Day 1 Sessions

Keynote: An Economics Update for the Construction Materials Industry
Pierre Villere, Allen-Villere Partners

Pyro Process Optimization Using Modern Gas Analysis Systems and New Digital Services
Felix Bartknecht, SICK

Gas analysis systems are crucial tools in cement plants, for instance for optimizing the combustion process, increasing product quality or reducing emissions. Often equipment downtime results in high costs. To prevent it, monitoring the condition of these extremely important measurement devices is essential for achieving the best possible plant availability and product quality. With condition monitoring solutions, operating entities of cement plants have the option of visualizing and evaluating the condition data of their analyzers and measuring devices anytime and anywhere. To help users to schedule maintenance in a more targeted manner and respond efficiently to potential failures, condition monitoring provides information at an early stage and reveals critical changes in condition quickly and with foresight. This means that service technicians are on-site early on and with the right spare parts, thus reducing downtime to a minimum. This presentation will focus on modern gas analyzers systems for emission monitoring and process control in cement production while highlighting the benefits of new digital services for predictive maintenance and condition monitoring.

Case Studies from the U.S. and Canada of the Grinding Optimization Using AI And APC Modules
Matthias Hacker, KIMA Process Control

The MILLMASTER with the famous fill level index by SMARTFILL is operated in plenty of cement mills in the US and Canada. Several users confirm a boosted production with a fundamental increase and describe their experience in this paper of the new autonomous mill operation. In order to optimize grind­ing processes, it is necessary to measure the most important parameter the fill level per chamber- as precisely as possible. This key parameter cannot be measured directly, it needs to be determined by acoustic or vibration measurement. Because of the obvious disadvantages previous measuring methods (like microphones) are quite use­less for now­a­days needs.

Reducing Fugitive Belt Conveyor Dust
Jerad Heitzler, Martin Engineering

Cement plants can experience the problems of dust from belt conveyors. This dust is hazardous and becoming more important to mitigate. Much of a facility’s dust is created at a belt conveyor transfer point because material is in a free fall and fines are exposed to air flows.

This presentation will teach attendees how simple mechanical techniques can make a significant impact on dust at a belt conveyor transfer point. Attendees will learn how they can design, repair or maintain new or existing transfer points in a manner that seals air in the skirted area until that air can be slowed to a velocity that can no longer carry dust. Examples and successes of the techniques used will be discussed.

Learning Objective:

  1. Understand what proper belt support is and why it affects dust.
  2. Learn the limitation of skirting systems and how to get the most out of them.
  3. Discuss the proper transfer point design to seal air and slow its velocity.

Cleaning And Maintaining Silos
Dennis Blauser, Marietta Silos

Keep your silos operating efficiently; lower or eliminate your silo cleaning costs; keep your silos structurally sound and your personnel safe, and lower your silo operational costs. Marietta Silos is the largest concrete silo repair company in the United States.

Maximizing Bucket Elevator Efficiency with Heavy-Duty Belt Technology
Brian Giese, BEUMER Group

This presentation explores how bucket elevators can operate at peak efficiency using Heavy-Duty belt technology. Viewers will understand best practices to help maximize the efficiency and lifespan of bucket elevators. Additionally, an in-depth look at how CRH (formerly Lafarge) used Heavy-Duty belting to achieve these results will be provided.

Continuous, Fast and Reliable Process Gas Measurement in Rotary Kilns
Yeray Garcia, ENOTEC

The production of clinker is a very tough one: The high temperatures and high dust load inside the rotary kiln make it extremely difficult for any gas measuring technology to deliver reliable information in a continuous (24/7) and fast way in order for cement plants to optimize their pyro-process. Furthermore, the increasing usage of alternative fuels and the progressively stringent environmental regulations has become a huge challenge for the cement industry.

This presentation will show how to achieve such goals while reducing fuel consumption, emissions and overall maintenance.

Upstream Gas Conditioning For Carbon Capture Scrubbers With Wet Electrostatic Precipitation Technology
Steve Jaasund, LDX Solutions

Both the cement and lime industries are experiencing an increased environment concern about carbon dioxide emissions.  It is likely that this will drive the installation of CO2 scrubbers at kilns in both industries.  Recent experience with CO2 scrubbers in other industries has demonstrated the importance of the cleanliness of the gases entering a scrubber system.  In particular, both solid and liquid particles such as sulfuric acid mist will cause problems such as excessive reagent consumption and equipment fouling.  This paper will describe the potential of wet electrostatic precipitators to greatly reduce the particulate load at the inlet to a CO2 scrubber in order to minimize reagent consumption and maintenance problems at the downstream scrubber.

Day 2 Sessions – Carbon Management Track

Yuliya Kravtsov, President , Sapphire Americas

The Present and Future of the EPD Ecosystem for Cement and Concrete
Mikaela DeRousseau, Data & Methodology Manager, Building Transparency

Advanced Pozzolanic Cement- Key to Ultra Low Carbon Concrete Products
Danny Gray, Executive Vice President of Strategy & Business Development, Eco Material Technologies

Flash Activation of Clay: High Product Quality and Energy-Efficient Process
Steven Miller, Global Product Manager, Preheater, FLSmidth

With the right treatment, calcined clay can replace up to 40% of the clinker.  FLSmidth has been studying different process solutions, conditions and clay qualities using flash calcination. A flash calciner with preheater and cyclone quenching ensures the highest product quality including color control, the lowest specific energy consumption and CO2 emissions.
This presentation will provide an overview of the market potential for calcined clay. In addition, the discussion will include FLSmidth’s patent pending clay activation process, which includes the grinding and drying of the raw clay, heating and activation, control of the color of the activated product, and the cooling of the clay.

Performance Benefits of CO2 Capture Using Carbonated Cements in Manufactured Concrete Products and as an SCM in Ready-mix Concrete
David Smith, Senior Technical Director, Solidia Technologies

Alternative Calciner, Kiln Fuels

Carbon Capture, Utilization and Storage

Clinker Optimization, Substitutes, SCM

Renewable Energy-Powered Plants