46 FLSmidth Discover Cement Site reports
Grey/white
production:
an achievable
ambition
In a climate of ambitious public housing construction
projects, the demand for white cement is growing
in Saudi Arabia. Riyadh Cement has turned to
FLSmidth to realise its vision of capturing 100
percent of the local white cement market.
fter its commissioning in 2007, Riyadh
A Cement Company (RCC) quickly began
to meet the growing demand for
grey cement in the domestic Saudi Arabian and
neighbouring markets. A second grey line was
commissioned in 2010, increasing the combined
production capacity to 11,000 tonnes per day.
In 2011, RCC became a subsidiary of Saudi
White Cement Company. As market demand for
white cement was increasing, RCC sought ways
to increase its flexibility by switching from grey
to white production. Saudi White Cement Com-
pany was already a renowned producer of white
cement and sufficient raw materials were readily
accessible to the plant.
Mr Sultan Al Dhuwaihi, Chief Projects Officer at
RCC’s owner, Saudi White Cement Company, says:
“We already have about a 30 percent mar-
ket share within white cement and we want to
increase our capacity to achieve our ambition of
capturing 100 percent of the market.”
The project team first considered constructing
a new line specifically for white cement. However,
following discussions with FLSmidth, it was quickly
determined that converting one of the existing
grey lines to produce white cement was a highly
economical option.
Reusing assets
FLSmidth has developed a concept for modifying
the existing equipment typically used in grey
cement production in a cost-efficient way so that it
can be used for dual production of white and grey
cement. In recent years, FLSmidth has conducted
several such conversions, including for Adana
Cement in Turkey.
Before determining on the proposed solution,
RCC representatives visited the Turkish site to
observe the plant in operation. This visit, along
with FLSmidth’s track record with RCC, led to the
decision to convert the existing grey cement line
to dual production, instead of building a complete-
ly new production line. Early in the project, testing
of the raw materials was conducted at FLSmidth’s
Research and Development facility in Denmark to
ensure guarantees in whiteness and quality would
be met.
Mr Sultan Al Dhuwaihi says: “We have a good
relationship with FLSmidth as they have supplied
us with various equipment and services, through
the years, so we had a good impression of their
ability to deliver. It is advantageous to have an
equipment supplier with proven know-how about
the technology for white cement production. In
fact, nobody else has the same high level of know-
how.”
Omar Rabia, Sales Manager at FLSmidth,
explains that the aim was to achieve a payback of
one year or less.
“It was important to be able to show the value
of proceeding with the proposal by demonstrating
experience, flexibility and the right pricing,” he
says.
FLSmidth Discover Cement 47
CONVERSION FACTS
Instead of constructing a new
white cement line, Riyadh
Cement saw significant economic The conversion of one of Riyadh Cement's existing
benefits in converting an existing grey cement lines to a dual process cement line for
grey line to dual production. white and grey cement includes modifying the kiln and
preheater area:
■■ Minor modification to the preheater tower
■■ The FLSmidth Duoflex® burner, which is ideal for
white cement production
■■ Quenching equipment, including water pumps
■■ A complete electrical package, including
modifications to the control system
Upgrade benefits pleted, as well as most of the purchasing, with final
The main part of the project involves installing delivery expected in the beginning of 2018. The
an FLSmidth Duoflex® burner inside the kiln with construction partner for the project is the Turkish
quenching to take place inside the kiln tube and
We already have about a 30 company, Partner Teknik.
implementing relatively minor changes to the percent market share within Mr Sultan Al Dhuwaihi comments: “The
existing preheater. white cement and we want to process so far has been good. We have had good
A considerable amount of existing equip- design meetings and have received almost all
ment is being reused, including the oil handling increase our capacity to achieve engineering documentation, so we are looking
equipment, clinker cooler, raw material storage our ambition of capturing forward to the mobilisation phase. I am confident
system and raw mill grinding equipment. With the we can rely on FLSmidth’s capabilities and tools
proposed modifications, the kiln is expected to
100 percent of the market.” as well as their know-how and experience so that
produce a minimum of 2,000 tpd white clinker we can quickly achieve our ambition of having full
MR. SULTAN AL DHUWAIHI
with a maximum heat consumption of 1,350 kcal/ capacity of white cement in 2018.” ■
CHIEF PROJECTS OFFICER AT RCC’S
kg clinker. OWNER, SAUDI WHITE CEMENT COMPANY
Next steps
With a mid-2018 target for commissioning, the OMAR RABIA
engineering phase of the project has been com- ora@flsmidth.com