Cement: GL Bal

News Tips for 2021 Smart Technology Fans Solar Power Waste Northern Europe Snowmen BIGBOSS Cement
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JANUARY 2021 MAGAZINE

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NOVEMBER2013
GLOBAL CEMENT MAGAZINE: DEAR READERS
gl bal
cement
On the cover... News Tips for 2021 Smart Technology Fans Solar Power Waste Northern Europe Snowmen BIGBOSS Cement Bagging
gl bal
January 2021
cement
TM
TM
PHOTOGRAPHY COMPETITION 2021 WINNER
This issue’s front cover showcases the winning entry in
Bagging
the Global Cement Photography Competition 2021. It was MAGAZINE
BIGBOSS Cement
submitted by David Alvarenga of Yguazú Cementos SA and
Snowmen
shows the inside of the clinker dome at the company’s plant
Northern Europe
in Villa Hayes, Paraguay.
Waste
Solar Power
Fans
David’s winning entry beat more than 250 other entrants Exclusive Official Magazine for
Smart Technology
from all around the world in the eyes of the judges and Global Cement Conferences: Global CemFuels,
Tips for 2021

earns him a cash prize. See if your entry is among the other Global Ash, Global Slag, Global CemProducer,
News
showcased finalists on Pages 8-12. FutureCem, Global CemBoards, Global WellCem,
Global CemProcess, Virtual Events
globalcementMAGAZINE
Editorial Director
Dr Robert McCaffrey
[email protected]
(+44) (0) 1372 840 951
Welcome to the January 2021 issue of Global Cement Magazine - the world’s most
Editor
widely-read cement magazine - and Happy New Year! We hope that the Christmas
Dr Peter Edwards
and New Year break offered you the opportunity to take stock after 2020, the most [email protected]
unusual year in living memory, and to recharge for the challenges that 2021 will (+44) (0) 1372 840 967
inevitably bring. Hopefully the picture for the global cement sector - and the wider
economy - will be one of gradual recovery. However, as Proudfoot’s Angus Maclean
points out in his five point plan for the year (Page 14), there will be a ‘rollercoaster
Web Editor
race’ to recover among cement producers. To paraphrase, Angus anticipates that David Perilli
the first quarter of 2021 will be the final quarter in which the global economy will [email protected]
be in suspended animation due to the pandemic. The second and third quarters (+44) (0) 1372 840 952
will record significant year-on-year growth, with the fourth quarter representing
something of a plateau. A lot of the recovery is reliant on the rapid roll-out of
vaccines for Covid-19, which have been developed at incredible speed by a number
Editorial Assistant
of companies. In our clamour to get back to ‘normal’ - more on this topic on Page Jacob Winskell
65 - it is easy to lose sight that the development of even a single effective vaccine in [email protected]
less than a year, rather than the normal 5-10 years is incredible. Indeed, as we go (+44) (0) 1372 840 953
to press the first recipients have just been given the Pfizer vaccine in the UK. If you
had suggested that as a possibility to me in May 2020, I’d have shaken your hand
off... digitally of course.
Commercial Director
Elsewhere in this issue, we have a look at digital payload optimisation with authors Paul Brown
[email protected]
from INFORM (Page 16), ‘smart’ servicing with Beumer Group (Page 20) and Mobile: (+44) (0) 7767 475 998
carry an in-depth interview with Ishmael Ordonez, Senior Vice President for
Administration at ‘green’ cement producer BIGBOSS Cement in the Philippines
(Page 50). We also take in the cement sector of Northern Europe, one that has
been contracting in recent years (Page 32) and there are technical contributions Company manager
Sally Hope • [email protected]
on fans (Page 43), air cannons (Page 44), roof-top solar installations (Page 56)
and a bagging plant installation (Page 58). Last but not least, the runners-up and Subscriptions
Amanda Crow • [email protected]
selected other finalists in the Global Cement Photography
Competition 2021 are showcased on Pages 8-12. Office administration
Jane Coley • [email protected]
Enjoy the issue!
Views expressed in articles are those of the named author(s).
For details on submission, see: www.GlobalCement.com
Peter Edwards
Editor
ISSN: 1753-6812
Published by Pro Global Media Ltd
Printed on Programme for the Endorsement
Ground Floor, Octagon House, 20 Hook Road,
Cement
Industry of Forest Certification (PEFC®) certified papers Epsom, Surrey, UK KT19 8TR
Suppliers’ by Pensord, a company with ISO 14001:2004 Tel: +44 (0)1372 743837 / Fax: +44 (0)1372 743838
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Global Cement Magazine January 2021 3

cooling tower. Despite an abu
Subscribe snowmen formed every week
GLOBAL CEMENT: CONTENTS
Ad Index
shotgun blasts and high-press
plant vast amounts of time and
In 2018, the plant tried a
adjusted the chemistry of the
Features Below: IGS 200L air all air cannons with IGS 30
cannons with high veloc- high velocity nozzles. The imp
8 Global Cement Photography CompetitionityWinners nozzles have entirely
eliminated delays due to
matic. Following the changes,
months without snowmen-re
Will your entry be part of our 2021 showcase? snowmen at a cement plant
in Indiana, US. build-ups were formed and,
14 Proudfoot’s Five-point plan for 2021

Consulting firm Proudfoot presents its top tips for the
cement sector’s recovery over the year ahead.
Technical
16 Payload optimisation: How to get
the most out of your trucks
Authors from INFORM GmbH look at ways to
save outgoings via fleet optimisation.
20 Service 4.0: On-site,

without being there

Beumer’s Smart Glasses open up
new opportunities for maintenance
and trouble-shooting. 54 Global Cement Magazine January 202
22 Global Concrete News
24 Products & Contracts News
Europe
26 News
30 A letter from Buzzi Unicem
32 Cement in Northern Europe

Global Cement turns its attention to the cement industries of

Denmark, Estonia, Latvia, Lithuania, Norway and Sweden.
4 Global Cement Magazine January 2021

undance of these, 2-3 velocity of the discharge. That is often sufficient to
k. The staff had to use eliminate build-up problems.
sure water, costing the
Why did this approach work?
GLOBAL CEMENT: CONTENTS
d money.
different approach. It This new approach worked because volume (mass)
process and replaced and velocity are the most important variables for
00L air cannons with cleaning efficiency. This is because both are posi- Americas
provements were dra- tively correlated to force, momentum and kinetic
the plant ran for eight 38 News
energy, the three main components of power. 42 Titan Florida earns global cement sector’s first
related delays. Fewer TRUE Platinum Zero Waste Certification
when snowmen did Force = mass x acceleration
Momentum = mass x velocity
Kinetic Energy = 0.5 x mass x velocity2
43 Successful fan retrofit at a cement plant in South America
An air cannon with more force, more momentum, Howden reports on a rapid fan retrofit project.
and more kinetic energy will clean more powerfully.
Volume 44 Eliminating snowmen at a cement plant in Indiana

The majority of air cannons in the cement industry
Integrated Global Services reports on an air
are 70L air cannons. When a 70L air cannon is un-
cannon system retrofit in the US.
able to provide sufficient cleaning power, suppliers
often recommend upgrading to a 150L cannon.
Why do they not make the same recommenda-
tion (up to 300L) when a 150L air cannon is unable
to provide sufficient cleaning power? The plant in Asia
Indiana had many 150L air cannons but was unable
to eliminate the snowmen from the centre of the 46
News
tower.
IGS’s laboratory data confirms the positive cor-
relation of volume and power. Air cannons were 50 Plant report: BIGBOSS Cement, Philippines
placed in front of a 66.8kg (145lb) sled at distances
of 12.7mm, 914mm and 1524mm. They were dis- BIGBOSS Cement’s Ishmael Ordonez speaks about the company’s
background, its unusual production process and local markets.
charged with varying gas volumes, velocities and
21 56 Installation of roof-top solar panels

at JK White Cement’s Gotan plant
Roof-top solar installations offer a rapid return on investment.
58 Innovative engineering: The fastest

ever installation of a packaging line
Haver & Boecker reports on an ingeneous approach to a tight
project deadline and limited footprint in Australia.
Middle East & Africa

60 News
Regulars & Comment

63 Global Cement prices 64 Subscriptions 65 The Last Word
Cement prices from around the world.
Subscribers receive extra information.
66 Advertiser Index & future issues

GLOBAL CEMENT MAGAZINE: DIARY DATES
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ADVANCED PROCESS CONTROL
INNOVATIVE MEASUREMENTS
KILN SHELL COOLING

ON THE SPOT
WITH KILNCOOLER
INFRARED CONTROLLED
WATER COOLING OF KILN SHELL
– expansion of kiln‘s operation time
– reduced mechanical tension
– fast, but carefully cooling down
– energy savings
THAT‘S WHAT WE CALL THE KIMA PROCESS.
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KIMA January 2021.indd 1 15/12/2020 16:33

GLOBAL CEMENT: PHOTO COMPETITION 2021 - WINNER
News Tips for 2021 Smart Technology Fans Solar Power Waste Northern Europe Snowmen BIGBOSS Cement Bagging
gl bal
January 2021
cement Contents
TM

Subscribe
Ad Index
Bagging
BIGBOSS Cement
Snowmen
Northern Europe
Waste
Solar Power
Fans
Smart Technology
Tips for 2021
News
Above - Winner:
The winning image in the
Global Cement Photography
Competition 2021 was submit-
ted by David Alvarenga from
Yguazú Cementos. It is shown
on the front cover of this issue
of Global Cement Magazine. It
shows the inside of the clinker
dome at the company’s Villa
Hayes plant in Paraguay.
Right - First Runner Up:

The first runner up was Irfan
Hussain, with his image of
Pioneer Cement in Pakistan.

GLOBAL CEMENT: FIRST RUNNER UP

GLOBAL CEMENT: PHOTO COMPETITION - RUNNERS UP
Above - Runner Up:

Heracles GCC Milaki Plant,
Greece, by Thanassis
Anagnostopoulos.
Below - Runner Up:

LafargeHolcim Alesd plant in
Romania, by Cristian Carstoiu.

GLOBAL CEMENT: SELECTED FINALISTS
Right - Honourable Mention:

Cemento Fortaleza, Merida, Yucatan, Mexico.
André Wehner, Gebr. Pfeiffer, Inc.
Below Right - Finalist:

New graffiti on the west-facing side of the Kirchdorfer cement plant
in Austria. Claudia Feßl, Kirchdorfer Zementwerk Hoffmann GmbH.
Bottom of Page- Honourable Mention:

Biskria Cement, Algeria. Monousos Petrakakis, Athens, Greece.
Below - Honourable Mention:

Editions of ‘Cement’ by Fyodor Gladkov at the Novorossiysk Cement
Museum, Novorossiysk, Russia. Anna Dobrovan.

GLOBAL CEMENT: SELECTED FINALISTS
Above - Honourable Mention: Walk on Mars, Elena Beresneva. The location is the Uralsky
Mars clay quarry, Bogdanovich City, Sverdlovsk Region, Russia.
Above Right - Honourable Mention: Finished Cement, by Fazlul Karim Chowdhury,

LafargeHolcim Bangladesh Ltd.
Right - Honourable Mention: Photograph of Scene in cement by

Maxim Zubov, Nizhny Tagil, Russia.
Below - Finalist: A new finish mill at the Ash Grove Cement Louisville plant in Nebraska, US.
José Venegas-Guevara, Ash Grove Cement, a CRH Company.
Scan the QR code...
...or visit...
www.globalcement.com/
photography-competition
...to see more entries

from the Global Cement
Photography Competition!

19 JANUARY 2021 ON YOUR DESKTOP
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GLOBAL CEMENT: TRENDS
Angus Maclean, Proudfoot
Proudfoot’s Five-point plan for 2021
Based on recent conversations with top construction and building materials executives
and its 75-year history of implementing industry best practice around the world,
consulting firm Proudfoot presents its five top tips for the global cement sector in 2021...
M ost of us would probably say that 2020 was

nothing like the year we would have an-
ticipated 12 months ago. The year brought massive
idly and to be sure that you have access to the
necessary raw materials, fuels and logistics capaci-
ties, particularly in the second quarter of 2021.
uncertainty and many challenges to the global ce- Margins are likely to come under pressure dur-
ment sector. It also brought big changes in the way ing 2021, both from the supply side, e.g.: when
we work and live. We are all now experts at work- securing raw materials, and the demand side, e.g.:
ing remotely and at video conferences. As I write, from construction clients. As the construction
the second wave of Covid-19 is peaking in Europe market moves from residential/commercial to
and there is now line of sight to Covid-19 vaccines. infrastructure, there may be pressure on volumes
There could be a third wave in the first quarter and price. By launching rapid, targeted cost reduc-
Above: Angus Maclean, of 2021, but vaccines raise the likelihood that re- tion, optimisation of capital projects and revenue
Proudfoot.
strictions could be lifted in the spring, bringing a enhancement programs, you can compensate for
much-needed boost to the global economy. these challenges and, at the same time, get your
Hence, we anticipate that there will still be sig- sales staff back up to full speed.
nificant uncertainty in the first quarter of 2021 and
Decarbonation
2
anticipate that sector performance will be similar
to the same period of 2020 for most players. The Lower carbon prod-
second and third quarters of 2021 should, we think, ucts are increasingly
present significant volume increases, meaning that required by the mar-
all players will need to be ready to run at full capac- ket. Operating with
ity. The fourth quarter of 2021 should see a plateau. recycled materials
Our strategies for navigating in these uncertain and circular econo-
conditions are: mies with lower
emissions is becom-
Race to recovery and ing the way to get
1
resilience ahead of the com-
Plan for a ‘rollercoaster race petition. There was
to recovery,’ as there will a lot of publicity in
still be significant uncer- the market with Net
tainty during the first half Zero campaigns and
of 2021. Improve your sales Green Deals pledges
and operation planning and in 2020.
financial forecasting even Proudfoot fore-
further, as these will be key casts that ‘discipline
to managing preservation in execution’ of the
of cash runways. Proud- plans will be key in the coming year to enable the
foot’s recommendation is to pledges to be achieved. So, accelerate your new
maintain customers’ expec- product programmes and service offerings. Ac-
tations by being extremely celerate co-financing projects in CO2 capture and
easy to do business with. storage (CCS), new cementitious mixes and renew-
Similarly, with suppliers, able energy projects like solar and wind farms with
increase the frequency of partners, for example private equity firms. The ce-
communication in order ment sector offers them the possibility of being seen
to ensure they are able to to invest in environmental, social and governance
respond to changes rap- companies.

GLOBAL CEMENT: TRENDS
Asset footprints
3
Current asset
footprints are not nec-
essarily adapted to the
future markets and
the coming decarbon-
ised world. Implement
‘ahead of the future’
environmental and
pollution regulation
changes to be ahead
of the pack! Eliminate
old plants and or up-
grade them now. For
plants covered by the
EU Emissions Trading
Scheme (ETS) do not
wait until payments
stop.
There will be opportunities to acquire, divest,
bolt-on and close plants. Redesign your footprint
based on the future market attractiveness and value People
5
creation potential. Nobody wants to overpay or
undersell. However, by accelerating your opera- Covid-19 social distancing, lockdowns,
tional due diligence and post-merger integration working from home and downsizing scarred
capabilities, you can take the lead. Shareholders, for the cement sector’s workforce during 2020.
the most part, wrote off 2020. They will want to see The result is that many excellent candidates
returns, speed and certainty to cash in 2021. Other are now available or looking to move. Get
sectors are going to be less attractive, so this could ahead of the pack and recruit staff who
present the sector with an opportunity to increase would not normally be attracted to the ce-
its shareholder attractiveness. ment sector. Implement heads-up leadership
and active management behavioural change
Digitise programmes. These will help lead your staff
4
Digital programs will be out of the crisis by engaging, enthusing and
an important lever as in energising them!
previous years, as these
can help the sector achieve
many of its goals. Unfortu-
nately, these programs are
not yet delivering the value
they initially promised.
We recommend imple-
menting next generation
operational and digital
Target Operating Models Top: Cement producers, their
(TOMs). These use digital staff, customers and suppliers
have all been forced to adapt
and operational solutions
to new business practices over
and tools to enhance each the past 12 months.
element / building block of
an efficient cement busi-
ness, in contrast to costly Left: While Covid-19 was
global IT / Operational extremely disruptive during
Technology / Internet of 2020, cement producers
should be able to see
Things proof of concept beyond the pandemic
projects. Digitisation should not only optimise the in 2021. Be ready!
value chain, end-to-end, but also humanise the
processes. New technologies need to add to existing
human capabilities, not replace them.

GLOBAL CEMENT: PAYLOAD OPTIMISATION
Thomas Bergmans and Dirk Schlemper, INFORM GmbH
Payload optimisation: How to

get the most out of your trucks
Payload, or how much a truck can safely load and haul, is a key specification for truck
buyers. On the road to lower costs and better service in cement logistics, higher payload
ratings promise to deliver more with less. This article looks at the limits of such traditional
approaches and explores digital ways to boost the payload of your fleet.
A ny home improvement project requires at least

one trip to the local DIY shop. As we all know,
hauling heavy construction materials like cement
bulk and bagged cement operations, managing
payload is key to safety, efficiency and profitability.
In particular, bulk material logistics is all about
bags can be challenging without the right vehicle or weight, and every kilogram saved from a truck or
trailer. However, even the most powerful and sturdy trailer’s tare weight means more payload and greater
car/trailer combination has its payload limit, i.e. profitability per job.
the maximum amount of weight it can safely hold Here is a simple calculation: Saving 200kg from
and transport. Overloading a trailer might be very a cement bulk truck that undertakes 2.5 loads per
tempting, as it avoids multiple trips to and from the day results in a payload gain of 500kg per vehicle
shop. These are both time-consuming and add extra per day. With a fleet of 150 vehicles over a 12-month
costs to the project. However, safety considerations period, the gain amounts to 18,750t. Using 28t bulk
outweigh all others. Overloading a vehicle beyond its tankers, that equates to 670 full truckloads. Or in
payload limit can cause serious accidents and major other words, one truck out of the 150 trucks is not
damage to the chassis, brakes, wheels, or engine. needed.
For this reason, the trend among truck and
Losing to gain trailer manufacturers is to produce vehicles with
Whether you are a ‘DIY-er’ or a dispatcher at a ce- the lightest possible tare weight to allow for as much
ment plant running the outbound logistics for your payload as is legally permitted. It is an envelope that
Right - Figure 1:
Payload optimisation
in cement logistics.

Left - Figure 2: Digital

Planning Speed in FTL and LTL
Operations.
is constantly being pushed, with new approaches to

challenge the design of structural and mechanical
components in search of the perfect solution.
Another way to gain payload is to cut weight
from your truck’s body that is not needed, for exam-
ple by removing onboard compressors. Depending
on size, on-board units may weigh up to 400kg, plus
the additional weight of the power take-off (PTO)
to tap the truck’s diesel engine. Many customer sites
provide cleaner, onsite compressor units which can
be used to unload cement into silos instead.
The limits of losing

As a first step, all these measures are great and are
needed. But, as with all first steps, there are limita-
tions as to what can be achieved. Some of them may
even be beyond a cement producer’s control. Many Payload 4.0
operate a mixed fleet of their own trucks and con-
tract hires or make use of the spot market. Stripping 200kg from a truck is a mechanical chal-
A more challenging way to move more payload lenge that requires traditional tools, but boosting
is to increase the loaded ratio of your fleet. A truck fleet productivity from 2.5 to 3.0 is a planning
running empty or inefficiently, is money down the challenge that requires digital tools powered by al-
drain. Reducing empty runs can be achieved by gorithms. The cement transport planning phase is
finding suitable backhauls for the return trip to the generally split into three stages: strategic planning,
cement plant. Fly ash hauls from nearby coal-fired tactical scheduling, and real-time optimisation.
power plants, for example, can mean a substantial More than any other job, being a dispatcher
gain in payload. Removing inefficiencies by improv- brings a tremendous amount of pressure and stress.
ing the overall quality of your strategic, tactical, and Each day is a challenge. Stages two and three of the
real-time planning is the ultimate yet most reward- planning phases can take their toll in particular. The
ing challenge. It offers the highest gain in payload, decisions they have to make are incredibly complex
productivity and profitability. and time-critical: assigning trucks and haulers,
Let us circle back to the simple calculation above: juggling with ad-hoc orders, tracking and tracing
with a fleet of 150 trucks and an average productivity all trucks and orders in real-time, tackling driver
of 2.5 loads per day, the total annual shipping vol- shortages and driver hours of service, balancing
ume would be 2.65Mt. If productivity of each truck costs and service levels, maintaining a high on-time
was increased to let’s say three loads per day, just in full (OTIF) performance, dealing with customer
125 trucks would be needed to ship the same annual complaints, etc. In short, when it comes to creating
volume. This means 25 fewer trucks. Remember, complex delivery schedules and fleet configurations
reducing the weight resulted in a saving of just one for the following shift(s), spreadsheet-based tools or
truck.

For an LTL fleet with 250 trucks, two to

three trips per shift and up to 10 stops per
trip, tailor-made LTL algorithms need up to
15 minutes to punch out an optimised deliv-
ery schedule for the fleet.
Electric payload
With the promise of zero tailpipe emissions,
the era of electric freight transportation
has almost arrived. Development of battery
technology is making electric heavy-duty ve-
hicles technically and commercially viable.
Several truck manufacturers have already
introduced EVs. Diesel undoubtedly will re-
main the hauling industry’s primary fuel for
several years to come, but electric trucks will
become an increasingly important piece,
particularly in urban LTL distribution.
The European Automobile Manufacturers
Association (ACEA) expects 200,000 elec-
Above - Figure 3: Tailor- other legacy systems are not enough to support the tric trucks to be on the road by 2030, around
made LTL algorithms can decision-making process. 4% of the total fleet.
improve bagged cement
Substantial gains in planning speed and quality At this stage, however, electric trucks
logistics significantly.
will only come from AI powered optimisation tools come with higher costs than diesel models,
that are embedded into a wider digital supply chain. along with range limitations and added
They allow transport planners to do incredibly com- weight that will cut into the payload capacity.
plex, time-critical calculations with ease. What‘s On the plus side, they offer less noise which
more, algorithms can take a larger range of variables makes them suitable for early or late-night
into account and can process more data faster than deliveries, even at urban construction sites
the human mind can, effectively removing human and thus reduce peak traffic over the day.
error from the dispatch formula. This, in turn, leads Access to low or ultra-low emissions zones
to significant efficiency increases and subsequently will further spark the adoption of commer-
carbon footprint reductions across your entire fleet. cial EVs in the building materials industry.
Much of this technology has its roots in supply Besides payload constraints, integrating
chain optimisation; and in the mid-1990s, sparked electric vehicles into your fleet will also add
by massive improvements in low-cost computer further dimensions to the daily planning
power, it also entered our industry. Redlands in challenge in terms of battery capacities, out-
France (now LafargeHolcim) was the first company side temperature, charging infrastructure,
in the aggregates and ready-mix industry to use elevation profiles of routes, etc.
the authors’ transport planning tool to optimise
their truck fleet operations. Six years later, Pioneer Trailer for rent
in Australia (now Hanson and part of the Heidel- Whether your fleet is powered by diesel
bergCement Group), followed. or battery, digital planning tools powered
The time required to solve a transport planning by algorithms will bring the highest gains
problem grows relative to the size of the problem. in payload, productivity, and profitability
Less than truckload (LTL) planning for bagged ce- to your operations. Even cement produc-
ment logistics, for example, usually involves several ers with a mixed fleet of their own trucks,
stops along a delivery route, compared to just one contract hires, and spot market loads will
stop in bulk cement logistics. Figure 2 gives an indi- benefit significantly. Like the DIYer in our
cation of what algorithms are capable of in terms of opening case, improper planning leads to
speed and quality nowadays. extended rental periods or additional hires,
For a full truck load (FTL) fleet with 250 trucks, thus higher costs and project delays. Cement
three to six trips per shift and one stop per trip, it producers who are content with their status
takes less than two minutes for the author’s trans- quo and hesitate to invest into latest digital
port planning tool to come up with an optimised planning tools, should pay heed to the old
delivery schedule for the entire fleet. DIY-er advice: “Always pick the right tool
for the job!”

13 APRIL 2021 ON YOUR DESKTOP
Cement and clinker shipping,

trade, transport and
logisitics - from silo to site
www.cem-trans.com
VIRTUAL
Cemtrans2021.indd 1 15/12/2020 18:02

GLOBAL CEMENT: NEW TECHNOLOGY
Beumer Group
Service 4.0: On-site, without being there
With Beumer Smart Glasses, the company’s customer support staff can access customers’
systems and solve problems together with on-site staff, without being there.
M achine malfunctions that are not eliminated

quickly can become expensive. To help get
machinery back up and running as quickly as pos-
Dortmund made this digital solution ready for the
market. “From October 2018 to January 2019, long-
term tests were carried out with various customers,
sible, Beumer Group developed the pioneering including one with live testing with a long-term cus-
Beumer Smart Glasses. The Beumer Customer Sup- tomer from the building materials industry,” reports
port technicians use them to take a virtual look ‘over Kirsch. The user has been using a high-capacity
the shoulder’ of the customer’s service technician Beumer paletpac palletiser and a high-capacity
to solve the problem together. This digital solution Beumer stretch hood packaging system for years.
reduces travel times and costs.
“With the Beumer Smart Glasses, our custom- Reduce idle times
ers can get in live contact with our service experts Traditionally, if users are not in a position to handle
anywhere and at any time,” explains Christopher faults by themselves, the Beumer Group would send
Kirsch, team leader of BG.evolution, a Beumer a technician to minimise downtimes. Customers can
Group spin-off company at the Technical University also receive qualified telephone support for trouble-
of Dortmund. “Beumer is working on a customer shooting, which is available 24/7. However, it can be
problem with the support of start-ups to develop challenging to successfully communicate complex
‘Minimum Viable Products’. These are minimally problems quickly and clearly over the phone. The
equipped prototypes whose market potential and Beumer Smart Glasses make it possible.
customer acceptance we put to the acid test,” ex-
plains Kirsch. This makes it easier for the Beumer Just put them on and get started
Group to decide quickly whether a new technology To use the Beumer Smart Glasses, an employee at
makes sense to develop into a finished product. the machine puts them on and starts the Beumer
Together with their colleagues from Beumer Support App via voice command. The employee
Customer Support and the Department for Research transmits a service number and a pin code to the
and Development in Beckum, the employees in hotline. A connection with images and sound is
then established. The Beumer technician receives
the same image as the customer. The technician can
directly give instructions and display all relevant
information in the field of vision. The employee has
both hands free to follow the instructions of the ex-
pert and carry out the necessary actions.
Through this approach, faults can be solved
quickly and precisely at any time. Beumer’s experts
are available around the clock, seven days a week.
Right: The service technician
“Language barriers or the lack of specialised knowl-
has all important information
displayed in the live image edge are no longer relevant for trouble shooting,”
of the camera via the Beumer explains Kirsch. “Together with the user, we can also
Smart Glasses. better validate why the fault occurred based on the
recorded images.”
“Users can add the Beumer Smart Glasses as an
extension to their monthly or annual hotline ser-
vice agreement. Many of our customers are already
showing clear interest,” explains Christopher Kirsch.
Together with BG.evolution, the Beumer Group is
currently developing further digital products under
the umbrella of ‘Smart Solutions.’

ADV-Plastretard-2018-297-210.pdf 1 27/06/2018 13:10
CM
MY
CY
CMY
K
GLOBAL CONCRETE: NEWS
Germany: COBOD supplies concrete printer to 3D-printed apartment project site
D enmark-based COBOD has supplied its BOD2 3D construc-

tion printer (shown right) to the site of the world’s first
3D printed commercial apartment building in Wallenhausen,
Bavaria, Germany. COBOD’s partner PERI will use the product to
print a 380m2 complex that consists of five apartments across
three floors.
Henrik Lund-Nielsen, general manager and founder of
COBOD, said “We are incredibly pleased that we are beginning
to see the fruits of the many 3D construction printers we have
sold. The actual building projects have been delayed by the
Coronavirus outbreak, but now they start to be revealed. This
new German project is really a great milestone as the com-
mercial nature of the building proves the competitiveness
of the 3D construction printing technology for three-storey UK: Regen supplied to
buildings and apartment buildings. This opens entirely new sustainable bridge
markets for our printers.”
A stainless steel and concrete bridge,

the first of its kind in the UK, has
been built in Pooley Bridge, Cumbria.
The structure (shown left) replaces its
250-year-old stone predecessor that
was destroyed by severe flooding. The
new bridge has been designed to with-
stand extreme weather conditions.
Hanson UK, part of Heidelberg-
Cement, worked with contractor Eric
Wright Civil Engineering to create a be-
spoke concrete mix for the lower arch
of the steel bridge that was designed
and constructed to provide structural
strength. The high early strength
concrete mix included Hanson Regen
ground granulated blastfurnace slag.
In total 1200m3 of concrete contain-
ing Regen was supplied from Hanson’s
Americas: LafargeHolcim starts ECOPact rollout nearby Penrith concrete plant to create
the lower arch, bridge deck, bridge
L afargeHolcim began the roll-out of its ECOPact low-carbon con-

cretes in its Latin America region in late November 2020, when
it launched the product range in Ecuador, Colombia and Mexico. It
abutment and walls, highway ap-
proach retaining walls and several
temporary works.
says this will help it meet growing demand for green products in
the region. ECOPact products launched in the EU, the UK, the US
and Canada earlier in 2020. The group will launches the range in
other markets in early 2021.
UK: Cemfree supplied to flood defences
D B Group has supplied its Cemfree concrete product to a site

in Birmingham, West Midlands, for use by the Environment
Agency in a flood defence project (see right). It says that the
agency will use the concrete for kerb bedding and backing over
several kilometres in conjunction with various recycled products
in an effort to reduce the project’s carbon footprint. Cemfree is a
low carbon concrete made using ground granulated blast furnace
slag (GGBS) and pulverised fly ash.

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GLOBAL CEMENT NEWS: PRODUCTS & CONTRACTS
Contents
Ethiopia: 5000t/day plant deal for Abay and FLSmidth
Subscribe
Ad Index
D enmark-based FLSmidth says that its contract with Abay Industrial
Development Share Company for engineering, procurement and su-
pervision on the upcoming Dejen cement plant is now effective. The 5000t/
day plant will cost US$120m and will create new 300 jobs, according to the
supplier. It said that the plant will ‘play an important role for the develop-
ment of local infrastructure.’ The supplier is responsible for design and
engineering, full equipment supply, automation systems, installation and Greece: FLSmidth
commissioning, as well as training and extended supervision. Key deliveries
are due to begin in late 2021.
services for Titan
FLSmidth president Carsten Riisberg Lund said, “We are happy to see
the contract now in effect. Following months of challenging working
conditions on sites around the world, we are eager to get started on the
T itan Cement has signed a
new service agreement with
Denmark-based FLSmidth. The
project. This contract once again underlines our position as the preferred agreement covers sustainabil-
supplier of sustainable and productivity-enhancing solutions to the global ity, digitisation and productivity
cement industry.” support for 17 of the producer’s
cement plants in Europe,
Africa and the Americas.
Titan Group strategic
Kuwait: ACICO contract for Cemengal planning director Antonis
Kyrkos said “We are con-
S pain-based Cemengal says that it has received a second order from

ACICO Cement for a 1Mt/yr ball mill with a XP4i-130 type Magotteaux
classifier for a new grinding plant.
stantly on the lookout for
more efficient ways of run-
ning our operation. With this
The company said that the project, which it expects to commission dur- service partnership agree-
ing the first quarter of 2021, encompasses “Full engineering and complete ment, we tap into a wealth
supply of mechanical, process, electrical and automation equipment, as of know-how and hundreds
well as steel manufacturing from the raw materials handling areas up to of specialists without car-
the silos for cement discharge. In addition to the delivery of technology, the rying the full cost. The
contract includes site supervision, training and commissioning activities.” two-and-a-half-year agree-
The supplier said that the new mill would help the client to satisfy ment allows both parties to
growing demand for high quality cements for major infrastructure devel- work strategically on main-
opments in Kuwait. tenance programmes and
upgrade projects based on
data and the best allocation
Belgium: Magotteaux launches Expand wear parts of resources.”
M agotteaux has launched Expand, a vertical roller mill wear parts prod-
uct line for the cement industry. The equipment supplier says that the
range offers high resistance, consistent production, energy efficiency and
lower maintenance and replacement frequency. It also uses a scrap buy-
back program to address product lifecycle concerns. The wear parts line
comes in two variants: Expand One, the standard metal matrix composite
(MMC) product; and the higher performance Expand+.
Bangladesh: Holcim Water Protect launched
L afargeHolcim Bangladesh has launched Holcim Water Protect, a

water-resistant cement that has been developed in collaboration with
the group’s Innovation Centre. The company reports that the product
is formulated and customised for the Bangladeshi market by leveraging
LafargeHolcim Group’s Smart Blend Technology (SBT).
It adds that Holcim Water Protect ‘ensures reduced capillary action, re-
sisting the permeation of water thus making it damp and seepage resistant.’
The company says that use of the product will result in ‘stronger and more
durable homes’ compared to using OPC.

GLOBAL CEMENT NEWS: PRODUCTS & CONTRACTS
India: Shiva plant contract for ThyssenKrupp and Larsen &Toubro
S hiva Cement plans to invest around US$200m

towards a new integrated cement plant in Sunder-
garh district, Odisha. The 1.36Mt clinker unit will also
and indirectly. Commissioning is scheduled to take
place by March 2022.
Parth Jindal, the managing director of JSW
include a 1Mt/yr grinding unit, an 8MW waste heat Cement, the parent company of Shiva Cement, said
recovery (WHR) unit, 4Mt/yr crushing plants at its “The new clinker unit at Shiva Cement in Odisha will
dolomite and limestone quarries, a connecting 10km provide a strategic advantage to service the needs of
belt conveyor and a dedicated railway siding with a our customers in the region and further strengthen
12km track to the main network. JSW Cement’s leadership position in the Green Ce-
ThyssenKrupp Industries India will supply a ment category in India.”
4000t/day clinker production line for the project. Shiva Cement intends to use the new plant as
Larsen & Toubro has been awarded the contract for a strategic hub to access markets in the east of the
civil, mechanical and refractory erection work. The country. It is part of the group’s aim to achieve a pro-
unit is expected to create around 500 jobs directly duction capacity of 25Mt/yr by 2025.
Germany: Floating solar power Image: Floating solar panels

at HeidelbergCement’s
S pain-based Isigenere has installed a 739kW floating

solar power plant on a lake at HeidelbergCement’s
Dettelbach quarry in Bavaria, Germany. The 1896-
Dettelbach quarry.
Source: Isigenere.
panel solar power array, Bavaria’s largest, will power

HeidelbergCement’s operations at the quarry.
Austria: A TEC Flash Dryer for Tanzania: New pozzolana product

Lafarge Mannersdorf from Mbeya
L oesche subsidiary A TEC has won a contract for

the supply and installation of a Flash Dryer for
alternative fuels (AFs) in the kiln line of Lafarge
M beya Cement, part of LafargeHolcim Tanzania,
has launched Lafarge Tembo Pozzi, a pozzolana-
based cement product. It is intended to replace
Zementwerke’s 1.1Mt/yr Mannersdorf cement plant imports of fly ash, according to local press. At present
in Lower Austria. The supplier said that it will com- the country imports 40,000t/yr of fly ash for the con-
plete the project in early 2021. struction industry.
India: Double Shree Cement order for Gebr. Pfeiffer
S hree Cement has ordered two vertical roller mills from

Gebr. Pfeiffer for an upcoming clinker line at its Raipur
cement plant in Chhattisgarh. They are the 35th and 36th
Gebr. Pfeiffer mills to be ordered by the company.
An MVR 6000 R-6 type raw mill will grind 800t/hr of
raw material and have a drive power of 8700kW. It will be
equipped with an SLS 6000 VR high-efficiency classifier.
An MPS 2800 BK type mill will be used to grind coal at
a rate of 28t/hr. This mill will have a drive power of 720kW
and will be equipped with the latest version of the inte-
grated SLS 2900 BK high-efficiency classifier optimised for
MPS mills.
Gebr. Pfeiffer said “While the core components of the
mills as well as the drive units will be supplied by Gebr.
Pfeiffer from Europe, the Indian subsidiary Gebr. Pfeiffer
(India) will provide components such as the mill and
Above: An MVR 6000 R-6 vertical roller mill previously
classifier housings, the steel foundation parts as well as installed by Gebr. Pfeiffer for a client in Africa.
internal parts of the classifiers.”

GLOBAL CEMENT NEWS: EUROPE Contents Subscribe Ad Index
France: Ciments Calcia to shrink asset and carbon footprints
H eidelbergCement’s subsidiary Ciments Calcia

plans to stop clinker production at two plants as
part of a Euro400m investment and reorganisation
structures of our French sites,” said Dominik von
Achten, chairman of the managing board of Heidel-
bergCement. “We want to considerably speed up the
programme for several of its sites in France. Around modernisation of our plants in order to enhance our
Euro300m of this will be spent at the integrated Airva- performance in France, while ensuring alignment
ult cement plant. The company also intends to: convert with the goals of the Paris agreement. This is why we
its integrated Gargenville cement plant into a grind- focus our initiatives on the main CO2-emitting plants
ing plant and shut down its kiln systems and quarry in France.”
operations; convert its integrated Cruas
white cement plant into an automated ce-
Image: Ciments Calcia’s Airvault plant.
ment terminal for the distribution of white Source: Ciments Calcia website.
cement; and adapt the organisation at its
French headquarters at Guerville. The plan
will cut 162 jobs but create 20 new ones.
“As part of our global business excel-
lence initiative, we intend to further
optimise effectiveness, processes and
Germany: Catch4Climate project moves to planning stage
T he Catch4Climate project has moved into the planning

stage of its oxyfuel pilot plant at Schwenk Zement’s Mergel-
stetten cement plant in Heidenheim, Baden-Württemberg. The
The cement producers formed CI4C –
Cement Innovation for Climate in late 2019.
The aim of the Catch4Climate project is to
group, which also comprises Buzzi Unicem’s subsidiary Dycker- create the basis for a large-scale applica-
hoff, HeidelbergCement and Vicat, signed a letter of intent with tion of CO2 capture technologies in cement
the state’s Prime Minister in Stuttgart in mid-November 2020. plants enabling the later use of CO2 as a raw
The consortium intends to build and operate its own dem- material in other processes such as carbon
onstration plant on a semi-industrial scale, to use the oxyfuel capture and utilisation/storage.
process to capture CO2. In the future, the captured CO2 will be
used to produce so-called ‘reFuels,’ climate-neutral synthetic
fuels such as kerosene for air traffic, with the help of renewable
electrical energy.
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NEWS: EUROPE
Germany: Low-CO2 cement from

Buzzi Unicem’s Dyckerhoff
B uzzi Unicem subsidiary Dyckerhoff has

received general building inspection
approval from the German Institute for Build-
ing Technology for the Portland composite
cement CEM II / CM (S-LL) produced by its
Amöneburg and Deuna factories. It is the first
to receive approval to sell this class of cement,
which contains both slag and limestone,
in Germany.
The use of CEM II / C cements reduces CO2
emissions from building with cement and con-
crete due to their lower clinker factor. CEM II /
CM (S-LL) emits 39% less CO2 per tonne of ce-
ment compared to CEM I cement. Compared
to the current binder mix, CEM II / C cements
have the potential to reduce CO2 intensity
With
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Ireland: CRH earnings rise

despite pandemic
C RH recorded earnings before interest,

taxation, depreciation and amortisation
(EBITDA) of Euro2.8bn in the first nine months
of 2020, up by 2% year-on-year on a like-for-
like basis from the corresponding period of
2019. The company said that it expected full-
year EBITDA in 2020 to exceed 2019 levels on
a like-for-like basis at over Euro3.6bn. Sales
fell by 3% to Euro17.0bn but the group added
that it had ‘continued strong cash generation.’
CEO Albert Manifold said “Markets con-
tinue to be impacted by the global pandemic
and, while we have seen some lower activ-
ity levels, I am pleased to report further
Reichelstrasse 23
improvement in trading performance, with 39124 Magdeburg
an advance in both profitability and margins.
The outlook for the coming months remains
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uncertain and visibility is limited, however
I am confident that we are well positioned phone: +49 (0) 391 532969-0
for the challenges and opportunities that
lie ahead.” fax: +49 (0) 391 532969-21
e-mail: [email protected]
Global Cement Magazine 27 web: www.hardtop-gmbh.com
GLOBAL CEMENT NEWS: EUROPE
Germany: VDZ presents 2050 carbon neutrality roadmap
T he German Cement Works Association (VDZ)

published a study entitled ‘Decarbonising cement and
concrete: a CO2 roadmap for the German cement industry,’
has the volume of CO2, particularly as the process-
related emissions specifically associated with
clinker production cannot be lowered by
detailing the planned transformation to cement industry-wide employing conventional means.’ As such, the
carbon neutrality by 2050. association proposed a ‘completely new ap-
The study says that a decarbonisation scenario based on proach to the production of cement and its
conventional reduction measures would cut carbon dioxide use in concrete’ in order to realise full climate
(CO2) emissions by 36% between 2019 and 2050. Chief ex- neutrality. It proposes that cement produc-
ecutive officer Martin Schneider said that the sector is already ers help to reduce concrete’s clinker factor,
‘reaching the limits of its potential for any further reduction in capturing the remaining CO2 from necessary
cement production.
Image: VDZ’s Düsseldorf Headquarters.
Schneider said “We have placed the de-
Credit: Julia Vogel. carbonisation of cement and concrete at the
heart of our activities. It will be essential to
achieve an integrated approach, incorporat-
ing the entire construction value chain.” In
order for this more radical scenario to work,
he added “Another essential factor will be to
involve society as a whole in this process.”
Switzerland: First cement

sector sustainability bond
L afargeHolcim has launched a Euro850m

sustainability-linked bond with a cou-
pon of 0.5% maturing in 2031. It says it is
www the first bond of its kind in the building
materials industry and that it is part of its
commitment to reach its 2030 CO2 reduc-
POSITION SOUGHT tion target.
“We are proud to be the first in our
industry to launch a sustainability-linked
Highly experienced Mechanical Engineer (IMECHE) bond. The order book of Euro2.6bn dem-
strong history of site management, installations, onstrates the confidence of investors in
commissioning within cement, energy, waste and power the company’s financial strength, strategy
and ability to deliver on its sustainabil-
industries seeks suitable position. ity targets,” said Géraldine Picaud, Chief
Financial Officer of LafargeHolcim.
Chief Mechanical Engineer Bond investors will be entitled to a
15 years with a Global Cement Engineering group higher coupon should the company not
meet its objective, incentivising Lafarge-
Holcim to reach its target of 475kg net
• Over 25 projects and sites around the world, including cement CO2 per tonne of cementitious material
plants/mills in Ireland, Ukraine, Pakistan, Vietnam, Uganda, by 2030.
Turkey, Algeria, Indonesia, Slovenia, etc,
• Handled customer orders and queries from fabrication issues
through to construction,
• Assessed commissioned works for maintenance and upgrade needs,
• Supervised a variety of sites and construction projects,
• Carried out maintenance and fault repairs,
• Currently based in Southern UK, able to relocate,
• Languages: Romanian / English / Spanish / Italian.
Enquiries to: PO Box 200, GLOBAL CEMENT

[email protected]
28 Global Cement Magazine
GLOBAL CEMENT NEWS: EUROPE
Italy: Cementir sales rise over first nine months
C ementir Holding sold 7.7Mt of grey cement, white cement and

clinker in the first nine months of 2020, up by 11% year-on-year
from 6.9Mt in the first nine months of 2019. Earnings before inter-
UK: CMA writes to Hanson
over data breach
est, taxation, depreciation and amortisation (EBITDA) declined by
2% over the period, to Euro178m from Euro182m, while sales also
declined, by 1% to Euro897m from Euro906m.
T he Competition and Markets
Authority (CMA) has written
to Hanson UK, part of Heidelberg-
One notable region where the trend was reversed was Egypt, Cement, to express concern and set
where, in spite of a 2.5% fall in cement and clinker volumes, EBITDA out actions to prevent a recurrence
rose by 40% to Euro6.81m from Euro4.86m and sales rose by 16% of a breach of market data, which
to Euro31.3m from Euro27.1m. EBITDA also rose in the Nordic and occurred on 11 September 2020.
Baltic, Turkey, China and Asia-Pacific regions. Hanson made a payment in error
CEO and Chair Francesco Caltagirone said “Results significantly to the Mineral Products Association
improved in the third quarter, with cement up by 19% and EBITDA (MPA). During the transaction, Hanson
up by 12% compared to the third quarter of 2019.” inadvertently revealed ascertainable
cement volume data, in breach of the
CMA’s Cement Market Data Order.
The company has explained that
the breach arose due to an adminis-
trative error.

GLOBAL CEMENT: SUSTAINABILITY
Buzzi Unicem
A letter from Buzzi Unicem
Following the publication of the article Sustainability in cement: Who’s on top? in the October
2020 issue of Global Cement Magazine, the publishers received a letter from Buzzi Unicem,
which is reproduced here in full, with permission of the letter’s signatories.
W ith regard to the article ‘Sustainability in ce-

ment: Who’s on top?’ published in the October
issue of the Global Cement Magazine - Sustainability
• The clinker factor is conditioned by the availa-
bility of clinker substitutes (fly ash – precisely in
the areas of the world most attentive to reducing
section, we would like to bring to your attention the environmental impacts - is disappearing; slags
position of Buzzi Unicem, a company mentioned in and pozzolanas are available at competitive
the analysis. prices only when relatively close to the plants)
and above all by the regulatory framework in
The observation concerns our constant commit- force in each country. For example, the US
ment to provide complete, accurate information in market basically prefers pure Portland cements,
a transparent manner, in line with the international while the European market allows for a wide
GRI standard. In fact, we seek to facilitate the com- use of mixed cements with the result that the
parison of our company’s performance with that of clinker factor can differ by up to 20 points.
other businesses in the sector, to better understand
which specific areas we need to improve in and how. With a view to transparency and greater clarity, the
While we understand that for the sake of brevity ranking published, which has some errors/inaccura-
only a few parameters were used to assess a com- cies that, while irrelevant to the results, would have
With a view to transparency and greater clarity, the ranki
pany’s sustainability (a more complete and accurate been better to avoid, should have taken into con-
errors1/inaccuracies that, while irrelevant to the results, would h
comparison would have required a broader report), sideration the aspects mentioned above, not merely
have taken into consideration the aspects mentioned above, n
we found that the strong dependence onWith local comparing
a view todata. transparency aggregated data. Precisely for this reason,
Preciselyand for greater clarity,
this reason, fortheyears
ranking
now published, which
in its annual has
repor
market conditions was not taken into account errorsfor
1
for
/inaccuracies years
that, now
while in its
irrelevant annual
to thereports Buzzi
results, would Unicem
have beenhas
details of the main sustainability indicators broken down by count
better to avoid,
some of them (alternative fuel use, biomass fuel
haveuse, provided thethe
taken into consideration details
aspectsof mentioned
the main sustainability
above, not merelyindi-
comparing aggr
data. Precisely forWe thishope that
reason, for in the
years future
now in itsanannual
expert and
reports authoritative journal
Buzzi Unicem has provid
clinker factor), instead implying that they depend cators broken down by country.
details of the main sustainability
will take note indicators
of thesebroken down by country.
suggestions and deal more attentively
exclusively on choices made by the producers.
We hope that in constructive
the future
We an dialogue
hope that expert
in the and and to avoidjournal
authoritative
future an expert any negative
andsuch impacts
as Global
authorita- on the
Cement Ma
will take note ofactively committedand
these suggestions to improving
deal more their level of
attentively sustainability.
with the issues to allow
Based on the article published we consider it appro- tive journal such as Global Cement Magazine will
constructive dialogue and to avoid any negative impacts on the reputation of companies t
priate to point out some factors that we believe to becommittedIftake
actively you
to note of their
consider
improving these suggestions
it appropriate,
level andfeel
please
of sustainability. deal
freemore at- this letter
to publish
important: tentively with the issues to allow for a constructive
If you consider it appropriate, please feel free to publish this letter in your magazine.
dialogue and to avoid any negative impacts on the
• The use of alternative fuels depends first and Thank
reputationyou for your attention.
of companies that are actively committed
foremost on their availability and on the grant-
Thank you for to improving their level of sustainability.
your attention.
ing of permits as they are considered ‘waste,’
Sincerely Yours,
such permits being issued by local authorities
Sincerely Yours,
Thank you for your attention.
according to more or less stringent rules that
vary from place to place. Sincerely Yours,
Michele Buzzi
Michele Buzzi Massimo Paris
Massim
• Biomass content is strongly influenced by the
Chief Executive Chief Executive Quality
Quality Assurance and Sustainabili
level of separate collection achieved in a given
country.
Michele Buzzi Massimo Paris

Chief Executive Quality Assurance and
Sustainability Director

16 MARCH 2021 ON YOUR DESKTOP
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Virtual
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Alternatives to OPC, clinker factor reduction,
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GLOBAL CEMENT: NORTHERN EUROPE
Peter Edwards, Global Cement Magazine
Cement in Northern Europe
Global Cement kicks off 2021 with a look at the cement sectors of Denmark, Estonia, Finland
Latvia, Lithuania, Norway and Sweden.
W hile there are various definitions of Northern

Europe, this review takes in four Scandina-
vian countries - Denmark, Finland, Norway and
Having gained independence upon the collapse
of the Soviet Union in the early 1990s, the Baltic
countries - Estonia, Latvia and Lithuania - have
Sweden - plus three in the Baltic - Estonia, Latvia smaller economies and GDP/capita rates in the
and Lithuania. Six of these seven countries are EU range of US$18,000-23,000.
Member States. The exception is Norway, which,
while not a member, is closely aligned with the bloc Cement sector - By country
via its membership of the European Economic Area. There are 10 cement manufacturing plants that share
The seven countries are home to a total of 32.8 a capacity of 13.7Mt/yr in the seven countries in this
million people. Nearly a third of these (10.1m) live review, plus one 0.5Mt/yr slag grinding plant. Of the
in Sweden, with Denmark (5.8m), Finland (5.5m) seven countries, Sweden has the largest cement sec-
and Norway (5.4m) each home to similar numbers tor, with 3.1Mt/yr. Denmark, despite having just one
of people. Of the Baltic countries, Lithuania is the plant, has the second-largest cement sector (3.0Mt/
most populous (2.8m), with 1.5 times as many peo- yr). Finland and Latvia are tied with the third-largest
ple as Latvia (1.9m) and more than twice as many as industries (2.0Mt/yr) (See Figure 1).
Estonia (1.3m).
Cement sector - By company
Modern economies The region defined in this review is unusual in that
The seven countries in this review all have market each country only has one cement producer. Three
economies. The largest economy among them is countries - Estonia, Norway and Sweden - have
that of Sweden (US$556bn) and the smallest is that HeidelbergCement subsidiaries as the backbone of
of Estonia (US$30.7bn). Those in Scandinavia are their cement industries. The German multinational
characterised by high taxes that fund extensive so- is the dominant force in the region, with a share in
cial welfare programs. They have among the highest 5.64Mt/yr of capacity across six plants. This is suf-
standards of living in the world with GDP/capita ficient to give it almost 40% of capacity in the region.
rates in the range of US$50,000-80,000.

SWEDEN
3.1Mt/yr • 21.8%
DENMARK
3.0Mt/yr • 21.1%
2
FINLAND
2.0Mt/yr • 14.1%
RUSSIA
LATVIA 10
2.0Mt/yr • 14.1%
NORWAY FINLAND
1.8Mt/yr • 12.7% SWEDEN
9
LITHUANIA
1.5Mt/yr • 10.6%
8
NORWAY
RUSSIA
5
ESTONIA ESTONIA
0.8Mt/yr • 5.6% 1
3
The second-largest producer in the region is
4 7 LATVIA
Cementir Holding (3.0Mt/yr), via its Aalborg Port- 11
6
land Cement subsidiary in Denmark. Schwenk
Zement, which operates a plant in Latvia (2.0Mt/ LITHUANIA
DENMARK RUSSIA
BELARUS
yr) and 34% of Akmenés Cementas in Lithu-
RUSSIA
ania (0.5Mt/yr), is third-largest (2.5Mt/yr). Ireland’s
CRH is the fourth-largest producer, with 2.2Mt/yr
across its Finnsementti operations and its 25% stake GERMANY POLAND
in Estonia’s Kunda Nordic Tsement. Akmenés Ce-
mentas is the smallest producer. It is partly owned
by Germany’s Schwenk Zement (34%) and by This Page - Figure 1: Cement plants in Northern Europe. Plants listed below and colour coded
HeidelbergCement (8.65%). Local investors hold by main shareholder (left column), with overall capacity shown on the right. Source: Global Cement Directory 2021.
the remaining 57.35%. LafargeHolcim is not present
in the region and Cemex left in 2019. = 1Mt/yr (Integrated) = 1Mt/yr (Grinding)
Denmark HEIDELBERGCEMENT
1. Norcem, Brevik, Norway, 1.2Mt/yr (I).
2. Norcem, Kjøpsvik, Norway, 0.6Mt/yr (I). HC
Denmark has a single cement pro- 5.6Mt/yr
3. Cementa, Skövde, Sweden, 0.6Mt/yr (I).
ducer, Aalborg Portland Cement, 4. Cementa, Slite, Sweden, 2.5Mt/yr (I). 39.4%
which has made cement at its Rørdal 5. Kunda Nordic Tsement, Kunda, Estonia, 0.8Mt/yr (G).
site near Aalborg, Jutland, since (75% owned by HeidelbergCement, 25% by CRH).
1889. Today it has seven kilns, two for grey cement CEMENTIR CEMENTIR
(2.1Mt/yr total) and five for white cement (0.9Mt/ 6. Aalborg Portland Cement, Aalborg, Denmark, 3.0Mt/yr (I). 3.0Mt/yr
yr). It is part of Cementir Holding, the Italian mul- 2.1Mt/yr Grey & 0.9Mt/yr White. 21.1%
tinational and global white cement market leader. SCHWENK LATVIJA SCHWENK
Prior to its acquisition by Cementir in 2004, it was 7. Brocēni, Latvia, 2.0Mt/yr (I). 2.5Mt/yr
17.6%
owned by Blue Circle (1990 - 2000) and FLSmidth CRH
(2000-2004). 8. Finnsementti, Parainen, 1.0Mt/yr (I).
CRH
Today the Rørdal plant supplies the Danish and 9. Finnsementti, Lapeenranta, 0.5Mt/yr (I). 2.2Mt/yr
10. Finnsementti, Raahe, 0.5Mt/yr (G - Slag). 15.6%
wider Scandinavian grey cement markets, including
with low-clinker cements such as its Futurecem™ AKMENÉS CEMENTAS
11. Akmenés Cementas, Akmené, 1.5Mt/yr (I). AKMENÉS
product. It is a major producer of white cement, 0.9Mt/yr
(34% owned by Schwenk, 8.65% by HeidelbergCement).
exporting to more than 70 countries around the 6.3%

1870, with three kilns in operation by the

1920s. Production was halted between 1939
and 1942 due to the removal of equipment
from the site during the Second World War.
Extensive renovation came in 1957-1958
under Soviet control, when the company
was known as Red Kunda. The plant made
more than 1Mt of cement in a single year
for the first time in 1973. Upon the col-
lapse of the USSR in 1991, the company was
renamed Kunda Nordic Tsement in 1992.
It underwent a major overhaul in the late
1990s under the Swedish Scancem group,
before that company became part of Heidel-
bergCement in 1999. Today, CRH owns 25%
of the company’s shares.
Since March 2020 the former integrated
site has only ground clinker from other fa-
cilities. The company said that the closure of
the wet kiln was forced by the rising cost of
Above: The Aalborg Portland world. Aalborg Portland Cement also controls seven emitting CO2 under the EU Emissions Trad-
Cement plant in Rørdal, near
terminals in Denmark, with 35 ready-mix concrete ing Scheme (ETS), which made continued
Aalborg, is the only cement
plant in Denmark. plants controlled by its subsidiary Unicon. Cementir clinker production uneconomic at the site.
Source: Cementir. reports that the plant’s alternative fuel substitution Prior to its closure the Kunda plant emitted
rate is 60%, while it supplies 36,000 local homes more than 1050kg of CO2 per 1t of cement,
with hot water for heating. This will rise to 50,000 in way in excess of the EU average of 766kg/t.
2022. It is also building a 8MW captive wind farm. Estonia made 129,000t of cement in the
While it has no production capacity in Denmark, first half of 2020, down by 31% year on year
HeidelbergCement has imported cement into the from 187,000t in the first half of 2019. Eesti
country since 2006 via its DK Cement subsidiary. Statistika has reported that the sharpest de-
Cement originates from its Norwegian and Scan- cline was in June 2020, by 41% year-on-year
dinavian plants and is imported via its Randers to 25,800t from 43,700t.
terminal in Jutland. Schwenk Zement serves the Estonian
market via its network of terminals in
Below: The Kunda Nordic
Tsement plant produced its Estonia Finland, Sweden and Norway.
last clinker in early 2020. It
made 571,000t of cement There is only one cement manufac- Finland
in 2019, its last full year of turing plant in Estonia, at Kunda on
clinker manufacturing.
Source: Kunda Nordic the country’s north east coast. Ce- Finnsementti is the only pro-
Tsement website. ment has been made in Kunda since ducer of cement in Finland. It
traces its history back to 1914
and the commissioning of
the country’s first cement plant in Parainen,
in the south west of the country. Previously
also running plants in Lohja Kalkkitehdas
Osakeyhtiö (1914), Lappeenranta (1938)
and Kolari (1968), the company has since
shrunk to just two integrated cement plants
at Parainen (1.0Mt/yr) and Lappeenranta
(0.5Mt/yr). It also operates a 0.5Mt/yr slag
grinding plant in Raahe on the Gulf of
Bothnia.
The company was controlled by Scancem
between 1993 and 1999. Unlike some of
Scancem’s other assets, the Finnish assets
were sold to the Irish group CRH. In 2021
the company supplies the vast majority of
cementitious materials in the country.

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As well as its three cementitious product sites,

Finnsementti also operates five slag and cement
terminals across Finland at Kirkkonummi, Marie-
hamn, Pietarsaari, Pori and Oulu (shown right).
Germany’s Schwenk Zement supplies cement to
the Finnish market via its Embra subsidiary. It im-
ports material into Loviisa, Naantali and Joensuu.
Scandinavian Cement also owns a cement import
terminal in Hamina.
Latvia The Brocēni plant was renovated from 1947 on- Above: Finnsementti’s Oulu
wards, during Soviet control of the country. Both terminal was opened in 2012.
Source: Finnsementti
Cement production in Latvia dates plants diversified during the second half of the 20th website.
back to 1867 with the establishment Century, leading to the production of roofing slates,
of the JSC C CH Schmidt plant in bricks, lime, limestone and ceramic tiles, as well as
Riga. A new plant in Brocēni came cement. The Riga plant has since closed.
online in 1938. Intially with a capacity of 60,000t/ Upon independence in 1991, cement demand in
yr, two Polysius kilns were added in the early 1940s Latvia dropped significantly. A number of owners
but the plant suffered damage during the Second took on the Brocēni plant, with RMC taking over in
World War. the late 1990s. In 2005 Cemex took over the reins
from RMC, with plans for investment in Latvia.

Right: Schwenk Zement

took over the Brocēni plant in
Latvia from Cemex, as well as
an extensive terminal network
in Northern Europe, in 2019.
Source: Schwenk Latvija
website.
A new Euro300m plant began production at the

Brocēni site in 2010 after a three year construction
project. Another nine years later, Cemex decided to
exit the Latvian market as part of efforts to reduce
its debt, selling the plant, plus an extensive Northern
European terminal network to Germany’s Schwenk
Zement in 2019.
Right: View from the pre-
heater tower at the Akmenés In 2021 the 2.0Mt/yr plant is one of the largest in
Cementas plant in Lithuania. Northern Europe. As well as supplying the domestic
Source: Global Cement. market, around 70% of the cement made in Brocēni
is exported to Lithuania, Estonia, Sweden, Finland
and Belarus. HeidelbergCement operates a cement
terminal in Riga.
Lithuania
Like its northern neighbour, Lithu-
ania has a single integrated cement
plant, the Akmenés Cementas plant in
Akmené. The company has produced
cement on the same site since 1952. During the
Soviet era, the plant was run as a wet process facility,
with up to eight kilns that supplied cement all over After Lithuania gained its independence in 1991,
the USSR. the plant underwent a period of rationalisation to
adjust to market demands and was progressively
upgraded to modern standards. A new 4500t/day
dry process line from Germany’s KHD Humboldt
Wedag has been in operation since 2014.
The plant is predominantly owned by local in-
vestors, with a 34% stake held by Schwenk and an
Right: The Norcem Kjøpsvik 8.65% stake held by HeidelbergCement, which also
plant is the most northerly operates teminals in Kaunas and Klaipėda.
in the world, lying just
inside the Arctic Circle.
Source: Norcem. Norway
As elsewhere in Northern Europe,
HeidelbergCement is the dominant
force in the Norwegian cement sec-
tor. It operates two integrated plants
Opposite Page: The Cementa via its Norcem subsidiary. The original Norcem
Slite plant, the largest in was founded by the merger of three Norwegian
Northern Europe.
cement manufacturers in 1968. It became part
Source: Cementa website.
of Scancem in 1996 and then HeidelbergCement
in 1999.
The larger of Norcem’s two plants is in Brevik,
around 160km to the south west of Oslo. It was
founded as Dalen Portland Cementfabrik in 1916
and made its first cement in 1919. Today it is a

GLOBAL CEMENT
1.2Mt/yr facility that could become the first in the

global cement sector to fully decarbonise cement
production. Its long-standing carbon capture and
„
storage (CCS) project with Aker Solutions has been
in development since 2010.
The Vicat - King“
The project will use amine-based sorb- German production
ants to selectively capture CO2 from the plant’s
exhaust stream. The partners signed an agree- excellent performance
ment with Aker Solutions to order a CO2 capture,
liquification and intermediate storage plant for
the plant in June 2020. In September 2020, the
Norwegian government introduced a bill to
parliament to allow funding for industrial scale im- Vicat apparatus,
plementation of the project. If enacted, the legislation different models acc. to
will provide for the majority of required funding, EN, DIN, ASTM, BS
estimated at more than US$820m for installation
and operation for five years. It is anticipated that the
project will begin to capture and store CO2 in 2023
or 2024.
Around 1300km to the north is Norcem’s
Kjøpsvik plant. At 68.1° north, it is the world’s most
northerly cement plant and lies just within the
Arctic Circle.
Schwenk Zement operates strategic terminals in Automatic Vicat apparatus
Norway in Oslo, Bergen, Stavanger and Etne. acc. to EN 196-3, DIN 1164,
ASTM C187
Sweden 230 V / 50 Hz,
As in Norway, HeidelbergCement is with delay timer
the dominant force in the Swedish ce-
ment sector. It operates two integrated
plants under its Cementa subsidi-
ary. The largest is located in Slite on the island of
Gotland in the Baltic Sea. At 2.5Mt/yr it is the largest
of the plants in this review and is perfectly situ-
ated for marine shipments to mainland Sweden via Computer controlled Vicat apparatus
Cementa’s 17 domestic cement terminals. The plant with 6 or 8 measuring places
uses around 60% alternative fuels and is involved in
acc. to EN 196-3, EN 480-2,
the CemZero project with Vattenfall, which seeks to
electrify the cement production process.
ASTM 191, test method B
Cementa also operates the 0.6Mt/yr Skövde 230 V / 50 Hz
plant in the south of the mainland. It closed its
0.3Mt/yr Degerhamn plant on Öland at the end
of April 2019. The unit continues as a terminal.
Schwenk Zement operates terminals at Surte,
Landskrona and Västerås.
TESTING Bluhm & Feuerherdt GmbH

Motzener Straße 26b • 12277 Berlin / Germany
Phone: +49 30 710 96 45-0
Global Cement Magazine 37 www.testing.de • [email protected]
GLOBAL CEMENT NEWS: THE AMERICAS
US: PCA to develop 2050 carbon US: PCA 2020 Safety Innovation Awards
neutrality roadmap
T he Portland Cement Association (PCA) says it

plans to develop a roadmap by the end of 2021
T he Portland Cement Association (PCA) has an-
nounced the winners of the 2020 Safety Innovation
Awards, which recognise ‘creative safety-enhancing
to help its member companies achieve carbon projects in the cement industry’ across five categories.
neutrality across the concrete value chain by 2050. Buzzi Unicem USA’s Joliet, Illinois cement terminal
It maintains that ‘concrete is critical to building a won the distribution award for its barge entry ladder,
sustainable future’ and reinforced the benefits of con- which reduced fall hazards associated with unloading
crete such as energy efficiency, lower life-cycle costs, cement from barges. Ash Grove Cement’s Durkee, Or-
durability and resilience. The roadmap is intended to egon cement plant won the general facility award for its
solve problems facing the industry such as develop- burner pipes cart upgrade, which reduced safety haz-
ing new technologies to reduce energy consumption ards associated with moving cement kiln burner pipes.
and to develop and adopt related regulations. Further hazard reductions were made by Buzzi Unicem
“As the second most used material on earth and USA’s Chattanooga, Tennessee cement plant’s finish mill
a cornerstone of our economy, we understand the access platform and the Monarch Cement Company’s
critical role cement and concrete play in our nation’s Humboldt, Kansas cement plant’s noise reduction up-
future, and we are committed to an industry-wide ef- grade, which jointly won the milling/grinding award.
fort that achieves carbon neutrality,” said Tom Beck, The pyroprocessing award went to GCC of America’s
Chairman of the PCA and President of Continental Pueblo, Colorado plant for its semi-automated clinker
Cement. Rick Bohan, Vice President, Sustainability for feeding system, while the quarry award went to Ash
the PCA added, “Developing a roadmap to carbon Grove Cement’s Louisville, Nebraska plant for its dump
neutrality by 2050 further demonstrates our indus- box hardened material extraction tool.
try’s commitment to be a part of the solution and PCA President and CEO Michael Ireland said “Our
tackle this global issue.” industry prioritises the safety of its employees above
The PCA says that the industry has reduced energy all else. We are proud of our members’ efforts to pursue
consumption by 35%, emissions intensity by 11% and excellence in safety innovation for their company and
has increased its use of alternative fuels since 1990. their colleagues.”
Colombia: Sales fall for Argos
G rupo Argos subsidiary Cementos Argos has

reported a 13% year-on-year fall in cement
sales volumes to 10.7Mt in the first nine months of
2020 from 12.3Mt in the first nine months of 2019.
As a result, revenues fell by 5% to US$1.85bn from
US$1.94bn, partially netted by the price improve-
ments in Colombia and in the US, together with
devaluation of the Colombian Peso.
Earnings before interest, taxation, depreciation Colombia: First South American paper
and amortisation (EBITDA) fell by 3% to US$342m bag plant for Mondi
from US$353m. The company said that “Volumes
were affected by the hurricanes and intense rains in
the US, together with the gradual recovery of the
Colombian operations that still remain affected by
A ustria-based Mondi Group plans to open its first
South American paper bags plant in Cartagena in
January 2021. The unit will start with one production
Covid-19 lockdowns.” line that has a capacity of approximately 50m bags/yr.
Meanwhile, Cementos Argos is celebrating its The bags will be targeted at the cement, chemical and
inclusion in the Dow Jones Sustainability Index for food industries. The group said that the plant is located
the eighth consecutive year. The company said that in a free-trade zone with good access to ports in Panama,
the listing acknowledges its ‘good practices in eco- the east coast of the US, the Gulf of Mexico and other
nomic, environmental and social matters.’ Its owner Caribbean ports.
Grupo Argos came second in the materials sector, “We are excited to be expanding our footprint to
which accounted for 4.3% of the total index weight, Colombia, helping us to provide innovative, sustainable
while the company itself came third. and customer-focused paper packaging solutions to
customers in South America,” said Claudio Fedalto, Chief
Operating Officer for Paper Bags at Mondi.

GLOBAL CEMENT
US: Energy Stars for Buzzi
T he US Environmental Protection
Agency (EPA) has awarded its 2020
Energy Star® certification to Buzzi Unicem
USA plants in Chattanooga, Tennessee
and in Festus, Missouri. This certification
is awarded to a facility for superior energy
performance in comparison to similar
plants in the US. This marks the 12th con-
secutive year that the Chattanooga and
Festus plants have received certification.
In order to qualify for Energy Star® rec-
ognition, cement plants must score at least
75 on the Energy Performance Indicator
(EPI) system used by the EPA to measure
energy efficiency. In addition, the plant
must have a satisfactory environmental
compliance record for the past three years.
Receipt of the Energy Star certification
means that these two plants perform in
the top 25% of similar facilities in the US.
Source: Cementos
Today’s most
advanced
Artigas website.
intermediate
Uruguay: Artigas to upgrade
Minas plant diaphragm
C ementos Artigas has announced
a US$40m investment in its Minas
clinker plant. The project will involve the
for modern
installation of a vertical roller mill and
cement silos to convert the site into a
fully-integrated facility. At the same time,
grinding plants
the company will close its Sayago grinding
plant, which currently grinds clinker from
the Minas plant. The combination of the Monobloc® design
clinker production and grinding capabili-
ties is expected to lead to a 40% reduction Hardened rolled steel
in production costs. Construction will start
in early 2021, with commissioning antici- Separation of air and material flows
pated during 2022.
Julio Rodriguez, CEO of major share-
holder Cementos Molins, said, “With this
new investment we continue to develop
our strategy, in which sustainability and
respect for the environment is the first Visit us at christianpfeiffer.com
priority. At the same time, it is also a clear
sign of our long-term commitment to the
Uruguayan market, in which we have been
present since 1991.”
Global Cement Magazine 39

GLOBAL CEMENT NEWS: THE AMERICAS
Brazil: Votorantim sales rise by nearly a quarter over first nine months of 2020
V otorantim Cimentos’ consolidated net sales in the

first nine months of 2020 were US$2.17bn, up by
23% year-on-year from US$1.76bn in the correspond-
US$145m in 2019. It said, “The economic opening after
the initial restrictions of the Covid-19 pandemic turned
out more positively than anticipated in the third quar-
ing period of 2019. However, its profit fell by 61% to ter of 2020, while the on-going recovery is projected
US$28.7m from US$73.9m to be gradual, considering the uncertain scenario.
Cement sales in the third quarter of 2020 rose by Currently, global gross domestic product (GDP) is
15% year-on-year to 9.7Mt from 8.4Mt in the third projected to decrease 4% in 2020 - less severely than
quarter of 2019. The company reported increased sales the previously published data, although uncertainty
volumes in Uruguay, the US and Canada, and an 18% around the recovery path for upcoming years due to
increase in Brazil, ‘maintaining the strong pace’ that it the second wave of Covid-19 remains considerable in
saw at the end of the first half of 2020. The company some countries, alongside viability of additional fiscal
said, “The significant emergency aid from government and monetary stimulus.”
during this period and its use in the direct purchase of
construction inputs, including cement, has supported
civil construction alongside the current historically low
interest rate. In addition, people continue to invest in
improving their homes, with retail sales of building
materials increasing nationally.”
The company’s third quarter adjusted earnings
before interest, taxation, depreciation and amortisa-
tion (EBITDA) rose by 94% to US$281m in 2020 from
US: Anchorage terminal due by 2022

Image: Anchorage, Alaska.
A ustin Quinn-Davidson, the acting mayor of Anchor-

age, Alaska, has announced that the city’s new
cement and petroleum terminal at the Port of Alaska will
be completed by late 2021. The Anchorage Daily News
has reported that the estimated US$203m terminal will
last for 75 years and will be able to endure future seismic
events like the earthquake that damaged the port in No-
vember 2018.
Municipal manager Bill Falsey said, “Even in these
challenging times, we can still do big and important and
challenging things.” He estimated the eventual total cost
of an upgrade to the port would be around US$1bn.
Canada: Death at Lafarge Richmond Bolivia/Paraguay: Supply coordination
T he Royal Canadian Mounted Police’s serious

crime unit has launched an investigation into
the death of one person at Lafarge Canada’s Rich-
T he Bolivian-Paraguayan Binational Chamber of
Commerce & Industry is working with Bolivia-based
FANCESA to export cement to Paraguay via the Parana-
mond, British Columbia integrated cement plant on Paraguay Rivers Inland Waterway. It is also promoting
19 November 2020. The Vancouver Sun newspaper exports from the new ECEBOL integrated cement plant at
reported that the incident caused the plant to be Caracollo in Oruro, Bolivia.
evacuated.
Spokesperson Jill Truscott said, “We are in shock
and are extremely concerned about the impact to
this individual’s family and friends. Steps have been
taken to protect all employees on site and the sur-
rounding community.”
WorkSafe British Columbia is conducting a sepa-
rate investigation.

27 APRIL 2021 • 11AM - 5PM CST ON YOUR DESKTOP
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GLOBAL CEMENT: WASTE
Mary Beth Kramer, Kramer Consulting
Titan Florida earns global cement sector’s first

TRUE Platinum Zero Waste Certification
Titan Florida’s Pennsuco plant diverts 97% of waste away from landfill and incineration...
T itan Florida’s plant in Medley - known as

Pennsuco - is the first cement plant in the
world to earn the highest level of certification pos-
annual diversion data that demonstrates continuous
compliance to achieve certification at four possible
levels: Certified, Silver, Gold or Platinum.
sible under the Total Resource Use and Efficiency To achieve the most rigorous level of certifica-
(TRUE) rating system for zero waste. Administered tion, TRUE Platinum certification, the Pennsuco
by Green Business Certification Inc. (GBCI), TRUE Complex accrued additional credits for starting
helps facilities around the world to define, pursue programmes like: repurposing used office supplies
and achieve zero waste goals while becoming more and materials, grass recycling/mulching, compost-
resource-efficient. ing, and xeriscaping, the process of landscaping that
“Titan Florida recognises that by pursuing zero reduces or eliminates the need for supplemental
waste it is helping to build a sustainable future for us water from irrigation, among other major initiatives.
all,” said Mahesh Ramanujam, President and CEO of For example, as part of the credit for waste re-
the US Green Building Council and GBCI. “Waste porting, the Pennsuco Complex became an active
impacts all facets of a business. Changing the way participant in the US Environmental Protection
we use resources delivers public health benefits, Agency (EPA) Waste Wise Program, where diversion
reduces our environmental impact and advances a data is submitted to the EPA annually and goals are
greener economy.” set for the following year. For its purchasing credit,
Facilities achieve TRUE certification by meeting Pennsuco adopted an Environmentally Preferred
program requirements and accruing credits on a Purchasing guideline that is authorised by employ-
scorecard. Each site is then audited and must submit ees and management and applied to suppliers of the
cement plant campus. All told, the Pennsuco Com-
plex diverted approximately 97% of its waste from
landfill and incineration in 2019.
“It’s not just about receiving an award,” said
Allyson Tombesi, the Environmental Engineer at
Titan Florida who led the zero waste recertification.
“Being zero waste is about considering how we can
minimise our impacts so future generations have the
opportunity to live in a sustainable environment.
The program was created with a goal to encourage
our employees to lead a zero waste lifestyle at both
the plant and at home. We hope to inspire our em-
Right: Allyson Tombesi, ployees and our industry to take action that benefits
Environmental Engineer the future of our planet.”
at Titan Florida. “Clearly, Titan has a corporate commitment to
zero waste,” says William Kissel, Director of Envi-
ronment & Land, Titan Florida. “Earlier this year,
Titan’s sister plant in the US, Roanoke Cement
Company, earned similar certification as Penn-
suco, becoming the world’s second cement plant
to earn TRUE Gold Zero Waste certification. Now,
Pennsuco sets the bar higher by achieving TRUE
Platinum certification. Titan America continues to
be recognised as an industry leader in sustainability
and environmental stewardship.”

GLOBAL CEMENT: FANS
Howden
Successful fan retrofit in South America
Howden reports on a rapid fan retrofit project for a client in South America...
Supply conditions
I n 2020 a cement plant in South America was in
need of a fan retrofit in order to reduce its energy
consumption. The retrofit had not been allocated as
This project was financed by Howden. Equipment
and installation was provided by Howden without
a capital expenditure project. In addition, in order to initial disbursement from the customer. Monthly
coincide with a planned shut down, delivery would payments, based on savings, were set up.
be needed within just 35 days.
Few OEMs could accommodate these challenges, Energy efficiency
but Howden was the right choice for the project. This The project will result in an overall reduction of
plant also became one of Howden’s first customers to 644kW/hr in energy consumption. This will provide
take full advantage of the project financing option. savings of approximately US$260,000/yr for the cus-
tomer. The return on investment will be realised in
Fan data approximately three years.
This retrofit project involved replacing the rotor,
shaft and input cone of the pre-heater kiln exhaust Delivery terms
fan. Technical data is summarised in Table 1. The project required delivery in only 35 days, in time
for the installation of the kiln outage. The equipment
weighs 22t with a rotor diameter of 3870mm.
Model Howden F18 TDR 420SH387 3TD8A Remote monitoring
Application Pre-heater kiln exhaust fan To track the equipment’s performance, a remote
Power (kW) 4500 monitoring panel, developed by Howden, was
installed to allow the remote analysis of the ven- Left - Table 1: Summary
Flow (m3/hr) 1,101,554
fan data for the South
tilator’s operating parameters, including energy
Weight (t) 22.0 American project.
consumption.
Rotor Ø (mm) 3870
Right: Fan impeller.
Left: The new fan awaiting

installation at the South
American site.

GLOBAL CEMENT: PROCESS OPTIMISATION
Chris Landers, Jeff Shelton & Marina Silva, Integrated Global Services (IGS)
Eliminating snowmen at a cement plant in Indiana
When clinker builds up, it often forms a snowman. If left unchecked, the snowman will
grow and collapse, which can lead to significant damage and production problems...
A ir cannons are commonly employed to prevent

snowman build-up. The standard recom-
mendation is a 70L reservoir tank with a fan jet
longer employed shotgun blasts or high-pressure
water washing, which has made the plant a safer
place and eliminated significant production and
nozzle. That recommendation, however, often lacks maintenance costs.
the power necessary to provide effective cleaning.
Increasing the volume of the tank and the velocity A typical story
generated by the nozzle ensures that the air cannon The story of this plant is quite typical. Not all plants
will have enough power to eliminate snowmen. can adjust the chemistry of their process, but most
can improve their air cannon efficiency. The simplest
2-3 Snowmen per week and most effective way to upgrade the system is to
A 1.3Mt/yr cement plant in Indiana, US, had several increase the volume of the reservoir tank and the
150L air cannons with fan jet nozzles installed in its velocity of the discharge. That is often sufficient to
clinker cooling. Despite an abundance of these, 2-3 eliminate build-up problems.
snowmen formed every week. The staff had to use
shotgun blasts and high-pressure water, costing the Why did this approach work?
plant vast amounts of time and money. This new approach worked because volume (mass)
In 2018, the plant tried a different approach. It and velocity are the most important variables for
adjusted the chemistry of the process and replaced cleaning efficiency. This is because both are posi-
all air cannons with IGS 300L air cannons with tively correlated to force, momentum and kinetic
high velocity nozzles. The improvements were dra- energy, the three main components of power.
matic. Following the changes, the plant ran for eight
months without snowmen-related delays. Fewer Force = mass x acceleration (Eq. 1)
build-ups were formed and, when snowmen did Momentum = mass x velocity (Eq. 2)
arise, the cannons eliminated them. The plant no Kinetic Energy = 0.5 x mass x velocity2 (Eq. 3)
Type of Air Cannon Pressure Type of Nozzle Distance moved at Distance moved at
762mm (3ft) 152.4mm (6ft)
70L 689kPa (100psi) Fan Jet 69.9mm (2.75inch) No movement
150L 689kPa (100psi) Fan Jet 177.8mm (7inch) 76.2mm (3inch)
150L 689kPa (100psi) High Velocity 6184mm (243.5inch) 4343mm (171inch)
Above - Table 1: Distance travelled by 66.8kg (145lb) sled when fired by 70L and 150L cannons at different distances and using different nozzles,
using compressed air.
A higher volume increases the duration of an air cannon’s blast. This leads to a greater cleaning area. Increasing the volume from 70L to 150L increased the cleaning
force (distance sled was moved) by a factor of 2.5 at 762mm (3ft). Also importantly, it was also found that the cleaning force at 1524mm (5ft) was greater than at
76.2mm (3ft) for the 70L cannon, where cleaning was increased by a factor of 2.
The impact on the cleaning area is magnified greatly by increasing the velocity with a High Velocity Nozzle. Velocity increase is a key for kinetic energy (see Eq. 3,
above). A two-fold increase in velocity yields an increase in kinetic energy of 4 times.The combination of increased volume and velocity result in much greater clean-
ing power, and the difference between success and failure.
This difference can be clearly seen when the two nozzles are fired directly against a cement block. The 70L cannon with a fan jet nozzle pushed the block but does
not break it. In contrast, the 150L cannon with a High Velocity Nozzle crushed the block.

GLOBAL CEMENT: PROCESS OPTIMISATION
An air cannon with more force,

more momentum and more kinetic
energy will clean more powerfully.
Volume
The majority of air cannons in Left: IGS 300L air cannons
the cement industry are 70L air with high velocity nozzles
cannons. When a 70L air can- have entirely eliminated
non is unable to provide sufficient delays due to snowmen
at a cement plant
cleaning power, suppliers often in Indiana, US.
recommend upgrading to a 150L
cannon.
Why do they not make the same
recommendation (up to 300L)
when a 150L air cannon is un-
able to provide sufficient cleaning
power? The plant in Indiana had
many 150L air cannons but was
unable to eliminate the snowmen
from the centre of the cooler. IGS protected the installation by installing safety
IGS’s laboratory data confirms the positive corre- cylinders on all of the air cannons. The IGS Safety
lation of volume and power. Air cannons were placed Cylinder automatically opens and closes between
in front of a 66.8kg sled at distances of 12.7mm, each air cannon blast. This action prevents heat or
914mm and 1524mm. They were discharged with debris from entering the reservoir tank, extends its
varying gas volumes, velocities and pressure to see life, and reduces maintenance. The regular move-
which combinations produced the most power and ment of the cylinder also prevents it from becoming
hence cleaning efficiency. stuck, which is a common issue with manual safety
Table 1 shows test results that compare 70L and shields.
150L air cannons. The IGS Big Blue produced twice
as much force, mass, and kinetic energy as the older The results
air cannons. This enabled its cleaning blast to pen- The plant in Indiana eliminated their build-up prob-
etrate into the centre of the area to knock the top lems. Although the adjustment to the chemistry
off the snowman. The old air cannons did not have alleviated the build-up problem, the plant operator
enough power to do so. attributes much of the success to the upgraded air
cannons. The added volume and velocity enabled
Velocity the cleaning blast to reach the middle of the area
Most air cannons in the cement industry employ where the snowmen formed. Furthermore, the IGS
a fan jet nozzle. That nozzle is designed to clean a safety cylinder protected the installation by prevent-
wide area at the cost of penetration. It cleans 1.0- ing the harsh environment from reaching the air
1.5m into the application, a range that is insufficient cannon’s internal. The plant is free from snowman
for most applications. It will always be insufficient build-up and the need to employ supplemental
when attempting to reach the middle of the cooler cleaning methods.
to eliminate snowman build-up.
In contrast, the high velocity nozzle is designed Conclusion
specifically for the cement industry. This nozzle is Many believe the myth that peak force is the most
designed to increase velocity and focus the air blast, important variable of air cannons cleaning. That is
both factors that make the nozzle effective at clean- why a 70L air cannon is often equipped with a fan jet
ing. The nozzle contracts the outlet, which generates nozzle. Although it generates a high peak force, it is
a blast that has more velocity. The result is twice as a weak, ineffective recommendation.
much velocity as the fan jet nozzle. The effects of IGS’ solution for the plant in Indiana focused
changing the nozzle can be seen in Table 1. on three areas: volume, velocity, and protection. By
increasing the size of the reservoir tank and chang-
Protecting the Air Cannons ing the nozzle, IGS ensured that the air cannon had
One of the unique challenges facing the plant in enough power to clean the snowmen in the middle
Indiana was the need to protect its air cannons. This of the cooler By fitting each air cannon with a safety
was because the cooler was a negative pressure unit cylinder, IGS ensured each air cannon would be pro-
with extremely high temperatures and corrosive ma- tected from the corrosive environment of the cooler.
terial. If the material reached the internals of the air When these three factors are successfully applied,
cannon, it would mean certain failure. the difference in cleaning is staggering.

GLOBAL CEMENT NEWS: ASIA
India: UltraTech Cement beats climate goal
U ltraTech Cement says it has beaten its goal of doubling its energy pro-
ductivity ahead of its deadline. It joined the EP100 initiative in 2018 and
agreed to double its energy productivity from the base year of 2010 with the
target year of 2035. It has now achieved this by investing in energy efficiency
measures such as upgrading clinker coolers, implementing variable frequency
drives to manage electricity flow and introducing new waste heat recovery
systems. The company says it is focusing on new technologies, changes
in product and energy mix, digitisation and carbon pricing. It foresees the
digitisation of its energy performance as a key enabler to identify the best op-
portunities to save energy.
“UltraTech firmly believes that companies in the building mate-
rial sector can come together to step up climate action for meeting the
global 1.5-degree ambition,” said Kailash Jhanwar, managing director of
UltraTech Cement. “Joining like-minded companies in EP100 gave us an op-
portunity to accelerate and scale-up levers to double energy productivity and
also drive the decarbonisation agenda.”
Vietnam: Production rises over first 11 months

despite pandemic
T he General Statistics Office (GSO) estimates that Vietnam produced a total

of 90Mt of cement in the first 11 months of 2020 of 90.0Mt, a rise of 3.4%
year-on-year from 87.0Mt in the same period of 2019. Production reached
9.1Mt in November 2020, a rise of 4.6% year-on-year from 8.7Mt a year earlier.
Vietnam produced 96.5Mt of cement in 2019, a 7.9% rise compared to 2018.
Vietnam: Plants ordered to close by 2030 China: President of CNBM

Engineering resigns
T he government of Quang Ninh Province has ordered
the closure of two cement plants in Ha Long, the
2.0Mt/yr Ha Long cement plant and 2.3Mt/yr Thang X ia Zhiyun has resigned as the president of China
National Materials International Engineering
Long cement plant, by 2030. The Viet Nam News news- (CNBM Engineering). However, he will remain a
paper has reported that the closures aim to protect the director of the company, a member of the strategy
local environment and nature as part of the city’s move and investment committee of the board of direc-
towards becoming a tourism and service hub centred tors and a member of the nomination committee.
on Cua Luc Bay. In 2014 the provincial government ad- The company is part of CNBM Group. It provides
vised the cement plants to stop expanding and relocate engineering services and equipment to the inter-
before 2030. national cement, housing, industrial equipment
and light industry sectors.
Iran: Production rises 14% in six months
C ement production in Iran rose by 14.4% year-on-year

to 35.6Mt in the first half of the current Iranian calen-
dar year, which began on 21 March 2020. It was 31.1Mt in
the same period of the previous calendar year.
The sector exported 5.8Mt of cement with a value of
US$128m during the six months to 21 September 2020.
Local press reported that 28 countries received Iranian
cement, with India, Afghanistan, Russia, Iraq, Qatar,
Kenya, Kuwait, Sri Lanka, Pakistan, Armenia, Turkmeni-
stan, Kazakhstan, Azerbaijan, Bangladesh, China and
Oman among the destinations.

Taiwan: Revenue falls for Taiwan Cement
T aiwan Cement’s revenue came to US$2.88bn in the first nine

months of 2020, a year-on-year decrease of 6%. However,
its operating income was US$800m, a 9% year-on-year increase
compared to the first nine months of 2019. Its net income was
US$640m, 4% higher than a year earlier.
“The fourth quarter is the traditional peak season for the ce-
ment market and we remain optimistic about our performance,”
said Edward Huang, Senior Vice President and Spokesperson of
Taiwan Cement.
Japan: Sumitomo Osaka
announces climate goals
Sri Lanka: Tokyo Cement to increase production
T okyo Cement Company (Lanka) has announced that it expects

to sign an agreement to increase the production of OPC and
S umitomo Osaka Cement has formu-
lated a set of medium-term goals and
long-term policies in order to enable it
other hydraulic cement products by 1Mt/yr. The investment will be to achieve carbon neutrality, in line with
made at its existing cement grinding plant in Trincomalee on the the Japanese government’s target, by
north east coast of Sri Lanka. 2050. These consist of a 30% reduction
Tokyo Cement said that the project would cost approximately in energy-derived carbon dioxide (CO2)
US$12m. Global Cement notes that this amount is fairly low for such emissions intensity between 2005 and
a large increase in cement capacity and therefore may represent 2030 and efforts toward carbon neutrality
increases in cement handling capacity, rather than grinding capac- in energy and process-derived emissions
ity. Tokyo Cement said that it expects the project to be completed by 2050. These efforts include: reduction
within 24 months. to the limit of fossil energy, development
and introduction of process-derived
CO2 emission reduction technology,
Indonesia: Semen Indonesia signs rail MoU carbon-free electric power, technology
development and supply expansion re-
S emen Indonesia has signed a memorandum of understanding

(MoU) with rail freight company Kereta Api Indonesia (KAI). The
MoU covers a planned increase in cooperation on rail-based trans-
lated to low-carbon cement and concrete
products, development and supply of
innovative bonding materials and devel-
portation and medium and long-term land leases, the conduct of opment and introduction of innovative
joint studies into railways and infrastructure and the development technology related to carbon capture,
of other forms of potential cooperation. utilisation and storage.
Pakistan: APCMA’s offices searched in Karachi
T he Competition Commission
of Pakistan (CCP) conducted
a search and inspection of the
The enquiry began based on
the information gathered through
various media reports and concerns
Karachi offices of the All Pakistan expressed regarding a concurrent
Manufacturers Association (APCMA) increase in cement prices across
on Thursday 19 November 2020. Pakistan, particularly during April
The search was carried out as part 2020. The APCMA stands accused
of an enquiry launched in May of orchestrating a price rise among
2020 to investigate possible anti- producers.
competitive activities by cement The CCP previously searched and
producers. Two different CCP teams inspected the APCMA’s main offices
entered and searched the offices in Lahore. That search allegedly
of the Chairman and Vice Chair- led to the discovery of WhatsApp
man of APCMA and impounded messages and emails that led in-
relevant records. vestigators to believe there were
grounds for further investigation.

China: Bauma China 2020 welcomes

80,000 visitors
T he Bauma China 2020 trade fair took place from

24-27 November 2020 in Shanghai, attracting 2867
exhibitors and a total of 80,000 trade visitors from
China. The organisers said that, despite the Covid-19
pandemic, the exhibition was able to take place across
a 300,000m2 area, thanks to a ‘sophisticated safety and
hygiene concept.’ It said, “In these difficult times, Bauma
China 2020 gave the entire industry a reason to enter
the coming fiscal year with confidence and hope.”
Thailand: Siam City to digitise India: Star to start grinding plant build
procurement processes
S iam City Cement has signed a new contract

with US-based SAP Ariba for the further
T he Chief Minister of West Bengal, Mamata Banerjee, says
that workers have cleared land in Jalpaiguri District on
which Star Cement will establish a 2.0Mt/yr grinding plant.
digitisation of its end-to-end procurement pro- The US$61m grinding plant will receive its clinker from the
cesses by using the latter’s software products. company’s Lumshnong cement plant in Meghalaya.
The producer first partnered with the company CEO Sanjay Kumar Gupta said that the plant, which will
for sourcing, contracts, catalogues, supplier bring the company’s total installed cement production ca-
information management and supplier col- pacity to 6.0Mt, will serve a state with a domestic cement
laboration in 2016. Following the latest release demand of up to 25Mt/yr.
in August 2020, SAP Ariba’s products support
the Thai language, making it easier for buyers
and suppliers to communicate and transact over Philippines: Holcim Philippines to
Ariba Network. merge subsidiaries
L afargeHolcim subsidiary Holcim Philippines has an-

nounced plans to merge with its subsidiaries Bulkcem
Philippine Incorporated and Mabini Grinding Mill Corpora-
tion. A special stockholders’ meeting will take place on 15
January 2021 to finalise the transactions.
Bulkcem Philippine Incorporated leases the Iloilo cement
terminal in Western Visayas, while Mabini Grinding Mill Cor-
poration leases the Mabini grinding plant in Calabarzon.
Pakistan: Three Wärtsilä engines

for expanded Pezu plant
L ucky Cement has placed an order for three

10MW 34DF dual-fuel engines for its Pezu
cement plant in Khyber Pakhtunkhwa from
Finland-based Wärtsilä. The engines are capable
of using various fuels but will be fuelled primar- Pakistan: Pioneer increases
ily by natural gas. They have been ordered to captive coal capacity
provide additional power for the unit’s captive
power plant due to an increase in cement pro-
duction capacity. The orders were placed in April,
August and November 2020.
P ioneer Cement has begun to generate power from its
upgraded 24MW coal-fired power plant. The plant previ-
ously had a power generation capacity of 12MW.

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GLOBAL CEMENT: PLANT REPORT
Interview by Peter Edwards, Global Cement Magazine
Plant report: BIGBOSS Cement, Philippines
Global Cement speaks to BIGBOSS Cement’s Ishmael Ordonez about the company’s
background, its unusual production process and local market conditions, with a focus on
its recently-commissioned Gebr. Pfeiffer ready2grind modular grinding system.
Global Cement (GC): Please could you introduce The plant itself is located in Porac, in Pam-
BIGBOSS Cement? panga, Luzon. It is around 100km north of Manila,
the capital of the Philippines, in the north of the
Ishmael Ordonez (IO): BIGBOSS Cement is a 100% country. It uses an unusual production process that
Filipino-owned producer of cementitious materials makes use of a volcanic material, lahar, which re-
that was established in 2017. It was named after the sulted from a major eruption of the nearby Mount
ultimate Big Boss, God Almighty, and is dedicated to Pinatubo in 1991. The lahar is a very siliceous
carrying out the work of Jesus Christ on Earth. The material that is found at the surface in a 25m-
major shareholder is Henry Sy Jr. thick layer. It extends for many square kilometres
in the area surrounding the plant. The lahar is the
Above: Ishmael Ordonez GC: Can you expand on the founding and primary ingredient for BIGBOSS’ cement. It is
is Senior Vice President for development of the company? mainly SiO2 and, if you analyse it using X-ray dif-
Administration at BIGBOSS fraction (XRD) it bears a strong resemblance to
Cement. He joined the
IO: Henry Sy Jr. is co-vice chairman of SM Invest- cement clinker. However, as it lies in the ground,
company in 2017. He was
previously also responsible ments, a major conglomerate in the Philippines. He the lahar is not activated. This is why our President
for operations, including also serves as chairman of SM Prime, the group’s and key innovator, Eng. Gilbert Cruz, developed a
the project to construct the property arm, which has interests in malls, resi- patent-pending process that activates this material,
company’s plant in Porac.
dences, offices, hotels and convention centres. Due turning it cementitious.
Prior to BIGBOSS Cement,
he worked in the beverage to the continued strong demand for such facilities
and pharmaceutical sectors in the Philippines, he decided to develop captive ce- GC: How does the BIGBOSS process differ
and, most recently, as Chief ment production capacity. BIGBOSS Cement is the from conventional cement production?
Administration Officer for
result of that dream.
International Care Ministries, a
non-governmental organisa-
tion that cares for the poorest
in Filipino society.
Right: The crater lake at the

top of Mount Pinatubo. The
volcano, which erupted in
1991, is a source of lahar, the
main raw material used by
BIGBOSS Cement.
50 Global CementMagazine January 2021

Left: Construction of the

ready2grind mill at the
BIGBOSS Cement plant in
Porac in mid November 2020.
IO: You can think of the BIGBOSS Cement plant supplier. These have a shared capacity of 110t/hr and
as being somewhere between a conventional came online in 2018 and 2019 respectively. The third
integrated facility and a grinding plant. This is a 70t/hr modular ready2grind vertical roller mill
is because there is a low-temperature heating from Gebr. Pfeiffer, which was commissioned in De-
step. In this patent-pending process, the lahar is cember 2020. These three mills combine to produce
heated to above 200°C in a diesel-fired chamber. around 4320t/day (1.4Mt/yr) of low-clinker cement.
This activates the material, converting it to what
we term Granulated Activated Sand by Heating GC: How do you distribute these products?
(G ASH).
The G ASH, plus some imported clinker, gyp-
sum, limestone and slag, are then ground in our
three mills. There are two ball mills from a Chinese
200km Left: Map of the Philippines,

with Manila, Batangas and
LUZON
BIGBOSS Cement plant
shown. Pampanga Province
is highlighted.
• BIGBOSS CEMENT
MANILA •
• BATANGAS
Far left: Lahar mud flow in

VISAYAS the immediate vicinity of
Mount Pinatubo.
MINDANAO
Global CementMagazine January 2021 51

As I mentioned, there were some delays

due to the pandemic. However, we were still
able to receive parts during the spring and
summer as the government classified pro-
jects such as this as ‘essential.’
GC: Were there any issues during commis-

sioning and how were they overcome?
IO: The inability for Gebr. Pfeiffer’s experts

to travel between Europe and the Philip-
pines was a major reason for the delays I
mentioned in my answer above. BIGBOSS
and its local partners had to undertake parts
of the project with Gebr. Pfeiffer assisting
from a distance. Online meetings have been
a big help in this regard. A lot of pictures
were sent back and forth to Germany.
Above: The ready2grind IO: We have two bagging lines, a Chinese one for the In late November 2020, Gebr. Pfeiffer’s
system comes largely two Chinese mills and a Haver & Boecker line for team were finally able to travel to the Philippines to
pre-assembled, resulting in
lower installation times. the ready2grind mill. They pack the products into assist with final commissioning and start-up. We are
40kg bags, which are sold to hardware stores via our grateful for a fruitful collaboration and were able to
sales team and a network of dealers. This is how we keep going with the project during a difficult period.
have chosen to enter the market. We are helped by
the green credentials of our products, which emit GC: What are the differences between grinding
around half the CO2 per tonne as conventional G ASH with a ball mill compared to a vertical
cement products. roller mill?
With the resources at his disposal, Henry Sy Jr.
could have simply bought another cement producer. IO: We grind our products to a fineness of around
There have been plenty of opportunities to do so in 4200cm2/g according to Blaine. However, the
the Philippines recently. However, he was looking to G ASH is easier to grind than clinker. In a ball mill
enter a niche, while also doing some good. Indeed, this means that the different components have a ten-
our company motto is ‘Green is Good.’ The less dency to separate as they progress through the mill.
clinker the better. However, due to the nature of a vertical roller
mill, this effect is significantly diminished. We
GC: Why did BIGBOSS decide to change supplier worked closely with Gebr. Pfeiffer to ensure that we
for the third mill? developed a mill that was capable of 70t/hr.
IO: When we decided to expand the plant, we also GC: What’s next for BIGBOSS Cement?
wanted to ‘level up.’ Gebr. Pfeiffer is a long-standing
company in the cement mill business, with an in- IO: BIGBOSS has plans to enter the bulk distribu-
credible history and reference list. It dealt with us tion market, either via packing in Big Bags or via
directly, not via a third party and shared our enthu- bulk road tankers. The silos and systems are in
siasm to develop the Philippines. place, as this has always been part of our long-term
The ready2grind modular mill concept was plan. However, to enter the bulk sector, we need
chosen due to its short construction time. We had to optimise our formulation to achieve a higher
estimated that the new mill would be commissioned compressive strength. The bagged formulations cur-
within eight months of the start of civil works, but rently reach 24-28MPa after 28 days. To be used in
restrictions surrounding the Covid-19 pandemic bulk projects, we need to achieve more than 40MPa.
ultimately extended this to around 12 months. It is something we are working on right now.
We are also thinking about the next plant(s).
GC: How did the project unfold? Manila is a good source of customers and so we are
looking to cover the market to the south, around
IO: The contract was signed in mid 2019 and civil Batangas. We are also looking at locations for plants
works started in early 2020. The machinery was in- further north in Luzon. We will very strongly con-
stalled in mid 2020 and cold commissioning began sider Gebr. Pfeiffer as a supplier for these plants.
in October 2020. Hot commissioning took place in Beyond this, we have longer-term plans to build
late November 2020 and the ready2grind mill was plants in the Visayas and Mindanao regions, in cen-
fully up and running in early December 2020. tral and southern Philippines respectively.

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Right: BIGBOSS Cement

commissioned its two
Chinese-made ball mills
in 2018 and 2019.
GC: Would these plants also be based on on site and a retention allowance to those not able
the G ASH process? to work. The corporate team was able to work from
home in most cases, with the occasional visit to our
IO: We would again intend to use volcanic resi- head office in Manila.
dues as the main raw material at any future plant.
These are available in many locations within the GC: What are the biggest future challenges for
Philippines due to the high levels of volcanic activity. BIGBOSS Cement?
GC: Is the Philippines still Build Build Building? IO: We are somewhat reliant on imported raw mate-
rial costs, particularly clinker. It is possible that these
IO: The government’s Build Build Build programme could rise in the future. That said, we could adapt
was hampered by the Covid-19 pandemic in 2020. our blend to use no clinker. The resulting product
However, there is a strong underlying drive for major would be able to meet the same strength as we do
new roads and infrastructure projects, housing de- at present. However, it would not be classified as a
velopments and so on, with some improvement in commonly recognised cement blend, which might
the market since September 2020. This is thanks to represent a commercial downside. As the user of a
the adoption of new working protocols, which have captive bunker-fuel-fired power plant, we are also
enabled a return to some kind of normality. Con- exposed to changes in international prices.
struction workers are now tested for Covid-19 and Imported cement, mainly from China and
wear PPE on site, for example. Vietnam, is also a threat to some extent. The market
needs this imported material at present, and so as
GC: How have sales changed since the long as the government maintains appropriate im-
plant was established? port tariffs, importers will continue to complement,
rather than threaten domestic producers.
IO: The plant only began to sell products at the end
of 2018, so there has only been one full ‘normal’ year GC: What is the biggest opportunity for
in the history of the company - 2019. Obviously, the company?
construction work was limited at points during 2020
due to limits on the number of workers allowed on IO: BIGBOSS Cement has huge potential to expand
worksites. to other areas of the country. On top of the govern-
ment’s Build Build Build programme, there is rising
GC: How was production at the plant affected? cement demand from the 105 million people that
call the Philippines home. Small housing projects,
IO: Parts of 2020 were very difficult. We were forced schools, hospitals and commercial spaces are all re-
to close the plant for a period in March and April quired, which will benefit all cement producers. As a
due to a government mandate. However, we suc- young and green producer of cementitious products,
cessfully put forward a case to grind our remaining BIGBOSS Cement is well positioned to leverage ex-
clinker stocks, which otherwise would have spoiled. isting trends to expand rapidly in the coming years.
This was done using a skeleton staff.
We also had to lockdown the plant. During this GC: Thank you. We look forward to following
period, the plant was in operation but nobody could BIGBOSS Cement as it grows.
enter or leave. Of our 200 staff, 100 were on site and
100 were off site. We provided necessary provisions, IO: You are very welcome indeed.
accommodation and a hardship allowance to those

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GLOBAL CEMENT: SOLAR POWER
SK Jain, Unit head, JK White Cement Works, Gotan
Installation of roof-top solar panels

at JK White Cement’s Gotan plant
JK White Cement reports on the installation of two photovoltaic solar installations at its
cement works in Gotan, Rajasthan, India.
T he JK White Cement Works in Gotan is the

first White Cement manufacturing factory in
India to have manufactured white cement using
The government of India has implemented the
National Action Plan on Climate Change, with
a focus on promoting renewable energy. It com-
dry process technology. It was originally commis- prises eight national missions that represent
sioned in 1984 with an initial production capacity multi-pronged, long-term and integrated strategies
of 50,000t/yr. It uses technology from FLSmidth, to achieve key climate goals. Solar energy is a major
which includes its kiln, state-of-the-art continuous priority among these, with a government target
on-line quality monitoring and control by X-Ray to increase solar energy generation to 100GW by
analysis and PLC systems, which ensure the purest 2022. To contribute to the national target, JK White
white cement. Cement works has installed two roof-top PV power
Over the years, continuous process improve- generation systems.
ments and modifications have increased the plant’s
production capacity to 610,000t/yr, now at its low- Case Study 1 - 150kW solar power system
est-ever energy levels. on new administration building
JK White Cement has installed a 150kW solar power
Solar power in India system on its new administration building. It con-
The world’s population is expected to grow to about sists of three inverters and 462 PV panels. The peak
10 billion in year 2050. In order to provide the grow- power rating of each panel is 325W. Each inverter
ing population with rising living standards, further is connected to panels that share a peak power ca-
economic development is essential, which, in turn, pacity of approximately 50kW. This is achieved via
will require more energy than we use today. This using eight strings in parallel i.e.: six strings of 19 PV
energy should ideally be generated from renewable panels and two strings of 20 PV panels in series. The
sources so as to be environmentally friendly. Solar PV panels convert solar energy into direct currrent
radiation can be used via the accumulation of heat in (DC) electrical energy and the inverters convert it to
solar collectors or via direct conversion into electric- alternating current (AC). Each of the inverters has
ity by photovoltaic (PV) panels. a local display and the facility to communicate with
devices via Wi-Fi, Ethernet or a
mobile app.
The 415V output sup-
plies of the three inverters are
connected in parallel and syn-
chronised with Rajasthan State
Electricity Board’s grid supply
at the motor control centre
Right: The final touches (MCC) feeder of the plant’s
are added to the PV panels new administration building.
on the top of the
administration building. An energy meter is installed at
an MCC feeder to measure the
power generated and monitor
trends.
Initial studies to assess the
suitability of the roof of the new
administration building were
conducted in June 2018, prior

GLOBAL CEMENT: SOLAR POWER
to the development of civil drawings of the roof to

assess the solar capacity of the available areas in July
2018. The solar PV installation matrix was decided
upon in August 2018 and technical specifications
were locked in during September 2018. Techno-
commercial offers were finalised in October 2018.
Installation took place during January 2019, with test-
ing and synchronisation with the grid taking place in
February 2019.
After complete installation, the project team
checked the currents and voltages of each string to
confirm that the power generation from all PV panel
strings was uniform. To enable monitoring of the
system, the connectivity of all inverters was checked
using the mobile app and the solar system was
hooked-up to the plant’s energy monitoring system.
The installation of solar PV panels on the new
administration building was a significant challenge.
The anchoring could not have be done on the roof
itself, as this would have resulted in water ingress.
There were also large gaps between the construction During the 2019-2020 financial year (ending 31 Above: The project team on
beams, making it a challenge to distribute the load March 2020), the cost saved thanks to solar power the roof of the administraion
building. Left to right: OP
of the PV panels uniformly throughout the terrace. generation was approximately US$21,000. This gives Gurjar, Diwakar Bishnoi
To do this, small beams were installed on the a payback period of four years and four months. A and Rahul Dwivedi.
roof, perpendicular to the existing beams. These total of 210,990kWh of power did not have to be
small beams were anchored only at existing beams. taken from the grid, reducing CO2 emissions by
The PV structures were installed on the small beams. 173t/yr.
A provision was also made to allow water to pass at The total expenditure on the club mess instal-
2m intervals to avoid water ponding on the roof. lation was US$54,000. The cost saved via the
Another issue relates to the location of the plant. generation of solar power is estimated to be around
It is surrounded by a number of lime kilns, which US$15,500, indicating a payback period of 3.9 years.
emit significant dust. This can limit power genera- The power generated in March 2020 was 14,068kWh.
tion. The PV panels are therefore cleaned regularly Extrapolated over 12 months, this leads to a 115t/
with the help of special water nozzles and wipers to yr reduction in CO2 emissions. Both installations
minimise water consumption. reduce India’s dependence on imported energy and
have low maintenance costs, while contributing to
Case study 2 - 100kW solar power system the aims of the government’s National Action Plan Below: PV panels on the roof
on a club mess building on Climate Change. of the club mess building.
JK White Cement subsequently installed a 100kW
solar power system on its club mess building com-
prising two inverters and 300 PV panels. The peak
power rating of each PV panel is 335W. Each in-
verter is connected to nine strings of PV panels i.e.:
six strings of 17 PV panels and three strings of 16 PV
panels in series.
The project began in July 2019 with feasibility
studies. It was synchronised to the Rajasthan State
Electricity Board in February 2020. As with the prior
project, it was necessary to add perpendicular beams
to support the panels on the building. The location
of the panels also required some air-conditioning
units to be moved to another location.
Benefits from above two installations

The total cost of the installation on the new adminis-
tration building was US$90,000, including material
supply, panels mounting structures, PV panels, civil
construction, meter installation and synchronisa-
tion with the Rajasthan State Electricity Board.

GLOBAL CEMENT: BAGGING
Haver & Boecker
Innovative Engineering: The fastest ever

installation of a packaging line
Cockburn Cement, an Adbri Ltd company, is a leading supplier of cement products to

Western Australia’s mining, agriculture and construction industries. In 2017, the company
awarded its tender for a new packing line to global technology developer Haver & Boecker.
While the choice of technology may have been easy, the installation was not without its
challenges. Powered by innovative thinking and engineering expertise, the partnership
overcame all constraints to execute one of the fastest ever installs of a high capacity
Haver & Boecker packing line without any supply interruption.
C ockburn Cement’s Kwinana packing plant is

one of seven Cockburn Cement manufactur-
ing and distribution facilities located in Western
capable of quickly changing from one product to
another requiring only 15 minutes of downtime,
significantly faster than the older machines.
Australia. When the plant’s grey product packing Dinesh Kapadia, Engineering Project Manager,
machine and associated palletiser were approach- Cement and Lime at Adbri Ltd, said “With Haver
ing the end of their useful life in 2017, the company & Boecker’s technology, we were confident we
began a competitive tender process to upgrade its could meet our objective of producing 4800bags/hr.
equipment. It also gave us the opportunity to continue with a
Below: Cockburn Cement Having previously experienced the quality and standardised technology for ease of operation and
and Haver & Boecker took an performance of Haver & Boecker equipment, the maintenance as well as spare parts inventory.” The
innovative approach to the
company selected a 14 spout Roto-Packer® RVT14 RVT14 also requires less maintenance, creates less
installation of the Kwinana
plant’s new bagging and - the latest in high capacity packing technology – to waste and produces cleaner bags than the previous
palletising line. replace the incumbent technology. The RVT14 is machines.
Innovation in installation
Spatial limitations within the plant meant the RVT14
would need to be installed in the same location as
the existing packer and palletiser. With ongoing
demand from key customers, the removal of the ex-
isting packing equipment and the installation of the
new system had to be completed without interrupt-
ing market supply. This presented some challenging
installation constraints.
While stock was built up and the rest of the plant
remained operational, the timeframe to stop the old
packing line, decommission the old machine and
commission the new one was still very tight.
“A conventional build methodology would have
required a considerable amount of time, estimated at
three months,” explains Kapadia. “It would have also
meant considerable additional cost through stock
building and off-site storage of material.”
However, with some innovative thinking, the
Cockburn Cement team proposed an alternative
solution. “We used the high quality detailed draw-
ings provided by Haver & Boecker to develop
a modular design,” explains James Keys, Project
Manager, Cockburn Cement. “Prior to installation,
the packing system would be assembled in four

GLOBAL CEMENT: BAGGING
modules outside the packing area in a space 300m

from the plant.”
Adding value
According to Adam Scata, Operations Manager at
Cockburn Cement, “The modular install had its
risks but Cockburn Cement, together with Haver &
Boecker, managed them well. They provided excel-
lent support to our team as the innovative modular
design concept was developed.”
This included the packing machine layout which,
designed in close consultation with the Cockburn
Cement project team, ensured the footprint of the
machine was the best achievable fit within the pack-
ing shed.
“The Haver & Boecker technicians also sup-
ported the incorporation of the blend back system to
recycle all flush and waste material. This eliminated
any waste going to landfill, offering both cost savings Above: Assembly of the four
and sustainability gains,” explains Scata. modules took place 300m
from the installation site.
Further efficiencies were realised by implement-
ing a double pallet stacker to increase throughput. A
pallet scanning system was also installed to improve
Left: Installation of the mod-
quality control and health, safety and environment ules at the final location.
factors by ensuring stable stacks in warehousing.
Rapid high-capacity installation

Once assembled and ready for installation, the mod-
ules were transported by self-propelled modular
transporters from the assembly area to the installa-
tion site. Demolition of the existing machines was
carried out in 48hr to provide a clean floor for instal-
lation of the new machine by crane.
At any one time, Haver & Boecker had up to
three technicians onsite to supervise. “The Cock-
burn Cement team developed a great working
relationship with the Haver & Boecker team, from Below: The new packing
the managing directors, through to the on-site in- line was in operation just
42 days after the previous
stallation personnel,” adds Scata. line was demolished.
From powering off the old machine to commenc-
ing the wet commissioning of the new equipment
was just 42 days – the fastest ever install of a high
capacity Haver & Boecker packing line.
Commercial outcomes
The new bagging plant is nominally rated at
4800bags/hr for general purpose cement and deliv-
ers substantial efficiency, reliability and productivity
benefits. The higher throughput means Cockburn
Cement can now meet market demand through a
single eight-hour shift operation, whereas previ-
ously two shifts were required.
This reduced operational time allows mainte-
nance functions to be carried out during business
hours and it has seen a reduction of product waste
through the recycling of spillage and flush material.
The cleaner bags and improved product presenta-
tion has also led to greater customer satisfaction.

GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Contents
Oman: Long-awaited Duqm plant breaks ground
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R aysut Cement has held the groundbreaking ceremony for
its new 1.0Mt/yr Duqm grinding plant. The project will cost
US$30m. CEO Joey Ghose said that the plant would “Contribute
significantly to our ambitious capacity expansion targets of 10Mt/yr
by 2022, which is expected to be further scaled up to 22Mt/yr in the
near future. Secondly, it will help us generate more employment
opportunities, aiding our efforts to enhance social and economic
progress in Oman.”
Image: Port of Duqm,
The company acquired the lease to the site in the Port of Duqm Oman, during construction.
in September 2019 as part of an on-going series of ‘calibrated’ in-
vestments in ‘locations where demand is high and locally-available
additives are in close proximity.’
Ghose added, “Our aim is to develop Raysut Cement into a
global leader in cement manufacturing, supply and exports. The Qatar: Strong September
development of Duqm is an important element in this strategy. Our
expansions are dovetailed to the opportunities that exist and are
2020 sales
upcoming in the markets we focus on, for instance in East Africa - a
booming market for the next 50 years.” Q atar witnessed robust month-
on-month cement production
growth during September 2020 as
the country scaled back its Covid-19
restrictions. Cement production in-
Tanzania: New Tanga plant talks progress creased by 9.1%. Cement was one of
a number of sectors to buck a wider
T anga Cement says that talks with the government about a new
0.5-0.75Mt/yr grinding plant in Arusha are progressing. Discussions
about the project with the authorities originally began in 2016. At
trend of a continued industrial slow-
down, according to the Planning and
Statistics Authority (PSA). However,
present the cement company transports cement to the region using a the volume of cement produced was
freight train that was inaugurated in 2020. 3.1% lower than in September 2019.
Cameroon: Dangote notes strong position
D angote Cement’s subsidiary in Cameroon estimates

that it had a market share of 39% in the first nine
months of 2020. It reckons the total cement market in the
country was over 2.6Mt in the same period and that it sold
around 1Mt.
Dangote said that the market was mainly driven by
individual construction projects and public housing es-
tates. In February 2020 the subsidiary said it planned to
‘do better business’ in 2020 by focusing on the construc-
tion sites of stadia, roads, hotels and other construction
projects in preparation for the 2021 Africa Cup of Nations
Above: The Khalifa International Stadium in Doha, Qatar, will play an
football tournament, which has now been postponed important role in the 2022 FIFA World Cup. Both Qatar and Cameroon will
to 2022 due to the Covid-19 pandemic. host major tournaments next year. Credit: Fitria Ramli / Shutterstock.com
Mozambique: Sino Energy signs MoU regarding plant purchase
S ino Energy, a manufacturer and supplier of foot-

wear and related accessories across mainland
China, has agreed in principle to purchase a 65% stake
Sino Energy signed a non-legally-binding
Memorandum of Understanding (MoU) with Sino-
Harbor Construction Group (Hong Kong) on 23
in the 0.4Mt/yr cement plant located in Northern November 2020. The MoU gives Sino Energy until
Pemba City, Cabo Delgado Province. The plant was April 2021 to carry out due diligence and conduct
built in 2016 but has suffered due to low demand. further negotiations.

CEMENT NEWS
Zimbabwe: Strong third

quarter for Lafarge
L afargeHolcim subsidiary Lafarge

Cement Zimbabwe has said that ce-
ment demand has increased by 34%
quarter-on-quarter in the third quar-
ter of 2020 following the end of the
national coronavirus lockdown. The
company said that cement demand in
July 2020 was the highest in that month
since July 2003 due to a 7% year-on-
year sales rise.
Company chair Kumbirai Katsande
said “As business activity progressively
continued to gain momentum into
the third quarter of 2020, the demand
for cement consequently outstripped
supply, causing a considerable supply
backlog.” Katsande said that the short-
age will ease as demand decreases in
line with higher rainfall in the fourth
quarter of 2020.
Nigeria: Dangote reports impressive nine month results in 2020
D angote Cement reported group sales of US$2.0bn

for the first nine months of 2020, up by 12% year-
on-year from US$1.79bn in the first nine months of
The company also said “Our vision is for West and
Central Africa to become cement and clinker inde-
pendent, with Nigeria being the main export hub. This
2019. Its cement volumes rose by 7% to 19.2Mt from will notably contribute to the improvement of regional
18.0Mt, while its earnings before interest, taxation, trade within the Economic Community of West African
depreciation and amortisation (EBITDA) rose by 17% States region and beyond with the African Continental
to US$934m from US$797m. Free Trade Area.”
Dangote Cement CEO Michel Puchercos said,
“Dangote Cement’s strategy to offer high quality
products at competitive prices is meeting custom-
ers’ expectations in Nigeria and across the continent,
where we continue to deploy excellent marketing
initiatives and operational excellence. We remain com-
mitted to protecting our staff and communities by
being fully compliant with health and safety measures
in all our territories of operation. We are focused on
adapting to the rapidly-evolving markets in which we
operate.” The group added that the third quarter of
2020 was its strongest third quarter to date.

GLOBAL CEMENT NEWS: MIDDLE EAST & AFRICA
Algeria: GICA exports clinker to Hispaniola
G roupe des Ciments d’Algérie (GICA) has completed the export

of 41,000t of clinker to Haiti and the Dominican Republic. Al-
geria Press Service has reported that the company exported the
clinker, produced at the Hadjar Soud cement plant, from the Port
of Annaba.
GICA CEO Youcef Merabet said, “The Hadjar Soud cement plant,
which operates two production lines totalling 0.9Mt/yr of cement
production capacity, will promote its exports in 2021.”
Egypt: Stake shuffle at Egyptian Tourah Portland
M etallurgical Industries Holding sold its 18% stake in Egyptian Tou-

rah Portland Cement for just under US$3m in December 2020.
Arab African International Securities (AAIS) acted as broker for the
transaction. In October 2019, the Financial Regulatory Authority (FRA)
approved HeidelbergCement subsidiary Suez Cement’s mandatory
tender offer (MTO) for 100% acquisition of Egyptian Tourah Portland
Image: The Egyptian Tourah Portland cement plant. Cement for around US$33m. The company’s 1.0Mt/yr cement plant is
Source: Company website.
Egypt’s oldest, established in 1927.
Nigeria: Borders reopen for cement exports
D angote Cement and BUA Cement have been allowed to export

goods by land following a closure of land borders in mid 2019
due to smuggling. The government has granted permission for Dan-
gote Cement to export its products to Niger and Togo, according to
the Business Live newspaper. BUA Group has also received approval.
However, Lafarge Africa has reportedly not yet received permission.
Kenya: EAPCC disputes with Nigeria: BUA Cement improves access to power
staff and neighbours
E ast African Portland Cement Com-

pany (EAPCC) has threatened
B UA Cement has donated six transformer units with a total ca-
pacity of 400kW to Okpella Community in Edo State. The Daily
Independent newspaper has reported that the company’s aim is to
‘recovery proceedings’ in relation to the improve local access to electricity.
alleged unlawful extraction of building Managing director and chief executive officer (CEO) Yusuf Binji
materials on its land in Mavoko County said, “Our commitment to sustainability, sustainable development
by China Road and Bridges Corporation goals and sustainable business practices will remain critical to our
(CRBC). EAPCC says that it has twice business at BUA Cement. We will keep pursuing an inclusive, safe,
contacted the construction company, resilient, and sustainable environment. Corporate social responsibil-
which is engaged in building the Nairobi ity is how we colour the lives of those around us.”
Expressway toll road, to order it to desist.
The cement producer is seeking a buyer
for the parcels of land, which are also
home to illegal squatters.
In November 2020, a union repre-
senting 150 of EAPCC employees who it
made redundant on 1 September 2020,
rejected the company’s offer to take
back the workers on a three-year con-
tract with a pay cut of 50%.

GLOBAL CEMENT MAGAZINE: PRICES
EU ETS: CO2 emissions permits cost

These pages give Global Cement Magazine‘s Euro29.62/t on 7 December 2020, a 1.6%
monthly review of global cement prices week-on-week rise from Euro29.14/t
- in US$ for easy comparison. Some price on 30 November 2020, a 16.5%
information is only available to subscribers rise month-on-month from
to Global Cement Magazine. Subscribe on Euro25.42/t on 6 November 2020
Page 64. In this issue subscribers receive and a 18.8% rise year-on-year
information from: China, Nigeria, Pakistan, from Euro24.94/t on 7 December
Tanzania and Uzbekistan. 2019.
Prices are for metric tonnes unless other- India: Cement prices in southern
wise stated. US$ conversions from local India grew during the third quarter
currencies are correct at the time of original of 2020. According to Motilal Oswal,
publication. prices in the region had been strong
and were up by 18% year-on-year in the
three months to 30 September 2020, while
prices in north, west and central India are up by
Egypt: Ordinary Portland Cement prices as at 7 7%, 6% and 5%. Quarter-on-quarter prices were
December 2020: Arabian Cement Co (Al Mosalah) unchanged in the south, with rises of 3%, 1% and
= US$50.47/t; Arabian Cement Co (Al Nasr) = 2% respectively in the north, west and central re-
US$47.73/t; Cemex (Al Nasr) = US$46.97/t; Cemex gions quarter-on-quarter respectively.
(Al Fahd) = US$46.01/t; Minya Portland Cement In the fourth quarter of 2020, the average price
(Minya) = US$47.41/t; El Nahda Cement (Al Sakhrah) had risen by 0.8% quarter-on-quarter by early De-
= US$46.33/t; Wadi El Nile Cement = US$46.78/t; cember 2020, bucking the usual trend for this part
Lafarge (Al Makhsous) = US$48.37/t; Arish Cement of the year, which has typically seen quarter-on-
(Alaskary) = US$46.77/t; Sinai Cement (Sinai) = quarter declines of 0.7-1.1% in recent years.
US$46.97/t; Suez Cement (Al Suez) = US$49.00/t; Year-on-year the average price across the coun-
Helwan Cement (Helwan) = US$49.51/t; Misr Beni try had risen by 7% compared to the fourth quarter
Suef = US$48.37/t; El Sewedy Cement = US$50.59/t; of 2019, reaching US$4.88/bag (50kg). This was led
Misr Cement Qena (Al Masalah) = US$47.29/t; South by rises of around US$0.95-1.22/bag (~20%) in
Valley Cement (Ganoub Elwady) = US$46.14/t. April-May 2020, with prices in the south still up by
White cement prices as at 7 December 2020: US$0.81/bag as at early December 2020, an 18%
Sinai White Cement (Alabid Elnada) = US$159.45/t; year-on-year rise to US$5.33/bag.
Sinai White Cement (Super Sinai) = US$156.90/t; Motilal Oswal added that prices in Maharashtra
El Menya Cement (Super Royal) = US$152.43/t; El had risen by around 10% to US$4.80/bag. Prices
Menya Cement (Royal Elada) = US$154.98/t; Menya in Gujarat remained steady quarter-on-quarter at
Helwan Cement (Alwaha Alabiad) = US$154.67/t. US$4.75/bag. This has taken prices in the West of
Blended cement prices as at 7 December 2020: India up by 1% quarter-on-quarter to US$4.78/bag.
Sinai Cement (Al Nakheel) = US$41.14/t; El Menya Prices in the north have risen by US$0.18/bag to
Cement (Al Omran) = US$39.86/t; Helwan Ce- US$5.28/bag, up by around 7% year-on-year. Prices
ment (Al Waha) = US$42.60/t; El Sewedy Cement in central India have also risen, by around 5%, to
(Sewedy Tashtibat) = US$43.05/t. US$4.83/bag.
Sulphate-resistant cement prices as at 7 Prices in the east of India have fallen by around
December 2020: Arabian Cement US$0.34/bag since May 2020. However, prices are
Company (Moqwem Mosalah) marginally higher year-on-year at US$4.40/bag.
= US$51.54/t; Cemex (Al
Mukawem) = US$48.68/t;
Minya Portland Cement
(Asec Sea Water) =
US$48.87/t; Lafarge Do you have your finger on the cement
(Kaher Al Behar) = price pulse where you are?
US$51.54/t; Suez If so, Global Cement Magazine needs you!
Cement (Al Suez Sea
Water) = US$50.78/t; Contact: Peter Edwards
El Sewedy Cement (El [email protected]
Sewedy Al Mukawem)
= US$51.74/t. Regular contributors receive a free
subscription to Global Cement Magazine!

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Independent Analysis • Industry Trends • Global Cement News

National & Regional Reports • Interviews • Technology

GLOBAL CEMENT: THE LAST WORD
A return to normal?
Peter Edwards Editor, Global Cement Magazine ([email protected])
T he Covid-19 pandemic upended most people’s

normal routines around the world in 2020. Many
column inches have been devoted to ‘the new normal.’
Different generations also have their own views
of what is ‘normal.’ This is often a conscious decision
to deviate from whatever norms have come before,
What will ‘normal’ look like in a week, a month, or be it the clothes we wear, the music we listen to, our
a year? When government rules change every other preferred foods or entertainment, even the way we
week, the question is an ever-shifting goalpost. Com- communicate. Previously dominated by ‘moody teen-
ments can age rapidly and make the author look silly, agers,’ digital communications and social platforms are
even a few days later. now, due to Covid-19, part of all of our lives.
At the moment ‘normal’ may, depending on your So ‘normal’ varies across different times, places and
location, might include a lockdown, home-working, subsets of the population. This shows that ‘normal’ can
home-schooling, a lack of meaningful socialising, an change, most often without a grand plan or strategy.
inability to travel and/or other restrictions. From the So... do we want to change ‘normal’ and, if so, how?
‘start’ of 2021 it is impossible to say very much about Can we? Should we?
how the year will pan out. One thing is for sure - it will A further look in the comments section under-
be another rollercoaster, with plenty of ‘new normals’ neath a cross-section of news articles indicates that
to take in along the way. the answer to the above question is often ‘Yes.’ There
But what makes something ‘normal’ anyway? As is a wide-ranging dissatisfaction with our current
an adjective in everyday use ‘normal’ means ‘conform- (and previous) normalities. A recurring comment
ing to a standard, usual, typical or expected situation,’ is ‘Normal is what led to this in the first place,’ where
whether the topic is behaviour, height, blood pressure or this is variously Covid-19, climate change, populism,
any other facet of the world around us. In mathematics, adversarial politics, childhood obesity, unhealthy work
‘normal’ is defined as perpendicular to a tangent line or practices and all manner of other modern phenomena.
curve. In statistics the ‘normal’ distribution describes The clear implication of such comments is that
a probability distribution that is symmetrical around we need to ‘do something’ about normality, which
the mean. otherwise will continue to lead us up the wrong path.
We can define ‘normal’ behaviour in other ways Indeed, this sentiment now seems to be resonating
too. One online comment that stuck out to me while I with national governments, several of which have re-
was reading around this topic defined it as ‘...the most cently pledged to ‘build back better.’ This doesn’t mean
popular form of weird.’ Peeking beneath this comment’s physically re-building towns and cities with cement
tongue-in-cheek exterior, there is a grain of truth. and concrete, but restructuring how societies work for
Everyone deviates from ‘normal’ behaviour to some ex- people and the planet. There is finally a recognition
tent, but on average we can identify an expected ‘mean’ that, rather than green technologies costing money,
behaviour. A normal distribution of normality, if they provide jobs (and tax receipts). This could offer
you will. a powerful economic vaccine against the worst of
Of course, ‘the most popular form of weird’ varies Covid-19’s economic symptoms. Take China, the first
enormously across different cultures and has changed country to suffer the effects of Covid-19 and one of
throughout the ages. In the 19th Century it was com- the biggest users of coal in history. It has committed
mon to spit in public across much of Europe. In 2021, to net zero CO2 emissions by 2060. The EU will cut
you might be arrested or fined. In Japan blowing your emissions by 40% by 2030. The early days of the Biden
nose is bad manners, while not doing so in much of Administration will see the US rejoin the Paris Accord.
rest of the world would be equally unusual. Hand In late 2020, major cement producers lined up
gestures are a total minefield. A thumbs up, often a to pledge to hit stringent emissions targets, many as
positive signal or greeting, can mean exactly the op- part of the NYC Climate Week. These companies are
posite in parts of the Middle East. An OK sign might redefining the cement sector’s ‘normal,’ shaping our
be used by an Italian show their appreciation of a meal sector for the years ahead. Hopefully many more will
or by an American to indicate all is well. In Brazil the add their names in 2021. Global Cement, for its part,
same signal is very rude, as Richard Nixon found out will continue to emphasise sustainability, whatever
during a trip when he was US Vice President in the ‘normality’ brings us next.
1950s.

GLOBAL CEMENT: ADVERTISERS JANUARY 2021
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MAGAZINE
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Tips for 2021
News
Advertising Paul Brown: +44 (0) 7767 475 998 / [email protected]

enquiries:
Editorial Peter Edwards: +44 (0) 1372 840 967 / [email protected]

enquiries: Jacob Winskell: +44 (0) 1372 840 953 / [email protected]
American Cement VIRTUAL Conference 41 [email protected] • www.AmericanCement.com
Asian Cement VIRTUAL Conference 49 [email protected] • www.AsianCement.com
Christian Pfeiffer 39 [email protected] • www.christianpfeiffer.com
Coal Mill Safety Pte Ltd 26 [email protected] • www.coalmillsafety.com
David Brown Santasalo OBC [email protected] • www.dbsantasalo.com
FutureCem VIRTUAL Conference 31 [email protected] • www.FutureCem.com
Global CemFuels VIRTUAL Conference 53 [email protected] • www.CemFuels.com
Global CemProducer VIRTUAL Conference 13 [email protected] • www.CemProducer.com
Global CemTrans VIRTUAL Conference 19 [email protected] • www.Cem-Trans.com
Global Concrete VIRTUAL Conference 23 [email protected] • www.Global-Concrete.com
HARDTOP Gießereitechnologie GmbH 27 [email protected] • www.hardtop-gmbh.de
KettenWulf IBC [email protected] • www.kettenwulf.com
KIMA Process Control GmbH 7 [email protected] • www.kima-process.de
KORFEZ Eng. 35 [email protected] • www.korfez-eng.de
Magotteaux IFC [email protected] • www.magotteaux.com
Pro Global Media Book 2021 55 [email protected] • www.GlobalCement.com/advertise
Qinghua Refractories 29 [email protected]
SICIT Group 21 [email protected] • www.sicitgroup.com
Testing Bluhm & Feuerherdt GmbH 37 [email protected] • www.testing.de
Wintech Industries GmbH 61 [email protected]
Next issue: February 2021 Advertising deadline: 11 January 2021

Country Report: Spain Interview: Cement Decarbonisation, WCA & Decarb Connect
Interview: Dinah McLeod, GCCA
Distribution: Global Concrete VIRTUAL Conference
Preview: Asian Cement VIRTUAL Conference Technical: Alternative fuels, Burners, Refractories, Shredding
FutureCem VIRTUAL Conference Concrete Technology, Bagging, Palletising, Wrapping

Maintenance
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RECLAIMER CHAINS
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For over 90 years, KettenWulf, as an expanding global company, has stood for quality,
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KettenWulf Betriebs GmbH T + 49.(0)2973.801-0

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David Brown Santasalo_Cement_Full Page_Advert.indd 1 Mill Drives, Girth Gears & Pinions
27/11/2020 10:14:16
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DB Santasalo Jan 2021.indd 1 15/12/2020 14:30

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News Tips for 2021 Smart Technology Fans Solar Power Waste Northern Europe Snowmen BIGBOSS Cement

BIGBOSS Cement Bagging

Contents Subscribe Ad Index

JANUARY 2021 MAGAZINE

innovative longer- lasting Lower maintenance

Process optimization services

Magottaux Jan 2021.indd 1 15/12/2020 14:23

PHOTOGRAPHY COMPETITION 2021 WINNER

This issue’s front cover showcases the winning entry in

Tips for 2021

Global Cement Magazine January 2021 3

14 Proudfoot’s Five-point plan for 2021

20 Service 4.0: On-site,

22 Global Concrete News

24 Products & Contracts News

30 A letter from Buzzi Unicem

32 Cement in Northern Europe

4 Global Cement Magazine January 2021

Volume 44 Eliminating snowmen at a cement plant in Indiana

21 56 Installation of roof-top solar panels

58 Innovative engineering: The fastest

Middle East & Africa

Regulars & Comment

Global Cement Magazine January 2021 5

Contents Virtual Global CemProducer 3

Virtual Asian Cement Conference

Virtual Future Cement Seminar

3rd Global CemProcess Conference Virtual Middle Eastern Cement 2

15th Global CemFuels Conference

6 Global Cement Magazine January 2021

KILN SHELL COOLING

THAT‘S WHAT WE CALL THE KIMA PROCESS.

KIMA January 2021.indd 1 15/12/2020 16:33

JANUARY 2021 MAGAZINE

Right - First Runner Up:

8 Global Cement Magazine January 2021

Global Cement Magazine January 2021 9

Above - Runner Up:

Below - Runner Up:

10 Global Cement Magazine January 2021

Right - Honourable Mention:

Below Right - Finalist:

Bottom of Page- Honourable Mention:

Below - Honourable Mention:

Global Cement Magazine January 2021 11

Above Right - Honourable Mention: Finished Cement, by Fazlul Karim Chowdhury,

Right - Honourable Mention: Photograph of Scene in cement by

Scan the QR code...

...to see more entries

12 Global Cement Magazine January 2021

19 JANUARY 2021 CONFERENCE & ‘EXHIBITION’

Diego Hall: L’Amali Plant, Argentina

CemProducer 3 2021 FP - Virtual.indd 1 15/10/2020 08:52

Angus Maclean, Proudfoot

Proudfoot’s Five-point plan for 2021

M ost of us would probably say that 2020 was

14 Global Cement Magazine January 2021

Global Cement Magazine January 2021 15

Thomas Bergmans and Dirk Schlemper, INFORM GmbH

Virtual Future Cement Seminar

3rd Global CemProcess Conference Virtual Middle Eastern Cement 2

15th Global CemFuels Conference