cyclone system, ACS used the specific

operang condions of the plant, such as the parcle size distribuon,

density inlet concentraon, temperature and gas flow rate.

ACS provided a Hurricane cyclone system composed by 12 opmized

cyclones of 700 mm arranged in two baeries of six cyclones in parallel.

Operang Condions / Results

Parcle density (Kg/m3) [0.6]

Median Volume Diameter (m) [2.3]

Actual flow rate (m3/h Wet) [37,513]

Gas temperature (C) [327]

Product load into cyclone system (mg/Nm3) [42,100]

Guaranteed efficiency (%) [> 90.0]

Expected total pressure drop (kPa) [1.3]

Conclusion

ACS succeeded in reducing the dust level to guaranteed values. The

client is very sasfied with the quality of the PET Coke which is within

the requested specificaons.

Advantages of the Hurricane system:

Very high efficiencies

Very economic soluon

No temperature restricons

Near zero maintenance costs

Custom design

Robustness and no moving parts

Low pressure drop

A similar applicaon in the cement industry is also found in the clinker

cooler exhaust gas, which can also be used for energy recovery

purposes, aer being cleaned.

See more in: hp://www.acsystems.pt/index.php?id=28&set_lang=en
http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/http://www.acsystems.pt/

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DIARY DATES

12th TMB International Technical Seminar & Exhibition

8-10 October 2013, Antalya, Turkey

www.tcma.org.tr

13th Global Gypsum Conference & Exhibition

21-22 October 2013, Toronto, Canada

www.GlobalGypsum.com

18th Arab-International Cement

Conference & Exhibition

11-13 November 2013, Dead Sea, Jordan

www.aucbm.org

13th NCB International Seminar & Exhibition

19-22 November 2013, New Delhi, India

www.ncbindia.com

9th Global Slag Conference & Exhibition

10-11 December 2013, Dubai, UAE

www.GlobalSlag.com

1st Global Well Cem Conference & Exhibition

13-14 January 2014, Dubai, UAE - See Below

www.Well-Cem.com

1st Global Boards Conference & Exhibition

30-31 January 2014, London, UK

www.GlobalBoards.com

8th Global CemFuels Conference & Exhibition

24-25 February 2014, Vienna, Austria

www.CemFuels.com

Asian Cement & Lime Conference

24-25 March 2014, Bangkok, Thailand

www.AsianCement.com

57th IEEE-IAS/PCA Technical Seminar13-17 April 2014, Washington DC, USA

3rd Global CemTrader Conference & Exhibition

2-3 June 2014, London, UK

www.CemTrader.com

14th Global Gypsum Conference & Exhibition

29-30 September 2014, European location TBA

www.GlobalGypsum.com

9th Global Insulation Conference & Exhibition

30-31 October 2013, Location TBAwww.GlobalInsulation.com

Links to all events: www.Cement-Events.com

Full 2014 Media Book: www.propubs.com/advertise

13-14 JANUARY 2014 DUBAI, UAE

Global Cement is pleased

to present the frst-everconerence dedicated to theproduction and optimisationo well cements. Bringingtogether producers andusers in one centrally-located venue, the GlobalWell Cem conerenceand exhibition will ocuson making contacts, onnetworking, on technicalinormation exchange andon business. I well cement is

your business, make it yourbusiness to be at Well Cem!

gl balcement

MAGAZINE

Organised by:

gl bal wellcemCONFERENCE & EXHIBITION 2014

1st

Founding sponsors:

Sponsored byArab Union for

Cement and BuildingMaterials:

TM

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http://www.maerz.com/

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Swiss lime kiln

manuacturer and

ThyssenKrupp company

Maerz Oenbau AG is the

world leader in the feld

o lime plant engineering.

Here the company

presents its most recentlycompleted projects and

recent orders.

Recently-completed projects

Dongbei Special Steel Group - China

SINOCHEM International endering Co. Ltd., as the

buyer or Dongbei Special Steel Group Co., Ltd., based

in Dalian (Liaoning), China, placed an order with Maerz

or the construction o a Maerz PFR kiln. Te R4S-typekiln was designed to produce 600t/hr o burnt lime,

processing limestone with a grading o 40-80mm and

using producer gas with a caloric value o ~6200kJ/m3

as uel.

At the end o 2012 the industrial production stage

was reached and the contractual perormance and

quality parameters, as listed in able 1, were achieved.

Te customer conrmed that

the contractual perormance

guarantees were ullled and the

plant was accepted.

Xinjiang Zhongtai Mining

and Metallurgy - China

aigang Group International rade Co., Ltd. as the

buyer and Maerz Oenbau AG as the seller, signed a

contract or the installation o three Maerz PFR lime

kilns or Xinjiang Zhongtai Min-

ing and Metallurgy Co., Ltd.,

based in Urumqi, China. Te

kilns were each to produce 600t/

day o burnt lime using carbide

gas as uel.

In February 2013 the con-

tractual guarantee test run was

carried out. Te perormance and quality parameters as

shown in able 2 were achieved.

Chememan - Thailand

Chememan Co., Ltd., based in Bangkok, Tailand, en-

trusted Maerz with the supply o engineering, materials

and equipment as well as technical assistance or the

installation o a second lime kiln, a

Maerz PFR kiln at its Saraburi lime

plant. Te rectangular E5-type kiln

was to produce 300t/day o burnt

lime using pulverised coal as uel.Te new kiln plant was recently

commissioned and the industrial

production started shortly afer

start-up o the kiln. During the contractual guarantee

test run the perormance and quality parameters shown

in able 3 were achieved.

Guangxi Liuzhou Iron & Steel - China

Guangxi Liuzhou Iron & Steel (Group) Company, Liu-

zhou, China, which has operated our Maerz PFR kilns

or several years, earlier placed an order with Maerz or

the construction o another kiln at its Liuzhou plant.

Te R4S-type kiln was to produce 600t/day o burnt

lime, processing limestone with a grading o 30-90mm

using converter gas as uel.

Afer erection work was completed in a very short

period, the new Maerz Kiln No. 5 is now in industrial

production. It has achieved the perormance and qualityparameters shown in able 4.

Refractarios Bsicos - Mexico

Reractarios Bsicos o Mexico placed an order with

Maerz or the supply o engineering, licence, know-

how, key equipment, erection services and technical

assistance or the installation o a Maerz PFR lime shaf

kiln at its Mitras plant. Te new R4S-type kiln was to

produce 600t/day o quicklime using natural gas as uel.

In February 2013 the industrial production stage was

reached and the contractual guarantee test run was car-

ried out. Perormance and quality parameters are shown

in able 5.

Maerz Ofenbau AG


LIMESubscribeContents Ad Index

Kiln capacity (t/day) 600

Heat consumption (kCal/kg) 3750

Loss on ignition (%) 300

Limestone size (mm) 35-90

Heat consumption (kCal/kg)830

Residual CO2-content (%) 1.7

Reactivity of lime (t60 value in seconds) 45

Kiln capacity (t/day) >600

Heat consumption (kCal/kg) 660

Limestone size (mm) 19-64

Heat consumption (kCal/kg)

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LIME

Ongoing projects

Cemento Sur - Peru - See below right

Cemento Surs lime plant in Juliaca, Peru is currently a

major construction site or three new 500t/day Maerz

PFR kilns. Te plant location, at an extremely high alti-

tude o ~3900m above sea level is high even by Peruvian

standards and presents a challenge not only or the

limestone calcining technology involved, but also or

the erection team that is currently setting up the plant.

Te project, proessionally managed by the owner, is

really on the ast track, with contract excavation work

starting only six months afer signing the contract. Te

civil works or the kiln oundation as well as the neces-

sary buildings was nished in December 2012 so that

the erection o the kilns steel structure could begin.

Te time needed or setting up the buildings was per-

ectly used or pre-assembling large modules o the kiln

shell and platorms steel structure. Tis speeded up the

installation o the kiln shell parts on the kiln oundation,

so that it was possible to start with the reractory liningwork afer only our months rom the oundations being

ready to take a load.

Te kilns will be commissioned in late summer 2013

and will then mainly serve the South Peruvian mining

and building industries.

New projects

Negev Industrial Minerals - Israel

Negev Industrial Minerals (NIM), having previously

ordered a 300t/day Maerz PFR lime kiln at its Mishor

Rotem plant, has now entrusted Maerz with the supplyo engineering, know-how, equipment as well as techni-

cal assistance or the installation o an additional natural

gas ring system on the same kiln.

SCHAEFER KALK - Germany - See above left

Long-standing Maerz customer SCHAEFER KALK has

placed another order with the company or the supply o

a new PFR kiln at its Steeden lime plant.

Te new R3S-type kiln with a circular shaf design is

to produce 500t/day o sof burnt lime, processing lime-

stone with grain sizes o 60-150mm using natural gas

and/or lignite dust as uels.

Te new lime kiln plant will begin operations in

the nal quarter o 2014.

CELCO - Romania

Romania-based CELCO S.A. has contracted a new

Maerz lime kiln or its Corbu lime plant in Constana

County. Te Maerz High Perormance Single Shaf

kiln will be o the kiln type H3-1 and is to produce

150t/day o quicklime. Natural gas will be used as

uel and limestone with a grain size o 20-40mm and

40-80mm will be processed. Te kiln is due or com-

missioning at the end o 2013.

Yidong Dongxing Chemical - China

SUMEC International echnology Co., Ltd., as the

buyer, angshan Shenying echnology Co., Ltd., as

the end-user and Maerz Oenbau AG as the seller have

signed a contract or the installation o three 550-600t/

day Maerz PFR lime kilns or Yidong Dongxing Chemi-

cal Co., Ltd., located in Inner Mongolia, China.

Te R4P-type Maerz kilns are o a circular shaf de-

sign and will each produce up to 600t/day o burnt lime.

Tey will be red with mixed gas with a caloric value

o ~7500kJ/m3. Limestone with a grading o 50-90mm

will be processed by all o the kilns. Te new kilns will

be commissioned at the end o 2013.

Izvestnyak-Centr - Russia

PSP Engineering a.s., rom Perov, Czech Republic as

the buyer and Maerz Oenbau AG as the seller have

signed a contract or the supply o engineering, licence,

know-how, materials and equipment as well as techni-

cal assistance services or three Maerz HPS kilns to be

supplied to the nal customer, Izvestnyak-Centr Ltd

o Russia.

Te new Maerz High Perormance Single Shaf kilns

o the H4-1-D type will each produce 200t/day o burntlime, processing limestone with grain sizes o 40-70mm

using natural gas. Commissioning o the plant is sched-

uled or the middle o 2014.

Handymans Paradise Lime

Manufacturing - Zambia

Polysius, a Division o TyssenKrupp Engineering (Pty)

Ltd rom Johannesburg, South Arica, as the buyer and

Maerz Oenbau AG rom Zurich, Switzerland, as the

seller, signed an agreement or the procurement and

erection o a lime production plant in Ndola, Zambia,

or Handymans Paradise Lime Manuacturing Co. Ltd.,as the end-user.

A R4S Maerz PFR kiln is the core piece o the new

lime production plant. It has a shaf cross section o

~12.6m2 and will have a capacity o 600t/day o burnt

lime, processing limestone with a grain size o 60-

120mm. Pulverised coal dust and, optionally at a later

date, wood dust will be used as uels.

Maerz will delegate experienced personnel to super-

vise erection and commissioning o the new kiln plant

and to train the kiln operators personnel.

Below: Ongoing

work at Cemento Surs

high-altitude Juliaca

lime plant.

globalcementMAGAZINEOctober 2013 9

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HYDRATEDLIME

Calciumhydroxide(Ca(OH)

2)

CO2

Carbonation

H2O

Calciumcarbonate

(CaCO3)

LIMESTONE

Calcination

Heat(900-1200C)

CO2

Calciumoxide(CaO)

H2OHeat

Slaking

QUICKLIME

Dr Robin Gibson, Limeco Ltd

HyperLime: CO2-absorbing hydraulic lime

10 globalcementMAGAZINEOctober 2013

LIMESubscribeContents Ad Index

The use of Ordinary Portland Cement and derivative binders pervades the masonry construction

industry due solely to cost and availability but at the expense of workability, performance and,

importantly, sustainability...

Above: Limecos range of

HyperLime products.

While cement manuacturing uses the abundantraw materials limestone and clay, the process isovershadowed by energy consumption and CO2 emis-

sions. Cement production delivers around 900kg o

CO2 emissions per tonne.1 Global cement production

is responsible or 5% o man-made CO2 emissions, owhich masonry construction contributes 20%. Tese

emissions are determined by limestone decomposi-

tion and the use o horizontal kilns or calcination

(up to 1500C) to deliver the cementitious species,

alite (C3S) and belite (C2S). Te addition o water to

cement hydrates alite/belite produces calcium silicate

hydrate (CSH).

Studies have suggested that the minor Ca(OH)2 con-

tent o cement mortar may reabsorb modest amounts

o CO2 over a 100 year period. However, this has no

meaningul impact on emissions today.2

Eorts to reduce the carbon ootprint o cement

by dilution with byproducts such as y ash (FA) or

ground granulated blast urnace slag (GGBS) re-

main highly contentious as CO2 is doubtless

emitted during their manuacture. An

identical position exists over the use o

waste solvent, old tyres or similar

as decarbonised uel or kilns.

Standard 1:3 v/v cement:sand

mortars (25% w/w cement) have

CO2 ootprints in the region

o 220kg/t.

Cement is used to prepare

mortar, plaster and render(mortar). Cement mortars are

recognised to have poor work-

ability and are impermeable

to water vapour, which causes damp in buildings. In

addition, cement mortars are requently too strong or

masonry applications leading to material ailures rom

thermal expansion or other movement. Tis is due to

the expansive hydration o alite/belite species, which

lls voids within mortars to deliver an impervious mon-olithic structure. Te practical use o cement mortars

requires additives, (e.g. plasticisers) or other eatures

(e.g. expansion joints) to overcome their serious inher-

ent limitations.

As a result, Limecos research has been ocused on

the development o high-perormance sustainable bind-

ers as alternatives to cement and gypsum or masonry

construction applications.

Hydrated lime, or Ca(OH)2, has been used as a

binder or thousands o years. However ultra-low rates

o set and low strength preclude its use in modern

construction. However Ca(OH)2 remains an important

substance or the chemical and construction industries

due to ubiquity o high-quality limestone deposits and

processing capability o >200Mt/yr across the globe.

High-calcium limestone can be calcined in ultra-

ecient gas red parallel-ow regenerative (PFR) kilns

without decrepitation, unlike cement or other impure

limestone where coal or horizontal kilns must be used.

PFR kilns are up to 80% more energy-ecient compared

to other kilns3 and will become more important as the

energy mix shifs toward shale gas. Te CO2 ootprint

or this type o Ca(OH)2 is ~750kg/t. Most importantly,

however, is the ability o the hydrated lime to react with

and sequester atmospheric CO2, regenerating limestone,which orms part o the lime cycle (See Figure 1).

Hydrated lime is added to cement mortars to improve

workability (i.e. 1:1:6 mix), however the cement CO2

Below - Figure 1:

The lime cycle.

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I

Ventilatorenfabrik Oelde GmbHP.O. Box 37 09D-59286 OeldePhone: +49252275-0Fax: + 49 25 22 75 -2 [email protected]

In our production, we use high-tech clinker coolers in order to achieve

high operational capacity. Optimal cooling requires a precise and quickly

adjustable air supply to the coolers. Venti Oelde has provided us with

high-efficiency fans with air-flow volume regulation and inlet measuring

nozzles. This allows us to use our cooler potential to the maximum and

ensure stable and trouble-free long-term operation.

Process gas cleaning plants

Process gas dust collection

Secondary fuel technology

Process gas fans

Optimization of air-handling systems

Ventilating and air-conditioning plants

nnovative solutions

by Venti Oelde.
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emission penalty

remains, deliver-

ing mortar with

CO2 ootprints o

~190kg/t. Other

specialist binders

are available, (e.g.

natural hydraulic

lime or NHL),

which are manu-

actured rom

impure limestone to deliver a blend o belite, limestone,

lime and alite. Tis composition is analogous to 1:1:6 v/v

cement mortars as NHLs contain the alite/belite cemen-

titious species.4

Teir composition precludes manuacture in e-

cient gas red PFR kilns relying on coal red vertical or

cement horizontal kilns. Limeco estimates that a stand-

ard 1:3 v/v NHL:sand mortar still has a CO2 ootprint o

~150kg/t. NHLs are used solely as binders or special-

ist restoration work and remain niche due to slow andunreliable setting rates combined with poor workability.

However their lower levels o alite/belite deliver mortars

with some vapour permeability (porosity) and exibility

under load.

Te key perormance element o all commercial

hydraulic binders, cement or NHL, is the ormation o

CSH. Te challenge, thereore, or Limeco was to create

a sustainable binder technology, rich in CO2-absorbing

Ca(OH)2 that delivered sucient CSH or structural

purposes without employing alite/belite.

o this end, Limeco has developed a hydraulic lime

binder technology, which employs hydrated lime with

a proprietary highly-active silica additive that is made

rom sand.5

Upon mixing Limeco binder with aggregate and

water, it reacts quickly to orm CSH, leaving over 80%

ree Ca(OH)2 to adsorb

atmospheric CO2. Te

high lime content aords

excellent workability and

the rate o set and 28 day

strengths are comparable

to 1:1:6 mixes or gypsum

plasters.Limeco has worked

with its suppliers to accu-

rately determine the CO2

ootprint o its products. Work in the laboratory and

eld shows that Limeco binders absorb over 75% o the

CO2 emitted during their manuacture within 1 year

(See Figure 2), delivering mortars with CO2 ootprints

o ~40kg/t o mortar. Tis compares to CO2 emissions

o 150-220kg/t or cementitious binders.

Tis is demonstrated by pH indicator staining,

Ca(OH)2 analysis and gravimetric assessment o mor-

tars made with Limeco products. Such mortars gain

weight over time as CO2 is absorbed. Sucient ree

Ca(OH)2 is retained or autogenic sel-healing (See Fig-

ure 3). Recycling the mortars is also simple.

By utilising limestone and sand raw materials and

processing these with the most ecient gas uelled plant

to deliver a quick setting and workable CO2-absorbing

lime binder technology, Limeco has launched a range

o ruly Sustainable products within Europe under its


HyperLime has low bulk density and is typically used

as 1:3 v/v HyperLime:aggregate mix (HyperLime ~10%

w/w) so it is competitive on cost. HyperLime binders donot contain the known carcinogens, crystalline silica or

heavy metals. Current HyperLime 2 and HyperLime 3.5

products are CE marked (EN459:2010) and HyperLime

5 will be launched shortly.

Limeco works with international licensees as su-

cient raw materials are available worldwide to make

over 50Mt o HyperLime.

References

1. IPCC, IPCC Fourth Assessment Report 2007 (AR4),Working Group

III Report Mitigation of Climate Change,Chapter 7, 2007.

2.

Knut O. Kjellsen et al., CO2 uptake during the concrete life cycle: TeCO2 balance of concrete in a life cycle perspective,Norden Nordic Innova-

tion Centre, December 2005.

3. Entec UK Limited, EU Emissions rading Scheme Phase II. Review of

new entrants benchmark Lime,Report or UK Government Depart-

ment o rade and Industry, Report Version 2, August 2006.

4. For example: http://www.stastier.co.uk/nhl/ino/pds/Hydraulic-

ity_and_Properties_o_NHL.pd, Setra Marketing 2006. Accessed 10

October 2012. Also see: www.c-e-s-a.r.

5. HyperLime website, www.hyperlimeco.com.

12 globalcementMAGAZINEOctober 2013

LIME

100

80

60

40

20

0

Carbonation(%)

0 50 100 150 200 250 300 350


Age of mortar (days)

Below - Figure 3:

HyperLime carbonation.

Above - Figure 2:

Carbonation rate of

HyperLime mortars.

HyperLime 2% (mass gain)

HyperLime 2% (free lime)

HyperLime 3.5% (mass gain)

HyperLime 3.5% (free lime)

Below: HyperLime as

mortar for brick-laying.

Below right: HyperLime

as a render.

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VARIETY FOR THELIME INDUSTRY

LIME

GEBR. PFEIFFER SE Barbarossastrae 50-54 67655 Kaiserslautern Germany

Phone: +49 631 4161 0 Fax: +49 631 4161 290 E-mail: [email protected] www.gpse.de

VERTICAL

ROLLER MILL

SEPARATOR

BALL MILL

DRYER

LIME HYDRATOR

Pfeiffer MPS vertical roller mill

with grit discharge
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Dirk Lechtenberg, MVW Lechtenberg & Partner

Alternative fuels - What about the environment?

- Part 1


ALTERNATIVE FUELSSubscribeContents Ad Index

Alternative uels are now a frmly-established reality in well-developed cement industries

around the world and increasing amounts o alternative uels are also being used in developing

economies. Here, MVW Lechtenberg & Partners Dirk Lechtenberg uncovers a wealth oinormation regarding the use o alternative uels in the German cement industry, especially with

reerence to the relatively unexplored negative aspects o their use. Alternative uels may mean

lower CO2 emissions, avoidance o landfll and decreased costs but they may also entail higher

numbers o truck movements, higher dust emissions and higher specifc energy consumption per

tonne o cement. Part 2 o Dirk Lechtenbergs research will ollow in the November 2013 issue o

Global Cement Magazine.

When a cement plant announces tothe public that secondary uels romwaste or biomass will be used, its at this

stage (at the very latest) that the ques-

tion is posed as to whether such

alternative uels have a nega-

tive or harmul inuence on

the environment and the

immediate environs o the ce-

ment plant. Te possibility that all

burning can have a negative eect on

the environment should be obvious to

everybody. In many cases this topic

is discussed in an animated man-

ner as it has a very emotionaleect. It is, in many cases,

understandably aicted

with residents existential

concerns.

When a cement plant announces a

new uel, the neighbouring vegetable

grower, or example, is worried he

will no longer be able to sell his

vegetables. Residents may be

concerned that alternative uels

will lead to dust or odour pol-

lution. A classic example is the

burning o tyres. Who hasnt seen the

pictures o rising black clouds o smoke i a

tyre storage depot catches re?

O course each cement plant operator will try to con-

sider the topic o emissions scientically. Ofen they will

try, using data and gures, to prove to neighbours and

in the worst case, opponents o such co-processing, that

no such eects on mankind and the environment need

to be eared.

No eects at all? Well, claiming that there will be no

ill eects will surely be incorrect. Also the cement plant

operator ofen has no suitable and independent data

and acts at his disposal. Te use o alternative uels willalways have an inuence on the operational behaviour

o a cement plant and, as a result, on the immediate en-

virons o the plant. Tis begins with changed logistics

or the uels to be utilised. I previously a truck delivered

20t o coal to a cement plant with a caloric value o ~

500GJ/t, in uture maybe 30 trucks will be required todeliver the same caloric value o alternative uels. Tese

are direct consequences and eects that will surely be

elt by immediate neighbours o a cement plant.

For the main part, the possible displeasure o the

residents will not be ocused on the immediate eects

but on the indirect eects, such as altered emissions

rom a cement plant.

For the latter, every cement producer will o course

immediately have worldwide cement association sta-

tistics or those o the Cement Sustainability Initiative

or such to hand (and presented using nice photos) in

order to emphasise the advantages o using alternativeuels to all possible critics. Emissions data prognoses

are also presented, especially regarding saved ossil

CO2 emissions, in order to illustrate the advantages o

the plants intentions.

For many decades environmentalists have been

struggling worldwide to publicise emissions data rom

industrial acilities, not only to pillory possible environ-

mental contaminators but also to promote awareness o

responsible behaviour among all industrial acilities. Re-

member - 20 or 30 years ago environmental protection

in industrial complexes in many countries in Europe

or example, was still being handled as an aferthought.

Environmental protection was a necessary evil.

Nowadays the situation is presented somewhat di-

erently. Environmental protection and sustainability

are the slogans that we encounter every day in indus-

trial company statements. For sustainable companies

there is even an index o its own on the New York Stock

Exchange. Only sustainably-run companies nowadays

have a chance to attract new employees, to receive com-

pany loans or to sell their products. Everything is green,

light or sustainable. Te act that appearances ofen

deceive is something that we witness more and more

in the consumer or ood industry. Egg boxes with pic-

tures o hens running around in the open. Who wantsto buy eggs laid by hens in cages? Light butter, which

is merely rothed up with nitrogen and as a result no

longer weighs 500g but 340g and is hence light.

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What does this have to do with a cement plant which

wants (and has to) use alternative uels in order to re-

main competitive? A cement plant, even i it is highly

modern, will always aect the environment. Te truck

which brings the uels and raw materials; the quarry

(which can bloom into a nature paradise and can ofen

possess richer ora and auna than the land which was

previously there), the emissions rom heat generation

irrespective o the uels that are used and the emissions

rom limestone calcining.

For a cement plant operator to announce to possible

critics that the planned secondary uel employment has

no kind o eect, especially in the internet age and with

constant, globally-available inormation, is surely not

the correct method.

In many guidelines on the topic o co-processing the

theme o public relations regarding the use o alternative

uels is only discussed peripherally. It is pointed out that

it is purposeul to enter dialogue with the stakeholders

while statistical data (published by the cement industry

itsel) is used to convince the public.In this article we want, or the rst time, to make avail-

able to stakeholders and possible critics anonymised,

real emissions data or allexisting cement plants in the

Federal Republic o Germany that use alternative uels,

as a basis or an independent dialogue between cement

plant operators, in order to have an open discussion.

No light butter, but data and acts that are compared

with the latest ndings on possible eects o emissions

on man and nature. Te latter in order to make available

an independent basis or a dialogue which, owing to the

uniorm production methodology in the cement indus-

try worldwide, can also be used worldwide.Te basis o these emissions data is the online

measurements recorded by the monitoring authori-

ties o 34 cement plants comprising 42 kiln lines in

Germany perormed with continuous measurement

systems. All results are rom 2008-2010.

As each cement plant has varying legal approval

pre-conditions, as well as dierent technical and raw

material-dependent prerequisites, we have made the

eort to prepare this raw data independently and in

such a way that a comparision is possible using dierent

parameters. Tis data was prepared by:

Conversion of the uniform measured variables;

Adjustment of the start-up phases in which no

secondary uels are utilised;

Capture of day average values;

Comparison of the substitution quotas and

material volumes as well as the actual clinker

production volumes;

Evaluation of the specic CO2 emissions and energy

consumption per tonne o clinker;

Comparison with European as well as other emission

limit values;

Comparison with best available technology

standards.

Furthermore we also give, afer presentation o the

evaluation results, a ew suggestions on how these inde-

pendent data, in an understandable orm, can be usedor approval processes and or communication with

stakeholders.

Overview of the German

cement industry

In the survey period, 2008-2010, the German cement

industry was characterised by a clinker production

capacity o 25.4Mt in 2008 and 23.0Mt in 2010 (See

able 1). Apart rom the noticeable nancial crisis in

the country through stagnating building activity, the all

in clinker production is also attributed to a decreasing

clinker actor.During this time, the kiln types mainly consisted

o simple preheater kilns as well as aged and energy-

intensive Lepol and shaf kilns. Te relative proportions

o these are shown in able 2.

Since carrying out initial trials with the alternative

uel BRAM (Brennsto aus Mll: uel rom waste) at

Miebach & Shnes Wittekind Zement plant in Erwitte,

employment o alternative uels has evolved into be-

coming the mainstay in uel supply. Te reasons behind

using alternative uels are manyold:

Reduction of fossil CO2 emissions;

Reduction of fossil raw materials and fuels;

globalcementMAGAZINE October 2013 15

ALTERNATIVE FUELS

2008 2009 2010

Clinker production (Mt) 25.366 23.232 22.996

As at: 1 January 2009 As at: 1 January 2010 As at: 1 January 2011

No. Capacity (t/day) % of capacity No. Capacity (t/day) % of capacity No. Capacity (t/day) % of capacity

Kilns with pre-heater 41 103,700 93.1 41 103,700 93.1 41 104,660 94.1

Lepol kilns 8 6500 5.8 8 6500 5.8 6 5350 4.8

Shat kilns 8 1200 1.1 8 1200 1.1 8 1200 1.1

TOTAL 57 111,400 100 57 111,400 100 55 111,010 100

Average capacity Rotary kilns 2249t/day 2249t/day 2336t/day

Shat kilns 150t/day 150t/day 150t/day

Above - Table 1:

Clinker production in

Germany, 2008-2010.1

Below - Table 2:

Type and capacity o

cement kilns in Germany,

2008-2010.1

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ALTERNATIVE FUELS

Service performance in waste valorisation with ac-

companying benets o environmentally compatible

valorisation (avoidance o landll space, utilisation o

energy content, creation o waste valorisation struc-

tures or (almost) all types o waste material(s);

Signicant reduction in the import of fossil fuels, with

resultant increase in GDP;

Creation and preservation of workplaces;

Increase in competitiveness;

Cost savings in aspects of cement production.

MVW Lechtenberg & Partner has seen that in discus-

sions between cement plant operators and stakeholders,

mainly the green arguments are reerred to.

Te German cement industry surely also designates

these green arguments to be seen as acts in the approval

process, yet it will also present the arguments o work-place retention and securing production in Germany. As

we will show in the ollowing, the emission values and

environmental standards o the Federal German cement

industry that need to be complied with are regarded

worldwide as exemplary, but with consequential and

necessary investments as well as ongoing operational

costs, cement production in the Federal Republic is

also considerably more expensive than in many other

countries. In order to avoid Germanys uture cement

needs being covered by cheap imports that stem rom

lower environmental requirements and production

costs coupled with minimal logistics costs, a realisticconsideration o the undamental economics o cement

production is vital.

Alternative fuels in Germany

Te German cement industry has been employ-

ing alternative uels or some 25 years. Starting rom

around 4.1% substitution in 1987, the German cement

industry achieved on average around 61% substitu-

tion rate in 2010. On the other hand, specic thermal

energy consumption raised slightly, as can be seen by

Figure 1. Tis rise can be explained by the increased

energy requirement or evaporation o the water con-

tent in alternative uels, as well as by heat losses owing

to increased gas volumes. While ossil uels are as a

rule considered absolutely dry, with a residual mois-

ture content o 3-5%, alternative uels as a rule have a

higher water content, around 10-30%,

egcoct2013ns

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