highlight 1 2008

2007

Transforming resources to meet tomorrows needs

CEMENT & MINERALS

April 2008

Cement & Minerals

For several years it has been FLSmidths aspiration to develop the Groups minerals activities to the same size as its cement business. Through the acquisi-tions in 2006/2007 of the materials handling activities in Koch and RACHO and the separation activities in GL&V FLSmidth Minerals has now taken a decisive step towards fulfilling this objective. As a result of these and other events, 2007 was a year of historic significance to the FLSmidth Group. A year that marked the first decade since FLSmidth consolidated its minerals operations into a single company. During that period annual turnover has climbed from a modest EUR 54m to more than EUR 858m. 2007 also saw the cement and minerals markets continuing to boom and was another terrific year for everyone involved in the two industrial sectors. This is reflected in our annual figures which report the largest order backlog ever and a level of earnings that enables us to intensify our focus on long-term objectives: sustainability, R&D and creating value through optimised processes. In other words, all the elements that are necessary to maintain a competitive operation. As a natural consequence, as from this issue, our customer magazine Highlights will expand its coverage to include news from and for the minerals markets. In cement and minerals, we may be supplying different products and technological applications to different customers. But there is a common de-nominator underlying it all. Our success in the cement industry is anchored in a long history of complete solutions from the raw end to the final product with a comprehensive range of customer services. With the past years acquisitions we now offer similar complete solutions covering the entire minerals processing flow sheet. Our global suite of mineral brand names offers customers a unique One Partner One Source solution, which has been our main value proposition in cement for now 126 years. With our twin business units Cement and Minerals we shall engineer our common future. And Highlights Cement & Minerals is proud to share this future with our readers.

I wish you pleasant reading of the latest edition of our expanded and integrated magazine.

J. Huno RasmussenCEO, FLSmidth

Editor: Anders Klinkby Godiksen (responsible under Danish law) Brenda KaplanV. Ragini ShahHenrik VintherCharlotte PinsonNeal BiegeProduction: Gunnar AndreasenTranslations: Martin Bojesen

Editorial office: FLSmidth A/SVigerslev All 77,DK-2500 Valby, Copenhagen, DenmarkTel: +45 36 18 10 00 Fax: +45 36 45 44 27Email: [email protected]: www.flsmidth.com

All rights reserved

Lay out: Blue Business A/S ISSN 0909-8992

Front cover: With last years addition of minerals engineering companies, the FLSmidth Group is both the cement and minerals industries leading resource and business partner when it comes to utilising the worlds natural resources, from raw material to final product. Read more on pages 8 9 and 24 31.

2 Highlights April 2008

Contents

Ozarw Cement upgrades plant 3

Lafarge awards contract in USA 4

LSR Group opts for the best 6

New Russian plant uses wet materials 7

Minerals for ever 8

Maintenance for Chilean copper mines 10

Aurox orders complete minerals plant 11

Botswanan nickel project 12

FLSmidths strong presence in Russia 13

Worlds largest cement mill 14

HOTDISC three years after 16

Orders flood in for largest OK mill 18

Binani expands capacity 20

FLSmidth Minerals the One Source 24

FLSmidth Engineers of Cement 28

Modern and efficient (Dalmia) 32

Gujarat on the threshold of milestone 34

Full ownership of Autec 35

Keep updated 35

First robotics laboratory in Russia 36

Joint research in energy and emissions 38

Beat the Autopilot reopens 39

On the job 40

Highlights April 2008 3

CEMENT

Ozarw Cement upgrades plant

Polish cement producer is set to increase capacity and step up alternative fuel use.

Commissioned in 1978, the Grupa

Ozarw cement plant is located 160 kilo-

metres southeast of Warsaw. The plant

was originally supplied by FLSmidth

and consisted of two 3,500 tpd lines.

In 1995 as part of the Polish govern-

ments privatisation programme Irish-

based CRH acquired a majority stake in

the company. Under the new owner-

ship, the plant launched a comprehen-

sive investment programme.

Multiple-stage modernisation effortThe first stage of the programme focused

on maximising production capacity by

streamlining the existing facilities. The

second stage, completed in 1999, meant

replacing kiln line No. 1 with a modern In

Line Calciner (ILC) pyroprocessing system.

The existing raw material handling and

finish grinding systems were upgraded.

At the time, Ozarws new kiln was

Europes largest with a rated capacity of

8,000 tonnes per day. The plant ranked

among the worlds most energy-efficient

and environmentally friendly cement pro-

duction facilities.

Recently, it was decided to further

increase the plants capacity, using the

second existing cement production line.

After modernisation and upgrading, this

line will be able to produce 7,000

tonnes per day. FLSmidth is providing

machinery for the upgrade, including an

ATOX raw mill, an ATOX coal mill, a Mul-

ti-Movable Cross-Bar cooler and an OK

Vertical Roller Mill for cement grinding.

Alternative fuelsIt was important for CRH that the

upgraded production line should be

capable of burning alternative fuels

offering cheaper fuel consumption and

more environmentally aware cement

production. For this reason, FLSmidth is

supplying a DUOFLEX burner, equipped

with alternative fuel channels.

FLSmidth has designed a solution with a

shortened kiln (about 80 metres long),

with a double-string preheater built

above the kiln which will be of the ILC-

Low-NOx type.

Leading the wayEver since Ozarw was planned back in

the seventies, the company has had a

tradition of developing new projects in

close collaboration with FLSmidth. The

recently signed contract will enable CRH

to remain among the leading cement

producers in Poland in terms of energy

efficiency and high environmental

standards. At the same time, Oarw cement plant will become the biggest

cement manufacturer in Poland and one

of the largest in Europe.

Kiln No. 2 (in the foreground) is to be shortened and provided with an ILC preheater. In

the background is the existing ILC system (kiln No. 1) which FLSmidth completed in 1999


Lafarge awards contract for its largest kiln line in North America

Lafarge North America has awarded FLSmidth a contract to supply its largest kiln line in North America.

The new kiln line will produce 7,200

tonnes per day and use the most modern

processes allowing Lafarge to maintain

highly competitive positions in terms of

safety, product quality, and production

costs. In addition, this project will help

enhance the plants overall performance.

Lafarge North AmericaLafarge is the world leader in building

materials, with top-ranking positions

in all of its businesses: Cement, Aggre-

gates & Concrete and Gypsum. With

88,000 employees in 80 countries,

Lafarge posted sales of EUR 17.6 billion

and net income of EUR 1.9 billion in

2007. Lafarge North America Inc., a

Lafarge Group company, is the largest

diversified supplier of construction ma-

terials in the United States and Canada.

Its materials are used for residential,

commercial, institutional and public

works construction.

The Lafarge Group has been committed

to sustainable development for many

years, pursuing a strategy that combines

industrial know-how with performance,

value creation, respect for employees

and local cultures, environmental pro-

tection and the conservation of natural

resources and energy. The Lafarge

Group is the only business in the con-

struction materials sector to be listed in

the 2007 100 Global Most Sustainable

Corporations in the World. To make

advances in building materials, the

Lafarge Group places the customer at

the heart of its concerns. It offers the

construction industry and the general

public innovative solutions bringing

greater safety, comfort and quality to

their everyday surroundings.

Integrated solutions that optimise valueFLSmidth attributes the success of this

contract to its ability to provide a com-

plete integrated project and proven

technology. During the contract discus-

sions, the Lafarge and FLSmidth project

teams collaborated on developing a

plant layout that optimises reliability,

ease of maintenance, and long term

trouble free operation. In addition to

engineering services, project manage-

ment, training and commissioning, all

major machines and auxiliary equipment

are included:

FRM(FullerRollerMill)59/575forrawgrinding

CF(ControlledFlow)homogenisationblend silo with storage capacity of

10,000 tonnes

Three-supportkiln,5.60mdiameter x 84 m long

2string,5-stagepreheater,withalow-NOx In-Line Calciner (ILC) de-

signed for coal, natural gas or pet-

coke

DUOFLEXTM kiln burner Multi-MovableCross-BarTM cooler

(MMC 18 x 87) with mid-cooler

Heavy Duty Roller Breaker (HRB)

ATOX25.0millforsolidfuelgrinding OK42-4verticalrollermillforfinish

grinding

CompleteFLSmidthAirtechjetpulseprocess bag filter packages including

FabriCleanTM, DuoClean and nuisance

filters.

FRM (Fuller Roller Mill) for raw meal grinding


CEMENT

Many of the FLSmidth Group companies

and divisions will be represented in the

project, including Pfister, Airtech, Pneu-

matic Transport and Airloq.

Pyro processing system offers flexibility and low cost operationTo achieve savings in the initial construc-

tion, the height of the preheater tower

and kiln piers were minimised by the use

of both a compact twin-string preheater

and the horizontal design of the Multi-

Movable Cross-Bar cooler. Operating

cost savings are also attained with the

preheater configuration which is opti-

mised in terms of heat economy and

power consumption given the moisture

content of the raw materials.

To ensure compliance with the strict

emission limits and provide flexibility

for the future, an SNCR (Selective Non-

Catalytic Reduction) system will be in-

corporated in the preheater. The design

also allows for the addition of a HOT-

DISCTM reactor, enabling the line to eas-

ily be modified to combust bulky waste.

OK mill the preferred solution to meet strict demands in North AmericaWith a rsum of demonstrated results,

the OK mill has proven its ability to oper-

ate at the higher Blaine cements required

for the North American market at a lower

power consumption. As evidence of the

markets acceptance, the scope of sup-

ply includes three OK -42 mills; one will

be used in Joppa, and the other two will

replace and supplement existing cement

grinding equipment at other Lafarge facil-

ities in North America (see also page 18).

Execution to ensure long term successTo help Lafarge achieve its aggressive

reliability goals throughout the life of

the plant, a package that links parts

availability with a comprehensive pre-

ventive maintenance and optimisation

programme is included in this contract.

As a result, seamless continuity between

project team and aftermarket services

and support will be ensured. The new

line will be commissioned in late 2010.

Multi-Movable

Cross-Bar cooler

2 string, 5-stage preheater,

with ILC Calciner

ILC calciner for low

NOx and CO emissions

HOTDISC reactor

for high substitution

of solid waste fuels

(future option) DUOFLEX main

burner for multiple

fuels

LSR Group opts for the best

Leading Russian Group invests in energy and environmentally optimised cement plant.

A new greenfield cement plant with

a capacity of 5,000 tonnes per day is

to be built near the town of Slantsy,

about 200 km west of St. Petersburg.

LSR Group, a diversified Russian holding

company has established the OOO Ce-

ment company to build and operate the

plant, and FLSmidth has received a con-

tract to supply equipment and services

for the project.

Environmental considerationsLSR Group, whose activities include

building materials manufacture, con-

struction and real estate development,

chose FLSmidth because of its 125 years

of experience in the cement industry

and its proven expertise in equipment

capable of producing cement using

non-traditional raw materials. In addi-

tion to the natural deposits of limestone

and clay, the area near the new plant

has huge amounts of waste materials

accumulated from the extraction and

processing of oil shale. These materials

will serve as additional raw materials

for the cement-making process. So by

building the new plant, LSR Group will

not only boost the cement production

capacity in the Leningrad region, but will

also significantly improve the environ-

mental situation near Slantsy.

Optimised technological solutionThe cutting-edge technology to be used

for the new project includes two EV

crushers, FLSmidth MVT raw material

stores, an ATOX raw mill and two CF

raw meal silos. The pyroprocessing part

of the project will comprise a 4-stage

ILC preheater, a 3-support kiln and an

SF Cross-Bar cooler. For finish grinding,

two UMS cement mills complete with

FLSmidth MAAG gears as well as FLS-

midth Ventomatic packing equipment

will be supplied.

The scope of supplies also includes

FLSmidth Airtech fabric filters, an

FLSmidth Automation quality control

and process control system in addition

to a complete electrical package. Trans-

port to the site and training of the staff

is also part of the contract.

FLSmidth Group CEO Jrgen Huno Ras-

mussen comments: Russian customers

wish to secure the future of their plants

by using modern cutting-edge technol-

ogy and environmentally optimised solu-

tions. Our St. Petersburg and Moscow

offices provide a strong basis for main-

taining our strategy and continuing to

grow in the expanding Russian market.

St. Petersburg with its famous Winter Palace (above) is just 200 km east of LSR Groups

new greenfield plant near Slantsy. The plant site (below) is next to huge deposits of oil

shale waste that will serve as additional raw material



New Russian plant to use wet raw materials

CEMENT

OOO Kurskaya Stroitelnaya Companiya is a new player on the Russian cement market. It has chosen FLSmidth to engineer and supply its first plant.

Located close to the city of Kursk, ap-

proximately 700 kilometres south of

Moscow, OOO Kurskaya Stroitelnaya

Companiyas new greenfield cement

plant will have a capacity of 3,500

tonnes of clinker per day and will come

on stream in 2010.

Designed for high moisture ma-terialsSpecial consideration has been given to

the high moisture content of the raw

materials characteristic to the plant. The

storage equipment has been designed

with this in mind and the Kursk plant

will use a drier-crusher to handle the

sticky raw materials. The so-called ET

drier crusher is specially designed for

pulverising and drying wet materials,

such as chalk and marl, in one operation.

FLSmidth has configured the entire

pyroprocessing system for the optimal

balance of heat economy, power con-

sumption, and drying requirements of

the high moisture raw materials. The

two-stage ILC preheater will ensure low

emission of NOx and CO while at the

same time supplying sufficient heat to

the ET drier crusher. The most modern

two-support ROTAX-2 kiln (4.55 x 54m)

will be supplied, offering an installation

with considerable reduction in kiln di-

mensions compared to conventional kiln

systems. Clinker cooling will take place

in the proven and efficient SF Cross-Bar

cooler.

The cement grinding equipment in-

cludes two 46x14 UMS ball mills and

high efficiency SEPAX separator units

to ensure relatively low power consump-

tion and high cement quality.

A complete supply packageThe contract with FLSmidth comprises a

complete range of equipment and engi-

neering services for the new plant. This

includes not only raw material handling

and pyroprocessing, but also cement

grinding and packing as well as the

complete electrical system and control

equipment.

The greenfield project at Kursk is the

third major contract landed by FLSmidth

in Russia in less than four months.

Signing the contract for Kurskayas new greenfield plant attracted great media attention.

The insert shows a 1:500 3D-printed model of the 3,500 tpd plant

A seasoned CEO is at the helm of the FLSmidth Groups new Minerals organisation. Christian Jepsen, the name is Danish, and so are his roots. But living and working in the US since 1995 has had a marked influence. He has learnt to appreciate Ameri-can values whilst retaining Danish family relations and being a member of the Groups Corporate Management. His job is now to carry out the Groups growth strategy for Minerals the most comprehensive inte-gration process since 1990 when FLSmidth acquired US-based Fuller Company, today named FLSmidth Inc.

Why expand into minerals?It has always been FLSmidths aspiration

to develop the minerals activity to the

same size as the cement business. 2007

marks the first decade since FLSmidth

consolidated its minerals operations into

a single company. During that period, the

turnover has climbed from DKK 400m

to more than DKK 6,400m, and the

number of employees has grown from

150 to 3,100. For over 125 years now,

Cement has been the mainstay of our

business. But just like human beings we

find it much more comfortable to stand

on two equally strong legs. Through the

acquisition of GL&V Process and RACHO

in 2007 FLSmidth Minerals has now

made a major step towards fulfilling our

aspirations.

One Source One PartnerThis is how we will brand ourselves in

the future. As is traditionally the case in

Cement, in Minerals we now offer the

industry complete solutions. It is our

intent to move FLSmidth Minerals from

being a product supplier to becoming a

solutions and systems supplier within

any given flow sheet in the minerals

processing industry and supported by

a world-class aftermarket offering. By

combining the state-of-the-art tech-

nology from the suite of brand names

that resides within FLSmidth Minerals,

we today offer the most complete

flow sheet. And by taking advantage

of the substantial amount of engineer-

ing know-how, systems and resources

within FLSmidths global organisation,

we today offer unprecedented solutions

that will add significant value to our cus-

tomers in terms of technology and fast

time-to-market.

Other synergies?On top of the process ownership we

now have the strength to undertake

large-scale R&D programs. Both the

cement and minerals industries are

booming these years, which calls for in-

novation. New ideas and concepts are

often created by crossing frontiers and

challenging old traditions. Solutions for

the cement and minerals markets will

serve as inspiration across the organisa-

tion - as well as externally. This applies,

for example, to automation, materials

handling and new products. Minerals is

a business with big numbers. Minerals

processing plants handle capacities up

to 150,000 tonnes per day (tpd) where

20,000 tpd in cement is considered

gigantic. Another example is Operation

and Maintenance contracts. In Minerals,

we have done this type of business for

several years and we see a similar trend

in Cement.

Minerals forever

Christian Jepsen is the CEO of the

new integrated FLSmidth Minerals

organisation


Global organisationTo support our aspirations as well as

successfully execute the historically high

order backlog and allow for further

growth, we have developed a new

organisational structure that is ideally

suited to meet these challenges. Three

regional divisions covering North and

South America (Americas); Europe, Mid-

dle East and Africa (EMEA); and Asian

Pacific (APAC) will act as our front of-

fices supported by global technical and

commercial product specialists and by

fully fledged regional back offices.

Sustainability is part of our val-ue propositionIndeed, and a serious challenge to the

industry. But it also brings great engi-

neering and business opportunities. In

Minerals, for instance one major issue

is the large amount of water needed in

the process. Dorr-Oliver brings state-of-

the-art solutions for recycling water, and

with our R&D focus we can develop and

optimise processes and thereby support

our customers efforts in creating sus-

tainable mining operations.

The FLSmidth wayThe Minerals strategy will leverage the

company and to some extent counter-

balance the historically cyclical cement

market. In Minerals, machine supplies

roughly account for merely one tenth of

the total investment which may run up

to the huge sum of 2.5 billion US dollars

for developing a new mine. With these

ratios in mind, it is obvious that civil

works require a specific skill set which

we today do not have. It is therefore

not part of our business model to offer

the market complete turnkey solutions

similarly to what we offer to the cement

industry.

From Cement to MineralsChristian, you have picked up the baton

whilst continuing as CEO of FLSmidth

Inc. and EVP in the global Corporate

Management?

That is true. In FLSmidth we as employ-

ees are fortunate that we always have

the opportunity to explore new oppor-

tunites and thereby challenge ourselves.

In my case, I happened to be at the right

place at the right time and more impor-

tantly be prepared. Part of the prepara-

tion is my knowledge of American busi-

ness life and culture combined with the

fact that I have the fortune of working

with so many talented, dedicated

and experienced men and women. It is

a privilege to work with George Rob-

les, now Deputy CEO, and John Mertz,

COO, who have spearheaded the very

successful development of FLSmidth

Minerals since it became a separate

company in 1994.

Bringing the new FLSmidth Minerals in

front as a market leader is a challenge I

could not resist. And we will move fast.

We have ambitious plans and new ways

of making them happen. I offer you to

take a look at our brand new website

www.flsmidthminerals.com and you will

see how.

MINERALS

A brand new Minerals

website, flsmidthminerals.com,

has been launched

flsmidthminerals.com


Complete plant maintenance services to Chilean copper producers

As a One Source supplier of equip-ment and technical services in minerals process plants, FLSmidth Minerals also provides complete plant maintenance services.

FLSmidth Minerals and Minera Los

Pelambres have agreed to extend the

existing Operation & Maintenance

contract which was originally signed in

1999. Minera Los Pelambres, a copper

molybdenum operation in the central

Chilean Andes, is owned by London

Stock exchange listed Antofagasta

Minerals (as majority shareholder) and

a Japanese Consortium.

The contract is the third renewal for the

complete maintenance services for the

copper/molybdenum processing plant.

The renewed agreement is an extension

until 1 January 2011. The maintenance

involves a highly qualified labour force

of 180 FLSmidth Minerals employees

and 100 subcontractor personnel.

The scope of the renewed contract

includes the maintenance execution,

maintenance engineering, short and

mid term planning and continuous im-

provement with a strong emphasis on

environmental issues and the safety of

the workers and equipment. This also

includes equipment previously supplied

by Dorr-Oliver Eimco, now part of the

FLSmidth Group.

Collahuasi plant also chooses FLSmidth MineralsFLSmidth Minerals is also supplying in-

tegral maintenance service to the Com-

paa Minera Doa Ines De Collahuasis

molybdenum filtering plant and port

facilities for shipping copper concentrate

located at Puerto Patache. This 70-

people team, including the Administra-

tor Manager of the Project, serves me-

chanical and electrical instrumentation

areas as well as industrial cleaning.

The service scope for Collahuasi also

includes total planning for equipment

service at the filtering plant, molybde-

num plant, stock pile and shipping sys-

tem (conveying belts, ship loaders, etc.).

The Contract was initiated in March

2007 and termination date is set for

February 2012.

The two contracts highlight FLSmidth

Minerals as the industrys One Source

One Partner for all its mineral processing

needs.

Semi-autogenous grinding (SAG) mill


Ground-breaking order for complete minerals plant

MINERALS

The Australian company, Aurox Resources Limited, has awarded FLSmidth Minerals a compre-hensive contract for a complete processing plant to produce magnetite iron ore concentrate. This project marks a milestone in FLSmidths strategy to become a one source supplier to the miner-als and mining industry.

Located at Balla Balla in the West Pilbara

region of Western Australia, Auroxs

new facility is designed to produce ini-

tially up to six million tonnes per year of

magnetite concentrate. The very large

and homogeneous Balla Balla ore body

has an estimated 25+ year mine life,

and a future expansion of capacity to

ten million tonnes per year has been

provided for.

FLSmidth Minerals is designing and sup-

plying the complete plant and related

port facilities. The scope of equipment

supplies includes materials handling

systems from the mine, through the

processing plant and to the ship loading

conveyor. The whole supply package will

be delivered as a joint project by several

FLSmidth companies and divisions:

FLSmidthMineralsandFLSmidthKOCH are to supply a relocatable

gyratory crusher station

FLSmidthKOCHwillalsoprovideorestockpiling and reclaiming equipment

as well as concentrate stacking re-

claiming and shiploading equipment

FLSmidthMineralswillsupplySAGand ball mills

FLSmidthKrebsisprovidingcyclonesand pumps

FLSmidthDorr-OliverEimcoissup-plying concentrate and tailings-

thickening as well as clarification and

filtration equipment

FLSmidthAutomationistheproviderof complete plant automation, and

FLSmidthisrenderingservicestocoordinate construction, equipment

installation and plant commissioning.

By choosing FLSmidths new One Source

project model, Aurox will reduce the

project time by about six months. Other

benefits by opting for this novel supply

concept are technology and perform-

ance synergies.

FLSmidth Group CEO, Jrgen Huno

Rasmussen sums it up as follows: The

project confirms our strategy and vision

for the future. The acquisition of Dorr-

Oliver Eimco and Krebs Engineers last

year combined with the other acquisitions

in previous years means that FLSmidth is

now the only player in the world who can

provide complete plants to both the ce-

ment and the minerals industries.

According to schedule, the first magnet-

ite iron ore concentrate will be delivered

to the port in 2010. The concentrate will

be shipped to China to be used in steel

production.

The Balla Balla project area is located in the West Pilbara region

of Western Australia

Balla Balla proposed plant site layout


Botswanan nickel project underscores market leadership

MINERALS

With four major nickel process-ing orders received in the past year totaling over USD 220 million, FLSmidth Minerals has become the leader in sup-plying nickel ore processing technologies and equipment to installations around the globe. FLSmidth Minerals is the leader in rotary kiln-based pyro-ferro-nickel systems and now as the result of the acquisition of Dorr-Oliver Eimco in late 2007 is also the leader in hydrometallurgical process technology.

Tati Nickel Mining operates two nickel

mines in Botswana, Southern Africa.

Recently acquired by Russian nickel and

palladium giant MMC Norilsk Nickel,

Tatis Phoenix open-pit mine (started

in 1995) and the Selkirk underground

mine (started in 1989) are rich in Nickel

ore producing upwards of 20,000

tonnes per year (tpy).

After recent testing and feasibility stud-

ies, it was found that the ore mined at

Tati has extremely high values of resist-

ance and hardness placing it in the

top ratings of all ores being processed

around the world. For this reason, Tati

was chosen as a test site for proprietary

processing technology from Activox,

created originally in Australia. The

Activox hydrometallurgical technol-

ogy processes sulphide concentrates

using ultra fine grinding and pressure

leaching to ultimately produce saleable

nickel cathodes. Combining the Activox

technology with Tatis current opera-

tions has resulted in expansion projects

to increase the tonnage of concentrate

produced at these mines and created

opportunities for FLSmidth Minerals

to supply equipment for these expan-

sions.

Scope of supplyThe nickel refining process consists

of conventional crushing and screen-

ing, ball milling, flotation, concentrate

regrind milling, cleaner flotation, thick-

ening and filtration. FLSmidth Minerals

is to supply a total of thirteen Dorr-

Oliver Eimco high-density thickeners

(HDT) all with SAF2205 stainless steel

internals, complete with tanks and sup-

port legs. Eight of the thickeners are of

35 metre diameter.

Seven of the thickeners will be posi-

tioned in a multiple-staged counter

current decantation (CCD) circuit and

use technology developed originally

for EIMCO deep cone paste thicken-

ers (DCPT). The principle behind this

technology is that both gravity and com-

pression pressure created by the depth

of solids inside the HDT increases the

settling rate of the solids. The thickeners

will be used for iron removal and water

recovery from the concentrate and tails.

Order work in progressFLSmidth Minerals engineers from South

Africa worked at the Tati Nickel Demon-

stration Plant in Botswana to optimise

the thickener design for solid-liquid

separation and minimisation of frothing

on thickeners due to sulphur. This order

is the culmination of several onsite sedi-

mentation testwork campaigns at the

Tati plant.

The equipment deliveries will be stag-

gered with final shipment taking place

at the end of September 2008. The

Activox refinery start up is scheduled for

2009 and plans are to start production

of the first nickel cathodes in the latter

part of the year. It is anticipated that

the total expansion will increase nickel

production to 43,000 tpy more than

double the current output.

MCC Norilsk Nickel also operates one of

the largest pyrometallurgical complexes

in the world in northern Russia. They

have acquired low and high pressure

leach technology and have plans to

build multiple hydrometallurgical plants

throughout the world. FLSmidth Miner-

als has supplied solids/liquid separation

equipment to both Tati and Cawse

Nickel and is strategically positioned

to offer solutions to future solid/liquid

separation problems.


FLSmidth has been active in the Russian market for over a centu-ry. Before the revolution in 1917, FLSmidth built all the major ce-ment factories within todays CIS region. These days the market is again open to foreign suppliers and the industry is expanding rapidly.

BreakthroughIn 2005, FLSmidth received its first sig-

nificant order in Russia for a cement

grinding plant for Sebryakov Cement.

Subsequently, FLSmidth opened its own

representative office in Moscow effec-

tive 1 March 2006 and is now forming

an actual subsidiary company.

2007 was a breakthrough. FLSmidth

landed two major contracts with the

Moscow office acting as an important

go-between. The first was with Euroce-

ment Group for its Podgorensky Ce-

mentnik project and the next was with

LSR Group (see page 6).

The worlds largest countryThe Moscow office covers all the CIS

countries. This is a large and diverse

market with great cultural and climatic

variations. Despite their differences, the

countries in this region all share a grow-

ing demand for cement and all speak

the Russian language.

Expanding officeThe Moscow office is undergoing a

well-planned expansion, and the fifteen

strong staff will increase to twenty over

the coming months. All FLSmidth Group

companies and divisions are at the same

premises. This creates synergy and ena-

bles the various members of the Group

to discuss and agree on how to best

and most successfully serve the Russian

market.

One-stop supplier with local presenceFLSmidth is the only supplier in the

market who can offer complete design,

all equipment and after-sales service for

cement and minerals plants says Gen-

eral Manager Richard Eimert. More-

over, FLSmidths pyroprocessing and air

pollution control systems comply with

all current European and international

standards in terms of NOx, SOx, dust

and other emissions. Plants supplied by

FLSmidth are among the worlds most

modern and environmentally safe. The

environment is becoming an important

issue in Russia.

A booming marketA building boom combined with high

cement prices and inefficient produc-

tion facilities has spurred a demand for

new plants and modernisation projects.

Already at this point in 2008, FLSmidth

has signed two more major contracts

with Russian cement producers. One is

for a 3,500 tonnes per day greenfield

project (see page 7). The other includes

machinery supplies for a new 5,500

tonnes per day clinker production line at

an existing cement plant.

Group synergiesRussia offers great synergies between

cement and minerals. According to An-

ton A. Mitrofanov, FLSmidth Minerals,

also based at the FLSmidth Moscow of-

fice, the company plans to expand Min-

erals activities in Russia and recruit more

staff to cope with the growing business.

Both Russia and the CIS countries are

developing fast, and FLSmidth is well

prepared to continue the efforts that

originally started more than a century

ago, Richard Eimert concludes.

FLSmidth builds strong presence in Russia

MINERALS

The FLSmidth Groups new integrated

Moscow office is centrally located

Richard Eimert, General Manager for FLSmidth Russia


Worlds largest cement mill in operation

If you need to grind a lot of cement, its worth checking out the Nuh Cement Plant in Turkey. Operated by Nuh Cimento, the plant runs an FLSmidth-supplied ball mill the largest cement grinding mill in the world.

In 2006, Nuh Cimento signed a contract

with FLSmidth for the worlds largest

ball mill installation. The huge cement

grinding plant provides economies of

scale based on well-proven technology

and simple operating and maintenance

procedures. It produces 300 t/h OPC

cement at Blaine 3500 (cm2/g).

Nuh Cimento: capacity to supply the entire regionTurkey is one of the biggest cement

producers in Europe and the Marmara

region, where the Nuh Cement Plant is

located, accounts for around 30 percent

of the countrys production. Having

nearly doubled its capacity to 4,100,000

tonnes of clinker per year, Nuh Cimento

Sanayi A.S. can now boast the highest

clinker production capacity in Turkey.

Nuh Cement is the only cement pro-

ducer in Turkey which has a supply of

raw materials right next to its plant. Nuh

Cement also has its own port on the

Marmara Sea near Istanbul and a 300

metre tunnel eliminates the need for the

highway transportation of clinker and

cement.

The plant has sufficient capacity to cover

not only local demand in the Marmara

region and the rest of Turkey, but also

to serve as a competitive platform for

substantial exports. In 2005, FLSmidth

participated in the completion of a 6000

tpd third production line including a

ROTAX-2 kiln, designed to fulfil export

demand to neighbouring countries.

An impressive grinding installationAt 5.8 metres in diameter and 18.5

metres in length, the two-compartment

UMS-type mill with a Stanex diaphragm

is impressive to behold. Side-driven by

FLSmidth MAAG Gears Lateral Gear

Drive, size LGD 80, the huge gear unit

is rated for a capacity of 10,100 kW at

13.62 rpm for the mill.

The first compartment is 6.12 metres in

length and the second 12.38 metres.

These are initially charged with ball

grinding media of 166 tonnes and 380

tonnes respectively. At full load, the

weight of the rotating parts includ-

ing the mill body with linings, grinding

media and grinding material is about

1,100 tonnes.

The contract with FLSmidth includes

not only the impressive UMS mill, but

also a SEPAX 560M separator and two

FLSmidth Airtech baghouse filters one

for the mill and one for the separator

which help keep emissions under the

European standard of 30 mg/Nm3.

The system works in a closed circuit with

the mill. The finished product is carried

by air from the separator and is then

separated in a bag filter before proceed-

ing to the silos.


The FLSmidth Group pitches inAlong with the new cement mill from

FLSmidth, the project required equip-

ment from numerous other wings of the

FLSmidth Group. FLSmidth Automation

supplied a complete package for control

and optimisation of the mill operation,

including material sampling equipment,

an on-line fineness analyser and the

mill optimisation and ECS/ProcessExpert

control software.

Also, FLSmidth Moellers Materials Han-

dling supplied the pneumatic transport

system for ground trass, and FLSmidth

Pfister provided the dosing equipment.

CEMENT


The worlds largest cement grinding plant,

a 5.8 x 18.5 m UMS ball mill, being installed

at Nuh Cement in Turkey

FLSmidths innovative combus-tion device reduces fossil fuel usage and reduces environmen-tal impact at HOLCIM Rohoznik, Slovakia.

In 2003 a contract was signed between

FLSmidth and HOLCIM for the upgrad-

ing of the HOLCIM Slovensko Rohoznik

plant line 2 in Slovakia some 50 km

north of Bratislava. The upgrade project

increased production from 2,000 to

3,500 tonnes per day (tpd). It included

FLSmidth equipment such as a new

ATOX raw mill, a new SF Cross-Bar cool-

er and a 5-stage ILC preheater which

was prepared for later implementation

of a HOTDISC reactor to burn lumpy

solid alternative fuels. In March 2005,

HOLCIM Slovensko put the HOTDISC

into operation. This was the second

HOTDISC to come onstream after the

initial installation of Kjpsvik, Norway.

Operational experience and challengesIn the autumn of 2004, installation work

began for the HOTDISC and related

equipment. The HOTDISC was preas-

sembled within the preheater structure

while the kiln remained in operation. It

was coupled to the kiln system during

a shutdown in the spring of 2005. The

first feed of alternative fuel to the HOT-

DISC took place in March 2005.

During initial operation the lifetime of

the refractory presented some chal-

lenges. Solving the problems required

the combined knowledge of various

departments in FLSmidth. Research

& Development contributed with site

measurements and advanced Computa-

tional Fluid Dymamics-modelling. A PhD

study looked closely at the combustion

mechanisms. The Process Department

contributed with operation conditions

and the Fuel Systems Department

worked on the refractory concepts and

the HOTDISC design.

The HOTDISC was subsequently modi-

fied based on the research and assess-

ments of all the departments involved.

HOLCIM Slovensko was very co-oper-

ative during the modification tasks on

site, helping out with local suppliers,

manpower, etc.

The HOTDISC is now operating with

a fuel mix from four different sources:

coarse shredded refuse-derived fuel (RDF)

and rubber, sludge, whole car tyres and

truck tyres. The total alternate fuel firing

capacity is now in excess of 12 tonnes

per hour (tph), substituting more than

half of the calciner fuel. There has been

a reduction in CO2 emissions by almost

7,500 tonnes during the first 10 months

of 2006 and NOx emissions have been

reduced by approximately 25%.

According to the operators, running the

HOTDISC is easy and the reactor is very

reliable. If the alternative fuel feed stops,

kiln operation continues unaffected. The

HOTDISC is also highly flexible, and no

modifications are needed when chang-

ing alternative fuel supplies and types.

HOLCIM Slovensko is satisfied with the

HOTDISC installation. The HOTDISC

technology has allowed the Rohoznik

plant to achieve a high substitution rate

of alternative fuels.

Award-winning conceptIn December 2006, the Slovakian plant

received the Golden Ant Award for its

HOTDISC installation. The award is or-

ganised by associations and consultan-

cies active in the waste management

industry. When receiving the award,

Rohoznik Plant Manager, Marin Tk

stated: Besides providing a safe, en-

vironmentally sound and non-residual

waste management solution, the HOT-

DISC also saves non-renewable natural

resources, reduces emissions, and par-

tially helps to protect the market from

the pressure of dramatically rising en-

ergy costs. One of the unique features

appreciated by the Golden Ant Com-

mittee is the HOTDISCs capability to co-

process a wide variety of waste-derived

fuels with reduced need for energy- and

cost-demanding pre-processing.

At the 2nd Global Fuels Conference held

in London at the beginning of February

2008 where the impact of fuels on proc-

ess, production, emissions and quality

was discussed, FLSmidth Alternative

Fuels was honoured with an award for

its HOTDISC technology. The category

was: Most innovative technology for

alternative fuels. The judges were won

over by the fact that the HOTDISC is a

major innovation that allows bulky solid

alternative fuels to be burnt efficiently.

The HOTDISC can also be retrofitted into

existing plants, making it a truly elegant

engineering solution.

With a recent order from the Anhovo

Plant in Slovenia there are now five

HOTDISC installations sold worldwide.

About the HOTDISC

The HOTDISC is a simple combustion

device which is integrated with the

preheater and calciner systems. It can

burn anything from small-size waste

to complete car tyres and large pieces

of timber. It also provides gains in fuel

economy, energy efficiency and envi-

ronmental impact. Today most new

cement plants are prepared for this

technology.

HOTDISC three years after


CEMENT

The HOTDISC is fed with a mix of four different fuel types including

whole car tyres and coarse shredded waste

The HOTDISC installed at HOLCIM Rohoznik in Slovakia



Orders flood in for largest OK mill ever designed

FLSmidth has been contracted to supply five of the largest OK mills ever designed two for cement and slag grinding in India and three for cement grinding in the USA and Canada.

FLSmidth commissioned and started its

first two OK mills in India. Now, the Bhi-

lai JP project in Bhilai, Chhattisgarh, has

contracted FLSmidth to supply two OK

42-4 mills.

The new mills will have a capacity of

170 tonnes per hour (tph) PSC at 4300

Blaine. With an installed motor capacity

of 5,500 kW, they will form one of In-

dias largest slag grinding facilities and

the selection of machinery and equip-

ment will substantially reduce energy

consumption.

The project is a joint venture between

Jaypee and the Bhilai Steel plant. Jaypee

Group owns JP Cement Co. Ltd., one of

Indias largest cement producers and an

important industrial group in the coun-

try. The Bhilai Steel plant is part of the

Steel Authority of India, a public sector

undertaking which manufactures steel

in India.

The FLSmidth machinery and equip-

ment will be delivered over the next few

months, and commissioning is sched-

uled within 27 months from the start of

the contract.

Lafarge goes for the OK millIn December 2007, FLSmidth and La-

farge signed a contract for a complete

new 7,200 tonnes per day cement pro-

duction line. Three OK 42-4 mills with a

rated motor capacity of 5,500 kW were

included in the contract. The OK mills

will be the largest vertical cement mills

ever designed by FLSmidth for cement

grinding and the largest in operation in

North America.

Lafarge North America chose OK mills

due to their proven ability to grind ce-

ment clinker to the rigidly defined qual-

ity requirements for the North American

market. One mill will be used for the

modernisation of its cement plant in

Joppa, Illinois, (see page 4) and will have

a guaranteed production of 245 tph at

3800 Blaine OPC. The other two will

replace and supplement existing cement

grinding equipment at two other Lafarge

facilities.

25-3 27-4 30-4 33-4 36-4 39-4 42-4

The OK mill size indication represents

mean grinding track diameter (before

the hyphen) and number of grinding

rollers (after the hyphen)

CEMENT

Lafarge North America is part of the

Lafarge Group, a world leader in build-

ing materials.

One size bigger Since 2001 when FLSmidth and Kobe

Steel introduced the OK 39-4 mill with

a throughput capacity of 260 tph, raw

mills and kilns have grown in size and

capacity. This made the need for a big-

ger cement mill inevitable. In 2007,

FLSmidth introduced the new OK mill

size 42-4 with a capacity up to 310 tph

for cement and 200 tph for slag.

The introduction of the size 42-4 mill

takes the FLSmidth OK mills range to

seven different sizes. The range goes

from 1350 to 5500 kW installed power,

and provides enough capacity to meet

the widest range of customer demand.

One mill, many productsThe OK mill is the leading roller mill for

finish grinding of Portland, slag and

blended cements, with a wide range of

additives such as puzzolana, gypsum,

limestone and fly ash. The design

combines the grinding, separation and

drying processes into a single unit. And

the OK mills excellent drying capacity

makes it well suited for grinding blast

furnace slag or blended cements from

one or more wet components.

Compared to traditional ball mill opera-

tions, the OK mill reduces the energy

needed for cement grinding by 30-45

percent for cement grinding and by

40-50 percent for slag. This makes the

OK mill extremely useful for increasing

the profitability and competitiveness of

plants.


Building the 1.5 million tonne- per-year (tpy) Binani Cement Plant in India took just 18 months an industry record. And a recently completed expansion has further extended the plants capacity. Highlights visited the plant to see it in operation.

The first foundation stone for the Binani

Cement Plant was laid on 12 October

1995. After that, it took just 18 months

to complete construction and commis-

sioning setting a new industry record.

Ten years on, Binani has enhanced its

capacity with a new 6,500 tonne-per-day

(tpd) production line. The Binani Plant

management has now set an internal

target of 8000 tpd from the new line.

The Binani Cement Plants new produc-

tion line boasts many of FLSmidths

most advanced machinery. It supple-

ments the 6,300 tpd first line, also built

by FLSmidth. Originally designed to

produce 4,750 tpd, the first line was

successively upgraded to its present

level with the help of FLSmidth.

The Binani Cement Plants expansion

produced its first clinker on 30 July

2007, roughly 19 months after mobilis-

ing onsite.

Binani: a newcomer to cementBinani Cement is a subsidiary of the

diverse Braj Binani Group. Founded in

1872, the Group is active in numerous

industries, including zinc, glass fibre

and downstream composite product

production.

The Binani Cement Plant was Braj Bana-

nis first entry into the cement market.

The plant is located in Binanigram,

Sirohi, in the state of Rajasthan in north-

west India and sits about 425 metres

above sea level. The plant produces

three cement types: OPC grades 43 and

53 and PPC. Since 2007, production of

PPC has increased from 49 percent to

65 percent of total production.

As the main markets lie in the west and

northern parts of India including Gu-

jarat, Rajasthan, Punjab, Haryana and

state of Delhi cement is transported by

rail or road.

Binani also has two mines with 191 mil-

lion tonnes of reserves. The Amli mine

is two kilometres from the plant and

supplies 90 percent of the necessary raw

materials; while the Thandeberi mine,

seven kilometres away, supplies the re-

maining 10 percent.

Binani marks 10-year anniversary with new line

P. Sheoran, Wholetime Director & President (works), in front of some of the plants many awards



Equipment in the new production line

Raw material handling systemExisting limestone crushers were modi-

fied to deal with the additional capacity.

Limestone is conveyed to the existing

storage facility, which houses an

FLSmidth longitudinal stacker and re-

claimer. An additional reclaimer has been

added, and the stacker has been upgrad-

ed to 1,700 tph. Modifications also al-

low the stacker to swing 180 degrees to

build piles on both sides. The limestone

is taken from storage to a feed bin sta-

tion. From there it is transported, along

with sandstone and iron ore, for further

processing in the raw mill.

Raw mill systemA three-fan system consisting of an

ATOX 45 vertical roller mill with a 2897

kW motor, the raw mill circuit is de-

signed to produce 450 tph of raw meal.

The mill is equipped with an RAR 47.5

separator and an external mechanical

recirculation system.

Raw meal homogenising and storageThe homogenising system consists of a

CF continuous flow homogenising silo

with a capacity of 20,000 tonnes. The

CF silo discharges material from seven

regions, each with six subsectors, pro-

viding a total of 42 withdrawal areas.

Pyroprocessing systemThe pyroprocessing system is made up

of: a double string, six-stage preheater;

an SLC-I precalciner; a 74 metre long

three-support kiln with a diameter of

4.75 metres; and a 110 MW capacity

Duoflex kiln burner for coal and pet-

coke.

The worlds first MMC cooler When it came on-stream in September

2005, the Multi-Movable Cooler 14 x

111 was the first of its type in India and

the first new installation in operation in

the world. The heavy-duty roller breaker,

used as a clinker crusher, is also a first in

the Indian cement industry.

Coal grinding systemThe coal grinding system consists of an

ATOX 25 vertical roller mill with a 642

kW motor capable of grinding coal at a

rate of 50 tph.

Cement grinding systemTwo UMS 5.0 x 15 clinker grinding mills

with MAAG CPU central drives form a

closed-circuit system with a Sepax

separator. The system can produce 180

tph of cement at 3200 Blaine and the

finished product is conveyed to the two

new cement storage silos, which also

include an extraction system.

Lower energy used than average and a mix of fuels Energy consumption is very low: just

676 kcal/kg clinker compared to the

Indian average of 720 kcal/kg clinker.

Now, electrical energy is 71 kWh/ton

cement (this was higher when using pet-

coke), compared to the Indian average

of 90 kWh. Most of the coal is imported

from South Africa and Indonesia.

CEMENT


There are three firing points: the kiln,

the InLine Calciner and the Separate

Line Calciner. Solid flow feeders with FK

Pumps are used for fuel dosing, and the

advanced fuel dosing system is designed

to dose coal, petcoke and lignite in the

following combination:

kiln100percentpetcokeora combination of coal and petcoke

Separatelinecalcinercoaland lignite combination

Inlinecalcinercoalandlignite combination

Binani has used different alternative

agro-waste fuels in the plant depending

on availability (and cost) at any given

time. The maximum use of alternative

fuels is 6-7 percent.

All the alternative fuels used by the plant:

De-oiledcastorcake Mustardplantwaste Hennaplantwaste Sawdust Wastewheat Textilemillsludgefromwaste

treatment plant

Protecting the environmentBinani has always given the utmost im-

portance to a cleaner environment. All

technology, equipment, and operation

and maintenance procedures have been

chosen with the environment in mind.

This includes equipping the new line

with filters from FLSmidth Airtech: one

bag filter with fibre bags for kiln and

raw mill; and one electrostatic precipita-

tor for the cooler.

Emissions from line 1 have not exceeded

34 mg/Nm3. For the new line, Binani

hopes to meet, and be better than,

the European standard of 30 mg/Nm3

(compared to the Indian norm of 150

mg/Nm3). Also, to mitigate the warming

effect of greenhouse gases, Binani has

planted around 100,000 trees at Binani-

gram.

In 2006-2007, manpower was 375 em-

ployees, and has now increased to 580

employees. This increase is mainly due

to the additional line; but also because

turnover in the cement industry is high

and Binani wants to recruit more staff

than are leaving.

Heading for 10-12 million tonnes of cement per yearBinani has a vision: to increase capacity

to at least 10-12 million tonnes within

the next three to four years.

A 1.5 million tpy grinding unit will soon

be ready at Neem ka Thana. With this

the Binani Cement Ltd. capacity in

Rajasthan will stand at 6.0 million tpy.

In addition, Binani has acquired a part of

the Shandong Rangan cement plant in

China with a capacity of 0.5 million tpy

(and additional expansion will further

increase capacity by two million tpy).

The Group has also acquired a grinding

unit in Dubai with a capacity of one

million tpy, which is being upgraded

to 1.5 million tpy. Meanwhile, Binani is

planning to build a new clinker produc-

tion unit of two million tpy to be com-

missioned in Gujarat in 2010 along with

a 1.5 million tpy grinding unit.

The stacker and reclaimer system

Binani marks 10-year anniversary with new line


CEMENT

The ATOX 45 raw mill

The 14 X 111 Multi-Movable Cooler (MMC)

is the first of its kind in the world


FLSmidth Minerals is the indus-trys One Source for the worlds largest installed base of original equipment, enhanced products, technologies, and services un-matched in the mining and min-erals processing industries.

FLSmidth Minerals

Since its inception 10 years ago, FLSmidth

Minerals has benefited from more than

100 years of experience of both

FLSmidth and Fuller Company. We have

grown with this name from primarily

being a supplier of kilns, mills and crush-

ers to becoming an industry leader in

supplying complete mineral process-

ing systems. Our product lines include

FLSmidth, Fuller-Traylor, Technequip,

Vecor, Macmin, and Wests.

FLSmidth ABON

FLSmidth ABON manufactures feeding,

sizing, crushing and screening equip-

ment for an ever expanding range of

industries in the broad sphere of miner-

als handling and minerals processing

by-product activities.

FLSmidth Buffalo

FLSmidth Buffalo is a world class sup-

plier of feeding and crushing equipment

for mining and general industries. We

offer extensive experience in design, de-

velopment, manufacture and servicing

of this equipment.

FLSmidth Dorr-Oliver Eimco

Dorr-Oliver and EIMCO have long been

major pioneers and leaders in liquid/solid

separation solutions. These well known

companies and brand names each record

over 100 years of technical innovation in

the minerals processing industry.

FLSmidth Excel

FLSmidth Excel has been created to

focus on the aggregate producer as the

developer and manufacturer of the Rap-

tor, a high performance cone crusher.

With a modern manufacturing facility, a

centrally located crusher repair and re-

build facility, on-site crusher repair serv-

ices, responsive technical assistance, and

experienced engineering staff, FLSmidth

Excel is a radically different crusher com-

pany.

FLSmidth KOCH

FLSmidth KOCH designs, manufactures,

and services a broad range of material

handling equipment and systems for

various industries, from minerals and

cement to pulp and paper. In addition,

FLSmidth KOCH is active in supplying

coke oven plant technology, rolling mill

systems, and steel construction for hy-

draulic engineering.

FLSmidth Krebs

FLSmidth Krebs is the worlds leader

in hydrocyclone separation solutions,

serving process industries since 1952.

FLSmidth Krebs is recognised around the

world for its knowledge and expertise in

the use of hydrocyclones for the recov-

ery and classification of solids, removal

of oil from water, and severe-duty slurry

pumping.

FLSmidth MVT

FLSmidth MVT designs, manufactures,

and services a broad range of material

handling equipment and systems for

various industries, from minerals and

cement to pulp and paper. With com-

FLSmidth Minerals The one source for minerals processing technology

Dorr-Oliver flotation cells SAG mill

MINERALS

prehensive services for modernisation,

optimisation, maintenance, and rehabili-

tation, FLSmidth MVT delivers innovative

solutions for cost effective operation

and increased plant availability.

FLSmidth Mller

FLSmidth Mller was established in

1934 and joined FLSmidth in 1996.

Today, FLSmidth Mller specialises in the

design, engineering, procurement, erec-

tion, and commissioning of pneumatic

conveying systems and silos equipped

with pneumatic facilities. To date,

FLSmidth Mller has completed more

than 6,000 projects worldwide.

FLSmidth RAHCO

FLSmidth RAHCO designs, manufactures,

and services bulk handling systems for

the mining, aggregate, and bulk solids

industries. Its products include mobile

conveyors, radial stackers, portable con-

veyors, fixed/overland conveyors, and

at-the-face mining conveyors.

ECT Logo - 2C - Black & PMS 877 Silver

ECT Logo with tag - 2C - Black & PMS 877 Silverwith Grey Drop Shadow on ECEL

ECT Logo with tag - 2C - White & PMS 877 Silverwith White Drop Shadow on Oval

ECT Logo with tag - 2C - White & PMS 877 SilverExtra Stroke on Oval

Thickener Alumina calciner


MINERALS


Crushing

FLSmidth Minerals offers crushing prod-

ucts and technology with proven names

like Fuller-Traylor, ABON, and Buffalo.

This expertise is supported by more than

1,700 installed crushers, feeder-breakers

and sizers. All of its crushing and sizing

equipment is available for surface or

underground installation, for stationary

or mobile applications, and for climatic

conditions that range from tropical to

arctic.

Grinding

Since 1902, FLSmidth Minerals has sup-

plied over 2,500 mills, and many of the

largest plants operating today use its

world-renowned SAG and ball mills,

both gearless and gear driven, and in

some of the most extreme environ-

ments. The company offers a complete

line of grinding mills and systems for

wet and dry processing of metallic and

non-metallic materials.

Classification

FLSmidth Minerals manufactures classi-

fying and degritting equipment to settle,

dewater, concentrate, remove and re-

cover solids. FLSmidth Minerals delivers

cutting-edge solid-particle recovery and

classification technology for all liquid/

solid separation needs, from advanced

gMAX series hydrocyclones to heavy

media separation systems.

Sedimentation

FLSmidth Minerals supplies a wide range

of sedimentation equipment from well-

known brand names such as EIMCO and

Dorr-Oliver. Its engineers bring extensive

experience to help determine the most

cost-effective mechanism for customers

applications. This assistance includes de-

termining settling rates, detention times

required for clarification, the unit area,

and solids-retention times required for

thickening.

Flotation

Dorr-Oliver Eimco, now part of FLSmidth

Minerals, is the worlds largest supplier

of flotation equipment. WEMCO and

Dorr-Oliver flotation cells account for

more than two-thirds of all annual sales

globally, in the form of either self-aspi-

rated or forced-air flotation technology

or a combination of the two.

Filtration

FLSmidth Minerals has manufactured

pressure and vacuum filters since 1910.

Today Dorr-Oliver, EIMCO, and

Shriver filtration equipment for miner-

als processing flowsheets is used for

concurrent and countercurrent cake

formation, cake discharge, washing, de-

watering, settling, and drying.

FLSmidth Minerals Product lines


MINERALS

Pumps and valves

FLSmidth Minerals is a leading supplier

of high performance slurry handling

equipment for transporting liquid/solid

slurries to their desired destination.

The company specialises in equipment

that is rugged and durable, able to han-

dle heavy slurries, or even extremely cor-

rosive or abrasive materials.

Pyroprocessing

FLSmidth Minerals provides a wide

range of thermal treatment systems for

the minerals industries. Each system and

technology is based on extensive raw

material analysis and careful review of

product quality requirements. Products

supplied include rotary kilns and driers,

preheaters and coolers, fluid bed sys-

tems and gas suspension systems.

Materials handling

FLSmidth Minerals is the One Source

for both mechanical and pneumatic

conveying technologies for the mining

and minerals sector. The company offers

traditional trough-type belt conveyors as

well as, through FLSmidth KOCH, fully

enclosed pipe conveyors for both in-

plant and overland applications. Its ex-

perience includes complete crushing and

screening plants and ancillary equip-

ment such as tripper cars, conveyors and

feeders. Finally, through FLSmidth MVT,

the company offers all types of stacking,

reclaiming, and spreading technologies.

Specialty products

FLSmidth Minerals also offers a variety

of specialty products such as canal dig-

gers, excavators, coking plants, rolling

mills and rotary agglomerators.

Customer services

FLSmidth Minerals provides a wide

range of services for mineral process-

ing equipment and systems including

raw material testing, process design,

equipment installation, troubleshooting,

process and mechanical analysis and

commissioning of new plants. FLSmidth

Minerals Service Technology is the only

place in the world to get authentic,

high-quality, original equipment manu-

facturer spare and replacement parts for

FLSmidth, Fuller, Traylor and FLSmidth

Minerals supplied equipment.

FLSmidth Minerals can configure complete flow sheet solutions based on

proprietary technology. It offers a wide selection of engineered products that

can be applied to the various phases of mining and ore processing activities


Since 1882, cement engineering has been the backbone of FLSmidths business. For over 125 years we have had all the necessary expertise on board to set new standards for process and equipment.

In the following you will find a short

introduction to all our companies,

products and services as at April 2008.

FLSmidth

This is our main business unit for new

production lines, greenfield projects

and expansion projects. Its four Project

Divisions serve customers worldwide

through project centres in Denmark,

USA and India, supported by local repre-

sentative offices.

The Customer Services Division sup-

ports more than 500 cement produc-

tion plants around the world. A large

number of customer-focused business

units are part of the Division:

- Customer Service Projects handles

minor upgrading and modernisation

projects.

- Installation and commissioning sup-

port, operation and maintenance

contracts, inspection services, spare

parts and day-to-day support.

- FLSmidth Institute provides training

and seminars

- Alternative Fuels is a fast moving

business unit providing new sustain-

able solutions

- Materials Handling and Pneumatic

Transport offer a competitive selection

of conveying and handling systems

FLSmidths Project and Customer Services

divisions strive to make life easy for our

customers by maintaining a fast-moving

multi-talented team operating with a

high level of autonomy.

FLSmidth Automation

Automation is a unique business unit

specialising in mechanical and electronic

automation, developing software and

serving the cement and the minerals

industries. Automation has engineered

over 1000 plant control systems from

simple monitoring to total process con-

trol and electrification. Its product range

includes mini computers for raw mix

control, infra red scanning, fuzzy logic

programming and industrial robots for

laboratory automation.

FLSmidth Airtech

Backed by over 70 years of experience

in Air Pollution Control (APC) FLSmidth

Airtech is the most experienced and

professional partner when it comes to

controlling multipollutants from any of

our focus industries: Cement, Paper and

Minerals. FLSmidth Airtech has subsidiar-

ies in Spain, USA and India and provides

engineered solutions to ensure that spe-

cific emission requirements are met.

FLSmidth Ventomatic

The Groups packing specialist supplies

machines and complete solutions for

high-accuracy and high-capacity pack-

aging and dispatching of powder and

granulated products. Formed in 1957

in Bergamo, Italy, Ventomatic has a

worldwide network of agents and repre-

sentatives. A centralised spare parts stock

in Italy combined with local stocks and

distributors ensures fast delivery of spare

parts. Experienced Ventomatic engineers

based in Italy or abroad perform supervi-

sion and service visits.

FLSmidth Pfister

Pfister specialises in weighing and dos-

ing technologies. Founded in Augsburg,

Germany in 1894, Pfister is a company

with strong traditions. Today it is a

worldwide organisation with subsidiar-

ies in France, USA, Brasil, India, Malaysia

and China. Since day one Pfister has set

FLSmidth The engineers of cement production

FLSmidth Airtech fabric filter Inspecting ball mill


CEMENT

industry standards for top quality prod-

ucts that weigh and feed pulverised and

alternative fuels and coarse products.

FLSmidth MAAG

MAAG Gear AG based at Winterthur,

Switzerland, has been a well-known glo-

bal player in the international gear man-

ufacturing industry since 1913. MAAG

specialises in heavy-duty gear units for

driving roller and ball mills in the cement

industry. Its headquarters and global

service organisation are located in Swit-

zerland, and the company has modern

production facilities in Elblag, Poland.

FLSmidth Kovako

Small in workforce, financially success-

ful and a market leader in pneumatic

unloading systems, Dutch-based Kovako

Materials Handling is structured to pro-

vide professional and responsive service

to the bulk handling industry.

FLSmidth Automation plant control system Modern and green cement plant in Northern Ireland

CEMENT


The single source concept ena-bles long-term profitable solu-tions where high availability and robust technology go hand in hand. Our products perform excellently as stand alone solu-tions, but put together into an optimum process solution, even better results are achieved.

Raw materials

Crushing of raw materials for the cement

process is in good hands when treated

by EV Crushers, Hammer Crushers, Roller

Crushers and Twin Shaft Breakers, sup-

ported by a complete range of feeding,

sizing, stacking/reclaiming, conveying,

mixing and storage equipment.

Raw grinding

In the cement industry, one size does

not fit all. Plant conditions, raw ma-

terials, space constraints - just a few

of the many factors - determine what

vertical mill technology best suits the

customers needs. That is why FLSmidth

maintains a complete Vertical Roller

Mill product line with the ATOX and

FRM vertical mills. All mills are top per-

formers, bringing greater power and

efficiency to the entire cement produc-

tion process.

With heavy duty gears from FLSmidth

MAAG the grinding plant is complete.

Pyroprocessing

This product area is the heart of the ce-

ment plant with frontrunner equipment

and systems including the ILC preheater

in combination with an advanced kiln

system, a DUOFLEX burner and a HOT-

DISC (the latter may be added later).

Supported by Pfister fuel weighing and

dosing systems, Airtech flue gas clean-

ing and Automation control and moni-

toring equipment including advanced

robot technology for the laboratory, the

entire process is optimised to meet any

conceivable environmental standard.

Cooling

The availability and economy of the

cement production line heavily depends

on effective coolers. FLSmidth has a

long record for being at the cutting

edge. Over the past fifteen years, the

COOLAX, SF Cross-Bar coolers and most

recently the MMC coolers have set new

standards in the cement industry.

Finished cement grinding

A range of cement grinding options

are available depending on the plant

and project concerned. These include

the Hydraulic Roller Press, traditional

UMS ball mills with SEPAX separator

FLSmidth From raw materials to finished product

FLSmidth PfisterWeighing and dosing of fuel

FLSmidth Belt conveyor

FLSmidthRaw grinding plant

FLSmidth MAAGRaw mill gear unit

FLSmidth Mixing station

FLSmidth Crusher

FLSmidth Raw materialstore


CEMENT

FLSmidth AirtechFlue gas cleaning

FLSmidth AutomationControl and monitoring equipment and laboratory

FLSmidth Ventomatic

Packing plantFLSmidth Alternative fuels

FLSmidth Clinker cooler

FLSmidth Silo and storage facilities

FLSmidth Cement grinding plant

FLSmidth MAAG Cement mill gear unit

FLSmidth Cement silo and truck loading

FLSmidth AirtechFlue gas cleaning

FLSmidth Complete pyro system including preheater and burner

and MAAG gear units. With the energy

saving OK vertical mill for production

of portland cement, slag and blended

cements significant profitability can be

added to the process. Efficient dedust-

ing by Airtech filters and precipitators

completes the installation and ensures a

sustainable solution.

Storage and packing

Silos and storage domes for raw meal

blending or storage of finished cement

are a natural part of the scope of supply.

Complete packing plants for packing

of bag and bulk cement are supplied

by Ventomatic, our specialist company

within this field.

Bulk handling and unloaders

FLSmidth, FLSmidth Kovako and

FLSmidth Pneumatic Transport cover the

wide field of pneumatic and mechanical

handling equipment. Ship-unloaders

may even be incorporated in a complete

terminal project. The mechanical un-

loader handles both free flowing materi-

als like cement, fly ash and alumina and

coarse products such as limestone, coal

and clinker. Pneumatic ship unloaders

complete the product range and trans-

port powdery materials to the storage

using only a single pipeline, which is a

simple solution under difficult port

conditions.

Dalmia Cements modern and energy-efficient plant

Mr A. R. Bodkhe Sr. General Manager

Backed by 70 years experience in Indias cement industry, Dal-mia is well-known for its range of special cements and its sus-tainable production methods. A couple of years ago it commis-sioned a new 3,800 tonnes per day plant.

In 2004, FLSmidth received a contract

to supply and install materials handling

equipment and a pyro processing sys-

tem for Dalmia Cement (Bharat) Ltd.s

new production line at Dalmiapuram,

Trichy, Tamilnadu. The order was unique

in that it was submitted to FLSmidth

without inviting competitive bids.

According to General Manager,

Mr A.R. Bodkhe Sr., this decision re-

flected FLSmidths excellent handling of

the upgrading project in 2001-02 which

raised the throughput of the existing

pyro processing system to 3,000 tpd.

Scope of supplyThe new production line came onstream

in 2006 and has successfully reached

impressive performance targets:

Lowfuelconsumption:705kcal/kgclinker

Lowpowerconsumption:65kWh/tonne cement which is among the

lowest in India where the national

standard is 90 kWh/tonne cement.

FLSmidth materials handling equipment

supplies included

acircularlimestonestacker/reclaimer threesidescraperstacker/reclaimer

systems for raw mill additives, coal

and cement mill additives, respec-

tively.

The pyro processing system includes

a15,000tonneCFrawmeal blending silo

a5-stageILCpreheater a3.95mdiameterx62mlongkiln aDuoflexkilnburnerwithacapacityof

75 MW for coal and solid waste and a

1272 CFG cooler with CIS-MFR inlet.

To meet the increased power require-

ment, Dalmia built a 27 MW captive

power plant during 2005. The coal

stacker and reclaimer system also serves

Dalmias new power plant and therefore


CEMENT

Circular limestone

stacker/reclaimer

New preheater tower with ILC calciner

Well-established producer of special cements

Dalmia is synonymous with super specialty cements like: Oil well cement,

airstrip cement, railway sleeper cement, coastal cement and many others

plus the more usual OPC and PPC types.

The Dalmia Group established its cement division in 1939 during the

pre-independence era as a venture towards building up a self-reliant India.

1949 saw FLSmidths first involvement with Dalmia Cement: a 500

tonnes per day wet-process Unax kiln. In 1959, FLSmidth supplied another

500 tonnes per day wet-process kiln of the Folax type for an expansion

project.

Today Dalmia has an annual production capacity of 3.5 million tonnes

and has major plans to enhance their production capacity to 13.5 million

tonnes per annum by 2010.

had to be supplied and ready for opera-

tion within 9 months from the effective

date of the main contract.

Focus on sustainabilityDalmia Cement has a deep concern for

sustainable production and protection

of the environment. The Group has put

up over 53 wind turbines in Muppandal

(Tamilnadu) to generate inexpensive and

environmentally friendly power for their

cement plant.

The Group has undertaken an afforesta-

tion programme, including the planting

of 35,000 trees, which have reduced the

temperature level in and around Dalmi-

apuram.

The coal-fired power plant generates

an increasing amount of fly ash, and

Dalmia has boosted the use of this by-

product in their blended cements.

In addition, the new line will signifi-

cantly enhance Dalmias environmental

performance in terms of expanded use

of alternative fuels and more effective

emission control.

The alternative fuels used in pyro-

processing include used lubricating oil,

greases, sludge from furnace oil and

LSHS (Low Sulphur Heavy Stock), spent

carbon, and oil soaked cotton waste.

Dalmia set to more than double capacity to 8 million tonnesThe new line marks another step in de-

veloping the cordial relationship between

Dalmia Cement and FLSmidth. Recently

Dalmia entrusted FLSmidth with supply-

ing the equipment for the pyro section

of two more lines each with the capac-

ity of 4,500 tpd. One will be placed at

a greenfield site in Kadapa (Andhra

Pradesh) and is to be commissioned in

2008, and the other is for the Ariyalur

plant (Tamilnadu), which is to be com-

missioned in 2009.

Both lines will be equipped with a

4.35 x 67 metre ILC kiln with a six stage

preheater system, a Duoflex kiln burner

and a 4x5F SF Cross-Bar cooler.



Gujarat Cement Works on the threshold of a new milestone

CEMENT

Gujarat Cement Works is the largest production unit at a sin-gle location with a consistent production of 5 million tonnes per year (tpy). Since it was built in the mid nineteen nineties, it has undergone continuing de-velopment to become one of the most successful players in Indias cement industry.

The plant is a unit of UltraTech Cement

Limited and located at Kovaya in the

Amreli district of Gujarat state, India.

The plant is located two kilometres from

the southern coastline of Gujarat State

which has the longest coastline among

all states in India.

The initial installed clinker production

capacity was 4.2 million tpy based on

two kilns, each 6,500 tonnes per day

(tpd), which were installed in 1995-96.

Kiln I started producing in 1996 and kiln

II in 1997. The project necessitated land

acquisitions and leveling due to the low

levels near the sea shore.

Boosting production in stagesThe FLSmidth designed plant reached its

present record of 5.05 million tpy in two

stages during 2006-2007.

In the first stage, raising throughput

from 6,500 tpd to 7,200 tpd, the cooler

fans and the exhaust gas fans were up-

graded and the height of the SLC vessel

was increased.

In the second stage, from 7,200 tpd

to 8,000 tpd, the exhaust gas fan was

upgraded, the SLC vessel and the top

cyclones in kiln and calciner string were

replaced, a twin drive kiln arrangement

was installed and the cooler converted

to KQ-1901 series.

Optimised operationsThe plant includes four ball mills and

four packers and a state-of-the-art

captive jetty with a natural draught

of 11 metres and capable of taking

45,000 DWT ships. On the site is also a

waste heat recovery desalination plant.

Efficiently managed and maintained,

the equipment in the Gujarat Cement

Works is operating at optimum capacity.

The average running time of the ATOX

mills is 22.5 hours per day; the cement

mills 23 hours per day, and the jetty

berth is occupied around 95% of the

time.

The plant is self sufficient with electric-

ity from its combined cycle power plant

which will later be replaced by a lignite-

based 92 MW thermal power plant.

These unique features make Gujarat

the largest single location and one of

the most energy and power efficient,

complying with standards ISO 9001,

ISO 14001 and OHSAS 18000 along

with BVQI and EC certification for its

products. For three years in succession,

it has received Indias prestigious award

Exporter of the year.

FLSmidth is proud to be part of Gujarat

Cement Works success and is all set to

achieve new benchmarks.

Underlining the FLSmidth strategy to

strengthen and expand activities in both

Minerals and Cement, on 20 November

2007 Autec spol. s r.o. in the Czech

Republic became a full member of the

FLSmidth Group.

Autec is a technology company located

in Brno in the Czech Republic. Its core

competencies are specialised sample

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