Cemengal’s Plug&Grind Original was launched in 2012. Since then, the company has sold 14 systems in seven countries across three continents.

This year, the Spain-based grinding specialist proudly launched its new Plug&Grind® XL to the market, increasing grinding capabilities from 12tph to 30tph. The new unit enables producers to achieve a production output of nearly 0.25Mta and two units have already been sold to-date.

From order to dispatchThe Plug&Grind modular grinding system is the result of a close cooperation between Cemengal and certain European suppliers and are designed with the client in mind. Care is taken to anticipate and counteract any potential issues, particularly when the equipment is to be used in remote locations where nothing in life is easy, including repairing grinding equipment.

As soon as Cemengal receives an order for a Plug&Grind, the company’s Civil Engineering department kicks into action and undertakes a detailed civil engineering study to design the best layout configuration for the surface area available. This study is then given to the client so that the land can be made ready before the Plug&Grind unit arrives at the site.

Meanwhile, the firm’s Procurement department starts working on purchasing the necessary components and equipment. The containers are specially ordered, customised and produced for Cemengal, and delivered to the company’s workshop just outside Madrid, Spain.

When the containers arrive at the workshop, mechanical works start and

once completed, electrical components are installed. The mill frequency drive is assembled along with the remainder of the electrical and control room. Three local cabinets allow an easy and fast connection between containers.

The design approach that allows the containers to be assembled according to standard measures really bears fruit after

ICemengal goes XLby Moisés Rodríguez Núñez,Cemengal, Spain

This year marked the launch of Cemengal’s Plug&Grind® XL unit, which more than doubles capacity of its original version from 12tph to 30tph. The XL model has been designed for producers looking to produce up to 0.25Mta, with orders for these small yet higher output grinding units already secured.

MODULAR GRINDING PLANTS

NOVEMBER 2014 INTERNATIONAL CEMENT REVIEW

Cemengal has installed several Plug&Grind units in the past two years, including this

plant for a Kenyan cement producer

Once the concrete slab is poured, the

unit is ready for installation

©Copyright Tradeship Publications Ltd 2014

MODULAR GRINDING PLANTS

INTERMNATIONAL CEMENT REVIEW NOVEMBER 2014

the cladding is placed and the units are prepared for road and sea transportation, saving time and costs.

Elements to be erected on-site, such as ladders, platforms, handrails, transfer chutes, belts, liners, balls and connecting ducts, are packed and labelled appropriately, enabling the client to begin the erection of the Plug&Grind, thereby reducing supervisory expenses.

InstallationThe on-site erection of the Plug&Grind unit takes around a month. When the containers are levelled and fixed onto the concrete foundation, the client’s mechanical technicians join the containers together, mount the mill internals and install the platforms and ladders – all under the supervision of Cemengal engineers.

This is also the point where a key stage of the installation process takes place: the alignment between the mill and its special planetary gearbox which reduces the mill speed to the level required for the correct distribution of the grinding media inside the mill.

The electrical cabinets and the mill, fan and separator motors are wired to the electrical room while the Plug&Grind is connected to the main electrical network

of the entire plant and all signals are tested. If the network is not available, the client has the option of connecting the Plug&Grind to a diesel generator.

This stage is then completed by carrying out cold tests and verifying all equipment is running correctly during start and stop sequences by an automation technician in the control room.

Towards the first cementDuring the following couple of weeks, the mill is filled with the grinding media and

Plug&Grind starts to work towards the production of its first cement.

Once the plant is running satisfactorily, Cemengal prepares the guarantee test. This stage will see the unit work 24h a day, producing the quantity and quality of cement agreed during the purchasing contract.

At this point – just a few months after the start of the project – the Plug&Grind unit is fully commissioned and ready to help the cement producer meet market requirements. _____________________I

The design approach that allows the containers to be assembled according to standard measures

really bears fruit after the cladding is placed and the units are prepared

for road and sea transportation, saving time and costs.

A few months after the initial order, the Plug&Grind units are ready for operation

The Plug&Grind units arrive at the site as complete modular units

©Copyright Tradeship Publications Ltd 2014

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ThyssenKrupp

Resource Technologies

New 2,200 tpd cement plant on

stream

in Mexico

September 2013

Thyssen Sept Front cover.indd 1

25/07/2013 12:28

New 2,200 tpd cement plant on

stream

in Mexico

The monthl

y newslette

r covering t

he building

materials s

ectorI N TE R

N AT I

O NA L

CE M

E NT

R EV I

E W’ S

I SS U

E 1 7

9

J UN E

2 01 3

Building B

ulletin is p

ublished

monthly

by

Internatio

nal Ceme

nt Review

Old King

’s Head C

ourt, 15 H

igh Street

,

Dorking,

Surrey,

RH4 1AR

, UK.

Tel: +44 (0

) 1306 74

0363/383

Fax: +44

(0) 1306

740660

Email: inf

o@CemN

et.com

Website:

www.Cem

Net.com

BUILDING

BULLE

TIN

1

Contents

page no

Boral acq

uisitions

Two quarrie

s and a con

crete plant

2

Eurozone m

onthly out

put falls

Constructio

n activity d

own 1.1%

2

UK constr

uction out

look

Two furthe

r years of d

ecline forec

ast 2

Japan reb

uilding cos

ts

Reconstruct

ion estimat

ed at US$1

52bn 2

US constr

uction spe

nding dow

n

Dramatic f

alls seen in

May

3

MENA lon

g-term gro

wth

Forecast fo

r contractor

s positive

3

Summit's s

pending s

pree

Six acquisit

ions made in

the US

3

Weinerber

ger approv

al

Roof-tile ta

keover give

n green lig

ht 3

UK quarry

reserve s

hortages

Lack of con

sents impa

cting indus

try 4

SIG first-h

alf improve

ments

Good prog

ress in Con

tinental Eur

ope 4

Cemex rea

dy-mix inv

estment

UK plant re

placed and

modernised

4

Poland con

struction f

orecast

Sector to s

ee 11% gro

wth YoY

4

LSR brick p

roject

Financing r

eceived fo

r new plant

4

Saudi lime

stone deal

Arabian Ce

ment signs

contract

4

Outlook for

global build

ing materia

ls

THE OUTLO

OK FOR

the global

building m

aterials in

dustry rem

ains varie

d with str

ong grow

th in

most eme

rging coun

tries, a lik

ely recove

ry in Wes

t Europea

n and Au

stralian m

arkets and

a

challengin

g outlook

in the US

and som

e North A

frican mar

kets. Prici

ng also re

mains a k

ey

issue in m

ost market

s, accord

ing to an

informat

ive new r

eport from

JP Morga

n Cazeno

ve.

The analy

sts remain

cautious

on expos

ure to US

construct

ion spend

ing. Grow

ing macro-

economic

concerns,

a depress

ed housin

g market,

little incre

mental d

emand for

commerc

ial

space and

uncertain

ty on fede

ral fundin

g for high

ways are

among it

s concerns

. However,

US$5/t pr

ice increas

es announ

ced in Ap

ril are no

ted as suc

ceeding in

some loc

al markets

.

A recover

y in West

ern Europ

e is expec

ted this y

ear on the

back of s

trong grow

th in

residentia

l markets

in France

and Germ

any. Due

to austerit

y measure

s announc

ed by mo

st

countries,

the repo

rt expects

infrastruc

ture spen

ding to re

main flat

or to post

a slight d

ecline

compared

to last ye

ar. Uncert

ainty abo

ut the ma

cro-econo

mic situat

ion in peri

pheral Eu

rope

remains a

concern,

but its ou

tlook on C

entral and

Northern

Europe re

mains pos

itive. Simi

larly,

Eastern Eu

ropean co

nstruction

markets

should sh

ow a fast

paced im

provemen

t with mo

st

companies

reporting

strong tr

ading cond

itions in t

he region

, led by P

oland and

Russia.

JP Morga

n Cazeno

ve also ex

pects cont

inued grow

th in Asia

n deman

d this yea

r. While

the Austra

lian market

appears

to be seei

ng slight

improvem

ents, grow

th in Chin

a, India

and Indo

nesia rem

ains stron

g and it e

xpects gr

owth in th

ese market

s to rema

in robust

longer te

rm becau

se of rapi

d urbanisa

tion and

infrastruc

ture/hous

ing needs

for a grow

ing

population

base. How

ever, prici

ng volatil

ity remain

s inevitab

le as unp

redictable

volume

demand

combines

with sign

ificant inv

estments

in new ca

pacity.

A positive

outlook

on Sub-S

aharan A

frica and

a cautious

outlook

for Middle

East and

North

Africa du

e to polit

ical uncert

ainty in th

e region is

noted in

the repor

t . Further

more, hig

her

energy and

labour co

sts are lik

ely to put

margins u

nder pres

sure this y

ear. On the

other han

d,

markets in

Sub-Sah

aran Afric

a continue

to grow

driven by

residentia

l and infra

structural

demand

in-line wit

h a typica

l emerging

market.

Finally, in

Latin Ame

rica, hous

ebuilding

growth co

ntinues in

Mexico a

nd Brazil.

Cement

volumes w

ere up 11

.5 per cen

t YoY in B

razil in Ju

ne so volu

mes seem

to contin

ue to perf

orm

well. Prici

ng versus

cost incre

ases will b

e a simila

r issue her

e to the r

est of the

world.

Lafarge sell

s Australia

n gypsum o

perations

LAFARGE HA

S AGREED

the sale

of its Aus

tralian gy

psum ope

ration to

Knauf for

1200m. T

his

business g

enerated

an EBITD

A of 13m

in 2010

and is the

third plas

terboard p

roducer in

Australia,

with two

plants.

The two

bigger pr

oducers in

Australia

are CSR,

using the

Gyproc n

ame in Au

stralia tha

t

elsewhere

belongs t

o St-Goba

in, and Bo

ral. The A

ustralian g

overnme

nt would

not let tw

o of

the three

domestic

producers

merge an

d the deal

with Kna

af should

allow Bora

l to acquir

e

the remai

ning half

of Lafarg

e’s gypsu

m interes

ts in Asia.

The deal

with Lafa

rge is exp

ected to

be comple

ted in lat

e summer

or early au

tumn.

This follo

ws news

from earli

er in July

that Lafa

rge is in t

alks with

the Etex

Group fo

r the

sale of its

European

and Sou

th America

n Gypsum

assets at

an enterpr

ise value

of 1bn.

Under this

proposed

agreemen

t, Lafarge

would re

ceive net

cash proc

eeds of a

pproxima

tely

850m and

in additi

on would

receive a

20 per ce

nt interes

t in the n

ew partne

rship, wh

ich

would co

mbine the

European

and Sou

th America

n Gypsum

activities

of both gr

oups.

materials se

ctor

S

E 20 1

3

Building B

ulletin

Internatio

nal

OldKing

’s Head

Dorking,

RH41AR,

Tel:Tel:T +44 (0

) 1306

Fax:+44

(0) 1306

Email: inf

o@CemN

et.com

Website:

www.Cem

Net.com

UILDING

BULLETIN

1

pageno

acquisitio

ns

a concrete

plant 2

monthly o

utputfalls

activity dow

n 1.1%

2

construct

ion outloo

k

further year

s of decline

forecast

2

rebuilding

costs

Reconstruct

ion estimat

ed atUS$1

52bn

construct

ion spend

ing

Dramatic f

alls seen in

May

MENA lon

g-term gro

wth

Forecast fo

r contractor

s positive

Summit's s

pending

Six acquisit

ions made

Weinerber

ger approv

al

Roof-tile ta

keover give

n

UK quarry

reserve

Lackof con

sents

SIG first-h

alf

Goodprogr

ess

Cemex rea

dy-mix

UK plant re

placed

Poland con

struction

Sector to s

ee

LSR brick

Financing r

eceived

Saudi lime

stone

Arabian Ce

ment

North

hand,

Cement

perform

tions

1200m. T

his

producer

in

Australia

that

would no

t lettwo

of

Boral to a

cquire

Lafarge is

expected

to

Etex Gro

up for the

enterprise

valueof

1bn.

oceeds of

approxim

ately

newpartn

ership, w

hich

activities

of both gr

oups.

Subscription

September 2013

New 2,200 tpd cement plant on

stream

The Cement PlantOperations HandbookSixth Edition

Philip A. Alsop, PhD

The Concise Guide toCement Manufacture

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THE WAY HIGH MOMENTU

M

KILN BURNERS IMPROVE

THE COMBUSTION PROC

ESS

Focus on advanced technologie

s and products

Inte l l igent Combust ion Sol

ut ions

www.greco- l td.com

MEMBER OF

GROUP

February 2013

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THE WAY HIGH MOMENTU

M

THE COMBUSTION PROC

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June 2013

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February 2013February 2013February 2013June 2013June 2013

THE WAY HIGH MOMENTUM KILN BURNERS IMPROVE THE COMBUSTION PROCESS Focus on advanced technologies and products

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