Highlight 1 2008

C E ME NT & MINERALS

Transforming resources to meet tomorrow’s needs

2007

April 2008

Cement & Minerals
Editor: Anders Klinkby Godiksen (responsible under Danish law) Brenda Kaplan V. Ragini Shah Henrik Vinther Charlotte Pinson Neal Biege Production: Gunnar Andreasen Translations: Martin Bojesen Editorial office: FLSmidth A/S Vigerslev Allé 77, DK-2500 Valby, Copenhagen, Denmark Tel: +45 36 18 10 00 Fax: +45 36 45 44 27 Email: [email protected] Internet: www.flsmidth.com All rights reserved

Contents O´ zarów Cement upgrades plant Lafarge awards contract in USA LSR Group opts for the best New Russian plant uses wet materials Minerals for ever Aurox orders complete minerals plant Botswanan nickel project FLSmidth’s strong presence in Russia World’s largest cement mill HOTDISC three years after Orders flood in for largest OK mill Binani expands capacity FLSmidth Minerals – the One Source FLSmidth – Engineers of Cement Modern and efficient (Dalmia) Gujarat on the threshold of milestone Full ownership of Autec Keep updated First robotics laboratory in Russia Joint research in energy and emissions Beat the Autopilot reopens On the job 3 4 6 7 8 11 12 13 14 16 18 20 24 28 32 34 35 35 36 38 39 40

Maintenance for Chilean copper mines 10

For several years it has been FLSmidth’s aspiration to develop the Group’s minerals activities to the same size as its cement business. Through the acquisitions 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 denominator 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 year’s 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 Rasmussen CEO, FLSmidth

Front cover: With last year’s 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 world’s natural resources, from raw material to final product. Read more on pages 8 – 9 and 24 – 31.

Lay­ out: Blue Business A/S · ISSN 0909-8992 2 Highlights April 2008

O´ zarów Cement upgrades plant
Polish cement producer is set to increase capacity and step up alternative fuel use.

CEMENT

Commissioned in 1978, the Grupa O´ zarów cement plant is located 160 kilometres 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 government’s privatisation programme – Irishbased CRH acquired a majority stake in the company. Under the new ownership, the plant launched a comprehensive investment programme. Multiple-stage modernisation effort The 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, O´ zarów’s new kiln was Europe’s largest with a rated capacity of 8,000 tonnes per day. The plant ranked among the world’s most energy-efficient and environmentally friendly cement production facilities. Recently, it was decided to further increase the plant’s capacity, using the second existing cement production line. After modernisation and upgrading, this line will be able to produce 7,000
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

tonnes per day. FLSmidth is providing machinery for the upgrade, including an ATOX raw mill, an ATOX coal mill, a Multi-Movable Cross-Bar cooler and an OK Vertical Roller Mill for cement grinding. Alternative fuels It 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 ILCLow-NOx type. Leading the way Ever since O´ zarów 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, Oźarów cement plant will become the biggest cement manufacturer in Poland and one of the largest in Europe.



Highlights April 2008

3

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 plant’s overall performance. Lafarge North America Lafarge is the world leader in building materials, with top-ranking positions in all of its businesses: Cement, Aggregates & 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 materials 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 protection and the conservation of natural resources and energy. The Lafarge Group is the only business in the construction 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 value FLSmidth attributes the success of this contract to its ability to provide a complete integrated project and proven technology. During the contract discussions, 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 management, training and commissioning, all major machines and auxiliary equipment are included: • FRM (Fuller Roller Mill) 59/575 for raw grinding • CF (Controlled Flow) homogenisation blend silo with storage capacity of 10,000 tonnes • Three-support kiln, 5.60 m diameter x 84 m long • 2 string, 5-stage preheater, with a low-NOx In-Line Calciner (ILC) designed for coal, natural gas or petcoke • DUOFLEXTM kiln burner • Multi-Movable Cross-BarTM cooler (MMC 18 x 87) with mid-cooler Heavy Duty Roller Breaker (HRB) • ATOX 25.0 mill for solid fuel grinding • OK 42-4 vertical roller mill for finish grinding • Complete FLSmidth Airtech jet pulse process bag filter packages including FabriCleanTM, DuoClean and nuisance filters.

FRM (Fuller Roller Mill) for raw meal grinding

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Highlights April 2008

CEMENT

2 string, 5-stage preheater, with ILC Calciner

ILC calciner for low NOx and CO emissions

Multi-Movable Cross-Bar cooler

HOTDISC reactor for high substitution of solid waste fuels (future option)

DUOFLEX main burner for multiple fuels

Many of the FLSmidth Group companies and divisions will be represented in the project, including Pfister, Airtech, Pneumatic Transport and Airloq. Pyro processing system offers flexibility and low cost operation To achieve savings in the initial construction, 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 MultiMovable Cross-Bar cooler. Operating cost savings are also attained with the preheater configuration which is optimised 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 NonCatalytic Reduction) system will be incorporated in the preheater. The design also allows for the addition of a HOTDISCTM reactor, enabling the line to easily be modified to combust bulky waste. OK mill the preferred solution to meet strict demands in North America With a résumé of demonstrated results, the OK mill has proven its ability to operate at the higher Blaine cements required for the North American market at a lower power consumption. As evidence of the market’s 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 facilities in North America (see also page 18). Execution to ensure long term success To help Lafarge achieve its aggressive reliability goals throughout the life of the plant, a package that links parts availability with a comprehensive preventive 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.



Highlights April 2008

5

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 Cement company to build and operate the plant, and FLSmidth has received a contract to supply equipment and services for the project. Environmental considerations LSR Group, whose activities include building materials manufacture, construction 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 addition 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 environmental situation near Slantsy. Optimised technological solution The 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 FLSmidth 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. Transport to the site and training of the staff is also part of the contract. FLSmidth Group CEO Jørgen Huno Rasmussen comments: “Russian customers wish to secure the future of their plants by using modern cutting-edge technology and environmentally optimised solutions. Our St. Petersburg and Moscow offices provide a strong basis for maintaining 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 Group’s 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

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Highlights April 2008

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, approximately 700 kilometres south of Moscow, OOO Kurskaya Stroitelnaya Companiya’s 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 materials Special 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.

Signing the contract for Kurskaya’s new greenfield plant attracted great media attention. The insert shows a 1:500 3D-printed model of the 3,500 tpd plant

FLSmidth has configured the entire pyroprocessing system for the optimal balance of heat economy, power consumption, 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 dimensions compared to conventional kiln systems. Clinker cooling will take place in the proven and efficient SF Cross-Bar cooler. The cement grinding equipment includes two 46x14 UMS ball mills and high efficiency SEPAX separator units

to ensure relatively low power consumption and high cement quality. A complete supply package The contract with FLSmidth comprises a complete range of equipment and engineering 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.



Highlights April 2008

7

Minerals forever
A seasoned CEO is at the helm of the FLSmidth Group’s 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 American values whilst retaining Danish family relations and being a member of the Group’s Corporate Management. His job is now to carry out the Group’s growth strategy for Minerals – the most comprehensive integration process since 1990 when FLSmidth acquired US-based Fuller Company, today named FLSmidth Inc. Why expand into minerals? It has always been FLSmidth’s 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 Partner This 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 technology 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 engineering know-how, systems and resources within FLSmidth’s global organisation, we today offer unprecedented solutions that will add significant value to our customers 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 innovation. 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 organisation - 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.

Christian Jepsen is the CEO of the new integrated FLSmidth Minerals organisation

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Highlights April 2008

MINERALS

Global organisation To 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, Middle East and Africa (EMEA); and Asian Pacific (APAC) will act as our front offices supported by global technical and commercial product specialists and by fully fledged regional back offices. Sustainability is part of our value proposition Indeed, and a serious challenge to the industry. But it also brings great engineering and business opportunities. In Minerals, for instance one major issue is the large amount of water needed in the process. Dorr-Oliver brings state-ofthe-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 sustainable mining operations. The FLSmidth way The Minerals strategy will leverage the company and to some extent counterbalance 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 Minerals Christian, 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 employees are fortunate that we always have the opportunity to explore new opportunites and thereby challenge ourselves. In my case, I happened to be at the right place at the right time and more importantly be prepared. Part of the preparation is my knowledge of American business life and culture combined with the fact that I have the fortune of working with so many talented, dedicated

flsmidthminerals.com
A brand new Minerals website, flsmidthminerals.com, has been launched

and experienced men and women. It is a privilege to work with George Robles, 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.



Highlights April 2008

9

Complete plant maintenance services to Chilean copper producers
As a One Source supplier of equipment 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 improvement 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 Minerals FLSmidth Minerals is also supplying integral maintenance service to the Compañía Minera Doña Ines De Collahuasi’s molybdenum filtering plant and port facilities for shipping copper concentrate located at Puerto Patache. This 70people team, including the Administrator Manager of the Project, serves mechanical 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, molybdenum plant, stock pile and shipping system (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 industry’s One Source – One Partner for all its mineral processing needs.

Semi-autogenous grinding (SAG) mill

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Highlights April 2008

Ground-breaking order for complete minerals plant
The Australian company, Aurox Resources Limited, has awarded FLSmidth Minerals a comprehensive contract for a complete processing plant to produce magnetite iron ore concentrate. This project marks a milestone in FLSmidth’s strategy to become a one source supplier to the minerals and mining industry. Located at Balla Balla in the West Pilbara region of Western Australia, Aurox’s new facility is designed to produce initially 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 supplying 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: • FLSmidth Minerals and FLSmidth KOCH are to supply a relocatable gyratory crusher station • FLSmidth KOCH will also provide ore stockpiling and reclaiming equipment as well as concentrate stacking reclaiming and shiploading equipment • FLSmidth Minerals will supply SAG and ball mills • FLSmidth Krebs is providing cyclones and pumps

MINERALS

The Balla Balla project area is located in the West Pilbara region of Western Australia

Balla Balla proposed plant site layout

• FLSmidth Dorr-Oliver Eimco is supplying concentrate and tailingsthickening as well as clarification and filtration equipment • FLSmidth Automation is the provider of complete plant automation, and • FLSmidth is rendering services to coordinate construction, equipment installation and plant commissioning. By choosing FLSmidth’s 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 performance synergies.

FLSmidth Group CEO, Jørgen Huno Rasmussen sums it up as follows: “The project confirms our strategy and vision for the future. The acquisition of DorrOliver 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 cement and the minerals industries.” According to schedule, the first magnetite iron ore concentrate will be delivered to the port in 2010. The concentrate will be shipped to China to be used in steel production.



Highlights April 2008

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Botswanan nickel project underscores market leadership

MINERALS

Seven of the thickeners will be positioned in a multiple-staged counter current decantation (CCD) circuit and use technology developed originally for EIMCO® deep cone® paste thickeners (DCPT). The principle behind this technology is that both gravity and compression 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 progress FLSmidth Minerals engineers from South Africa worked at the Tati Nickel Demonstration 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 sedimentation testwork campaigns at the Tati plant. The equipment deliveries will be staggered 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 Minerals 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.

With four major nickel processing orders received in the past year totaling over USD 220 million, FLSmidth Minerals has become the leader in supplying nickel ore processing technologies and equipment to installations around the globe. FLSmidth Minerals is the leader in rotary kiln-based pyro-ferronickel systems and now as the result of the acquisition of DorrOliver 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, Tati’s 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 studies, it was found that the ore mined at Tati has extremely high values of resistance 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 technology processes sulphide concentrates using ultra fine grinding and pressure leaching to ultimately produce saleable nickel cathodes. Combining the Activox technology with Tati’s current operations 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 expansions. Scope of supply The nickel refining process consists of conventional crushing and screening, ball milling, flotation, concentrate regrind milling, cleaner flotation, thickening and filtration. FLSmidth Minerals is to supply a total of thirteen DorrOliver Eimco® high-density thickeners (HDT) all with SAF2205 stainless steel internals, complete with tanks and support legs. Eight of the thickeners are of 35 metre diameter.

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Highlights April 2008

FLSmidth builds strong presence in Russia
FLSmidth has been active in the Russian market for over a century. Before the revolution in 1917, FLSmidth built all the major cement factories within today’s CIS region. These days the market is again open to foreign suppliers and the industry is expanding rapidly. Breakthrough In 2005, FLSmidth received its first significant order in Russia for a cement grinding plant for Sebryakov Cement. Subsequently, FLSmidth opened its own representative office in Moscow effective 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 Eurocement Group for its Podgorensky Cementnik project and the next was with LSR Group (see page 6). The world’s largest country The 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 growing demand for cement and all speak the Russian language. Expanding office The 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 enables the various members of the Group to discuss and agree on how to best and most successfully serve the Russian market.
Richard Eimert, General Manager for FLSmidth Russia

One-stop supplier with local presence “FLSmidth is the only supplier in the market who can offer complete design, all equipment and after-sales service for cement and minerals plants” says General Manager Richard Eimert. “Moreover, FLSmidth’s 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 world’s most modern and environmentally safe. The environment is becoming an important issue in Russia.” A booming market A building boom combined with high cement prices and inefficient production 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 synergies Russia offers great synergies between cement and minerals. According to Anton A. Mitrofanov, FLSmidth Minerals, also based at the FLSmidth Moscow office, the company plans to expand Minerals 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.

The FLSmidth Group’s new integrated Moscow office is centrally located



Highlights April 2008

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World’s largest cement mill in operation
If you need to grind a lot of cement, it’s 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 world’s 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 region Turkey 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 country’s 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 producer 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 installation At 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 Gear’s 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 – including 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 proceeding to the silos.

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Highlights April 2008

CEMENT

The FLSmidth Group pitches in Along with the new cement mill from FLSmidth, the project required equipment 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 Handling supplied the pneumatic transport system for ground trass, and FLSmidth Pfister provided the dosing equipment.

The world’s largest cement grinding plant, a 5.8 x 18.5 m UMS ball mill, being installed at Nuh Cement in Turkey



Highlights April 2008

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HOTDISC three years after
FLSmidth’s innovative combustion device reduces fossil fuel usage and reduces environmental impact at HOLCIM Rohoznik, Slovakia. In 2003 a contract was signed between FLSmidth and HOLCIM for the upgrading 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 cooler 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 Kjøpsvik, Norway. Operational experience and challenges In the autumn of 2004, installation work began for the HOTDISC and related equipment. The HOTDISC was preassembled 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 HOTDISC took place in March 2005. During initial operation the lifetime of the refractory presented some challenges. Solving the problems required the combined knowledge of various departments in FLSmidth. Research & Development contributed with site measurements and advanced Computational 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 modified based on the research and assessments of all the departments involved. HOLCIM Slovensko was very co-operative 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 changing 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 concept In December 2006, the Slovakian plant received the Golden Ant Award for its HOTDISC installation. The award is organised by associations and consultancies active in the waste management industry. When receiving the award, Rohoznik Plant Manager, Marián Tkáč stated: “Besides providing a safe, environmentally sound and non-residual waste management solution, the HOTDISC also saves non-renewable natural resources, reduces emissions, and partially helps to protect the market from the pressure of dramatically rising energy costs.” One of the unique features appreciated by the Golden Ant Committee is the HOTDISC’s capability to coprocess 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 process, 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 environmental impact. Today most new cement plants are prepared for this technology.

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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



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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 Bhilai 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 India’s largest slag grinding facilities – and the selection of machinery and equipment 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 India’s largest cement producers and an important industrial group in the country. 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 equipment will be delivered over the next few months, and commissioning is scheduled within 27 months from the start of the contract. Lafarge goes for the OK mill In December 2007, FLSmidth and Lafarge signed a contract for a complete new 7,200 tonnes per day cement production 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 cement clinker to the rigidly defined quality 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.

The OK mill size indication represents mean grinding track diameter (before the hyphen) and number of grinding rollers (after the hyphen)

25-3 18 Highlights April 2008

27-4

30-4

33-4

36-4

39-4

42-4

CEMENT

Lafarge North America is part of the Lafarge Group, a world leader in building 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 bigger 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 products The 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 mill’s 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 operations, 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.



Highlights April 2008

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Binani marks 10-year anniversary with new line
Building the 1.5 million tonneper-year (tpy) Binani Cement Plant in India took just 18 months – an industry record. And a recently completed expansion has further extended the plant’s 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 commissioning – 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 Plant’s new production line boasts many of FLSmidth’s most advanced machinery. It supplements 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 Plant’s expansion produced its first clinker on 30 July 2007, roughly 19 months after mobilising onsite. Binani: a newcomer to cement Binani 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 Banani’s first entry into the cement market. The plant is located in Binanigram, Sirohi, in the state of Rajasthan in northwest 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 Gujarat, Rajasthan, Punjab, Haryana and state of Delhi – cement is transported by rail or road. Binani also has two mines with 191 million 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 remaining 10 percent.

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

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Equipment in the new production line Raw material handling system Existing limestone crushers were modified to deal with the additional capacity. Limestone is conveyed to the existing storage facility, which houses an FLSmidth longitudinal stacker and reclaimer. An additional reclaimer has been added, and the stacker has been upgraded to 1,700 tph. Modifications also allow the stacker to swing 180 degrees to build piles on both sides. The limestone is taken from storage to a feed bin station. From there it is transported, along with sandstone and iron ore, for further processing in the raw mill. Raw mill system A three-fan system consisting of an ATOX 45 vertical roller mill with a 2897 kW motor, the raw mill circuit is designed 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 storage The 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, providing a total of 42 withdrawal areas. Pyroprocessing system The 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 petcoke. The world’s 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 system The 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 system Two 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 petcoke), compared to the Indian average of 90 kWh. Most of the coal is imported from South Africa and Indonesia.



Highlights April 2008

21

Binani marks 10-year anniversary with new line

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: • kiln – 100 percent petcoke or a combination of coal and petcoke • Separate line calciner – coal and lignite combination • Inline calciner – coal and lignite 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-oiled castor cake • Mustard plant waste • Henna plant waste • Saw dust • Waste wheat • Textile mill sludge from waste treatment plant

Protecting the environment Binani has always given the utmost importance 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 precipitator 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 Binanigram. In 2006-2007, manpower was 375 employees, 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 year Binani 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 production unit of two million tpy to be commissioned in Gujarat in 2010 along with a 1.5 million tpy grinding unit.

The stacker and reclaimer system

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The 14 X 111 Multi-Movable Cooler (MMC) is the first of its kind in the world

The ATOX 45 raw mill



Highlights April 2008

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FLSmidth Minerals
The one source for minerals processing technology
FLSmidth Minerals is the industry’s One Source for the world’s largest installed base of original equipment, enhanced products, technologies, and services unmatched in the mining and minerals processing industries. FLSmidth Minerals FLSmidth Dorr-Oliver Eimco 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 crushers to becoming an industry leader in supplying complete mineral processing systems. Our product lines include FLSmidth, Fuller-Traylor, Technequip, Vecor, Macmin, and West’s. FLSmidth ABON FLSmidth ABON manufactures feeding, sizing, crushing and screening equipment for an ever expanding range of industries in the broad sphere of minerals handling and minerals processing by-product activities. 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 Raptor, a high performance cone crusher. With a modern manufacturing facility, a centrally located crusher repair and rebuild facility, on-site crusher repair services, responsive technical assistance, and experienced engineering staff, FLSmidth Excel is a radically different crusher company. FLSmidth Buffalo FLSmidth Buffalo is a world class supplier of feeding and crushing equipment for mining and general industries. We offer extensive experience in design, development, manufacture and servicing of this equipment. 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 hydraulic engineering. FLSmidth Krebs FLSmidth Krebs is the world’s 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 recovery 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-

Dorr-Oliver flotation cells

SAG mill

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prehensive services for modernisation, optimisation, maintenance, and rehabilitation, FLSmidth MVT delivers innovative solutions for cost effective operation and increased plant availability. FLSmidth Möller FLSmidth Möller was established in 1934 and joined FLSmidth in 1996. Today, FLSmidth Möller specialises in the design, engineering, procurement, erection, and commissioning of pneumatic conveying systems and silos equipped with pneumatic facilities. To date, FLSmidth Möller 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 conveyors, fixed/overland conveyors, and at-the-face mining conveyors.

ECT Logo - 2C - Black & PMS 877 Silver

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

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

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

®

Thickener

Alumina calciner



Highlights April 2008

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FLSmidth Minerals Product lines
Crushing FLSmidth Minerals offers crushing products 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 supplied 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 environments. 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 classifying and degritting equipment to settle, dewater, concentrate, remove and recover 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 wellknown 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 determining settling rates, detention times required for clarification, the unit area, and solids-retention times required for thickening. FLSmidth Minerals has manufactured pressure and vacuum filters since 1910. Today Dorr-Oliver®, EIMCO®, and Shriver® filtration equipment for minerals processing flowsheets is used for concurrent and countercurrent cake formation, cake discharge, washing, dewatering, settling, and drying. Flotation Dorr-Oliver Eimco, now part of FLSmidth Minerals, is the world’s 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-aspirated or forced-air flotation technology or a combination of the two. Filtration

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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 handle heavy slurries, or even extremely corrosive 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 systems 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 inplant and overland applications. Its experience includes complete crushing and

screening plants and ancillary equipment 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 diggers, excavators, coking plants, rolling mills and rotary agglomerators. Customer services FLSmidth Minerals provides a wide range of services for mineral processing 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 manufacturer 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



Highlights April 2008

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FLSmidth
The engineers of cement production
Since 1882, cement engineering has been the backbone of FLSmidth’s 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 representative offices. The Customer Services Division supports more than 500 cement production 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 support, operation and maintenance contracts, inspection services, spare parts and day-to-day support.
FLSmidth Airtech fabric filter

- FLSmidth Institute provides training and seminars - Alternative Fuels is a fast moving business unit providing new sustainable solutions - Materials Handling and Pneumatic Transport offer a competitive selection of conveying and handling systems FLSmidth’s 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 control 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
Inspecting ball mill

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 subsidiaries in Spain, USA and India and provides engineered solutions to ensure that specific emission requirements are met. FLSmidth Ventomatic The Group’s packing specialist supplies machines and complete solutions for high-accuracy and high-capacity packaging and dispatching of powder and granulated products. Formed in 1957 in Bergamo, Italy, Ventomatic has a worldwide network of agents and representatives. 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 supervision and service visits. FLSmidth Pfister Pfister specialises in weighing and dosing technologies. Founded in Augsburg, Germany in 1894, Pfister is a company with strong traditions. Today it is a worldwide organisation with subsidiaries in France, USA, Brasil, India, Malaysia and China. Since day one Pfister has set

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industry standards for top quality products 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 global player in the international gear manufacturing 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 Switzerland, and the company has modern production facilities in Elblag, Poland. FLSmidth Kovako Small in workforce, financially successful and a market leader in pneumatic unloading systems, Dutch-based Kovako Materials Handling is structured to provide professional and responsive service to the bulk handling industry.

FLSmidth Automation plant control system

Modern and green cement plant in Northern Ireland



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FLSmidth
From raw materials to finished product
The single source concept enables long-term profitable solutions where high availability and robust technology go hand in hand. Our products perform excellently as stand alone solutions, 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, supported 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 maWith heavy duty gears from FLSmidth MAAG the grinding plant is complete. Pyroprocessing This product area is the heart of the cement plant with frontrunner equipment and systems including the ILC preheater in combination with an advanced kiln system, a DUOFLEX burner and a HOTDISC (the latter may be added later). Supported by Pfister fuel weighing and dosing systems, Airtech flue gas cleanterials, space constraints - just a few of the many factors - determine what vertical mill technology best suits the customer’s needs. That is why FLSmidth maintains a complete Vertical Roller Mill product line with the ATOX and FRM vertical mills. All mills are top performers, bringing greater power and efficiency to the entire cement production process. ing and Automation control and monitoring 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 Crusher

FLSmidth Raw material store

FLSmidth Mixing station

FLSmidth Pfister Weighing and dosing of fuel

FLSmidth Belt conveyor

FLSmidth Raw grinding plant FLSmidth MAAG Raw mill gear unit

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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 dedusting 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 unloader handles both free flowing materials like cement, fly ash and alumina and coarse products such as limestone, coal and clinker. Pneumatic ship unloaders complete the product range and transport powdery materials to the storage using only a single pipeline, which is a

simple solution under difficult port conditions.

FLSmidth Airtech Flue gas cleaning FLSmidth Automation Control and monitoring equipment and laboratory

FLSmidth Clinker cooler FLSmidth Airtech Flue gas cleaning

FLSmidth Silo and storage facilities FLSmidth Cement grinding plant FLSmidth MAAG Cement mill gear unit­

FLSmidth Cement silo and truck loading

FLSmidth Alternative fuels FLSmidth Complete pyro system including preheater and burner

FLSmidth Ventomatic Packing plant



Highlights April 2008

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Dalmia Cement’s modern and energy-efficient plant
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 reflected FLSmidth’s 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 supply The new production line came onstream in 2006 and has successfully reached impressive performance targets: • Low fuel consumption: 705 kcal/kg clinker • Low power consumption: 65 kWh/ tonne cement – which is among the lowest in India where the national standard is 90 kWh/tonne cement. FLSmidth materials handling equipment supplies included • a circular limestone stacker/reclaimer • three side scraper stacker/reclaimer systems for raw mill additives, coal and cement mill additives, respectively. The pyro processing system includes • a 15,000 tonne CF raw meal blending silo • a 5-stage ILC preheater • a 3.95 m diameter x 62 m long kiln • a Duoflex kiln burner with a capacity of 75 MW for coal and solid waste and a 1272 CFG cooler with CIS-MFR inlet. To meet the increased power requirement, Dalmia built a 27 MW captive power plant during 2005. The coal stacker and reclaimer system also serves Dalmia’s new power plant and therefore

Backed by 70 years’ experience in India’s cement industry, Dalmia is well-known for its range of special cements and its sustainable production methods. A couple of years ago it commissioned 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 sysMr A. R. Bodkhe Sr. General Manager

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Well-established producer of special cements Dalmia is synonymous with super specialty cements like: Oil well cement,

had to be supplied and ready for operation within 9 months from the effective date of the main contract. Focus on sustainability Dalmia 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 afforestation programme, including the planting of 35,000 trees, which have reduced the temperature level in and around Dalmiapuram. The coal-fired power plant generates an increasing amount of fly ash, and

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 1949 saw FLSmidth’s first involvement with Dalmia Cement: a 500 pre-independence era as a venture towards building up a self-reliant India. 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.

Dalmia has boosted the use of this byproduct in their blended cements. In addition, the new line will significantly enhance Dalmia’s environmental performance in terms of expanded use of alternative fuels and more effective emission control. The alternative fuels used in pyroprocessing 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 tonnes The new line marks another step in developing the cordial relationship between

Dalmia Cement and FLSmidth. Recently Dalmia entrusted FLSmidth with supplying the equipment for the pyro section of two more lines each with the capacity 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 commissioned 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.

New preheater tower with ILC calciner

Circular limestone stacker/reclaimer



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Gujarat Cement Works on the threshold of a new milestone
Gujarat Cement Works is the largest production unit at a single 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 development to become one of the most successful players in India’s 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 stages The 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 upgraded 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 operations The 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.

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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 electricity from its combined cycle power plant which will later be replaced by a lignitebased 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 India’s 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.

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FLSmidth Automation acquires full ownership of Autec
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 preparation machinery for automated laboratories and specialised online analysers. Its customers are mainly in the cement and minerals industries. An important reason for FLSmidth to acquire Autec has been to complement and strengthen the FLSmidth Automation product portfolio, thus adding further value to the Group and our customers.

Keep updated
Highlights magazine Highlights digital version
2007
A pr i l 2 0 0 8

A busy working day leaves little time for studying technical literature. Highlights comes out twice a year and gives you a concise overview of the latest developments at FLSmidth, both on the cement and now also on the minerals front. Would you like to receive your own free hardcopy of the Highlights magazine, all you need to do is enter your name and company address in the subscription form at Highlights’ own website www.ehighlights.flsmidth.com or via www.flsmidth.com

C E M E N T & MINERALS
CEM EN T & MINERALS
Letter from CEO

Transforming resources to meet tomorrow’s needs

New Contracts

Product news

Projects in progress

Services

If you prefer the digital version, the website enables you to browse through our eHighlights edition and search through back issues. You can also sign up to receive the eHighlights email which is sent twice a year directly to your computer.



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First robotics laboratory at Russian cement plant
• Take most dry samples manually and let them proceed automatically directly to the robotics laboratory. Eventually, as more dry process technology is installed, automation of sampling procedures will increase. Configuring the sample conveying systems The sample transport configuration for the Old Plant and the New Plant consists of: Old Plant Wet samples: One single-position manual sending station connected to one eight-position receiving station. Dry samples: Clinker from wet kilns and finished cement: One eight-position sending station connected to one manual receiving station and one automatic receiving station in the robot cell (with an automatic sampler and sending station from the semi-dry line). New Plant: Wet samples: Three single-position sending stations from raw material grinding, raw mills and slurry basins, which send the samples to one eight-position receiving station. Dry samples: One single-position sending station dispatching clinker samples from the four kilns. One eight-position sending station serving the eight cement samplers. Dry samples are sent to an eightposition manual receiving station or the automatic receiving station in the QCX/ RoboLab.

JSC MordovCement is upgrading its wet-process plant. The modernisation programme includes automated laboratory systems that are being supplied by FLSmidth Automation. JSC MordovCement is located approximately 50 km northeast of Saransk, the capital of the Russian republic of Mordovia. The plant is in two sections, which are 2.5 km apart. The “Old Plant” operates four 600 tpd wet-process kilns from 1956, while the “New Plant” from 1963 operates four 1,800 tpd wet-process kilns. One of the four wet-process kilns in the Old Plant was recently converted to semi-dry, raising production to 2,300 tpd. In the New Plant, a 5,200 tpd dryprocess kiln is in the final design phase. Together, these two projects will in-

crease capacity from 3.5 to 6.1 million tonnes cement clinker per year. The challenges Designing an automatic sampling and analysis concept for a wet-process plant with a high degree of manual procedures offers several challenges. At MordovCement the sampling systems handle both wet and dry samples and must be prepared for future dry production lines. The plant with its slurry basins and slurry transport systems is not easy to automate, especially when delivering dry samples to a new laboratory facility. The fact that ambient temperatures some times drop to -40oC is an added complication. To reduce the high costs of automatic sampling and drying it was decided to: • Take wet samples manually and transport them automatically to the laboratory where they are dried before entering the robotics laboratory system.

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CEMENT

JSC Mordov Cement sampling & sample transport configurations

• ThermoScientific ARL9900 XRF (&XRD) analyser for elemental and mineral analysis • Malvern MS2000 Particle size analyzer for dry samples • Autec Turn Table Rack (TTR) for manual input and output of samples and collecting average samples • Cleaning cabinet for sample cups. Controlling the flow of samples Controlled by FLSA’s advanced QCX/ RoboLab software module, the robot cells include data acquisition from analysis instrumentation, reporting, trending and storage of results, as well as advanced functions for the sample transport system and the automatic laboratory. Samples introduced to the sample transport system in the plant stations are called to the laboratory based on QCX/ AutoSampling priority. Samples arriving in the manual receiving stations are
continued on next page

Configuring the plant laboratories The two, identical laboratories serving the Old and the New plants are equipped as follows: Manual equipment: • Receiving stations for reception of wet samples and uncrushed clinker samples • Drying equipment for wet samples • Manual mill and press for samples not prepared automatically (typically raw materials) • Malvern MS2000 particle-size analyser for wet mill samples. Fully automatic equipment (QCX/Robolab): • ABB IRB2400L robot • Pfaff receiving station for reception and dosing of samples from the plant. • Two Pfaff M100R mills for automatic grinding • Pfaff P40R press for automatic preparation of pressed pellets

• Autec DCF800-10 sample and flux dosing unit for fusion samples • PANalytical PerlX’3 fusion machine for preparation of glass beads

JSC Mordov Cement Laboratory configurations



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First robotics laboratory at Russian cement plant
(continued from previous page)

picked by the operator and processed manually, or dried and introduced to the automatic laboratory through the TTR’s input tray. Samples arriving in the automatic receiving station are picked by the robot and handled according to predefined recipes. The QCX/RoboLab software controls the actual preparation sequence. Future developments With its dynamic upgrading programme, JSC MordovCement is pioneering laboratory automation in the Russian cement industry. Soon other projects will follow, including those contracted by FLSmidth for Slantsy, Podgorensky and Kursk. At these sites, an automated laboratory will

be installed with new dry process equipment, and all stages – including sampling – will be dry from the beginning. Meanwhile, the Mordov project shows that laboratory automation can be applied to existing wet-process plants. But full automation of wet sampling is complex, and the multiple small process units in most Russian wet-process plants hardly justify investing in full automation at the sampling stage.

We recommend retaining some manual and semi-automatic procedures at the sampling stage, and using full automation for sample transportation and dry sample preparation. As dry-process technology replaces wet-process technology, fully automated dry sampling can easily be introduced – as long as the overall system is prepared for it.

Joint research effort in energy efficiency and emissions control
The Technical University of Denmark (DTU) has teamed up with FLSmidth to search for better ways of utilising energy and cutting emissions in cement production. Backed by a USD 5m grant from the Danish National Advanced Technology Foundation, the two partners will study and develop new technologies that reduce energy consumption and curb emissions. Cement production is an energy-intensive process which also generates harmful emissions to the atmosphere. With the rapid growth in cement output, a concerted effort is needed to ensure a sustainable future both for the industry and the world at large. Also the minerals industry will benefit from the studies and applications developed. The researchers will make detailed studies of the causes of pollution with a view to developing processes that generate fewer harmful emissions. These include both carbon dioxide greenhouse gases and emissions such as sulphur dioxide, nitrogen oxide and tracers. The research and development will take place at DTU laboratories and pilot plants. FLSmidth engineers will subsequently test the results at the company’s Dania research centre in Denmark and at full-scale production plants in collaboration with FLSmidth customers. A special advisory committee with representatives of the Danish companies, DONG Energy and Haldor Topsøe, and Swedish Vattenfall will ensure that developments in the power generating and chemical process industries are shared with the cement and minerals industries. The advisory committee members will also be able to channel ideas generated in the cement and minerals industries back to their respective industries. Yearly presentation days will be held to communicate the fundamental research results achieved to a wider public.

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Beat the Autopilot competition - now reopened!
Following up on the highly successful Beat the Autopilot competition; we are pleased to announce that the campaign is now available for sign-up without prior invitation – which means anyone may attempt to beat the autopilot. During the first week of the reopened competition we saw some 300 sessions played on average every day! This traffic is much more than anticipated and some waiting time for available servers might occur. However, when you log in a counter will tell you the specific waiting time. The competition uses a simulator based on the ECS/CEMulator training tool and is based on targets for five production parameters. You can try as often as you like and any time you like in order to keep improving your high score. The aim of the game is to use the sliders to adjust the five production process parameters in order to ensure a result as close as possible to the targets. In other words, try to do just as well for about five minutes as an ECS/ProcessExpert can do day-in, day-out with several times as many parameters. Your score will be registered each time you play. If it is your highest it will be recorded as your current high score. If it is among the ten highest, it will be included in the Top Ten list. Sign-up now and test your skills against the Autopilot! The winner will be awarded an allexpenses-paid trip to FLSmidth in Copenhagen, Denmark. The campaign is hosted on www.beat-the-autopilot.com and is available for sign-up now. The campaign will be available for a limited period until further notice. And by the way: when this text was written, the record of 9,163 points set by Mr. PK Tripathy from Shree Cement Ltd., India, was still unbeaten.

CEMENT

The web-based simulator in the Beat-the-Autopilot competition is a highly simplified version of the ECS/CEMulator



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So good, they acquired him twice
Right now, Pete Flanagan is working hard to complete the integration of Dorr-Oliver Eimco and FLSmidth Minerals in the Americas. As perhaps the only person to have been acquired twice by FLSmidth, he’s perfect for the job. On the job: Initially, Pete trained as an engineer. He graduated from Lehigh University in 1988, and immediately began working in the pyroprocessing department of Fuller Company in Bethlehem, Pennsylvania. Three years later, after Fuller Company was acquired by FLSmidth, Pete moved to Seattle to become District Manager. Eventually, he was selling Fuller-FLSmidth products to both cement and minerals customers in the western US and Canada. “Much of the technology used to manufacture cement and minerals is quite similar,” says Pete. “Also, buying patterns in the US and Canada are almost identical, so it made sense to cover both sides of the border and both industries.” In 1997, Pete left FLSmidth and moved to Calgary to run Eimco’s (soon to be Dorr-Oliver Eimco) Canadian operation. Two years later, he was chosen to direct the Technology department and relocated to their headquarters in Salt Lake City, Utah. In 2005, Pete was promoted to VP of global Sales and Marketing for the Hydro-metallurgical and Chemical Industries. When the company was bought by FLSmidth last August, it was a case of déjà vu for Pete. “I might be the only person to be acquired by FLSmidth twice.” Leading the integration of Dorr Oliver Eimco in the Americas Pete’s knowledge of both minerals and cement, and previous experience working at FLSmidth, make him a perfect choice to drive the integration of DorrOliver Eimco in the Americas. “It’s a busy time,” he explains. “We need to sell a lot more than FLSmidth Minerals has ever sold before (almost USD 1 billion in the Americas alone), improve our margins and at the same time execute a record backlog of work already in-house. To make this happen, we have to quickly integrate the two companies so we can more effectively marshal the combined resources. Fortunately, we’ve got a good head-start as the cultures of the two companies are so similar. I’m lucky to be surrounded by people on both sides with a can-do attitude. Everyone is extremely positive, which makes the entire integration process much easier.” Pete is also on the look out for synergies between the cement and mineral sides of the business. “The minerals business is booming. And as the integration of Dorr Oliver Eimco

nears completion, it’s becoming clear there are not enough resources, even in the combined group to meet the growth aspirations we have for minerals. Luckily, back office activities, the way plants are designed and some of the technology used in minerals are similar to cement. The next challenge is to figure out exactly how we can combine our activities to better leverage these similarities.” An exciting time to be part of FLSmidth All this work means that Pete covers a lot of ground. Although his desk is in Salt Lake City, he spends much of his time travelling – his region extends from Argentina to the northern reaches of Canada, and everything in between. “It’s a great time to be at FLSmidth. The demand for minerals processing technology is at an all-time high and we have a new value proposition. FLSmidth Minerals is the only company able to offer complete minerals production systems based on proprietary technology – and this is changing the way the industry procures projects. For many years FLSmidth has successfully applied this concept to cement. Now it appears the minerals industry is just as willing to trust FLSmidth with their complete flowsheets. Our challenge now is to deliver.” One thing is certain. Whatever happens, Pete isn’t going anywhere. “Wherever I go, I end up at FLSmidth anyway,” he laughs.

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