Report 2010 - Italcementi Group

Engineering, technical assistance, research and
development
(CTG S.p.A. – Group Technical Center)
In 2010 CTG S.p.A. carried out R&D, engineering and technical assistance activities for the
Group subsidiaries in Italy and abroad, providing services for 61.8 million euro (67.5 million
euro in 2009).
Staff at December 31, 2010, numbered 404 (412 at December 31, 2009), of whom 306 at
the headquarters in Bergamo, 94 in Guerville and 4 at Group companies.
The year’s operations reflected the following priorities:
– realization and start-up of the main projects already underway and implementation
of studies and projects for approved initiatives;
– technical assistance for plant maintenance and operations, and for improvement of
industrial performance;
– implementation of R&D projects relating to materials, products and technologies,
optimization processes and productivity improvement.
Work to complete the main projects proceeded at an intense pace. At Yerraguntla in
India, the new clinker production lines began operations in March (5,500 mt/day) and the
cement lines in July. In March the revamped kiln line at Matera in Italy began operations
(2,200 mt/day). At the new plant in Ait Baha, Morocco, clinker production began in July
(5,000 mt/day), while cement production began in December. Finishing operations
continued on the new cement and clinker production lines in Martinsburg, North America,
and the new cement 1 production line in Ait Baha, which began operations at the end of
2009.
With regard to the revamping of the Devnya cement plant in Bulgaria, a review is being
conducted on the plant dimensions, layout and program. For the opening of the Barry
quarry (Belgium) and the revamping of the Monselice and Rezzato plants in Italy, work
focused on basic engineering and licensing applications.
Assistance operations included action to improve product quality and raise technological
and production efficiency at a number of Group cement plants. To boost efficiency, the
STEP 2 project continued at 12 plants, with the number of plant analyses now standing at
41.
R&D work focused on materials and processes. During the year 9 patent applications were
filed (5 for additives, 4 for basic cement and clinker products with specific characteristics).
In sulfoalluminate binders, industrial tests concentrated on production of sulfoalluminate
clinker and its chemical and mineralogical characterization. For TX Active products, new
paint and roofing formulations were developed and successfully tested, as well as road
paving formulations.
In ready mixed concrete, a number of insulating formulations were developed using light
aggregates, and industrial tests were conducted.
Special attention was devoted to chemical transformation of CO 2 , cement formulations and
a new clinker with lower CO 2 production.
In additives, tests were conducted on the feasibility of a new generation of
superplasticizers.
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