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TRANSCRIPT
....we know the way forward
Hoervelsinger Weg 17-21 • 89081 Ulm • Phone: +49 731 1551-0 www.fum-vas.de
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Long-term satisfied customers are our driving force and the aim of the
work we do every day. More than 3000 customers that we have worked in
partnership with over the years can confirm this. Whether public facilities,
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CONTENTS
Palladian Publications Ltd15 South Street, Farnham, Surrey GU9 7QU, ENGLAND
Tel +44 (0)1252 718999Fax +44 (0)1252 718992
Email: [email protected]: www.worldcement.com
Volume 46: Number 11
November 2015
ISSN 02636050
THIS MONTH’S COVER....we know the way forward
Hoervelsinger Weg 17-21 • 89081 Ulm • Phone: +49 731 1551-0 www.fum-vas.de
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NOVEMBER
3926WORLD CEMENT REGULARS
05 Comment
09 News
19 Keynote: Milling in the Early British Cement IndustryEdwin Trout, The Concrete Society, UK, details the history and development of the early cement industry in Britain.
138 Product News
144 Regional Report Infographic
WORLD CEMENT PLANT TOUR
26 Plant Tour: Hanson Ketton PlantJoseph Green visited Hanson’s cement plant in Ketton, Rutland, to find out more about the company’s production line and environmental projects.
REGIONAL REPORT: AFRICA & THE MIDDLE EAST
32 Commissioning Amid a RevolutionSamir Sabry, BMIC Cement Company, Egypt, relates the difficulties associated with building a cement plant during the mass uprising of 2011, and the solutions devised to overcome them.
39 Growing with DemandSafar M. Dhufayer, SPCC, Saudi Arabia, outlines the growth of the company in parallel with the new initiatives of the Saudi government.
45 Olive Residue Utilisation Through the Coal MillMamoon Obeidat, the Operation Team and the Project Team at Manaseer Cement Industry, Jordan, summarise the simulation and real-time results of the co-grinding and pyro-trial of olive residue as an alternative fuel.
52 A Complete SolutionEric Hartmann, HAVER & BOECKER, Germany, outlines the turnkey project carried out for Cimfaso.
WASTE HEAT RECOVERY
58 ORC Solutions for Heat Recovery ApplicationsRiccardo Vescovo, Turboden, Italy, outlines the main features and installations of Organic Rankine Cycle units.
65 Waste Heat Recovery ProjectLucky Cement, Pakistan, outlines the projects undertaken by the company to reduce costs and limit environmental impact.
FILTERS, BAGHOUSES, ESPs
70 World Cement Interview: AAFWorld Cement talks to AAF’s Alberto Arregui, Environmental Systems Global Manager and AAF Spain General Manager, about the company’s more than 90-year history and the development of the air filtration market.
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CONTENTS
654575 Hot Gas FiltrationPierre Henri Thiéfaine, Kermel, France, discusses the use of a new fibre able to withstand high temperatures.
81 Solutions for ESP PerformanceThompson Tsai, Daniel Gunawan and Saengson Kriswatanakorn, Tai & Chyun Associates Industries Inc., Taiwan, discuss the flexible solutions available to increase the performance and reliability of electrostatic precipitators.
85 Investigating Filter Bag TechnologyLorenzo Balzaretti, Testori, Italy, describes how the company engaged in a programme to improve the gas treatment centres of two lines in Saudi Arabia.
91 Hot Gas Ceramic FiltersPurv Purohit, Ian Chisem, Richard Lydon & John Eleftherakis, Clear Edge, Germany, discuss the use of CerafilTM ceramic filter elements to meet increasingly stringent emission requirements.
DOMES, SILOS, STACKING, RECLAIMING
97 Stacking and Reclaiming High-Moisture MaterialsMarjan Bojdys, SCHADE Lagertechnik GmbH, Germany, highlights a case study from Eastern Europe that showcases the ability of the reclaimer to work with materials that have a moisture content above 20%.
103 Size MattersRebecca Pyper, Dome Technology, USA, reports on a 70 000 t cement storage dome for St Marys Cement.
WEIGHING, FEEDING, DOSING
107 Dry Mix Plants and Powder Handling SystemsKari Saarinen, Lahti, Finland, describes the benefits of fluidisation technology over screw conveyors.
BURNERS, PREHEATERS, PRECALCINERS, KILNS
111 Enhancing the Performance of Kiln BurnersRenata Favalli, Luis Filipe Fabiani & Luiz Felipe de Pinho, Dynamis, Brazil, relate the findings of an investigation into the performance of kiln burner heads.
119 Low-Cost Plant Upgrade SolutionsTahir Abbas, Cinar Ltd., UK, & Josef Keuschnigg Jun., PM-Technologies GmbH, Austria, present case studies of upgrade solutions.
ANALYTICS
127 Cover Story: Analytics in the Cement IndustryJens Büschl, Fritz & Macziol, Germany, explores how Industry 4.0 can be utilised to invent new innovations, improve customer service and to differentiate from the competition.
CRUSHING AND GRINDING
131 Primary Size ReductionExtracts from ‘Primary Size Reduction’ in Innovations in Portland Cement Manufacturing, in which author A.K. Chaterjee provides an outline of the size-reduction process by crushing.
NOVEMBER
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Steel workers in the UK are facing a bleak winter period, as job cuts threaten a reported one in six workers. Where once the UK steel industry employed upwards of 200 000 people, that number has reportedly dropped below 30 000 and continues to fall. Most recently, plant closures by SSE and Tata and the financial woes of Caparo could contribute an additional 5000 more to the unemployment line, leaving
entire towns to wonder at their future. The blame is apportioned in two key directions: cheap imports from China and the comparatively burdensome price of doing business in the UK.
Making a living in any heavy industry in the UK is expensive – just ask the few remaining cement producers here. Energy prices are among the highest in Europe, putting the country on the back foot not only when it comes to Asian imports, but also making it difficult to compete with neighbouring countries. With China’s own steel demand dwindling, there is no doubt that imports are an attractive option for construction projects looking to save costs.
The Chinese President Xi Jinping visiting the UK at the time of writing this column, and so of course the national newspapers here are full of calls for David Cameron to make the UK’s position clear. Cameron, amid accusations of kowtowing to Xi, has promised to ‘raise the issue’, but
one has to wonder what exactly he can say: ‘Please, sir, can you ask your companies not to sell their cheaper steel to our willing customers’?
The onus is on the UK government to introduce measures to make it easier to produce steel in this country. Meanwhile, the regulatory difficulties of either making it harder to export to Britain or encouraging contractors to buy British is adding fuel to the fire of those arguing that Britain is better off out of the EU. Further complicating matters is the £30 billion Chinese investment expected into the UK, which includes, among other things, the nuclear power and aerospace industries. Are the Chinese likely to specify British steel for such projects?
The cement industry experiences similar problems around the world. Most notably, we frequently report on www.worldcement.com that African countries are struggling with cheap Asian imports. We have also reported previously on the problem of intra-Asian cement ‘dumping’. One of the arguments against the more stringent environmental regulations now in force in the US was the danger of encouraging cheap imports. Now, the cost of doing business there has risen and so has demand. Time will tell whether those warnings come true.
So how should a government balance the needs of a public demanding infrastructure improvements with the needs of a developing industry? And with projects such as HS2 on the horizon in the UK, is the steel industry giving up too soon? Answers on a postcard please, or better still to our Linked In Group, where we now have almost 6500 members.
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WORLD NEWS NOVEMBER
November 2015 / 9 World Cement
NEWS HIGHLIGHTS
To read more about these articles go to:
• Cemex 3Q15 results
• CAC supports the Liberal Party’s commitment to lower emissions
• ThyssenKrupp receives order to build cement plant in Colombia
• Limited growth for Brazilian construction industry
OYAK Aslan Cimento Sanayii T.A.S. awarded KHD Humboldt Wedag a contract for the engineering and delivery of equipment to upgrade its cement grinding line. OYAK’s 7th KHD roller press will be installed at its plant in Darica-Kocaeli, Turkey.
The contract to install a new COMFLEX® grinding system will increase the capacity of cement grinding unit no. 1 by more than 100% and achieve energy savings of approximately 20%, allowing Aslan Cimento to maintain its position as one of the most significant companies in the Marmara region.
KHD’s scope of supply includes the engineering and delivery of mechanical and electrical equipment, as well as advisory supervision of erection and commissioning for the new COMFLEX® SC20-3250. This will be KHD’s 4th COMFLEX® grinding unit and 15th roller press system with V-Separator in Turkey.
The core equipment to be designed and delivered by KHD, as specified in this contract, includes:
l Clinker grinding system/COMFLEX® SC20-3250.
l Roller press RPZ 20-170/180 with ROLCOX® system for control and monitoring.
l Cascade separator, type VS 620 as static classifier.
l High efficiency separator SEPMASTER, type SKS-VC 3250 as dynamic classifier.
l System fan HKF 190/280.
The new COMFLEX® system will be integrated with the existing ball milll system. However, one of the primary reasons Aslan Cimento chose KHD’s COMFLEX® for this project is its ability to produce finished product without a ball mill unit.
With the installation of a COMFLEX® grinding system, Aslan Cimento will have a system that is equipped with the most advanced grinding technology in the market.
The commissioning of the new COMFLEX® system is planned for 2016.
Turkey KHD awarded OYAK contract
The JSW group has announced that it will be investing Rs.700 crore in setting up a 2.4 million t cement plant at Salboni in West Midnapore district, Bengal. The cement-grinding unit will be set up on 134 acres and the employment in the plant will be 1000, including 150 direct employees.
A 10 million t steel plant was originally planned for the site, but construction did not begin due to coal and iron linkages and problems with the land lease. According to Chairman Sajjan Jindal, the decision was made to construct the cement plant because the company wants to have some activity at Salboni while the steel project is delayed.
India JSW group announces new cement plant
The foundation-stone laying ceremony is currently planned for the first week of January 2016 in the presence of the West Bengal Chief Minister, Mamata Banerjee, and it is hoped that construction will be completed within 12 months. A source for raw materials for the grinding unit has already been finalised.
After the cement plant, a 300 MW captive power plant will be built in the following three months at a cost of Rs.2000 crore, and will be used for the cement project, with the balance consumed by other group companies.
November 2015 10 \ World Cement
EVENTS
11 – 17 April 2016
Bauma
Munich, Germany
www.bauma.de
Dangote Cement has commissioned its 3 million tpy cement plant in Mtwara, Tanzania. The plant reportedly cost some US$600 million to build and will provide direct employment for about 1500 people and further indirect employment for some 9000 people. The new plant is located in Msijute in Mtwara Rural District.
The additional capacity brought to the market is expected to bring down cement prices in Tanzania, which currently range between Sh.12 500 – 13 500 per 50 kg bag. During the commissioning ceremony, Aliko Dangote, the company’s Chief Executive, expressed his intention to make Africa a cement export continent, rather than being import-dependent. The
company has plans to be present in 18 countries, mostly across Africa but also in Nepal in Asia. The Tanzanian plant is the fourth to be commissioned this year as part of the company’s expansion strategy, and it hopes to commission plants in Senegal and South Africa before the end of the year.
Mr Dangote has been praised by many for the investment he has put into Africa. A representative for the President of Nigeria spoke at the commissioning ceremony, saying that Africa is taking its destiny into its own hands rather than waiting on outside investment. In turn, Mr Dangote praised the government and people of Tanzania for providing an environment that enabled investment.
Tanzania Dangote Cement commissions Tanzanian plant
According to reports, India’s Environment Ministry has granted UltraTech Cement clearance to expand capacity at its Awarpur plant in Maharashtra. It will be an investment of Rs.248 crore, with the company proposing to raise clinker production from 3.3 million tpy to 4.5 million tpy, and to increase cement output from 4.48 million tpy to 6 million tpy.
Having examined UltraTech Cement’s proposal in December 2014, the Expert Appraisal Committee of the Union Environment Ministry suggested green clearance, leading the Environment Ministry to grant clearance subject to certain conditions.
UltraTech Cement will be required to develop green belt in over 33% of the total project area, install air monitoring devices to monitor air emission, and continuous stark monitoring facilities to monitor gaseous emissions, amongst others.
UltraTech Cement must also earmark at least 5% of the total cost of the expansion towards enterprise social commitment and prepare a detailed CSP plan for every five years of the existing/expansion project.
The expansion is to be carried out within the existing 307.35-hectare plant area with the additional power requirements being 5.1 MW.
India UltraTech Cement expands capacity at Awarpur plant
The CHRYSO group finalised the acquisition of Swedish company Betongkemi Nordic AB on 31 July 2015. The company, which is based near Göteborg, was formed in 2008 and has since experienced strong growth on the Swedish market in both the ready-mix and the precast concrete segments.
Through this acquisition CHRYSO intends to consolidate its position in Europe, keep pace with
Sweden CHRYSO group acquires Betongkemi Nordic AB
01 – 04 December 2015
14th NCB International Seminar on Cement & Building Materials
New Delhi, India
www.ncbindia.com
19 – 21 April 2016
POWTECH
Nürnberg, Germany
www.powtech.de
15 – 19 May 2016
IEEE-IAS/PCA Cement Industry Technical Conference
Dallas, Texas, USA
www.cementconference.org
10 – 12 November 2015
20th Arab International Cement Conference & Exhibition
Cairo, Egypt
www.aucbm.org
12 – 14 May 2016
Cementtech
Nanjing, Jiangsu Province, China
www.cementtech.org
the development of Betongkemi on its domestic market, and develop a platform for expansion in Scandinavia from this base in Sweden.
The new subsidiary will offer CHRYSO technologies aimed at the ready-mix concrete, precast concrete, decorative concrete and cement markets. It will be named CHRYSO Nordic AB.
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November 2015 12 \ World Cement
IN BRIEF
Aalborg Portland has welcomed the Danish government’s decision to remove the NOX tax, as announced in the 2016 budget. The additional cost caused by the increased NOX tax in 2012 created a difficult competitive environment for the company, and the recent decision has given it confidence in the investing environment. The reduced tax burden will contribute to more jobs at the plant.
On 19 September, Buzzi Unicem’s Robilante plant celebrated its 50th anniversary with a day of celebrations for all those who work or have worked for and with the company. The day, which commemorated both Buzzi Unicem and its predecessor PRESA Cements, was attended by more than 670 current and former employees and family members, along with the Mayor of Robilante.
4B Components Ltd. announced that Randy Longbrake has been appointed as its National Sales Manager for the materials handling division. With a wealth of industry experience, he will enable 4B to continue to develop innovative solutions for its customers, thereby continuing its success at providing material handling products to many of the top companies in North America.
Seven industrial groups and two research laboratories have come together to create a research pole in the Lyon-St Etienne area, with a view to becoming a recognised centre for the study of polymerisation and polymeric materials in France. The Lyon – Polymer Science and Engineering pole includes Arkema, Bluestar Silicones, Hutchinson, Nexans, Solvay, Toray and Total, all of which signed a special partnership-agreement with the CNRS, INSA-Lyon, the Université Claude Bernard Lyon 1 and the Université Jean Monnet in St. Etienne on 1 July 2015.
The research pole is built upon the skills and technical expertise of two laboratories, the laboratory for the Engineering of Polymeric Materials and the laboratory of Chemistry, Catalysis, Polymers and Processes, and is also associated with the mixed SOLVAY/CNRS unit of the laboratory for Polymers and Advanced Materials.
Key aims of the pole include:
l To include the pole in other local laboratories, industrial groups and small to medium sized businesses.
l To develop long-term partnerships in order to maintain and develop high-level research, reinforce innovative applied research and build upon this expertise to develop innovative disruptive technologies.
l To build upon a broad skill set to aid with the training of both R&D scientists and technicians.
l To pool specific equipment, resources and analytical techniques.
It is hoped that the pole will become one of the flagship projects for the creation of the Institute d’Excellence of the University of Lyon in the next few years.
France New research pole in the Lyon-St Etienne area
Four Cemex USA cement-manufacturing plants have earned the US Environmental Protection Agency ENERGY STAR Certification in 2015. Plants in Miami, FL., Clinchfield, GA., Fairborn, OH. and Victorville, CA. have been recognised. This ranks the performance of these facilities among the top 25% of similar US facilities for energy conservation, and marks the ninth consecutive year of certification for the Clinchfield plant, the fifth for the Miami plant and the fourth for the Victorville and Fairborn plants.
Three Cemex USA ready-mix plants (La Porte, TX, Mission, TX, and Rosenburg, TX) met the ENERGY STAR challenge by committing to the pre-established goal of
reducing energy intensity by 10% within 5 years or less by the replacement and use of more energy efficient parts and equipment, such as dust collectors, conveyor belt pulleys and lighting.
“Cemex is committed to sustainable practices throughout our operations, including energy efficiency,” said Karl H. Watson, Jr., President of Cemex USA. “We are honoured to again be recognised by the EPA and ENERGY STAR for our commitment to sustainable practices.”
Cemex is a corporate partner of the EPA ENERGY STAR programme and is an active proponent of the importance of energy efficiency.
USA Cemex plants win ENERGY STAR certification
November 2015 14 \ World Cement
Turkey TÇMB International Technical Seminar and Exhibition attracts 550 delegates
The 13th TÇMB International Technical Seminar and Exhibition was held in Antalya, Turkey, on 7 – 10 October. The event is organised by the Turkish Cement Manufacturers’ Association with the aim of sharing current developments in the cement industry and has been running since 1987.
Some 17 papers were given during the technical portion of the event, which had as its theme ‘Sustainable Environment and Energy’. The papers covered low carbon technologies, industrial
symbiosis, use of wastes and innovation and new technologies.
The event was attended by 550 participants and 99 companies took part in the exhibition. Manufacturers were able to follow up on recent developments in the industry and participants had the opportunity to consider new investments while also benchmarking their businesses.
After a welcome cocktail on 7 October, the technical portion of the event began on 8 October with an opening address by Mr M. Şefik Tüzün, who noted that the journey of Turkey’s cement sector began with the Istanbul Darıca plant in 1911 followed by the Republic Ankara Cement Plant in 1928. He said that, with 52 integrated and in total 70 production units, the Turkish Cement Industry stands at the focal point of both the national economy and the global cement business. Turkey ranks first in European cement production and fifth in the world. Mr Tüzün added that the growth of the construction and cement sector began with housing, residential and commercial building before 2008, and has since been propelled by infrastructure and energy projects. Moreover, urbanisation all over the country, but particularly focused on earthquake zones, has been a key element to the cement industry’s growth. He estimated that as many as 7 million old housing units would be redeveloped over the next 20 years, with 1.7 million in Istanbul alone. The cement sector is contributing to the Turkish economy by using and following methods of sustainable production that are sensitive to the environment. Concluding his speech, Mr Tüzün thanked the sponsors and participating companies, as well as the organising team who put together the event.
Also invited to speak were Mr Koen Coppenholle, CEO of CEMBUREAU, who gave a presentation on ‘Sustainable Environment and Energy’, and Aisha Elaine Williams, World Bank Group Country Manager for Turkey, whose presentation was entitled ‘Sustainability in Cement Sector, A Business Case and Global Experiences’. Shri Ashwani Pahuja, Director General of India’s National Council for Cement and Building Materials, and Mr Ahmad Al-Rousan, Secretary General of the Arab Union of Cement and Building Materials, also gave presentations.
The event concluded with a special gala dinner. The main sponsors of the event were Aybars Makine, ABB, Remsan, Grace, Aerzen, Schneider Electric and Fosroc-Idea Constructive Solutions. Siemens was the Special Sponsor and Özgün Makine, Fritz & Macziol Group and CNBM were the Session Sponsors.
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Companies in the global cement industry are facing major challenges: If they are to improve productivity while simul-taneously decreasing costs, they need high-performance products that are also energy-efficient and offer maximum availability and flexibility. These products also need to com-ply with environmental regulations while providing maxi-mum safety for employees, machines, and material.
In order to tackle all these competing challenges, we have developed SICEMENT – the world’s most comprehensive range of products and solutions for the cement industry. Tap into the potential of modern cement production – while maintaining maximum reliability. SICEMENT Drives are best example for Siemens Integrated Drive Systems. Opt for CEMENTABILITY.
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Wrong: At FLSmidth we not only design, build and operate cement plants – we also build a competent and reliable local workforce through training. The results? A record-low employee turn-over rate of only 1,5%* helping to ensure a utilisation rate of 83%* vs. the industry average of only 73%*. The resulting high revenue proves that building people and communities also is good, sustainable business.
*Source: Impact Assesment Study, Deloitte & Qbiz 2015
Common misconception in cement production #2
Investing in training of the local workforce has no significant impact on the bottom line
Discover how we enable you to create a good, sustainable business at cement.flsmidth.com
16296_Misconception_Annoncer_420x297.indd 2 12/10/15 14:59
Wrong: At FLSmidth we not only design, build and operate cement plants – we also build a competent and reliable local workforce through training. The results? A record-low employee turn-over rate of only 1,5%* helping to ensure a utilisation rate of 83%* vs. the industry average of only 73%*. The resulting high revenue proves that building people and communities also is good, sustainable business.
*Source: Impact Assesment Study, Deloitte & Qbiz 2015
Common misconception in cement production #2
Investing in training of the local workforce has no significant impact on the bottom line
Discover how we enable you to create a good, sustainable business at cement.flsmidth.com
16296_Misconception_Annoncer_420x297.indd 2 12/10/15 14:59
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KEYNOTE
November 2015 / 19 World Cement
NOVEMBER
Milling in the Early British Cement Industry
IntroductionFor decades the ball mill has dominated the grinding processes in cement production, although more recently the vertical roller mill has gained popularity. The tonnages involved in the modern industry require processing plants on a substantial scale and huge inputs of electrical energy to power them – this hasn’t always been so. In the early days of cement production, the industrial enterprises concerned were small in scale, and harnessed the existing technology of corn milling, in much the same way as they adapted the crushing methods used for the preparation of clay and whiting, and the furnaces and bottle kilns used for producing glass and lime. The early mills were based
on those used to grind corn, with some adjustment to the dressing of the traditional French burr-stones. Our present perception of cement production as a heavy industrial process can easily distract from a historical awareness of the modest origins of our industry.
In so far as production processes feature in histories of the cement industry – as opposed to studies of significant people, manufacturing companies or the evolving chemistry of the product – the emphasis tends to be on pyroprocessing, with the kiln as the heart of the cement-making process and its most characteristic element. The ‘beehive’ and ‘bottle’ kiln, variations of the chamber kiln, and the development of shaft kilns leading to today’s
Edwin Trout, The Concrete Society, UK, details the history and development of the early cement industry in Britain.
Pitstone mill. (Source: The Concrete Society)
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rotary kilns have dominated the standard histories. Mills, both for raw materials and the finished product, receive less attention, though the milling process is a vital one and not without interest. Just as the grinding technology was adapted from agriculture and related processing industries, so the power sources of the day were also adopted. Muscle, wind and water power have all played their part in driving the processing equipment in cement plants, for crushing and homogenising raw materials – with edge-runners and wash mills – and grinding clinker between horizontal millstones.
Horse millsSome of the simplest were the horse-powered mortar mills used for the crushing of chalk as a raw material. Charles Pasley described the mortar mill in 1838:
“The principal parts of such a mill are two broad vertical iron wheels, carried around by means of a vertical shaft, connected with their common axle, turning on a pivot in the center [sic] of a shallow circular cast iron vessel called the Pan, and secured at the top to a tie beam of the building, in which the mill is erected. These wheels are purposely placed at unequal distances from the center, one of them being nearer to the pivot, and the other to the outside of the pan. The axle of the two wheels is attached rather loosely to the vertical shaft, so as to admit either of them to rise, in passing over any lump of the materials about to be ground, that may be larger or harder than usual. The wheels may be 4 1/2 or 5 ft dia., and 10 to 15 in. wide at the rim, which grinds the materials, and one of them may be placed at the central distance of 18 in. and the other of 24 in. from the center of the pan. A lever with a yoke for a horse at the extreme end is connected with the vertical shaft, and also with the ends of the axel by some framework over the center of the pan. The distance from the center of motion to the middle of the yoke, or in other words, the radius of the horse path, may be 11 ft.”1
Mortar mills were used at the cement plant at Sheerness in 1811, once Parker’s initial patent for Roman cement had lapsed, and continued to be referred to in the literature until as late as 1895.
Tide millsAs the cement industry came into being once the steam age had begun, it is perhaps surprising that traditional
wind and waterpower remained in use at so late a date, as the following examples will indicate. Throughout the nineteenth century we see multiple sources of power used, often at the same plant, and though the trend was towards greater use of steam – until the adoption of electricity in the 1890s – the harnessing of wind and waterpower for cement production continued long after they could reasonably be considered the norm.
Tide mills, a specialised form of water mill that harness the power of the falling tide, were used from the outset. James Parker’s discovery of the cementitious nature of septaria was first put into production by Samuel Wyatt at Northfleet, under the monopoly conditions of Parker’s patent. A tide mill had existed at this riverside site for many years and was previously described as a “corn mill” by Sun Fire Insurance in 1782. Contemporary reference to the new business arose just a year after its establishment, in Hasted’s survey of 1797, which described it as “now used for the making of a composition of stucco for buildings”, the principal application of Parker & Wyatt’s cement.
Writing on 30 July 1810, Goodrich noted that “Mr Green. Millwright [of Sheerness] made the stones for grinding cement for Mr Wyatt. He says ‘Mr Hall, of Dartford, is probably acquainted with this machinery from having given an estimate for putting in some new machinery at Mr Wyatt’s mill at Northfleet, where he has a Tide Mill for bruising and grinding and a Wind Mill for grinding only’”.2 This suggests that tidal power was used for the preparation of raw materials, and the windmill for grinding the finished product.
The tide mill was marked “cement” on the first Ordnance Survey map. In 1844, however, the London Gazette records the bankruptcy proceedings of Walter Westrup and Thomas Cocksedge, millers and ships biscuit bakers of Shadwell and Northfleet respectively. It would appear that the mill was no longer used for cement making and had reverted to flour milling.
Charles Francis, one of the major manufacturers of the early nineteenth century, made his famous Medina cement at the old tide mill on the west bank of the Isle of Wight’s Medina river. Built in 1790 as a corn mill, West Medina was sold to Charles Francis & Sons in 1840. The old buildings were used for cement production until the site was modernised in the 20th century under the ownership of APCM. Also briefly used for cement making was the tide mill at Thorrington in Essex.
Water millsMore conventional water mills were also turned over to cement making too. One of the earliest was William Atkinson’s Mulgrave cement plant at Sandsend, near Whitby in Yorkshire. It was established in 1811 on an estate owned by the Earl of Mulgrave, where, on the north bank of the Mickleby Beck, a wooden building contained the grinding mill. It was driven by a water wheel, itself powered by a millrace some three quarters of a mile in length. Here cement stone was “burnt in a kiln, then broken, and pounded with stampers, and last ground to powder in a mill”.3 The plant was finally closed in the 1930s after a working life of 120 years. Though the buildings
Figure 1. Side elevation of a horse mill (Source: Pasley, courtesy of the Concrete Society).
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Figure 2. Mulgrave cement mill, Sandsend (Source: Whitby Museum).
Figure 3. The wheelpit at Mulgrave cement mill (Source: Prof Dave Hughes).
Figure 4. Lode Mill with cement works, 1911 (Source: Cambridge Community Archive).
no longer exist, the kiln is still standing, and the wheel pit remains.
Another cement plant known to have harnessed waterpower in the Roman cement era is the Good Intent Mill at Isleworth. The Good Intent Society, established in 1801, was one of several cooperative societies set up to grind corn cheaply for members’ own use. In order to build a mill, the Society bought land for £300 and cleared the Thames riverfront. The co-op was wound up some time after 1826 and the site became a cement plant owned by William Ashby of Staines. His business, William Ashby & Son, was originally a river haulage company specialising in building materials, but very soon moved into cement manufacture. The raw materials were dredged offshore at Brightlingsea and bought up river to Isleworth where the mill was still standing in 1888.
Water mills were also turned over to cement grinding at Stoke on Trent and Ysceifiog, Flintshire in the first half of the nineteenth century, but perhaps the best attested is Lode Mill, on the Anglesey Abbey estate near Cambridge. Here a Georgian corn mill was acquired by the Bottisham Lode Cement & Brick Co in 1896, with four cement kilns erected alongside and a low-grade clinker was produced from the local marl. It was ground between five sets of horizontally mounted millstones. Operations were suspended when the market collapsed in 1903, but were revived in 1908 with the addition of two further kilns. Production ceased in 1920 and after Anglesey Abbey’s acquisition by the National Trust, the mill was restored to its earlier state and the associated kilns demolished.4
WindmillsWindmills, perhaps, represent the least expected form of cement mill from our present perspective, where surviving examples are now deemed an almost picturesque feature of the landscape. An early example is the translocated post mill set up by John Pattrick on the cliff tops at Dovercourt, Harwich in 1821, where he ground cement stones from the beach. The works continued until 1906, but by then had long been steam powered.
Another early example is the Victoria Road Mill, Woodbridge, where William Lockwood made Roman and then Portland cement. Originally builders, and agents for Parker & Wyatt, Lockwood’s company turned to cement manufacture in 1821. Having started with a horse mill, equipped with stones from Mountsorrel, Leicestershire, Lockwood had a windmill built in 1825. It comprised a tower mill, with patent sails and a fantail, was fitted out with granite edge-runners from Aberdeen, and is assumed to have used river-dredged material from the Deben. Unfortunately the mill lost three sails in a storm during 1841, with further damage two years later: “On Saturday morning about two o’clock … the sails of Mr Lockwood’s cement mill were struck by lightning, shivering a 6ft length of timber from the sails.”5 Gale damage probably caused it to cease wind-powered operations from that date.
Best known of the cement industry’s windmills is High Mill at Berney Arms in Norfolk. A mill has stood on
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the River Yare as it enters Breydon Water since 1797, but the surviving tower mill was erected in about 1865. It is 70 ft tall with a cap of the ‘Norfolk boat’ type and has four double-sided sails.
On the opposite side of the river was a factory making cement from a combination of chalk and mud taken from the Norfolk waterways, and the clinker was ferried
across to the earlier five-storey mill to be ground into cement. The plant belonged to the Berney family and was let repeatedly to tenants, one of whom was described as “brick and cement maker” in 1836. Originally the product would have been Roman cement, as is made clear in an early advertisement for the leasehold: “a Kiln, Windmill and Warehouses with every convenience for the manufacture of Roman Cement”.6
In 1828 the premises were described as “consisting of kiln, manufactory, ten horse steam engine, extensive warehouse, counting room, quay, roomy yard and two cottages.” Significantly the paper added: “the windmill is capable of being converted to any other trade requiring great power, as it is built to draw four pairs of stones.”7 That the purposes to which the mill was put were varied is attested by another advertisement from 1836 in which the Reedham cement plant and sawmills were to be let: “the Engine and Mill are employed in Grinding Cement, Sawing and Draining Marshes of which a rent is paid.”8
In 1847 the “patent sail windmill, able to drive four pair of stones” was employed by “Messrs Ramsden & Co in the Cement Trade,”9 and continued under Mr Reynolds to 1860. In that year “The Reedham Cement Works driven by steam and wind power” was advertised for let.
When the present mill was built in 1865, it was clearly as part of the adjoining cement plant and specifically designed for grinding clinker for Portland cement production. Ownership changed again and Burgh Castle Cement Co occupied Berney works from the early 1870s, but closed the kiln in around 1880. The mill continued to grind clinker brought by wherry from nearby Burgh Castle, with the resulting cement sent back again until 1883 when grinding ceased and the mill was converted to drainage.
Equally long lasting was the Arundel cement mill, which was built to serve the Sussex cement industry that grew out of an earlier trade in chalk whiting. The original post mill closed for business after the bankruptcy of Charles New and in 1825 was bought and converted to grind cement. In 1838 Messrs Broadbridge and Armstrong are recorded as cement manufacturers of Arundel and, according to the tithe map of 1840, John Broadbridge occupied the mill. By 1858, however, the milling concern was being run by William Atfield, “cement manufacturer.”10 As the original lease was shortly due to expire, the construction of a new mill was started in 1861. While the mill was being built, it seems that Atfield – described as a millwright and cement manufacturer – acquired property at Bognor consisting of a cement mill, cement kiln and two cottages. The kiln had been operational from 1830 to 1854, and was perhaps still in use while Arundel was out of service. Eventually the Arundel mill was complete and an opening ceremony was held in June 1864.
The new mill was a tower mill, painted white, and powered with four single-sided sails. Like its predecessor, it was used for grinding cement, with chalk being brought down river from Amberley, where there was also a windmill used for grinding cement. Atfield was succeeded
Figure 5. Berney Arms Mill, 1906 (Source: Alison Yardy, Mills Archive).
Figure 6. Arundel post mill, preceeding tower mill (Source: Mildred Cookson, Mills Archive).
Figure 7. Arundel cement mill c.1900 (Source: Mildred Cookson, Mills Archive).
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at the mill by his son, and later by a Mr Chamberlain. In 1898 (some sources suggest 1892) Arundel Cement Mill was damaged by fire and pulled down. Nothing remains today.
ConclusionWith little physical evidence of the early cement industry surviving, it is easy to be oblivious of this developmental phase in our history. In the infancy of cement making all existing methods of grinding were explored, including processes that were horse, wind and water powered. Corn milling technology was adapted to this new purpose. Specialist equipment and methods were developed, especially once the more abrasive Portland cement replaced the earlier Roman cement, and traditional mills were abandoned, or at best the buildings incorporated into new cement plants, as at Windmill Works, Bilston. Some traditionally powered mills lingered on, though these proved to be the exception in an industry that was rapidly expanding and modernising during the 1880s and 1890s.
Nevertheless, traditional French burr millstones remained key to the process throughout the 19th century. They consistently produced the finest powders from their combination of crushing and grinding actions, which was especially important as fineness became a more exacting requirement of the market. Despite modifications, such as the incorporation of emery, or the assistance of ancillary edge rollers and percussion mills, millstones were
not displaced in the finishing process until the advent of continental ball and tube mills in the 1890s.
NoteAbridged from Edwin Trout’s Traditional Milling Technology in the English Cement Industry, 1796-1899, published by the Mills Archive Trust, 2015.
The Mills Archive was established in 2002 as a permanent repository for historical and contemporary material on traditional mills and milling. It has rescued over 2 million documents and images, promotes research and conservation, and is the centre of excellence for its discipline. See more at www.millsarchive.org.
References1. PASLEY, C.W. Observations on limes, calcareous cements, etc. (1838).
2. GOODRICH, S. in FORWARD, A.E. Simon Goodrich and his work as an engineer compiled from his journals and memoranda. Transaction of the Newcomen Society, vol. XXXIV (1961-62).
3. ANON. A History of Whitby (1993).
4. WATTS, M. Lode Mill, Anglesey Abbey, Cambridgeshire (Unpublished report, 2012).
5. Suffolk Chronicle, 26 Aug 1843.
6. Norfolk Chronicle, 10 Feb 1821.
7. Norfolk Chronicle, 13 Sept 1828.
8. Norfolk Chronicle, 25 June 1836.
9. Norfolk Chronicle, 6 March 1847.
10. BLYTHMAN, G. Lost windmills of Sussex (2008), p.11-13.
26 \
HANSON KETTON PLANT
Plant Tour:
/ 27
Joseph Green visited Hanson’s cement plant in Ketton, Rutland, to find out more about the company’s production line and environmental projects.
IntroductionAs visitors wind their way through the scenic Rutland countryside, Hanson’s Ketton Cement Plant strikes an imposing figure on the horizon. Drawing closer, a real sense of energy and drive surrounds the plant, demonstrated by the constant stream of Hanson trucks entering and leaving the works. Driving through the entrance, visitors are met with the busy enthusiasm of a plant tasked with providing nearly 10% of the UK’s cement demand.
The Ketton plant started operations in 1928, beginning life with just one kiln. Four kilns were constructed in the 1920s followed by an additional two in the 1960s. The seventh was installed in the 1970s, marking the plant’s switch to dry process kilns. Kiln 8 was designed and built in the 1980s, and once operational, signalled the closure of Kilns 1 – 4. In 1987 Kilns 5 and 6 were also closed, leaving the Ketton site with two dry process kilns.
Today only Kiln 8 is operational at the Ketton Cement Plant after Kiln 7 was mothballed in September 2008. The plant boasts a cement production capacity of 0.9 million tpy, stored within 16 towering silos, three of which service London, six for bulk road transfer and seven for the packaged product. A quarter of the product shipped to London is by rail, another quarter in paper and plastic bags, with the remaining half travelling south by bulk tanker.
Ian Evans, Technical Development Manager – South, added that the neighbouring Ketton quarry “crushes around 1.3 million t of limestone a year” to feed the plant. The facility provides direct employment to around 220 people and has become increasingly prominent as a standard-bearer for sustainability and safety.
Plant processThe Ketton quarry is located adjacent to the plant, is over a mile wide and contains reserves of up to 20 years. Parts of the worked-out areas have been designated as Sites of Special Scientific Interest (SSSI). The rocks on site have been found to contain ammonites, brachiopods, bivalves, and fish remains. The Lincoln Limestone Formation is exposed in the lower quarry, while the top of this formation forms the floor of the upper quarry. The upper quarry is in the Rutland Formation. At the very top of the exposures is the base of
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November 2015 28 \ World Cement
the Oxford Clay, meaning that the entire spectrum of the Middle Jurassic period can be seen at the Ketton Quarry.
Stone has been extracted from the area since Roman times. To reach the limestone formations, Hanson is forced to dig through large deposits of clay. According to John Taylor, Ambassador for Ketton, once Hanson reaches the limestone, they drop “about 3000 t of explosives” to gain access to the material. Alternative raw materials are sourced from water treatment and the paper industry. Similar to the stream of trucks circulating the plant, multiple dumper trucks cut through the quarry supplying the 62 m deep crusher building sitting atop the clay. According to Taylor, the impressive trucks have the capacity to move “between 130 to 140 tph”. Some 72 hammers are housed inside the crusher itself, moving bulk material through at a rate of 1800 tph. The crusher sends material through onto the conveyor all at less than 75 mm.
The crushed material is subsequently transported along a conveyor belt stretching for over 0.5 miles. A recent investment has been made to the conveyor belt to provide cross-belt analysis planned to
improve product quality. Ian Evans commented that the investment was made to create “an even more consistent product than we currently produce”. The crushed limestone is sent along the belt towards the impressive 44 000 t storage dome processing 4000 tpd. Inside the storage dome the giant arms of the Polysius stacker and reclaimer slowly and methodically swing across the mountainous heaps of material. The quarry control room controls the stacker, while the kiln control room controls the reclaimer. The raw material is homogenised and stored inside the dome.
Having been through the homogenisation process, the raw material is ground in a Polysius vertical roller mill and dedusted by electrostatic precipitators. The 280 tph mill has two rollers weighing 108 t and a 3.8 MW motor.
Kiln 8 was constructed in 1985 for a total cost of £72 million. It utilises alternative fuels such as Profuel and Cemfuel. Kiln 8 also burns pulverised coal. Hanson buys coal from the international market, as consistency of the product is essential. The coal is analysed and homogenised in a similar manner to the raw materials.
Approximately 45% of the fuel is burned at the base of the preheater tower before the material passes into the kiln. Kiln 8 at the Ketton Cement Plant was supplied by Polysius and stands 68 m long and 4.2 m in diameter. The kiln processes 2800 tpd of clinker, which then goes to the grate cooler before heading to storage.
The clinker is processed through the two ball mills in operation. Each mill contains two chambers, processing 110 tph of clinker with a power output of 4.4 MW. A classifier inside the mill separates coarse grains that are fed back through for re-milling.
At this stage the final product is sent to the cement silos for storage before the process of bagging and packing can begin. Five days a week approx. 900 – 1000 t of cement is transported on train to be taken to Hanson’s dedicated depot based at Kings Cross.
Packing lineMany major global cement manufacturers are increasingly shifting the balance of cement packaging towards vented polythene from the traditional paper product. The Ketton Cement Plant has both a plastic and a paper packing line.
The primary drive behind this switch in focus lies in the benefits vented polythene packaging can offer over paper. The most apparent of these is the advantage vented polythene has when faced with water interaction. This is one of the most common causes of spoilage in paper sacks but is not a problem for vented polythene due to the protective waterproof barrier surrounding the cement. The barrier does not allow water to enter but still permits the cement to breathe.
Furthermore, due to the typically porous nature of paper sacks, which allow dust particles to escape, the packaging can often appear untidy and can contribute to general waste when in use. Vented polythene sacks can appear cleaner in comparison and reportedly offer a more pleasant handling experience for the user. Vented
The cement works illuminated at night.
Aerial shot of the Ketton cement works.
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polythene sacks are able to print in eight colours with 360˚ coverage.
The vented polythene sacks typically use less energy to produce and generate less solid waste than paper. The processing of the paper bags in the Ketton Cement plant is also environmentally sound. All paper bags that are split or damaged are recycled as fuel.
The Hanson Ketton Cement plant packing line provides a good example of where both products are
produced. BPI Visqueen provide the plastic bags, while Italian producer Fiorini International makes the paper bags for distribution. The cement plant has two packers. One Ventomatic rotary packer for the paper bags, and one packer for the plastic sacks, manufactured by Arodo. The paper sacks consist of craft paper with a PE liner to allow air movement between the cement and the outside world.
Thousands of such bags are stacked into orderly loads ready to be transferred into the trucks that hum around the plant and on to their destinations.
Environmental impactHanson’s Ketton Cement plant clearly takes its environmental impact seriously. One area that the plant is focusing its attention on is fuel consumption. Ketton utilises a variety of different fuels including biofuel. Waste and biomass account for over 70% of the fuel burnt in Hanson’s three cement plants. The company also has a 2020 target to reduce CO
2 emissions by 10% and to have 35% of its fuel usage made up of biofuel.
Another means by which the company is reducing its carbon footprint is through an award-winning solar farm. The renewable energy farm, which has been built on restored quarry land close to the plant, contains
8 MW solar farm at Ketton cement works.
Plastic packing line at the Ketton cement works.
55 000 panels producing 10 – 11 MW. The farm is widely regarded as an enormous success by staff at the plant, with the accomplishment persuading Hanson to explore the potential for similar installations at other sites.
The solar farm saves over 0.5 million tpy of CO2. Originally the farm had a capacity of 9 MW but this was recently increased by 3 MW. The farm provides 13% of the electricity used by the plant. As part of the agreement with the developer, Armstrong Energy, Hanson takes 35% of the solar power generated free of charge. The company then buys the remaining 65% at a fixed rate.
The solar farm in Ketton is the first of its kind in the UK cement industry. The success of the project has led Hanson’s parent company HeidelbergCement to consider options in Africa and beyond. There is even a possibility in the future for floating solar farms in ex-gravel works.
A further advantage of the solar farm is that Hanson expect the panels to need cleaning only twice in their 22-year lifespan. The ease of maintenance is a bonus to a company already reaping the rewards of the renewable energy project.
ConclusionThe enthusiasm and energy that meets visitors upon entry to the Ketton Cement Plant extends to its employees. It is clear that the Hanson staff at the plant care about the quality of the project and the developments that the plant is undergoing. The truck drivers, technicians, kiln operators and management share a goal to produce a product recognisable for its quality. This can be demonstrated with the recent supply of Ketton cement as the preferred choice for sprayed concrete to the Crossrail project. The drive surrounding the plant is evidenced by the attention to all aspects of health and safety, coupled with a determination to push forward with innovative new ideas and turn them in to reality.
Hanson’s Ketton Cement Plant still shows the evidence of past projects and developments. Walking through the plant it is possible to clearly see how the place has grown and changed as technology has advanced. With the addition of the solar farm, the plant begins to represent a movement from old to new, as Hanson endeavours to move with the times and constantly seeks to adapt its approach.
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