NORTH AMERICA

United States

Alamo Cement, part of the Buzzi Unicem group, ordered an IKN clinker inlet distribution system (KIDS) to upgrade the clinker cooler at its San Antonio plant in Texas. This system is scheduled for installation during the summer of 2001.

Ash Grove Cement's Chanute plant placed an order with F. L. Smidth for a circular stacker/reclaimer system for handling of limestone and one stacker for handling of raw materials. Erection is approximately 75% done; the single stacker is completed. Commissioning and production start-up is scheduled for March 2001.

At Arizona Portland Cement Co.'s Rillito plant, commissioning of the world's largest QUADROPOL was started in February 2000. Within a very short time, the first throughput and fineness warranties were attained. The grinding system, equipped with special wear-protection because of the abrasive raw material, supplies the four cement rotary kilns with raw meal. Krupp Polysius was the supplier.

Blue Circle Cement awarded a contract for the expanding of its Roberta plant in Calera, Ala. Humboldt Wedag will provide process and general arrangement engineering, both main and auxiliary equipment supply, erection advisory, and commissioning services. The new pyro line will increase capacity to 4,800 tpd. The main equipment scope of supply includes a Humboldt Wedag 5-stage preheater Type PR 8856/5 equipped with a PYROTOP and Low NOx precalciner; a PYRORAPID 4.8 meter diam 58 meter long, 2-station rotary kiln and a PYROJET burner. A Gebr. Pfeiffer vertical roller mill Type MPS 4750B will be supplied for raw grinding. Also, a Gebr. Pfeiffer vertical roller mill Type MPS BK will be provided for coal and pet coke milling. Blue Circle's plant upgrade is part of an overall project which is designed to increase annual capacity to 1.4 million tons. The expanded facility is expected come on line in early 2002.

Also at the Roberta plant, Blue Circle Cement ordered an IKN Pendulum Cooler for the new clinker production line of 4,800-tpd capacity. The Pendulum Cooler is equipped with a single cylinder hydraulic drive, a heat shield, electric roll crusher, control system, and PHD system for hopper drainage.

Blue Circle Cement placed an order for an IKN Pendulum Cooler to replace the existing Fuller cooler of kiln #1 at its Ravena plant. The new Pendulum Cooler is completely equipped with IKN Coanda nozzles and a single hydraulic drive. The pendulum supports were preassembled while the kiln was still in operation. The existing cooler internals were removed and the new pendulum suspended grate was installed during the kiln shutdown of only 25 days. The cooler was started up at the end of May 2000.

Calaveras Cement Co.'s distribution terminal in Stockton, Calif., awarded a contracted to BMH Marine to supply the first unloading with a Siwertell ship unloader in May 2000. The supply included the traveling Siwertell ship unloader, a Nordströms shore-based horizontal screw conveyor and pneumatic pump system, and a power distribution system within the terminal. The unloader is equipped with a side-tilting system and a clean-up unit. The downstream horizontal screw conveyor is provided with a specially designed cover belt with automatic belt-lifting arrangement for continuous, enclosed material feeding during operation along the screw conveyor length on the jetty.

Cemex placed an engineering order with BMH Marine for a 950-tph Siwertell ship unloader ST 490-F and a shore conveying system to be installed at its Richmond terminal. The unloader, which will be used for ships of up to 40,000 dwt, includes optional features such as central automatic lubrication, side tilting of the vertical arm, a collector unit, and the Siwertell Monitoring System. The shore conveying system includes a horizontal screw conveyor with a length of 150 meter, equipped with a belt lifter arrangement for continuous operation and completely enclosed transfer not only throughout the ship unloader but also between the unloader and the shore conveyor.

ESSROC Cement ordered an IKN clinker inlet distribution system (KIDS) to upgrade the existing cooler at the San Juan plant in Puerto Rico. The equipment has been shipped and the installation is scheduled during their plant shutdown in May 2001. ESSROC Cement operates two other KIDS at its plants in Speed, Ind. and Nazareth, Pa.

Hanson Permanente Cement replaced the existing hammer crusher with an IKN heavy-duty, electric roll crusher. The crusher handles approximately 5,000 tpd of hot clinker. The crusher was installed and commissioned in January 2000 and is equipped with water-cooled shafts. The specific power consumption of the crusher is less than 0.25 kWh/ton.

Holnam ordered an IKN Pendulum Cooler for their new 6,000-tpd clinker production line at its Portland plant in Florence, Colo. The Pendulum Cooler is equipped with a single hydraulic drive, high efficiency cooling fans, a heavy duty roller crusher at the discharge end of the grate and a heat shield to aid in stabilizing of the kiln system. A unique pneumatic hopper drainage system (PHD) evacuates the small amount of dust spillage in the undergrate compartments. The cooler is currently under erection.

Holnam also ordered a longitudinal stacker/reclaimer system from F. L. Smidth for handling of raw materials at its Portland plant. Erection commenced and commissioning and production start-up is on-going.

Holnam purchased a F. L. Smidth longitudinal stacker/reclaimer system with live harrow for handling of raw materials at its Holly Hill plant in South Carolina. Delivery to be commenced at job site by September 2001.

Holnam also contracted Krupp Polysius in August 2000 to construct a 6,000-tpd cement production line at its Holly Hill plant. Supplies include a roller mill with 505-tph throughput for raw material grinding; a 4-stage DOPOL '90 cyclone preheater with PREPOL-MSC calciner and bypass system, a rotary kiln and a REPOL clinker cooler; two 155-tph ball mills for cement grinding to a fineness of 3,800 Blaine; two SEPOL high-efficiency separators and two cement coolers; and a 41-tph roller mill for coal grinding.

Holnam awarded Krupp Polysius a turnkey order for the construction of a granulated blast furnace slag grinding plant in Midfield, Ala. in March 2000. The Polysius supplies consist of a 5.4 16.5 meter tube mill with 2 3,500-kW dual COMBIFLEX drive unit and SEPOL separator, the conveying equipment, a flash dryer, a high-efficiency cyclone, a hot gas generator, a filter and the silo feeding equipment. The plant is due to produce 77 tph of ground blast furnace slag as from spring 2001.

Holnam ordered a new 3,200-tpd cement production line for its Midlothian, Texas plant. Humboldt Wedag will provide process/general plant arrangement engineering, equipment supply, erection supervision, and commissioning services. The scope of equipment supply includes deliveries of a Humboldt Wedag 4-stage preheater Type PR 7954/4 with Pyro-Top LowNOx Precalciner equipped with a Pyro-Rapid 4.4 meter diam 54 meter long 2-station kiln and Pyro-Jet Burner. A Gebr. Pfeiffer 2,250-hp vertical roller mill Type MPS 4250B will be provided for raw milling. A KHD Humboldt Wedag 5.0 meter diam 14.5 meter long shell supported, 8,000-hp ball mill with central drive, equipped with a SKS 3000/210 high efficiency separator will be supplied for finish grinding.

Holnam ordered a new 1,500-tpd preheating burner for its Dundee, Mich. plant from C. Greco.

Kinder Morgan Bulk Terminals ordered a Siwertell ship unloader ST 640 M for cement and clinker for the Port of Charleston, S.C. in September 2000. The 800-tph unloader, supplied by BMH Marine, is the first one delivered of the new M-type series. Both cement and clinker are handled; the only change needed is a different inlet head. The unloader, which is suitable for ships of up to 60,000 dwt is equipped with a clean-up head for improved performance at the final phase of operation. Included in the supply was a traveling transfer trolley for continuous loading of the material onto the shore-side belt conveyor.

Kosmos Cement, operated by Southdown, Inc., awarded a contract to Humboldt Wedag for expanding and modernizing its Louisville, Ky. plant. The project will increase the plant capacity by 700,000 tons to approximately 1.6 million tpy. Humboldt Wedag will supply a 4-stage preheater Type PR 8254/4 LowNOx calciner with a PYROTOP mixing chamber for CO reduction. The kiln will be equipped with a PYROJET burner and a new PYROSTEP clinker cooler Type 2-091-12TSO. Humboldt will also supply a complete indirect coal firing system along with other auxiliary equipment and dust collectors. The plant upgrade will include a new preheater tower for stages I, II, and III constructed adjacent to the existing preheater which will be removed. The existing support tower will house the new preheater stage IV and the LowNOx calciner with PYROTOP.

As a part of the new cement plant being built at Lafarge's Sugar Creek Facility, a new clinker reclaim system has been designed. The new system includes a passive dust hood at the new clinker end dump hopper and an upgrade to the existing gypsum handling system. The upgrade to this system will include two new belt conveyors distribution gates dedusting and automation. The clinker handling system uses 65-ton mining trucks to haul the clinker from the new plant to the existing grinding circuit. By using a passive dust collection system Lafarge will not only meet air quality standards, but also save on baghouse operating costs and maintenance costs, provided the system performs as expected. Roberts & Schaefer Co. completed the engineering for this system.

At Monarch Cement Co.'s Humboldt cement plant in Humboldt, Kan., a new cement grinding system will commence operation at the end of 2001. The order for the new system, comprising a two-compartment mill and SEPOL high-efficiency separator, was awarded to Krupp Polysius in January 2000. The system's design permits production of cement type I at a fineness of 3,600 Blaine or cement type III at a fineness of 6,000 Blaine.

Monarch Cement placed an order with F. L. Smidth for the upgrade of two kiln systems from 1,000 to 1,700 stpd. The upgrade incorporates the latest technology in the form of adding a SLC-D calciner to the existing 4-state SP kiln along with replacing the existing coolers with SF Cross-Bar Coolers.

Mountain Cement operates two kiln lines at its Laramie plant. Recently both existing Folax coolers were upgraded with an IKN (clinker inlet distribution system) KIDS. The second KIDS for line number one went into operation in February 2000.

Phoenix Cement's expansion project encompasses a new kiln line to replace three existing kilns and two ball mills. Amongst other features, the kiln system includes a two-support friction drive SF Cross-Bar Cooler from F. L. Smidth and low NOx technology. Of the two vertical roller mills being provided, the OK mill will be the first ever to be applied in the finish grinding process in the USA.

RMC Pacific Materials' cement import terminal in the port of Redwood City, Calif. purchased a Siwertell ship unloader and screw conveyors in October 2000. The 800-tph ship unloader ST 490-F is used for the discharge of ships up to 40,000 dwt. Included in the supply, carried out by BMH Americas, is a conveying system based on aeroslides and pneumatic conveyors.

Southdown placed a order with IKN to replace the existing hammer breaker at its Charlevoix plant. The new roll crusher will process 4,490 tpd of hot clinker. Water jackets for cooling of the shaft are included with the equipment supply.

Southdown awarded a contract for the design and supply of a new 150-tph finish grinding system for its Victorville, Calif. plant to Humboldt Wedag, Inc. The scope of Humboldt Wedag's equipment supply includes the engineering and deliveries of a 5.0-meter-diam 16-meter-long shell supported ball mill, 8,000 hp, equipped with a MAAG CPU 47 drive, a SKS 250 high efficiency separator, cement cooler, and all dust collectors, fans and auxiliary equipment. This new finish grinding system is part of an overall project that will add about 3,300 tph additional clinker capacity to Southdown's quarry plant. Equipment deliveries were June through November 2000. Startup of the finish grinding system was expected in early 2001.

Southdown also contracted Humboldt Wedag for the design and supply of twin roller press systems for raw grinding at its Victorville plant. The raw grinding upgrade will increase the two existing ball mill raw grinding circuits from 415 to 680 tph. Humboldt Wedag will supply two roller presses, RP 10/140-110 equipped with V-SEPARATORS, VS-459 in a patented recirculating grinding plant. Each system will be equipped with high-efficiency separators, SKS 210/3000 and SKS 290/3500 matched to the existing ball mill raw grinding circuits. Each roller press grinding system normally operates independent of the other. However, each roller press system can operate with either ball mill and, also, produce independent of the ball mill in a finish grinding mode. The upgrade is part of an overall project which is designed to increase the plant's capacity to more than 3.1 million tpy. Equipment deliveries started in February 2000 and the raw grinding plant start-up was scheduled for the fourth quarter of 2000.

St. Lawrence Cement awarded Krupp Polysius an order for a 6,000-tpd cement production line in August 2000. The plant includes a roller mill with 505-tph throughput for raw material grinding; the clinker production system involving a 5-stage DOPOL '90 cyclone preheater with PREPOL-MSC calciner and bypass system, a rotary kiln and a REPOL clinker cooler; two 155-tph ball mills for cement grinding to a finished product fineness of 3,800 Blaine; two SEPOL high-efficiency separators and two cement coolers; and a 41-tph roller mill for coal grinding.

At TXI's Mithlothian plant, a circular stacker/reclaimer system for handling of raw materials and CF blending silo with LOW kiln feed system was purchased. Erection and trial run has commenced and final commissioning is expected to take place in the coming months, as the new line is ready for start-up. F. L. Smidth was the supplier.

Canada

After almost eight years of operating experience with the IKN KIDS, Ciment Quebec ordered an IKN Pendulum Cooler to replace the remaining Fuller grate at the St. Basil plant with a pendulum suspended grate. The new Pendulum Cooler is sized to cool 3,500 tpd and has a single hydraulic cylinder drive. A roll crusher complements the equipment supply. The cooler is currently being preassembled while the kiln is still in operation. The commissioning is scheduled to take place during the second quarter 2001.

At the Woodstock plant of Federal White Cement, a kiln line for the production of 900 tpd of buff-color clinker was commissioned in August 2000. The Krupp Polysius supplies included a DOPOL '90, a POLRO kiln, the feed material conveying system, and electrical equipment. The plant components are specially designed to permit straightforward future expansion of the production capacity to 2,000 tpd.

CENTRAL AMERICA

Mexico

Aspasco S.A. de C.V.'s Ramos Arizpe plant underwent a 3,150-tpd expansion, including ATOX 45 raw mill, CF homogenizing silo, six stage ILC preheater, ROTAX-2 two support kiln, 3 4 SF Cross Bar clinker cooler with hydraulic roller breaker, DUOFLEX burner, ATOX 17, 5 coal mill, OK 36 cement mill, and Ventomatic packing plant. The expansion, completed by F. L. Smidth, more than doubled the plant's capacity to 6,150 tpd.

Cementos Maya S.A. ordered a POLYCOM high-pressure grinding roll equipped with a STATOPOL C static uniflow inertial separator in February 2000 from Krupp Polysius.

Cementos Portland Moctezuma S.A. de C.V. purchased a 2,400-tpd clinker production line from Krupp Polysius in March 2000. This order meant that within only three years Polysius had built and commissioned two identical-type kiln lines for the Mexican company. Each consists of a 4.0 m 60 m rotary kiln with single-string and five-stage DOPOL '90 cyclone preheater, PREPOL-AS calcining system and REPOL reciprocating grate cooler.

After one of the two roller mills for cement finish grinding had already started production at the end of 1999, commissioning of the 3,000-tpd kiln line started at Cementos y Concretos Nacionales S.A. de C.V. in April 2000. The core components include a POLRO rotary kiln, a REPOL clinker cooler, two roller mills for cement finish grinding and the automation components POLAB AMT, POLAB CNA, and POLCID NT. Krupp Polysius was the supplier.

At Cruz Azul in Hidalgo, commissioning of the kiln line converted from grey to white cement started in November 2000. Among the scope of supplies from Krupp Polysius were a rotary cooler with a dedusting vapour filter, a combustion chamber for preheating the secondary air, and a POLCID NT process control system.

SOUTH AMERICA

Argentina

At Campana cement grinding installation included OK 36-4 vertical roller mill for slag cement and Ventomatic packing plant. Both were commissioned in the first quarter of 2000 to F. L. Smidth.

Cementos Avellaneda, Olavarria contracted F. L. Smidth to supply a 3,000-tpd production line including raw material store, ROTAX-2 two-support kiln, ILC 5-stage preheater, SF Cross Bar Cooler, UMS cement mill, and FRF homogenising silo. The company also ordered a longitudinal stacker/reclaimer system for handling of raw materials, silos for raw meal and cement and mill feeders. Erection started in the third quarter of 2000.

Ecocemento S.A. Ecorama installed a F. L. Smidth OK 27-4 vertical roller mill for grinding of slag and blended cement in the second quarter of 1999.

El Gigante, Avelleneda S.A. ordered a longitudinal stacker/reclaimer system from F. L. Smidth for handling of raw materials. Delivery is to be commenced in July and August 2001.

Bolivia

COBOCE Cement has placed an order for an IKN KIDS to upgrade the existing Fuller cooler at the Irpa Irpa plant. It was installed and successfully started up in January 2001.

Francesa installed a F. L. Smidth ATOX raw mill, upgrading existing kiln with SF Cross-Bar cooler and conveying of raw materials and clinker. Erection started April 2000 with start-up to take place in October 2001.

At Sociedad Boliviana de Cemento S.A., a new 1000-tpd clinker production line with raw material storage, ATOX 32.5 raw mill, and 1,000-tpd ILC-E kiln with COOLAX clinker cooler were commissioned in the third quarter of 1999. F. L. Smidth was the supplier.

Brazil

Camargo Correa Cimentos' 5,000-tpd capacity Greenfield plant placed an order with F. L. Smidth. FLS will supply all machinery and necessary ancillary, including gear units, electrostatic precipitators, control systems, and a packing plant. Also comprises are civil design, training, and supervision. First mechancial supplies will commence in the second quarter of 2001, with a large part of the machinery being locally manufactured.

At the Cauê-Pedro Leopoldo factory of Camargo Corrêa Cimentos S.A., commissioning of the production line converted from grey to white cement started in April 2000. Krupp Polysius modified equipment, including the preheater and silo, as well as supplying the engineering, the burner and the cooler, in order to convert the 800-tpd grey cement kiln line to 400 tpd of white cement.

Cantagalo purchased a UMS 46 14 mill and O-Sepa separator from F. L. Smidth.

Cia. Cearense de Cemento Portland, Sobral installed a F. L. Smidth ATOX 40 raw mill and UMS 46 14 cement mill with O-Sepa separator in November 1999.

At Cia. de Cementos do Brasillso, commissioning of a 105-tph cement grinding tube mill with SEPOL separator from Krupp Polysius was started in August 2000.

Cimensa Laranjeiras ordered a 3,000-tpd clinker production line consisting of an ATOX 35 raw mill; a CF silo with LOW kiln feeder; a ROTAX-2 rotary kiln system including COOLAX clinker cooler, electrostatic precipitator, EV crusher retrofit; and a UMS finish grinding installation. It was completed by F. L. Smidth in 1999.

Ciplan Cimento Planalto S.A. installed a 22-tph air-swept mill with SEPOL separator from Krupp Polysius for petcoke grinding in August 2000.

Chile

Cemento Melon upgraded its existing kiln with new kiln feed and 2 4 SF Cross Bar Cooler by F. L. Smidth. Commissioning of the upgraded kiln is expected to take place in September 2001.

Polpaico Mejillones purchased a 41-tph cement mill installation from F. L. Smidth comprising of a UMS 34 11 all auxiliary equipment, power, and control systems. Erection was slated to start in February 2001 and commissioning is expected to take place in September 2001.

At Polpaico South's mill, a UMS 4.6 13 cement mill installation was commissioned to F. L. Smidth in October 1999.

El Salvador

At Cemento de El Salvador, a 2,200-tpd turnkey project at the Metapan Plant comprising circular raw material store CHO, ATOX 35 raw mill, CF homogenizing silo, ILC kiln with COOLAX clinker cooler, UMS cement mill, control instrumentation and power distribution systems was completed in the third quarter of 1999. F. L. Smidth was the supplier.

Guatemala

Progreso San Miguel ordered an OK 33-4 roller mill for blended cement from F. L. Smidth. Erection was started in the second quarter of 2000.

Peru

Cementos Andino S.A. ordered a 58-tph POLYCOM high-pressure grinding roll with disagglomerator and SEPOL separator for cement finish grinding from Krupp Polysius in March 2000.

Cementos Lima awarded a contract for the largest kiln in the Americas to F. L. Smidth. It included a second phase preheater and COOLAX cooler extension to 7,500 of the original 3,750-tpd project that came on stream in 1997.

Venezuela

Cemex's Venezuelan division Vencemos placed an order with IKN to upgrade the clinker cooler of their kiln #7 line at its Pertigalete plant with a clinker inlet distribution system (KIDS). The cooler will be equipped with eight stationary rows. This is a repeat order from Pertigalete.