capability delivered

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Cement solutions

Capability

delivered


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When we build it, it works

Our industry-leading combination of proven technology and

process know-how allows us to provide the right solutions

to achieve both high quality cement and consistently high

production levels. From sample testing, equipment sizing andoperation to environmental compliance, our experienced

process design department can handle all the requirements

of fully integrated cement plants.

By matching high levels of engineering excellence with

equivalent expertise in project management, procurement

and quality control, FLSmidth delivers exceptionally dependable

results: When we build it, it works. Add our commitment

to service and support throughout the lifetime of a plant, and

youll understand why our long list of satisfied customers

includes many decades-long relationships.

A single-source supplier

For well over a century FLSmidth has been blazing new trails

in the world of cement, helping the industry become leaner,

greener and more profitable. No other supplier can call upon

and co-ordinate such a broad array of engineering resourcesand commercial experience.

From plant design and project management to equipment

supply and commissioning, we offer you one source for

everything it takes to design, build and operate successful

plants. And with more than 10,000 employees (approximately

50% of them engineers) in 40+ countries worldwide, were

there wherever you need us.

Unmatchedengineering expertise


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Innovation & technology leader

Our complete product portfolio is continually augmented

by the industrys most reliable pipeline of new products and

technologies. More than a century has passed since we

helped revolutionise cement production by introducing thetube mill and the rotary kiln, and we continue to innovate

at a robust pace: in the period 2009-2010, we have filed

for patent protection of nearly 100 new inventions. We

maintain the most extensive R&D operation in the business,

with centres in Denmark, the US and India. Our Dania test

centre in Denmark is the industrys largest, with laboratories

and pilot testing facilities for global projects including a

broad range of emissions and environmental solutions for

new and existing plants.

Key service areas

Advanced weighing and feeding equipment

Air pollution and emissions control

Alternative fuels

Laboratory services

Maintenance and support

Materials handling solutions

Grinding technology

Operating services

Operation & Maintenance (O&M)

Packing and transport

Power and instrumentation

Precision gear units

Process control

Pyroprocessing technology

Quality control

R&D

Studies and inspections

Training and seminars

Waste heat recovery


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We also offer flue gas cleaning systems and automation con-

trol and monitoring equipment. A waste heat recovery system

can be seamlessly integrated into new and existing plants to

turn your pyroprocessing waste gas into usable power.

Experience makes the difference

Because FLSmidth understands the workings of each and

every aspect of a plant and how one process interacts with

the next were better able to serve you. Our specialists

have the expertise to ensure that the entire pyroprocessing

system is optimised to your plants specific requirements. Our

knowledge of pyroprocessing systems enables us to provide

upgrades and retrofits that lead to significant improvement

in overall efficiency and economy with minimum disruption

to existing operations. Furthermore, we offer a singlesource

for a full range of quality spare parts, including OEM and

third-party items.

The pyroprocessing system is the heart of a cement plant.

For many years, FLSmidth has been the leading supplier of

reliable, high-efficiency pyroprocessing equipment, including:

- In Line Calciner (ILC)- ROTAX-2 and 3-base rotary kilns

- FLSmidth Cross-Bar Cooler

- DUOFLEX burner.

These core components are supported by a range of related

top-quality products that can help you ensure the most

sustainable production. FLSmidth Pfisterfeeders, for

example, are especially designed for precise dosing of

pulverised fuels such as petrol coke, lignite or coal-dust as

well as for kiln feeding of powdered bulk materials such as

raw meal, fly ash, bypass dust or cement products.

Core processingtechnologies

Pyroprocessing


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In-Line Calciner Preheater System

Delivering industry-leading, simultaneously

low NOx and CO emissions, the ILC also

offers uncomplicated and highly efficient

operation and is the standard for pyro-

processing systems today. FLSmidth will

design preheater systems to meet

specific plant requirements regarding

raw materials, fuels, and emissions.

FLSmidth Cross-Bar Cooler

The FLSmidth Cross-Bar Cooler builds

on the proven technology of our SF and

MMC coolers to provide one standard

clinker cooler for all types of plants. It

provides high reliability, consistently high

thermal efficiency and reduces operating

and maintenance costs. Highly modular,

it can be installed as an entirely new

cooler or as a complete or partial

upgrade of most existing coolers.

ROTAX-2 and 3-base rotary kilns

FLSmidth delivers the industrys best rotary

kilns, in both 2- and 3-base versions. The

available size range is suited to meet

even the most challenging raw materials

and fuels at the highest demanded

production rates. Proven operational

reliability and exceptional durability

ensures continuous performance with

low maintenance costs.

DUOFLEX Burner

With nearly 400 installations worldwide,

FLSmidths DUOFLEX burner fires rotary

kilns with pulverised coal or coke, oil,

natural gas or any mixture of these fuels,

as well as both liquid and solid alternative/

waste fuels. Standard types are available

for any fuel combination and a maximum

capacity ranging from 20 to 250 MW,

catering for even the largest of rotary

cement kilns.

KilnLoq gas analysis system

This high-temperature gas analysis system

collects compulsory data for optimising

and controlling a cement kilns combustion

and production process. The KilnLoq

probe offers simple and highly efficient

operation for high-temperature analysis

and is specially made for the cement

industry. System benefits include:

increased production, reduced fuel

consumption, reduced clean-out of

material build-ups in kiln and optimisedclinker through-put and quality.


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for precise mill feeding of powdered bulk materials such as

fly ash and bypass dust. We also offer a full range of ball

mills, roll presses, dryer crushers and high-efficiency separators

for all finish-product applications.

We also provide the most reliable heavy-duty gears in the indu-

stry, precisely designed and manufactured for raw and cement

mills. Efficient dedusting filters and precipitators complete the

installation package and ensure a sustainable solution. More-

over, FLSmidth is the only source you need for a full range of

quality spare parts, including OEM and third party items.

Controlling costs

Low power consumption and maintenance costs are hallmarks

of our mills, separators and auxiliary equipment as are fast

time to full production, high quality and the ability to remain

at rated output. All of which can help you run a profitableoperation and control the long-term cost of ownership.

FLSmidth offers the industrys most comprehensive portfolio

of grinding products, as well as the most diverse experience

in grinding technology including the ability to grind the most

difficult to handle materials such as sticky, high-moisture

materials. In the cement industry, one size does not fit all.Plant conditions and raw materials are just two of the many

factors that determine what vertical mill technology best

suits your plants needs.

Complete solutions

This is why FLSmidth offers a variety of products, including

ATOX and OK vertical mills as well as continuing service

for the FRM vertical roller mill. All our mills are top

performers, bringing greater power and efficiency to the

entire cement production process. The OK Mill is the only

vertical mill that was specifically designed to grind cement,

and consequently is the most efficient. Additionally,FLSmidth Pfister weighers and feeders are especially designed

Core processingtechnologies

Grinding


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ATOX Vertical Roller Mill

The ATOX raw mill saves space and energyand delivers highly reliable operation for

crushing and grinding all types of raw

materials, coal and pet coke. Its high-

performance separator and optimised

airflow ensure high separation efficiency

and low pressure loss for energy savings.

Large diameter rollers permit coarse feed

and ensure a thick grinding bed for max-

imum uptime. The ATOX mill is easily

adaptable to high airflow required by

especially wet or easy to grind materials.

WPU and WPV Gear Unit

The compact 2-stage and 3-stage

MAAG Gear bevel and planetary

gearbox transmits power from the

electric motor to the grinding table. It

reduces the speed of the electric motor

to the desired speed of the grinding

table and changes the horizontal input

axis to a vertical output axis. It combines

customer-specific design of gear units

with very high efficiency and operational

reliability. Other benefits include short

installation time, low-cost maintenance

and long service life.

Hydraulic Roller Press (HRP)

The roller press is used together with a

ball mill to grind cement clinker and brittle

material by subjecting it to immense

pressure, producing micro-cracks in the

material as well as a substantial amountof fine material. As an upgrade, the HRP

can increase capacity by up to 100%.

As part of a new installation, it can

reduce energy consumption by 20-30%

compared with traditional ball mill

grinding systems. Suitable for variety

of cement types, the HRP offers low

operational and maintenance costs, is

available with either welded or bandage

wear lining and has a hinged frame for

easy roller removal.

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OK Vertical Roller Mill

As the only Vertical Roller Mill (VRM)specifically designed to grind cement

clinker, blast furnace slag and a variety of

mixed cement types, the OK Mill is the

most efficient VRM for cement grinding

applications. It is proven to produce a

diverse range of product types that

surpass quality standards in all cement

markets around the world. The OK mill

combines drying, grinding and separa-

tion processes into a single unit for a

simplified plant layout. Flexibility and

simple design allow the OK Mill toachieve the fastest start-up times and to

reach full capacity within the first hours

of operation. With the lowest power

consumption of any vertical roller mill, it

uses 30-50% less energy than ball mill

systems and 10-20% less energy than

less efficient competing vertical mills.

The OK Mill combines high productivity

with stable, reliable operation and easy,

low-cost maintenance.


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FLSmidth offers long experience in the design, manufactur-

ing and servicing of a broad range of material handling

equipment and systems. Our products include crushing and

stacker/reclaimer systems, silo systems, bulk material and

bag loading and unloading systems for barges and ships andconveying solutions as well as complete material handling

facilities. All FLSmidth systems are supported by a worldwide

service organisation.

Crushing and storage

We offer a wide range of crushers for all types of raw material.

Increasingly strict requirements concerning quarry location

can sometimes affect limestone quality. FLSmidth provides

crushers that can handle limestone of inferior quality wet,

sticky. Moreover, we have the know-how to recommend

Materials handlingsolutions

exactly the right equipment for your crushing needs. Our

reliable, long-lasting equipment can help you increase capac-

ity and reduce power consumption, as well as reduce your

maintenance requirements.

FLSmidth also provides an extensive selection of stacker and

reclaimer systems that are compatible with any kind of raw

materials and all types of crushing installations and have

an impressive performance track record. We have commis-

sioned some of the largest stackers and reclaimers in the

cement industry, matching kiln throughputs of up to 13,000

tpd. These systems are ideal for both prehomogenisation

and buffer storage of raw materials and are designed for

heavy-duty operation.


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Transport systems

FLSmidth provides equipment for

transporting and storing of raw materials

and conveying, loading and unloading

of cement and other bulk materials.

We specialise in handling all types of

materials: dry, wet, powdery, lumpy or

sticky. We provide flexible solutions that

are designed for maximum efficiencyand the most effective use of space and

time. Our testing facility duplicates your

pneumatic conveying application, and

we simulate your specific field require-

ments to determine operating variables

and material characteristics. Our

pneumatic conveying systems have

moved millions of tons of dry bulk solids

in numerous applications.

We also deliver advanced expertise in

fully enclosed pipe conveyors in bothin-plant and overland applications. With

hundreds of installations including one

of the worlds longest pipe conveyors,

spanning 8.2 km in Peru FLSmidth is

considered the worldwide market leader.

Packing and loading expertise

We have decades of experience helping

cement plants determine the mostefficient ways to pack and ship their

product worldwide. FLSmidth Ventomatic

is one of the worlds leading suppliers

of complete plants and single machinery

for high accuracy and high capacity

packaging and dispatching of powder

and granulated products.

Our packing and loading products include:

- Automatic rotary and in-line packers

- Empty bag depalletisers- Bag applicators

- Bag treating systems

- Automatic and manual truck loaders

- Palletisers

- Bag sealing systems

- Control, supervision and monitoring

systems

Crushers

FLSmidth has over a century of experience

in crushing. As a world-class supplier of

crushing equipment for the mining,

cement and aggregate industries, FLSmidth

offers crushing products and technology

with proven capability, such as the EV

hammer impact crusher (left), ideal for

dry materials, and the ABON crusher,

which can handle sticky materials.


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FLSmidths automation solutions range from simple equipment

control to leading-edge process control solutions that seek to

optimise cement production. We combine extensive process

knowledge and experience as an equipment supplier across

the entire flow sheet, with more than 40 years of automationexperience and a track record of more than 700 control

systems and 450 laboratory systems. As a dedicated supplier

to the cement industry, we have more than 700 engineers

focused on optimising solutions for cement processes.

Automationsolutions

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ECS Process Control

FLSmidths process control product suiteincludes solutions such as plant control

systems, advanced process control, kiln

shell scanners, process simulation and

management information systems.

Common for all solutions is the built-in

cement process knowledge.

QCX Quality Control

FLSmidths quality control product suiteincludes automated sample preparation

and analysis, online process analysis and

blend mix optimisation. Quality control

solutions from FLSmidth ensure accurate,

reliable and consistent cement quality

control.

Electrical Solutions

FLSmidth supplies complete electricalpackages for cement plants combined

with state-of-the-art engineering expe-

rience. Accumulated knowledge of

industry-specific electrical systems enables

us to lower costs and mitigate risks.


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A full range of cement plequipment and expertise

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Stacker/

reclaimer

MAAGTMGearATOXTMmillEV Hammer

Impact Crusher

Pfisterfeeder ILC Prehea


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nt

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ROTAX-2TMkiln Automation

control systems

Cross-BarTM

cooler

Filter Ventomatic

packing equipment

OK mill


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Whether your project is a new installation or an upgrade of

an existing line, our specialists can assess the impact of using

alternative fuels from a quality, chemistry, corrosion and

emission perspective. Our complete range of high-quality

equipment gives FLSmidth the capability to provide thecorrect solution for any given application. Equally important,

an alternative fuel solution from FLSmidth is a good short-

and long-term investment.

A comprehensive approach

It is often challenging to replace traditional fuel with waste

fuel, as it may influence the process in the kiln and the clinker

quality. Using alternative fuels requires a comprehensive

approach to the design of the entire plant: receiving, sorting,

shredding, handling and dosing of fuels as well as com-

bustion must be considered to maximise fuel substitution.

Due to rising energy costs and ever stricter energy and

environmental regulations, alternative fuel technology is

rapidly becoming an important factor in controlling costs.

To gain a competitive edge, many cement producers

worldwide have set ambitious targets for increasing theirfuture usage of alternative fuels both waste-derived fuel

and biomass. FLSmidth is a technological leader in this field.

We invest substantially in researching and developing

alternative fuel technology, and many of our market-leading

products are specially designed for use with alternative fuels.

Rapid return on investment

Our focus is on developing and supplying complete alternative

fuel solutions that provide cement producers the ability to use

up to 100% alternative fuel in pyroprocessing installations.

This changes an alternative fuel into the primary fuel, with-

out decreasing either production capacity or product quality.

Reducing fuel costsand emissions

Alternativefuels


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FLSmidth can help you effectively accomplish each of these

stages. Our FLSmidth Pfister rotor weighfeeder, for example,

enables highly accurate dosing of extremely light or heavy, fine

or coarse products or even potentially explosive bulk materials.

From feasibility studies to assess project variables to full

implementation of an alternative fuels solution, no project is

too large or small for FLSmidth, including:

- Retrofits

- Complete project implementation

- Calciner modification or replacements

- Burner replacement

- Fuel handling systems, large as well as small

High-quality equipment Calciners for alternative fuels

Control systems

Conveyors

Flexible fuel burners

FLSmidth Pfisterfeeder

FLSmidth HOTDISC reactor

Storage and extraction systems

Waste & biomass processing equipment

FLSmidth Pfister

TRW-S/D alternative

fuel feeder

FLSmidth HOTDISC

reactor


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An experienced partner

Environmental regulations continue to be a mix of ever tight-

ening state, regional and national laws. FLSmidth offers the

broadest range of solutions to reduce plant level emissions,

including: products for particulate removal, industry-leadinglow NOx technology, SOx reduction technologies, THC/VOC

controls and a cost-effective solution to mitigate mercury

emissions. An experienced and professional partner in control-

ling multi-pollutants, we provide engineered solutions that

ensure specific emission requirements are continuously met.

It is FLSmidths goal to contribute to environmental sustain-

ability in fields where our products and services can have

an effect on the environment. Sustainability is becoming

increasingly important for cement production, and as the

industrys leading sustainable technology provider, we arein a position to offer solutions that minimise gaseous and

particulate emissions.

Reducing fuel costsand emissions

Emissionssolutions


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Ongoing R&D

The coming years are expected to see growing interest in

processes and equipment that will lead to more sustainable

cement production. A major goal for our research and devel-

opment effort is therefore to improve the energy andemissions efficiency of our products and services to

contribute to direct environmental improvements by helping

you achieve lower energy consumption and lower emissions

per unit produced.

Emissions guarantees

FLSmidth provides emissions testing services to help deter-

mine if plants need to take emissions-reducing measures.

For existing plants, we measure current emissions and make

improvement recommendations. For new plants, we utilisethe best predictive model in the industry, which calculates

with great accuracy what the actual levels will be once the

plant is up and operating at full capacity. When FLSmidth

builds or modifies a plant it utilizes its own program of

Continuous Emission Measurement Systems (CEMS), which

not only guarantees emissions compliance in terms of what

and how to report, but is also a fully integrated resource for

the plant process control system. All of which explains why

customers consistently cite our competence in emissions

technology as a key factor in awarding us their business.

Emissions Capabilities Complete on-site testing

Continuous Emissions Monitoring Systems (CEMS)

Electrostatic precipitators

Fabric filters

Gas emission control services

Gas emission measurement services

Integrated technologies

Nuisance dust filters

Optimisation services

Particulate Control

Patented mercury roaster system Gas suspension absorber (GSA)

Predictive tools and analysis

Process engineering

Pyro system upgrades

Selective non-catalytic reduction (SNCR)

Sorbent injection systems


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Plant and field services

Our service portfolio is dedicated to helping maintenance

managers reduce or even eliminate unscheduled stoppages.

A full range of maintenance services includes preventive and

predictive maintenance as well as troubleshooting and failureanalysis services. FLSmidth offers a range of essential audits

and inspections to help you evaluate plant operation and main-

tain a high level of productivity. Specific inspection services

range from electrical and mechanical, material handling and

gear inspections to total plant evaluations. Our specialists can

help you identify potential problems and quickly target and

repair malfunctioning equipment, always with a view to mini-

mising future occurrences. Other key areas of support include

automation services, erection and commissioning services,

technical support and troubleshooting and air pollution control

equipment services. Because FLSmidth understands the work-

ings of each and every aspect of a plant and how one pro-cess interacts with the next were better able to serve you.

FLSmidth supports more than 500 plants worldwide on a daily

basis, helping customers with everything from supplying

replacement parts and wear items to strategic planning for

a more profitable future. Our comprehensive support strategy

means you can look to FLSmidths Customer Services depart-ment as a single source for all your plants service requirements.

We not only offer a complete portfolio of services, we also

know how to determine the best solutions for your specific

installation and how to support the high kiln availability your

plant needs to be competitive and profitable.

Comprehensivecustomer services


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Testing services

FLSmidth conducts pilot plant feasibility studies ranging from

simple grinding and drying to more integrated pyroprocessing

systems, based on rotary kilns and gas suspension calcining.

We also have the capability and expertise to design your pilotplant, build it and optimise it for profitability. Each application

is analysed based on raw material characteristics and product

quality requirements before the optimum technology is

selected. Bench scale testing and extensive pilot plant facilities

are available, so the entire process can be analysed for

feasibility. The test results, coupled with extensive data from

commercial operations, are used to scale up to the commer-

cial size process.

Spare parts

We have always been committed to delivering spare parts

for as long as you need them whether your plant is nine

years old or 99. Our original drawings, documentation and

long experience in the manufacture and specification ofquality spare parts can help ensure optimum spare part

management even when it comes to spare parts for older

legacy control systems. When unexpected problems occur,

you can trust us to respond rapidly and accurately. We

have an exacting process to review your specific equipment

needs and to verify that the spare parts we provide match

your requirements. Additionally, as a one-stop supplier we

can deliver all your necessary OEM and third-party items.


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Comprehensivecustomer services

FLSmidth is committed not only to operating your plant as

efficiently as possible, but also to maintaining it in premium

condition. We perform regular scheduled checks on vital

equipment, ensure staff are well trained and constantly

monitor processes to spot and remedy potential problemsearly on. All this reduces costly unscheduled stoppages to an

absolute minimum. We are constantly looking to improve

processes and technology. From simple improvements based

on experience and insight to more radical upgrades, they all

act to keep your plant in perfect working order. Our aim is

to maximise your assets for the long term by optimising all

operations and maintenance.

Operation and Maintenance

An Operation and Maintenance (O&M) contract with FLSmidth

is the perfect outsourcing option for quality-conscious plant

owners. The basic principle of O&M is that we take over the

operation of your plant, guaranteeing output levels for anagreed price per tonne. All you have to do is account for

certain basic provisions and let us take responsibility for plant

performance. In this way, you can convert fixed costs to

variable costs, safe in the knowledge that you will only be

charged if we perform. By getting set guarantees from us,

you are able to make informed decisions and plan ahead,

particularly with regard to related aspects of the business,

such as finances or marketing.


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Upgrades

FLSmidth specialises in providing fast, creative solutions to

a wide range of major and minor upgrades, which can help

you increase capacity under challenging conditions, such as:

lack of space, production stoppages, old and outdatedequipment, new emissions requirements and other issues.

Our projects department brings together industry specialists

with expertise in process engineering, operations, alternative

fuels and more. Experience and know-how enable our

project specialists to assess situations quickly and accurately,

provide prompt quotations and follow through to project

completion.

Each upgrade project is unique and important parameters

including acceptable down-time, fuel costs, power costs,

and budget restraints are inevitably different. Therefore,

our project specialists are supported by FLSmidths global

organisation and, whenever necessary, can draw uponassistance from colleagues at our project centres in Europe,

the USA and India. Ultimately, FLSmidths upgrade services

are designed to achieve the best possible integration of all

your production resources to help you achieve the greatest

return on investment and lower the total cost of operation.


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Seminarsand training

Targeted training

Our training gives you the flexibility to apply precise know-

how and skills to the challenges that need them most. This

is true for all levels of your organisation, from top to bottom.

Operations and Maintenance (O&M) services, for example,are increasingly important to our customers. A large factor

in FLSmidths ability to supply a full range of O&M services is

our ability to train the entire range of people to provide them

from maintenance specialists to plant managers. This

extensive range of expertise enables FLSmidth to serve as a

single source for courses, seminars and tailored education.

With expertise drawn from more than a century of leadership

in cement production, FLSmidth is the industrys leading

provider of seminars and training in cement plant operation,

production and maintenance topics. It offers both standard

and customised training to meet your specific needs underthe direction of a training staff with experienced gained in

more than 100 plants. We also present the industrys two

leading annual seminars, the International Cement Produc-

tion Seminar and the International Maintenance Seminar, as

well as a growing range of cement industry courses, allowing

cement producers to network and benchmark across borders.


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Lessons that pay for themselves

FLSmidth uses proven assessment tools to measure the effects

of its training and the progress of participants in its classes.

In this way we can assure a direct link between current train-

ing and future value. Our seminars and courses can not onlyhelp you maintain high standards of quality and competence

in your operation, but are also an excellent way to improve

job satisfaction and retain valuable employees. There are

also immediate returns on an investment in training from

FLSmidth. Employees return to work inspired by new ideas

about optimising plant operation, lessons that quickly pay

for themselves by helping to reduce unplanned stoppages

and increase plant availability.


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Project Centre Denmark

FLSmidth A/S

Vigerslev All 77

DK-2500 Valby

Copenhagen

Tel: +45 3618 1000

Fax: +45 3630 1820

E-mail: [email protected]

Project Centre USA

FLSmidth Inc.

2040 Avenue C

Bethlehem, PA 18017-2188

Tel: +1 610-264-6011

Fax: +1 610-264-6170


Project Centre India

FLSmidth Private Limited

FLSmidth House

34, Egatoor, Kelambakkam

(Rajiv Gandhi Salai, Chennai)

Tamil Nadu 603 103

Tel: +91-44-4748 1000

Fax: +91-44-2747 0301


capability delivered

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