Pakistani technology leader excels in production performance

DGKhan is a technology leader in Pakistan’s cement industry operating three state-of-the-art production lines at their two plants, Khofli Sattai and Khaipur. The plants’ power and fuel consumption are the lowest in the industry. And because of their control and automation technology together with other modern operating and management tools, DGKhan has achieved extraordinary run factors at lowest cost.

At their Khofli Sattai plant, DGKhan installed the world’s first and biggest FLSmidth vertical finish grinding mill – the OK 39 – in 2008. This meant a huge reduction in energy consumption from 40 kWh per tonne of cement to 25 kWh.

DGKhan is very satisfied with the service and attention given by FLSmidth during the commissioning process to raise the Khofli Sattai mill’s performance to the desired level. The two kilns at the Khofli Sattai plant were recently upgraded by removing various bottlenecks from the production process. DGKhan was the first cement producer in Pakistan to upgrade its pyroprocessing line with Multi-Movable Cross-Bar cooler cassettes and a Heavy-duty Roll Breaker.

The Khaipur plant, which was contracted with FLSmidth in 2004, is one of the most advanced and modern cement plants – not only in Pakistan but in the whole world. It features state-of-the-art technology such as vertical raw and cement grinding mills, SF Cross-Bar cooler, fully automatic control and quality systems and fully covered raw material and clinker storage yards. Besides, all the dust-emitting points throughout the plant are equipped with the most effective dedusting equipment in the form of electrostatic precipitators and bag houses. The Khaipur plant also uses alternative, greener fuels such as rice husks, RDF and industrial waste as a substitute for coal and gas.

Long-standing relationship
D.G. Khan Cement Company Limited belongs to the Nishat Group which is one of the leading and most diversified business groups in South East Asia. It is the third largest cement producer in Pakistan with a capacity of 14,000 tpd.

For many years FLSmidth and DGKhan have worked as close partners. It all started with a kiln upgrade in 1992 and since then a number of projects have successfully been carried out. In addition to supplying machinery and equipment, the projects also include the training of staff at FLSmidth’s offices in Copenhagen, Denmark. FLSmidth continues to work with DGKhan in its ongoing effort to improve plant performance, which has led to some extraordinary results (see Table).

Outstanding achievements in the 2007 – 2008 financial year

• Highest ever limestone production at 2,740,990 tonnes
• Highest ever clay production of 628,110 tonnes
• Highest ever raw mill 2 availability (297.30 days)
• Highest raw meal production raw mill 2 (2,157,093 tonnes)
• Highest ever kiln 2 availability (343 days)
• Highest ever clinker production kiln 2 (1,368,945 tonnes)
• Lowest ever brick lining consumption kiln 2 (0.165 kg/ton clinker)
• Highest ever clinker sales local and export (150,410 tonnes)
• Highest ever cement export (395,046.40 tonnes)