Produce high-quality cement and minimise production stoppage
The SiloSafe Cement service addresses issues such as impeded cement quality development, lump formation, and coating on silo walls, which are all related to cement prehydration in the grinding process and in cement storage silos.
Service to avoid silo blockages and improve cement quality
Are you experiencing lumps and blockages in your cement silo, or a decrease in cement strength? These issues can be caused by less than optimal grinding and storage conditions. Our SiloSafe Cement service helps you prevent or remove the conditions that cause these issues, so you can stay focused on delivering high-quality product and running a successful business, achieving consistent revenues.
The cause of cement lumps and blockages is often prehydration, which is the premature reaction of cement with water. Water is always present during cement production either through injection during grinding, as a vapour from gases, or from the feed materials. Therefore, it is vital to avoid the conditions that cause prehydration in your mill system and cement silos.
Solving the root cause
One solution to lumps and blockages in the silo is to try to remove them by additional silo cleaning. This is not a desirable activity for regular operation. In addition to causing significant downtime and loss of sellable product, silo cleaning poses serious safety risks for personnel.
Other options for removing lumps and blockages - such as installing a cement cooler - require capital investment and increase annual maintenance spending.
In contrast, our SiloSafe Cement service identifies the root cause of problems and enables you to prevent them, for a cost that is negligible compared to the alternative options. The service is efficient, accurate, sustainable, and safe.
Alternatives to SiloSafe Cement service
and their costs
The figure shows a cost comparison of different options to address prehydration and silo issues.
Our SiloSafe Service offers the most cost-effective solution.
Significant commercial benefits
Apart from enabling safer working conditions compared to alternative solutions to silo issues, the SiloSafe Cement service offers important economic and commercial benefits. It decreases unplanned stoppages, and reduces product waste and the need for unnecessary silo cleaning. Through reliable and accurate laboratory tests and specialist recommendations, it also enables you to consistently produce high-quality cement.
Improved cement quality
The figure shows how our SiloSafe Cement service can improve and stabilise cement quality.
What is the SiloSafe Cement service?
Our SiloSafe Cement service is based on more than 135 years of cement grinding experience and intensive in-house research. Whether you already struggle with issues in your existing mill or have just installed a new mill and want to avoid problems, this service will support you. To help prevent silo lumps and produce high-quality cement, we gather information about all relevant aspects of your specific cement process, including operating data, physical and chemical properties of materials, and the condition of your equipment.
Based on this, we suggest the appropriate laboratory tests and collect samples of feeding materials and cement. We analyse these in an FLSmidth laboratory, using advanced techniques that we have uniquely developed, and we identify the root causes of problems. We then make specific, tailored recommendations for the best grinding temperature and water injection. These parameters can vary depending on several factors. Our specialist recommendations, conveniently provided in a report, are always specific to your particular plant process and based on accurate analysis.
In addition, you can combine our SiloSafe Cement service with onsite services, for example, to collect samples; to optimise your mill operation based on the specialist recommendations; to train operators; or to do additional inspections and adjustments in the grinding system.
Proven process for the best results
The SiloSafe Cement service follows a consistent, proven process to ensure the optimal outcome for your operations:
- Laboratory testing of feed materials and cement products to tests for the root cause of existing issues or identify potential problem areas.
- A thorough examination of test results and site data by our most experienced specialists.
- A detailed report, including:
- Laboratory test results
- Recommendations for improved cement quality
- Steps needed to prevent prehydration or correct silo problem
A site visit by a local FLSmidth operational service, commissioning, or process engineer to optimise mill operation, train operators, or help implement recommendations can be offered but it’s not a part of the standard service.