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www.mondigroup.com
IN TOUCH EVERY DAY
Effi cient solutions for
bagging cement
Mondi’s innovative industrial bag solutions
are optimised for high-speed fi lling needs
and fulfi ll even your toughest requirements.
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For more than a century, vertical roller mills have been used in the cement industry. For grinding cement raw material and coal these machines have long surpassed all other types of pulverizing machines.
For nearly 25 years, vertical roller mills have also been in operation in the cement industry for grinding cement and have been proven as innovative technology in many regions in the world.
Due to ITALCEMENTI’s extremely good experience with the performance of the LOESCHE mills, they placed another order for a LOESCHE vertical roller mill type LM 48.4 for grinding cement raw material at a capacity of 320 tph. Furthermore, a hot gas generator type LOMA LF 31 was part of the project.
Loesche vertical roller mills are ideally designed for such demands, guaranteeing a quick and simple changeover from one product to another and at the same time ensuring an energy ef�cient production for all cement types required.
For this Bulgarian cement plant with a vertical roller mill for cement raw material the client relies once again on the latest technology of the pioneer in grinding technology - Loesche GmbH.
For more information visit: www.loesche.com
LOESCHE GmbHHansaallee 243 40549 Düsseldorf, Germany
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LOESCHE – TRADITION AND INNOVATIVE ENGINEERING
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Refratechnik Cement GmbHRudolf-Winkel-Strasse 137079 GöttingenGermanyPhone +49 551 6941 [email protected]
Intelligent refractory technologyfor the cement industry worldwide.Refratechnik’s shaped and unshaped products give the required technological edge to your refractory equipment: outstanding chemical, mechanical and thermal characteristics, and excellent refractory engineering, installation and aftersales services. Benefit from our experience – refractories matched to your needs.
Mondi Industrial Bags, a business segment of Mondi’s Europe & International Division, is the leading international producer of industrial paper bags, selling around 5 billion bags per year. Thanks to its broad range of bag specifications, Mondi Industrial Bags serves major industries including cement and building materials, chemicals, food, feed and seed. The business segment operates a dense sales and service network, the specialised filling equipment department Natro Tech, as well as its Bag Application Centre, where researchers develop and test innovative packaging solutions.
CONTENTS MAY
Palladian Publications Ltd15 South Street, Farnham, Surrey GU9 7QU, ENGLAND
Tel +44 (0)1252 718999Fax +44 (0)1252 718992
Email: [email protected]: www.worldcement.com
Volume 46: Number 5
May 2015
ISSN 02636050
THIS MONTH’S COVER
www.mondigroup.com
IN TOUCH EVERY DAY
Effi cient solutions for
bagging cement
Mondi’s innovative industrial bag solutions
are optimised for high-speed fi lling needs
and fulfi ll even your toughest requirements.
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WORLD CEMENT REGULARS
05 Comment
09 News
19 The Concrete Initiative: Solutions for Europe’s FutureKoen Coppenholle, Chief Executive of CEMBUREAU.
109 Product News
112 Regional Report Infographic
REGIONAL REPORT: AFRICA AND THE MIDDLE EAST
24 Savannah Cement: StreamlinedBrian Wamwenje, ICT Manager at Savannah Cement, Kenya.
29 Sustained GrowthAhmed Methlouthi, Ministry of Trade, Tunisia.
32 Energy Crisis in the Egyptian Cement SectorIbrahim Ismail, Hesham E. Abdel Hafiez, Asmaa S. Hamouda and Ahmed Soliman.
39 Alternative Fuels in the Arab WorldDirk Lechtenberg, MVW Lechtenberg, Germany.
WORLD CEMENT PLANT TOUR
44 Plant Tour: Devnya CementLouise Fordham visited Italcementi’s Devnya Cement plant.
BAGGING & PACKING
57 A Compact System for CroatiaAndre Tissen, Beumer Group, Germany.
62 Scaling Up: Sacks and SkillsSigrid Eder, Starlinger & Co. GmbH, Austria.
67 Transforming Product PerceptionDavid Khanna, Commercial Director, bpi.visqueen, UK.
69 Bagging & Packing Round-upNews from Windmöller & Holscher and Haver & Boecker.
71 Premium PackagingGraham Rawlings, Concetti SpA, Italy.
STORAGE SOLUTIONS
77 Cement Silo OptimisationPeter King, Australian Silo Clean, Australia.
81 Bulk Materials ManagementRobin Shepherdson, Scale-Tron, Canada.
85 Assuring AccuracyArmin Waibel, UWT GmbH, Germany.
89 Experience for Good MeasurementGraham McGregor, Siemens AG, Canada.
MILLS
95 Good VibrationsKarl S. Gugel, Ph.D., Digital Control Lab, LLC, USA.
101 Modern and Energy EfficientWang Xuemin, Wang Qianqian and Chen Daiyan, CNBM (Hefei) Powder Technology Equipment Co., Ltd, China.
REFRACTORIES
105 Total RecallRoberto Ebrase, Eldir System, Italy.
HEKO Ketten GmbHEisenbahnstraße 2 | 58739 Wickede (Ruhr), Germany | Telephone +49(0)2377-9180-0 | Fax +49(0)2377-1028 | E-Mail: [email protected]
www.heko.com
HEKO componentsfor bucket elevators� Round link chains
� Central chains
� Plate link chains
� Rollers and Sprockets
� Bearings
� Buckets
HEKO offers the whole range of chains and other wear parts for bucket elevators
and chain conveyors. Proven in thousands of elevators and conveyors, worldwide.
Anzeige_BW_09_00:Anzeigenentwurf 06.03.2009 18:32 Uhr Seite 1
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WORLD CEMENT (ISSN No: 0263-6050, USPS No: 020-996) is published monthly by Palladian Publications, GBR and is distributed in the USA by Asendia USA, 17B S Middlesex Ave, Monroe NJ 08831.
Periodicals postage paid New Brunswick, NJ and additional mailing offices. POSTMASTER: send address changes to World Cement, 701C Ashland Ave, Folcroft PA 19032
Copyright© Palladian Publications Ltd 2015. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in the articles or the advertisements.
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According to recent reports, the China Refractory Association is expecting Chinese demand for refractory to decline over the next two to three years. Output for 2014 was 27.972 million t. By 2017, the China Refractory Association is expecting that to fall to 24 million t.
A decline in domestic demand makes sense in an environment of increasing emissions regulations and
slowing industrial growth. If you were to draw a Venn diagram of energy-intensive industries subject to environmental regulations and end-users of refractory, it could well be mistaken for a circle. And, of course, the refractory industry itself is energy-intensive and has fallen foul of the same over-development that has driven consolidation (and, in some cases, demolition) in the Chinese cement industry. Earlier this year, the Ministry of Industry and Information Technology (MIIT) launched standard conditions for the refractories industry that include requirements for production layout, energy efficiency, quality management, and so on. Like cement producers, refractory manufacturers are being encouraged to relocate, consolidate and control capacities. While a burgeoning export market (up more than 12% in 2014) will help ease the burden of overcapacity, modernisation and efficiency measures will need to be taken to meet environmental standards.
China is not alone in experiencing falling sales. Worldwide, refractory demand has been steadily declining in line with the drop in industrial production associated with the global economic crisis. As demand returns, there are some indications that users are turning towards higher quality refractory products with a view to their own process quality as well as a more cost-conscious, cautious approach. In the cement industry, where the cost of refractory on a per tonne basis is relatively minimal compared to, say, the steel industry, reliability is equally essential. The pressures of new and various alternative fuels and raw materials require the refractory industry to develop more resilient products in response. No doubt all these topics will be on the table at the UNITECR Congress in Vienna later this year, which World Cement will be covering in our September issue.
It is interesting that while in China industry is stepping away from coal, other countries are stepping towards it. This is notably the case in Africa and especially in Egypt, where a shortage of gas has forced the government to permit cement producers to use coal. Since that announcement, several contracts have been announced with major mill manufacturers (see one such example on page 9) as cement producers rush to make up for lost production time. More on this topic, and on the growth of alternative fuels in Egypt’s cement industry, is included in this month’s regional report, which has an energy focus (see page 32). We hope, as ever, that the articles included in this issue help you make the most of your process. Share your stories by emailing me on the address above or by joining our LinkedIn groups.
Economic silo, storage and transport solutionsI BAU HAMBURG: Your solution provider
For more information please visit:
www.ibauhamburg.de
I BAU hAMBUrgRödingsmarkt 35D-20459 HAMBURg�+ 49 (0) 40 36 13 090
IBAUHAMBURG
And last but not least: We offer you a reliable worldwideservice and a 24 hour hotline at 365 days of the year.
Single silos. Ring silos.
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22 chambers,diameters:
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Advanced technology for
self-discharging Cement Carriers
including the Midship tunnel.
Marine Cement terminals
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Shipunloaders
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Mini terminals.Silo systems.
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terminals.
Stationary ormobile types:
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The key for a well functioning plant: Components, all made to measure.
High stock availability:Just-in-time supply of spare parts.After-sales Service.
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I BAU CentrAl Cone SIloS – The base of the IBAU silo floor is formed by a central cone. The divisions result in external diameters of 14 to 27 m, from 2 to 22 chambers.
I BAU’s newest Multicompartment silo in Paris/France built for CIMENTS CALCIA / Semapa.
HAVER & BOECKERcovers with IBAU HAMBURgthe complete conveying chain:
PROCESSINg STORAgE MIXINg PACKINg FILLINg PALLETIZINg LOADINg
Anzeige_26.9_neu:Layout 1 15.12.14 09:44 Seite 31
Economic silo, storage and transport solutionsI BAU HAMBURG: Your solution provider
For more information please visit:
www.ibauhamburg.de
I BAU hAMBUrgRödingsmarkt 35D-20459 HAMBURg�+ 49 (0) 40 36 13 090
IBAUHAMBURG
And last but not least: We offer you a reliable worldwideservice and a 24 hour hotline at 365 days of the year.
Single silos. Ring silos.
Multicompart-ment silos. From 2 to
22 chambers,diameters:
14 to 27 m.
Advanced technology for
self-discharging Cement Carriers
including the Midship tunnel.
Marine Cement terminals
Central Cone Silos ePC-Contracting
Silo Conversions
Components
Spare Parts
Cement Carriers
Shipunloaders
Floating terminals.
Mini terminals.Silo systems.
Dome systems.Flat storage
terminals.
Stationary ormobile types:
From the5,000 class
up to the60,000 class.
Piling. Civil works. Steel structure, supply and erection. Electrical/mechanical supplyand erection.
Economic modifications with advanced cutting edge technology.
The key for a well functioning plant: Components, all made to measure.
High stock availability:Just-in-time supply of spare parts.After-sales Service.
We find the mostcost-effectivesolution for yourproject:effective. efficient.
I BAU CentrAl Cone SIloS – The base of the IBAU silo floor is formed by a central cone. The divisions result in external diameters of 14 to 27 m, from 2 to 22 chambers.
I BAU’s newest Multicompartment silo in Paris/France built for CIMENTS CALCIA / Semapa.
HAVER & BOECKERcovers with IBAU HAMBURgthe complete conveying chain:
PROCESSINg STORAgE MIXINg PACKINg FILLINg PALLETIZINg LOADINg
Anzeige_26.9_neu:Layout 1 15.12.14 09:44 Seite 31
Whether they are operating in crushers, tube mills, ver-tical mills, rotary tube kilns or in conveyor systems, where other drive solutions come up against their limits, Integrated Drive Systems (IDS) with tried and tested FLENDER® gear units and couplings work reliably and faultlessly. Wherever they are used, FLENDER drive com-ponents, as an integral part of IDS, impress with their highest operational reliability and durability. Their high efficiency saves on operating costs.
As a leading supplier of mechanical drive solutions as well, Siemens offers you proven technology of the highest material and manufacturing quality with FLENDER drive components. Based on decades of experience gained as a supplier to the cement industry, our range of services begins with consultancy and the development of suitable drive con-cepts and extends through project planning and design to start-up, customer service and worldwide support.
siemens.com/flenderapplications
Integrated Drive Systems (IDS) with FLENDER drive components
Moves cement works 24/7FLENDER drive components and Integrated Drive Systems (IDS): packed with power for highest availability in the building materials industryE2
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WORLD NEWS MAY
May 2015 / 9 World Cement
NEWS HIGHLIGHTS
To read more about these articles go to:
• New cement terminal to be built at the Port of Mumbai
• In the spotlight: health and safety
• US cement plants recognised for environmental excellence
• US GHG emissions have fallen 9% since 2005
Thailand Holcim divests stake in Siam City Cement Company
Holcim has sold its remaining share in Siam City Cement (Public) Company Limited (SCCC) via a private placement in capital markets. For its 27.5% minority stake, Holcim will receive a total consideration of around CHF655 million, resulting in a gain of approximately CHF365 million before taxes.
A member of a Hong Kong-based conglomerate, the Jardine Matheson Group, has purchased 24.9% of the shareholding and the other 2.6% has been acquired by several institutional investors.
SCCC operates the 14.5 million tpy Saraburi cement plant and achieved net sales of THB31.86 billion last year.
The proposed PPC and AfriSam merger will not proceed. South Africa’s PPC announced receipt of a conditional, non-binding merger proposal from AfriSam at the end of 2014, which was followed by extensive discussions between the two companies and consideration of the proposal by PPC’s Board. On 27 March, a statement on the merger proposal announced that: ‘The parties have not been able to reach consensus on the terms of the merger and therefore have terminated their discussions’.
PPC has said that it will continue with its strategy to strengthen its position in the Southern African market and expand into other African countries.
South Africa PPC and AfriSam merger will not go ahead
Egypt Fives classifier selected for Ain Sokhna plant
Fives will provide a new high efficiency separator for a petcoke grinding unit at Lafarge Egypt’s Ain Sokhna plant. The unit is being converted from an open to closed circuit by Imsat (Romania).
The FCB TSV™ Classifier will enable the grinding unit to produce 90 tph of pulverised petcoke at R 90 µm ≤5%. This will help Lafarge Cement Egypt to transition from the conventional fuel currently used in the pyroprocess at the plant to petcoke utilisation, which will enhance Lafarge’s ability to mitigate energy supply issues in the country.
The classifier selected for the plant is part of the 4000 MF series, with 90 kW installed power. It has an outer dia. of 4 m and will provide a nominal cut size of 60 µm, corresponding to the d80 of the finished product.
Sika has expanded its footprint in Asia-Pacific with the establishment of a subsidiary in Myanmar. Although the company has supplied the market in Myanmar through imports from neighbouring countries for some time, Sika Myanmar will further strengthen its presence in the country and enable it to better serve the region’s growing construction sector.
The new subsidiary forms part of Sika’s growth strategy, which includes an increased presence in emerging markets. In line with this, the company has also opened a new concrete admixture plant in Sri Lanka. Located in Ekala, the facility will produce high-end additives for the local construction industry.
Asia-Pacific Sika establishes subsidiary in Myanmar
Blaster NozzlesDampers Thimbles
® THE ORIGINALCERAMIC COMPOSITE
FOR NOSE BLOCKS
[email protected]+1 419-334-2650
SUPERIOR PRODUCTS CUSTOM ENGINEERED FOR YOUR DEMANDING APPLICATIONSSUPERIOR PRODUCTS CUSTOM ENGINEERED FOR YOUR DEMANDING APPLICATIONS
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May 2015 10 \ World Cement
EVENTS
Saudi Arabia Siwertell unloader will handle white cement at Port of Dammam
Siwertell has supplied a 5 000 S road mobile unloader to the cement division of the Rashed Al-Rashed & Sons Group. Located at the Port of Dammam in Saudi Arabia, the diesel-powered unloader will handle white cement at a rate of 250 tph. It includes a dust filter and double bellows system to ensure uninterrupted bulk material transfer to trucks or wagons. The unloader was delivered in March, just over two months after the order was placed.
Siwertell, which is part of the Cargotec group, also recently received an order for a 10 000 S road mobile unloader, which was scheduled for delivery to a customer in India at the end of April.Siwertell road mobile unloader. (Photo courtesy of Siwertell.)
Lafarge and Holcim have announced their planned asset disposals in the US. The proposed package of divestments has been negotiated with the Federal Trade Commission and is subject to the Commission’s review and approval. The divestments will be carried out pending the acceptance of the Commission and the completion of the LafargeHolcim merger deal.
The proposed divestment package includes:
l Three Holcim terminals in Michigan and Illinois.
l Holcim Skyway 600 000 t slag grinding station in Illinois.
l Holcim Camden 700 000 t slag grinding station in New Jersey, and a terminal in Massachusetts.
l Lafarge’s 1.1 million t Davenport cement plant in Iowa and seven cement distribution terminals along the Mississippi River. Summit Materials has entered into a definitive agreement with Lafarge North America to acquire these assets for a total consideration of US$450 million and its Bettendorf cement terminal in Iowa.
Summit Materials will integrate the Davenport plant and terminals into its Continental Cement Company business in Chesterfield, MO. Following the transaction, the combined business will comprise two cement plants (Hannibal and Davenport), as well as eight distribution terminals along the Mississippi River from Minneapolis to New Orleans.
USA Lafarge and Holcim provide further details on proposed asset divestments
10 – 12 June 2015
WCSB7
Bordeaux, France
www.wcsb7.com
15 – 18 September 2015
UNITECR 2015
Vienna, Austria
www.unitecr2015.org
7 – 10 October 2015
13th TÇMB International Technical Seminar and Exhibition
Antalya, Turkey
www.tcma.org.tr
7 – 9 October 2015
ILA General Assembly
Istanbul, Turkey
www.internationallime.org
13 – 16 October 2015
14th International Congress on the Chemistry of Cement
Beijing, China
www.iccc2015beijing.org
10 – 12 November 2015
20th Arab International Cement Conference & Exhibition
Cairo, Egypt
www.aucbm.org
Blaster NozzlesDampers Thimbles
® THE ORIGINALCERAMIC COMPOSITE
FOR NOSE BLOCKS
[email protected]+1 419-334-2650
SUPERIOR PRODUCTS CUSTOM ENGINEERED FOR YOUR DEMANDING APPLICATIONSSUPERIOR PRODUCTS CUSTOM ENGINEERED FOR YOUR DEMANDING APPLICATIONS
WahlNoseBlockAdB 3/19/15 11:48 AM Page 1
May 2015 12 \ World Cement
Elmadag, TurkeyAt the end of March, Loesche announced that it had begun commissioning of an LM 45.4 raw mill at VICAT’s Bastas Baskent Cimento plant in Elmadag, Turkey. The VRM, which has an installed drive power of 2100 kW, will grind 260 tph of cement raw meal at a fineness of 16% R 90 µm.
The mill was ordered by VICAT Service Technique Ciment in May 2014. Delivery took just 10 months, and commissioning has been scheduled for 3Q15. Mills of the same type can already be found in the Bastas Baskent Cimento plant, as well as in VICAT’s plant in Konya.
Loesche has also supplied the plant with weighing feeders, magnetic separators, metal detectors, shut-off and control flaps, vibrating conveyors, a bucket elevator and expansion joints.
Monay, VenezuelaAVIC International Beijing Co. Ltd has ordered two Loesche mills for a new INVECEM Industria Venezolana del Cemento plant. The new 2500 tpd cement plant is being established in Monay, Trujillo. It is one of three new plants being built in Venezuela as part of a joint project between the Chinese and Venezuelan governments.
Loesche will provide an LM 48.4 mill that will grind cement raw material at a rate of 280 tph at 12% R 0.09 mm. An LM 53.3+3C cement mill will also be supplied to the plant. This will have the capacity to produce 200 tph of OPC with a fineness of 3200 Blaine. Loesche’s scope of supply also includes LDC classifiers. Delivery of the main parts is scheduled for November 2015.
Worldwide Loesche grinding technology for cement plants in Turkey and Venezuela
The Bastas Baskent Cimento plant in Turkey.
Netherlands HeidelbergCement extends contract with Shanks
Shanks Group plc will supply HeidelbergCement with energy pellets following a six-year contract extension. Icopower, part of Shanks’ Solid Waste Division, will provide the cement producer with 54 000 tpy of its ICOPOWER® energy pellets, which will be used to power kilns at HeidelbergCement’s plants.
Shanks collects specific commercial waste to ensure the high calorific energy pellets meet strict production specifications. In the Netherlands, these pellets are not classified as a waste product due to their chemical composition.
Shanks is currently investing in a new storage shed for the pellets at its Icova site in Amsterdam. The ICOPOWER® energy pellets will be stored at the 2300 m2 shed before being shipped to customers in Scandinavia.
India BASF opens new construction chemicals plant in Nellore
BASF India Limited has opened its fifth construction chemicals plant in the country. The company’s newest facility is strategically located in the Naidupet area of Nellore, Andhra Pradesh, with good access to the road network and Krishnapatnam Port.
The plant is equipped with state-of-the-art technology, a multiple tank storage facility and a concrete lab. It will produce standard and custom-made performance based concrete admixtures, as well as construction systems. The new facility will enable BASF to strengthen its services in the region, providing timely support and high-performance solutions to customers in southern India.
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May 2015 14 \ World Cement
IN BRIEF
Atlas Copco has launched an employee-led sustainability initiative following a company-wide survey that involved over 3000 employees across 65 countries. The ‘Blue is the New Green’ programme aims to reduce consumption of resources such as water, electricity and materials. The scheme encourages staff to share sustainability ideas and work together to solve challenges.
US-based Tank Connection recently announced that the company would become an ESOP (employee stock ownership plan), effective as of April. “As we move into the future, the focus of our employees won’t change, but the mindset of our team will be as employee owners,” explains Tank Connection’s founding partner and President, Bill Neighbors.
Entries are now being accepted for the bauma Innovation Award. Exhibitors, research institutes and companies, and members of German construction industry associations are among those eligible to apply. Categories include: machinery; components; research; design; construction process/construction work. The awards will be presented in Munich, as part of the bauma 2016 opening ceremony.
Worldwide Latest industry appointments
l Adriano Greco has joined FCT International as Sales Director, based in the US. Greco is a well-known figure in the industry, with many years of experience. His previous roles include Managing Director of Greco and Sales Director at Gebr. Pfeiffer.
l SCHADE Lagertechnik GmbH has appointed Dr Christoph Seifert as Managing Director. Effective as of 1 February 2015, he is responsible for engineering, project management and purchasing. Together with Karl-Heinz Fiegenbaum who is responsible for sales and finance, Seifert makes up the company’s management team. He has some 25 years of experience in the international energy and mining industry.
l Eric Olsen has been named as future CEO of LafargeHolcim. His appointment, which will
commence open the closure of the merger project, has gained the approval of the Lafarge and Holcim Board of Directors. Olsen is currently Executive Vice-President – Operations at Lafarge, after joining the group in 1999 and becoming a member of its Executive Committee in 2007. He has performed a number of senior roles, with experience of ‘driving change’. Among others, this includes leading the integration of Blue Circle’s North American operations and restructuring cement assets, and leading the integration of Egypt’s Orascom.
l Advanced Emissions Solutions, Inc. has appointed L. Heath Sampson as President and Chief Executive Officer, as Dr Michael D. Durham retires from the company.
USA CalPortland receives 2015 Energy Star® Partner of the Year – Sustained Excellence Award
CalPortland has been recognised by the EPA with the 2015 Energy Star® Partner of the Year – Sustained Excellence Award for its impressive energy efficiency performance. The awards honour organisations that demonstrate commitment to environmental leadership, lowering their GHG emissions through superior energy efficiency achievements.
This is the eleventh year in a row that CalPortland has received an ENERGY STAR Award.
“CalPortland has been an ENERGY STAR partner since 1996. For nearly two decades that relationship has been instrumental in the continuous improvement of our energy program,” said Allen Hamblen, CalPortland President and CEO. “We have established a core culture of energy management that includes all levels of the company’s operations. Our employees are very proud of their accomplishments to improve energy efficiency, reduce emissions and contribute to the protection of our environment while reducing cost.”
Ful� l, innovate and think global. Always Interested.The world around us is changing fast, so is our company. We are very proud that we have manufactured the most beautiful equipment for customers all over the world. Our goal is always to ful� l the wishes and to exceed the expectations. We are global thinkers and always innovating with respect to the planet and the people. A new age asks for a new proposition which we like to present to you. We hope you like it as we do. We are Always Interested.
Tailor made ship unloaders in any sizeVan Aalst Bulk Handling is a � exible organization directed to assist its customers with tailor made solutions for their loading, unloading and pneumatic conveying projects. Van Aalst Bulk Handling provides design and technical engineering, manufacturing and supply of equipment and installation supervision. The customer can rely on one experienced and reliable source.
Also Interested? T +31(0)172 213 341E [email protected] www.vanaalstbulkhandling.com
Always Interested. Van Aalst Bulk Handling.
Van Aalst is the brand name of Van Aalst Bulk handling B.V. and Van Aalst Bulk Handling Corp.
PLEASE MEET US AT
BOOTH 12
INTERCEMLONDON
1-3 JUNE 2015
Pioneering technology for the cement industryWith more than 150 years of experience, we have unique know-how in the fi eld of cement technology. We off er the entire process chain from a single source: from the quarry to the cement loading facility, and from engineering, procurement, erection and commissioning to after-sales service. We ensure the highest level of plant availability through the perfect harmonisation of Polysius machines and processes.
www.thyssenkrupp-industrial-solutions.com
TKIS_Anzeige_Cement-3_Indonesia_420x297.indd 1 07.04.15 17:34
2 x 4,000 tpd (cement clinker) will be achieved when the second production line of PT Holcim Indonesia Tbk at the Tuban plant in Indonesia is on-stream. Commissioning of this production line started already.
ThyssenKrupp Industrial Solutions
TKIS_Anzeige_Cement-3_Indonesia_420x297.indd 2 07.04.15 17:34
Pioneering technology for the cement industryWith more than 150 years of experience, we have unique know-how in the fi eld of cement technology. We off er the entire process chain from a single source: from the quarry to the cement loading facility, and from engineering, procurement, erection and commissioning to after-sales service. We ensure the highest level of plant availability through the perfect harmonisation of Polysius machines and processes.
www.thyssenkrupp-industrial-solutions.com
TKIS_Anzeige_Cement-3_Indonesia_420x297.indd 1 07.04.15 17:34
2 x 4,000 tpd (cement clinker) will be achieved when the second production line of PT Holcim Indonesia Tbk at the Tuban plant in Indonesia is on-stream. Commissioning of this production line started already.
ThyssenKrupp Industrial Solutions
TKIS_Anzeige_Cement-3_Indonesia_420x297.indd 2 07.04.15 17:34
KEYNOTE MAY
May 2015 / 19 World Cement
The Concrete Initiative: Solutions for Europe’s Future
IntroductionConcrete. The second most widely used substance in the world after water, deeply rooted in our daily lives, providing the infinitely mouldable ‘liquid stone’ for long-lived, solid foundations and the backbone of mankind’s built environment. And yet, in spite of its many attributes, concrete does not receive the recognition it truly deserves. Some see it as grey, dull and boring. Others perceive concrete as a non-environmentally friendly construction product. The reality is quite different. Concrete has many attributes, and has a key role to play in ensuring sustainable construction. This is why we have set up The Concrete
Initiative: to debunk the myths, to highlight what concrete really does have to offer, and to launch a real debate on how to achieve truly sustainable construction.
For us, as representatives of the concrete industry, the primary goal is to engage with key stakeholders at EU level on what is needed to achieve sustainable construction, what we have to offer, and which policy framework is required. However, when talking about sustainability, there is a tendency to forget that it is about more than just the environment. Economic and social considerations must also form part of the mix. Therefore, under the umbrella of The Concrete
Koen Coppenholle, Chief Executive of CEMBUREAU, the European Cement Association, outlines the objectives of The Concrete Initiative and the social, economic and environmental challenges facing Europe today.
©HeidelbergCement – S. Fuchs.
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Initiative, we are working together with different stakeholders at EU level to identify and discuss social, economic and environmental challenges. In turn, we believe that this debate will allow us to identify sustainable construction solutions for the future. So what are the challenges that need to be tackled?
Social challengesAccording to the European Commission, 75% of the EU population lives in towns and cities, and this percentage is expected to continue to increase. This will result in additional pressure on housing, transport and energy infrastructure. At the same time, affordable housing needs to be made available to this growing population – without forgetting the fact that buildings must be safe and resilient, capable of withstanding extreme weather events and offer protection in the event of a fire. Thanks to concrete, people already have access to safe, affordable and resilient housing and infrastructure.
l Concrete is the key to a safe and resilient built environment, as well as solutions to societal challenges such as those induced by increasing urbanisation.
l Affordability, flexibility and energy efficiency make concrete a material of choice for infrastructure such as hospitals, schools, public buildings and transport infrastructure.
l Concrete can be cast into virtually any shape or form, which allows for design freedom and an almost infinite variety of applications.
As part of this campaign, The Concrete Initiative is committed to working with key stakeholders to accelerate the development, availability and use of affordable and safe construction solutions across Europe. At the same time, it is important for policymakers to enter into a deep debate with the concrete sector in order to identify an adequate regulatory framework, which will incentivise sufficient financing to boost sustainable construction practices.
Economic challengesThe economic crisis is a major challenge affecting Europe today. As a result, growth and jobs are high up on the political agenda. In this respect, the construction sector (including concrete) is fundamental to stimulating Europe’s recovery. Construction is the largest single economic activity and the greatest
industrial employer in Europe, with some 20 million jobs. As highlighted by the European Commission, one job created in construction translates into two additional jobs created elsewhere. But what does the concrete sector itself have to offer? The concrete industry as a whole employs some 550 000 people
in the EU, generating approximately e65 000 in added value per employed capita per annum. More importantly, concrete is a local business, employing local people. This means that the money and investment that goes into concrete is pumped back into the local economy. The components used to produce concrete – aggregates, cement, and water – are also sourced locally. As a result, we have a local production value, with concrete construction driving economic growth, innovation and jobs in Europe.
l As a central pillar of the construction sector, concrete is a driver of economic growth, with a unique multiplier effect on jobs and economic activity.
l Concrete is a main enabler of modern construction, providing multiple and unique properties, flexibility and value for money.
l Concrete is a local business across the entire value chain, deeply rooted in local economies. A local product for a local market.
In terms of jobs and skills, The Concrete Initiative is committed to engaging with education institutes to promote skills development. In addition, it will work with policymakers and relevant stakeholders to foster advances in the knowledge and understanding relating to the economics of sustainable construction, to identify barriers and to explore new models. At the same time, it is important that industrial policies and standards at EU level remain material neutral, focusing on the performance of the building or infrastructure itself. In addition, the full economic benefits of all building materials must be harnessed by further developing the Green Public Procurement Guidelines and criteria that include whole-life performance and durability.
Environmental challengesWith buildings accounting for 40% of the EU’s total energy consumption, there is clearly much that can still be done in this arena. There are also other environmental impacts that need to be tackled, including resource efficiency and recycling. Efficiency and low carbon solutions are not new subjects for
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As representatives of the
concrete industry, the primary
goal is to engage with key
stakeholders at EU level on
what is needed to achieve
sustainable construction, what
we have to offer, and which
policy framework is required.
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Did you know?
• 70% of the world’s population lives in concrete structures.
• Every E1 spent on construction output generates a total of E3 in total economic activity (GDP increase).
• The concrete used in the Channel Tunnel is contractually guaranteed to last 120 years.
May 2015 22 \ World Cement
the concrete industry, with The Concrete Initiative pointing to the fact that, for example, the carbon footprint of concrete has tumbled 44% over the past 60 years as technology has leapt forward. However, one of the major focus points of the environmental pillar is the fact that concrete can have an even greater positive impact during its use phase in buildings and infrastructure. For example, in terms of transport infrastructure, concrete road surfaces have lower rolling resistance and so can reduce the fuel consumption of vehicles, especially trucks. Every kilometre of concrete road can reduce CO2 emissions of vehicles by 1000 – 4000 t over a 30-year period when compared to flexible road surfaces, which could have a huge impact over the tens of thousands of kilometres of roads in Europe. It is also an extremely durable material.
The key point here is that concrete offers the highest level of ‘whole-life performance’, with the industry continually striving to provide a net positive environmental impact throughout the lifetime of its products. As part of its messaging on this subject, The Concrete Initiative aims to highlight the importance of considering all impacts, including those from raw material extraction, manufacturing, construction, use of the building, to end-of-life disposal or reuse, when assessing the impacts of a given construction. Currently, there is a tendency towards focusing on just part of the lifecycle, which can give a misleading idea of the overall impacts of buildings and infrastructure projects. In this respect, concrete offers optimum whole-life performance, as follows:
l Concrete absorbs temperature variations (by its thermal mass), which reduces energy consumption in buildings.
l Thanks to use of alternative fuels and byproducts from other industries, and end-of-life recycling, concrete is an integral part of the circular economy.
In terms of commitments, The Concrete Initiative will continue to provide industry input to European standards to further the goals of a low-carbon Europe and maximise the use of recycled products. In addition, it will provide guidance to specifiers, architects and builders on maximising the advantages of the thermal mass of concrete, contributing to greater energy efficiency. At the same time, on a more political level, it is essential that sustainability standards and regulations look at the performance of the whole building rather than its individual components, and take a ‘whole-life’ approach.
What have we done so far?At the beginning of 2014, The Concrete Initiative prepared the groundwork by identifying and meeting with key stakeholders in order to assess some of the issues that need to be dealt with. The campaign itself was subsequently launched on 27 May in Brussels,
Presenting The Concrete Initiative to the European Parliament.
Koen Coppenholle, CEMBUREAU Chief Executive.
bringing together a wide audience at EU level, including architects and other representatives from the construction industry, as well as the European Commission and the Economic and Social Committee. Given the parliamentary elections in May 2014, November provided an ideal opportunity to introduce the newly elected Members of the European Parliament to The Concrete Initiative at an event in Strasbourg.
However, the focus of The Concrete Initiative is not limited to policy makers. In order to ensure the right policy framework, it is up to us to ensure that those holding the pen receive the necessary technical input to assist them in their legislative drafting. With this in mind, a thematic lunch on the issue of recycling concrete construction and demolition waste was held at the end of October 2014. The topic of recycling is high up on the EU’s political agenda, further to the publication in July 2014 of the Communication on resource efficiency opportunities in the building sector.1 The role of these lunches is to launch a real debate between technical experts and policymakers working directly on relevant legislation. By ensuring that the right people were around the table, the debate enabled an open discussion on what works, what does not and what could be the potential solutions. Plenty of food for thought came out of this debate and the discussions will now continue as the issue evolves. Given the very positive feedback on this model, The Concrete Initiative will continue to organise such events. Items on the 2015 agenda include the competitiveness of the concrete sector and its role in the economy, safety, as well as renovation and rebuilding.
The Concrete Initiative also aims to illustrate its messaging through case studies from across Europe, which are regularly posted on the website (www.theconcreteinitiative.eu). In addition, the initiative provides a platform for stakeholders wishing to express their view on a topic of particular interest and relevance via a blog. Both of these items are open to contributions. For more information please contact the author via the Editor ([email protected]).
Summary
l Concrete: a local product for a local market.
l Concrete: a motor for jobs and growth.
l Concrete: a solution to policymakers’ objectives for carbon reduction, for recycling and for energy efficiency.
l Concrete: the backbone of modern society.
References1. Communication from the Commission to the European
Parliament, the Council, the European Economic and Social Committee and the Committee of the Regions on resource efficiency opportunities in the building sector. COM(2014) 445.
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Brian Wamwenje, ICT Manager at Savannah Cement, Kenya, describes how SAP® HANA has taken the organisation ahead of its competitors by significantly improving their customer experience and ensuring faster, more strategic decision-making throughout the entire business.
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SAVANNAH CEMENT:
IntroductionSavannah Cement is the newest entrant into the cement market in Kenya and has a state-of-the-art, eco-friendly cement grinding plant with a capacity of 1.5 million tpy.
The cement plant is strategically positioned near Nairobi, the region’s financial capital, which accounts for 50% of Kenya’s cement consumption. The
organisation is committed to sustainable environmental, economic and social well-being for not only the present but also future generations. Savannah Cement currently directly employs approximately 250 people and aspires to be the cement manufacturer of choice in the region. Outside of Kenya, the company is actively engaged
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in Rwanda, Burundi, Tanzania, Uganda, Democratic Republic of Congo, as well as South Sudan.
In the midst of frenetic business expansion into new territories, Savannah Cement was not only keen to gain a competitive advantage in a fierce market; it quickly identified the need for an agile technology platform through which to streamline its business processes and pursue its sustainability vision. Some of the business-critical objectives the IT team of 44 people set out to achieve were to:
l Eliminate duplicate transactions.
l Gain complete ownership of business processes.
l Obtain real-time feedback while transaction processing is in progress to support the appropriate corrective actions.
As such, it looked for a world-class technology vendor that would:
l Improve customer satisfaction, resulting in increased sales and revenue.
l Increase effectiveness, ignite value-chain improvements and improve supply chain efficiencies from an operational perspective.
l Lower the cost of doing business.
Selecting the platformAfter a rigorous selection process, Savannah Cement opted for SAP’s Business Suite on SAP HANA®, which combines data processing and application platform capabilities to bring speed and real-time functionally to analytics, business applications and data services.
SAP Business Suite powered by HANA delivers a unified way of addressing an organisation’s transactional and analytical requirements within a single in-memory platform, allowing companies to perform real-time planning, execution, reporting, and analysis across their end-to-end business processes – and in so doing, drive the entire business forward in real-time.
“SAP HANA is a revolutionary product in the relational database field. Contrary to belief, it’s not just for huge conglomerates with thousands of users. Throughout Africa, we have witnessed that it is changing businesses’ view of database management and offers up great business continuity strategies,” commented Brian Wamwenje, ICT Manager at Savannah Cement.
Project executionHowever, selecting the right technology solution to enable business requirements is the battle half-won, said Wamwenje. All organisations that have had to implement technology will attest to the fact that
technology only translates into a solution once it has been implemented and has proven its worth. It can be a painful process. This was not the case with SAP and the technology implementation company selected.
In this context, Savannah Cement collaborated with Sperkjet East Africa Limited (SEAl) and EOH for the SAP implementation project. The project kicked off in mid-January 2014 and went live on 1 May 2014 – an extremely short, successful implementation period for the second Business Suite on SAP HANA® implementation on the African continent.
This speedy implementation was enabled by engaging a knowledgeable implementation
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partner that possessed the required SAP HANA® expert knowledge and skills. Such a rapid implementation period also demands a tried-and-tested implementation methodology. The ASAP® methodology, combined with meticulously managed project resources and milestones, as well as rigorous quality assurance guidelines ensured the delivery of a highly successful project, which was delivered not only on time, but also according to the budgetary scope.
Business Suite on SAP HANA® and smart technology availability was a critical component for Savannah Cement. Through these technologies, server setup time was limited and the business continues to enjoy cost reductions on server monitoring and maintenance. Using add-on smart technology such as HANA Studio has also simplified traditional database management to simple, semantic tasks and commands, driven from a user-friendly Graphical User Interface (GUI).
All in all, SAP has enabled Savannah Cement to significantly reduce the traditional back-end tasks and multiple previously-required man hours spent on keeping their previous system going. The company has now also deployed a redundancy system (also running on HANA) and has cut costs when it comes to manpower that would have been utilised for a manual business process.
Today, the SAP technology platform runs across four geographical sites and is currently being utilised by 44 users who employ the solution for various business functions, including sales and distribution, procurement and material management, finance reporting and controlling.
The human element From a resources perspective, Savannah Cement now ascribes to a mode in which resource use aims to meet the needs of the individuals in the area in which the company operates, while also preserving the environment, so that all sustainability objectives can be met not only in the present, but also for generations to come.
Savannah Cement’s sustainability model revolves around environmental sustainability and economic sustainability. The company strives to tie its strategic initiatives with the globally acknowledged millennium development goals.
Corporate social investment is seen as value creation, ensuring that the company ventures into innovative sustainable programmes, firm in the belief that this will provide them with fundamental strategic and operational impact.
The anticipated benefits of this approach include:
l Shared values between Savannah Cement and the communities the company engages with.
l The promotion of competitiveness and innovation.
l The promotion of a truly sustainable business model.
l Integration of the business into the community.
l Development of human capital.
The proof is in the ROIOne can argue that a short technology implementation period is in itself impressive, but the question is: has Savannah Cement achieved the objectives it set out to achieve with SAP?
In the time since the implementation, the results have proven to be stellar. Benefits achieved include:
l Increased visibility, integrity and accuracy in operational reporting.
l Reduced period closure reporting lead time by 75% – 80% (from 8 – 10 days to 2 days).
l Reduced operational meetings from at least three each day to one per day.
l Increased market share from 8% to 11% since Go-Live. This is equally validated by a month-on-month increase in sales figures.
l Increased resilience in a business-critical system: the company has had zero system downtime since implementation.
l Faster turnaround in order processing, due to enhanced real time visibility, has led to increased customer satisfaction.
l Customer relations have become more congenial due to faster response times to customer queries and simplified business engagement models all driven by real-time reporting from their core transactional database.
l Savannah Cement has truly positioned its brand in the market as being customer-centric, offering a differential and intentional customer experience.
The final word“SAP HANA has completely changed our view of database management and has greatly simplified tasks, giving our business a cutting-edge advantage and incomparable agility. Clearly to us, SAP HANA was built to keep the business running simpler and better. We could not be happier.” concluded Wamwenje.
The Savannah Cement plant.
Global PublicationGlobal PublicationThat was a sample of World Cement’s May issue
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