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Cemento PANAM has achieved fantastic success reducing its carbon footprint and fossil fuel bill by implementing a 350 m long waste heat bypass system, using waste heat from the cooler to dry materials in its cement mills.

Way before energy prices skyrocketed, engineers at Fuller's research and development facility in Denmark had been working on a new type of combustion system that enables alternative fuels to burn more efficiently while also eliminating NOx. In 2018, Fuller contacted Mannok in Ireland with an offer to test the new technology at full scale to increase the rate of alternative fuels (AF) through the calciner in its Cement facilities.

Upgrading an existing ball mill circuit with hydraulic roller presses and TRIBOMAX® wear surfaces achieved a 127% increase in production, at the same time as lowering power consumption by 25%, at JK Cement’s Mangrol cement plant.

Calcined clay has the potential to save up to 40% of the CO2 emissions by replacing 30% of energy intensive clinker in cement production.

The team in Mannok’s cement facilities are celebrating the successful implementation of the FUELFLEX® Pyrolyzer, a new combustion system which is set to eliminate the need for fossil fuels in the clinker production process at the plant, the most carbon intensive stage of cement production.

To further eliminate CO2 emissions from the production of cement, Fuller will lead a new consortium to mature and deploy carbonation technologies in the industry. Funded by the EU Commission, world-class specialists will work alongside Fuller R&D engineers and experts from leading universities, technology providers and research institutions to solve one of the cement industry’s biggest challenges.

At the Cementos Molins plant in Sant Viçent dels Horts, efforts are underway to reduce emissions and increase efficiency.

Improved process efficiency, improved equipment reliability and a reduction in energy consumption of up to 3.8% on the cement raw mill are some of the results seen at Çimentaş İzmir after implementing advanced process control software from Fuller. We partnered up with Pacpro in Istanbul to implement the software, and Pacpro will now continue to provide locally-based support, backed by our global team of experts, to realise continuing operational success of the new system.

In 2020, Chinese government announced that China would attempt to reach ‘peak carbon’ by 2030 and achieve carbon neutral status by 2060. As a result, all the country’s heavy emitters are seeking ways to reduce their carbon emissions and meet this ambitious target. The pressure on the cement industry is high. Fuel substitution is one of the most straightforward routes to emissions reduction, as something that can be done immediately with readily available technology.

As an existing customer with a 2800 bag/hour VENTOMATIC® packing and palletizing line in operation for more than 20 years, Cementi Costantinopoli returned to us for this state-of-the-art expansion project, which adds capacity to pack 5000 25 kg bags/hour.

To further decarbonise the cement industry, Fuller and a series of leading industry experts have formed a new partnership called ECoClayTM. To reduce CO2 emissions from cement production by up to 50%, the ECoClay partners will develop and commercialise the technology needed to replace fossil fuels in the calcination of clay by fully electrifying the process.

When negotiations began with CalPortland for a new raw grinding circuit at their Mojave plant in California, the world was still relatively normal. And when contracts were signed in Spring 2020, no one expected the Covid-19 pandemic to last for more than a few months. But as the pandemic raged on, it wasn’t long before Fuller's project execution team realised they were going to hit supply chain problems.

Do you worry about your plant reliability? Sustainability? Cybersecurity? Finding skilled operators? With our latest ECS/ControlCenter v8 process control software platform, you don’t have to. As a cement producer in Bangladesh, Premier Cement, is finding out.

Cementi Costantinopoli is a family-owned cement manufacturer located in Southern Italy. With a product range including pozzolanic and limestone cements, the company wished to expand its packing and palletizing line to support increased demand. As an existing customer with a 2800 bag/hour VENTOMATIC® packing and palletizing line in operation for more than 20 years, Cementi Costantinopoli returned to us for this state-of-the-art expansion project, which adds capacity to pack 5000 bags/hour of 25 kg.

Our comprehensive hot kiln alignment services are a key element of your preventive maintenance strategy, enabling you to improve availability and productivity.

Votorantim Cimentos' Hasanoglan Plant in Turkey has a capacity of 2800 tpd of clinker and 1 million tpa of cement, all destined for the local market. The plant was operating an old Fuller mechanical packer with a capacity of 40 tph. Though the equipment had served them well, it was no longer meeting their needs in terms of productivity. Moreover, newer VENTOMATIC® packing technology could offer a more environmentally friendly dust-free performance and greater weighing accuracy.

Indian Cement producer Shree Cement installs Fuller ECS/PlantDataManagement across 16 plants and 24 lines to drive efficiency and deliver increased productivity. The order also includes the downtime analysis solution, ECS/UptimeGo and access to the mobile plant management app, SiteConnect.

Capital Cement in San Antonio, Texas was the first producer to have the Cross-Bar® Cooler installed in 2009 – still early days for the Fuller team working on the development, but little did they know that the new design would dominate the market in the following decade.

Data standardisation has unlocked the digital revolution in other industries. It’s time for the cement industry to harness that power for change. At this year’s Optimisation conference, hosted by World Cement, our Chief Digital Officer, Mikko Tepponen and Head of Digital Development, Anders Noe Dam delivered a call for data standardisation in cement.

Fuller-Kinyon (FK) N pump for easy pneumatic conveying of free-flowing bulk material. Our FK N pumps offer continuous operation to a process that depends on reliability. Low maintenance, low wear, with high capacities that can cover long distances. Our Fuller-Kinyon® (FK) screw pumps and pump systems are proven to deliver, with expertise stretching back 100 years.

Compressed air is one of the biggest energy consumers in any heavy industry process. But it’s also one of the most efficient ways of moving materials. So we’ve dedicated our expertise to creating a solution that lowers the cost of compressed air. The result? The Ful-Vane™ Air Compressor.

At the recent COP26 climate summit in Glasgow, India made the commitment to achieve net-zero emissions by 2070. As part of the roadmap to get there, India will bring its economy's carbon intensity down to 45 per cent by 2030.

Ssangyong Cement wanted to increase alternative fuels (AF) use at its Donghae and Yeongwol cement plants. They were interested in using the HOTDISC® reactor, one of our MissionZero flagship products. But, it didn’t fit within their existing SLC calciner layouts and a conversion to an ILC calciner to increase AF firing was not economically or technically feasible. They challenged us to redesign the HOTDISC reactor to suit an SLC calciner system.

New greenfield contract from Indian Cement producer Shree Cement sees Fuller deliver a series of sustainable equipment, including the world’s largest Cross-Bar® Cooler, the Fuller OK™ Cement mill and JETFLEX® Burner.

Vertical roller mills and ball mills are regularly taken out of operation for routine maintenance. Some plants even shut their mills down every week. Yet, gearbox inspections are typically scheduled for the annual maintenance shutdown when resources are stretched. This is making life harder than it needs to be for all involved. Let’s simplify things. Consider scheduling your gearbox inspection to later in the year when you can access the expertise and tools you need. This way you can be sure you’ll have access to the most experienced service technicians, equipped with all the tools they need to get the job done.

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CalPortland’s clinker crusher problems were solved by the new Heavy-duty Roller Breaker (HRB), supplied and installed by Fuller. Our one-stop-shop service was able to save them time and money, ensuring the successful completion of the project within the scheduled shutdown.

When Cementos Argos decided to upgrade the control system at its Cartagena cement plant, they started on an unexpected journey. A journey that would end with the implementation of a virtualised high-availability automation system to host a number of Fuller's software products for operation of the complete plant. And all running flawlessly from the start.