Cement Americas

APR 2019

Cement Americas provides comprehensive coverage of the North and South American cement markets from raw material extraction to delivery and tranportation to end user.

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34 CEMENT AMERICAS • Spring 2019 • www.cementamericas.com PRODUCTS reach out in dire need of refractory material for an urgent hearth repair project. The team quickly determined the optimal material for the project as well as quantities need- ed. The next morning, during the daily production meet- ing, the manufacturing facility was able to modify its pro- duction schedule and pre-arrange transportation. Plibrico delivered to the customer the truckload of material on-site in less than 24 hours from placement of the order." Smith also recalls an event over the July 4th holiday when a customer, an Oklahoma fertilizer plant, notified Plibrico of an emergency outage requiring, a small batch, of nonstan- dard Plicast LWI material. In less than 24 hours, the Plibrico team manufactured and shipped the required materials to get our customer back on-line fast." In another off-hour occasion, Plibrico's Canadian PliPart- ner needed a truckload of refractory material for an emer- gency repair. Their customer's operation was down, and it was costing their customer hundreds of thousands of dollars each day they were nonproductive. "The Plibrico team went into action and manufactured, coordinated and shipped the truckload of refractory in less than 48 hours," said Smith. At the end of the year, one of Plibrico's construction office contacted customer service early in the morning on behalf of a local aluminum plant. "Production was off-line at the plant and the construction crew had an immediate require- ment of several thousands of pounds of a finished good. Knowing what was at stake, again, the Plinrico team rear- ranged the production schedule, changed the line over, and had the material produced and shipped the same day," Smith said. Plibrico's ability to respond quickly is one of the reasons Plibrico has become the first thought in the minds of clients that need quick, "in the moment,"refractory solutions. Plibri- co's concept to completion, services and resources allow for fast turnaround on refractory materials and repairs to bring heating processes back on line swiftly. Strategic investments in our customers provide one of the fastest turnaround times in the refractory industry – consistently. Pilbrico, www.plibrico.com The 1980s saw the beginning of a shift in the cement indus- try. Slowly and steadily, cement producers began to adopt vertical roller mills (VRMs) for cement grinding instead of ball mills. Fast forward to today, and the VRM, with its supe- rior grinding efficiency and low power consumption, is the industry standard, according to FLSmidth. Since FLSmidth's initial OKTM Mill installation in 1982 through to the end of 2018, customers have bought a total of 184 mills, confirming FLSmidth's place as the industry leader for cement and slag grinding. Raw materials grinding was added to the OK Mill's résumé in 2017. Following the launch of this flagship VRM, three new OK Raw Mills were sold in 2018 – a strong indication that cement producers are favoring FLSmidth's modular mill design for both raw materials and cement grinding. The flexibility of the modular design is a key driver of its suc- cess. It uses the same core grinding parts in raw and cement mills, in multiple mill sizes, greatly reducing the capital investment for spare parts in a plant. FLSmidth has supplied VRMs to 67 countries around the world since the OK Mill launched in 1982. In the last two years alone, OK Mills have been sold in Indonesia, the Phil- ippines, Algeria, Turkey, United Kingdom, Pakistan, Nigeria, Kenya, Peru, Cuba, India, Nepal, Algeria and Egypt. Particularly in South Asia and Africa, where large-capacity plants are installed, cement producers choose single big mills to take advantage of the lower installation costs associated with a single mill versus multiple smaller units. Perhaps the most impressive example of this is at Shah Cement in Bangla- desh, where an 81-6 OK Mill, the world's largest vertical roller mill for cement grinding, was inaugurated in 2018 – featuring six rollers and a 8.1-metre diameter grinding table. FLSmidth has supplied OK Mills with grinding tables ranging between 2.8m and 8.1m in diameter. The number one sell- ing mill size is the OK 56-4 Mill, which is right in the middle of the available size range. Reliable production, low total cost of ownership and indus- try-leading energy efficiency are just some of the OK Mill's key characteristics. Its modular design with parts common- ality across applications and sizes enhances these benefits. FLSmidth, www.flsmidth.com FLSmidth Touts Competitive VRM Market

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