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DAL recently completed a top cyclone modification project at the CRH cement plant in Bulacan, Philippines — covering full engineering scope from detailed design through on-site technical supervision.

The work focused on upgrading the preheater top cyclone to improve pyro-process efficiency and operational stability. Execution involved close coordination with the plant's operations team to minimize downtime and work within the constraints of the existing infrastructure.

On-site supervision covered the full installation sequence: dismantling of the existing cyclone, new unit installation, riser duct modifications, welding, geometric alignment, and structural adjustments as conditions required during execution. QA/QC and safety protocols were maintained throughout. The upgraded system has since achieved stable operation, with performance results in line with project targets.

Fons Technology International has secured a new contract with a leading cement producer in Libya for the Libyan Cement plant. The project scope includes the supply of a Fons Delta clinker cooler with a capacity of 1500tpd, along with a rotary kiln outlet seal featuring an internal diameter of 4400mm.

This award marks another significant milestone in Fons Technology’s ongoing expansion across north Africa, reinforcing its role as a trusted provider of high-performance clinker cooling systems and critical pyro-process equipment. Designed for efficiency, reliability, and long-term operation, the new cooler optimizes heat recuperation, reduces electrical consumption and improves clinker quality, while the kiln outlet seal ensures effective sealing, minimized heat loss and stable kiln performance, according to Fons Technology International. 

A major engineering and equipment modernization project has been successfully completed at the Cementos Argos plant in Cartagena, Colombia, marking an important milestone in the delivery of advanced solutions for the cement industry.

The project underscores a continued commitment to providing high-performance, reliable, and future-ready technologies to cement producers across Latin America and beyond. The scope of work included the supply and installation of precision-engineered airslides and diverter gates, high-efficiency airslide fans with optimized discharge systems, and a new bucket elevator featuring an advanced bag filtration system. Additional equipment delivered as part of the project comprised robust double-flap valves, screw conveyors, auxiliary mechanical systems, and industrial lifting solutions designed for long-term operational reliability.

The modernization was seamlessly integrated into the existing plant infrastructure, resulting in improved material handling efficiency and enhanced operational stability. Importantly, the upgrades were completed without disrupting ongoing production, while also strengthening the plant’s long-term process reliability and maintenance planning capabilities.

The successful execution of this project highlights DAL’s expertise in managing complex turnkey deliveries, covering the full lifecycle from engineering design and manufacturing to installation and commissioning. Appreciation was extended to Cementos Argos for their cooperation and trust throughout the project.

Dal Engineering and Fons Technology International in Turkey have completed a number of orders for the cement sector in recent months.

From the DAL workshop, a kiln shell Ø3.8m x 2.600m was successfully dispatched to Lukavac Cement doo in Bosnia and Herzegovina.

DAL Engineering Group has similarly delivered and installed a fully integrated rotary dryer, measuring Ø3m x 22m, at ZKW Otterbein’s cement and lime plant in Germany. This advanced equipment is designed to optimise production processes, improving both efficiency and sustainability within the cement and lime sectors.

Meanwhile, Fons Technology International, part of the DAL Engineering Group, has successfully delivered and commissioned a state-of-the-art clinker roller crusher with a capacity of 4000tpd for the Bouskoura plant (LafargeHolcim group) in Morocco.

DAL has reported the signing of a number of new orders in the cement sector in Colombia, Russia, Egypt and Qatar.

Dal Machinery & Design has been awarded the contract for delivering two surface feeders with a capacity of 2x200tph to Cementos Argos' Rio Claro cement plant in Colombia. According to the planned schedule, the installation of two surface feeders was executed in December 2018 and they are now fully operating. Dal Machinery & Design's surface feeders are part of Argos' calcined clays project in the municipality of Rio Claro, Antioquia. The same equipment was installed in the cement plant Studen Agrana in Bosnia-Herzegovina where a Dal Machinery & Design surface feeder had been operating for 10 years, designed for long-term use and without any maintenance.

Meanwhile, Dal Teknik Makina began converting a grey cement line to white cement production at the Zhigulyovsk Building Materials plant in Russia in November 2018. Dal Teknik Makina supplied engineering and procurement of certain equipment, including an upgrade to the kiln unit at the Zhigulyovsk Cement plant. Together with the unique raw material base of the plant, the converted cement works will meet the highest requirements for strength, quality and aesthetic characteristics of the  white cement produced, claims Dal Teknik Makina.

Furthermore, Heidelberg-owned Helwan Cement plant in Egypt approached Dal Teknik Makina in February 2019 to improve its process performance on clinker production Line No1. Dal Teknik Makina (DAL Engineering Group) has taken all required data to evaluate the existing situation during a three-day technical audit, carried out discussions with the plant staff and evaluated an audit report to optimise the  Line 1 pyro-processing system. Dal Teknik Makina also offered solutions with particular focus on reducing specific heat consumption, increasing the plant's alternative fuel substitution rate, lowering energy consumption and raising kiln throughput.In addition, Dal Teknik Makina has been awarded a project to install a pilot-scale plant for calcium sulphoaluminate clinker production line in Qatar. Following a request from doctorate researchers from Gulf Organisation for Research & Development, Dal Teknik Makina engineers will evaluate the concept, identify potential operations issues and supply the complete engineering/instrumentation for the whole project.

Dal Teknik Makina has successfully carried out the modernisation of Kiln Line No1 at Nuh Çimento plant in Hereke, Turkey. Nuh Çimento plant has now increased its production capacity up to 3400tpd from 2800tpd, the specific heat consumption of clinker has been decreased to level of 740kcal/kg clinker from 870kcal/kg clinker and clinker temperature of 55˚C plus ambient temperature.

This project involved the design, manufacturing and erection of the preheater tower cyclones group, kiln feed transport system, clinker cooler, kiln hood, removing of dust cyclone at tertiary air duct, cooler vent fan modification, main bag filter duct modification and kiln inlet seal and commissioning of the system.

The first part of the upgrade project was the modification of the preheater tower, which as a result reduced the pressure drop, improved heat transfer and separation efficiency, and heat consumption.

The second part of the project was the retrofit of the grate cooler. The clinker cooler, kiln hood, cooler fans and cooler vent fan were replaced by FONS Technology International. In this part, kiln hood, cooler vent, exit pipe of WHR and tertiary air duct were modified as well.

Finally, the horizontal duct of main bag filter inlet was replaced by an inclined one to avoid dust accumulation. The last step was the replacement of the pneumatic kiln feed by bucket elevator.After the execution of the upgrade project, which, by the way was carried out in a record time of 35 days from flame off to flame on, great values were achieved. Moreover, with this project Dal notably decreased electrical consumption by 7kWh/t. The raw mill capacity was increased from 160tph to 185tph. Dal’s most recent release at Nuh Çimento plant is part of Dal - Filter-to-filter pyroprocess concept which covers the following production units:

• Kiln/VRM dedusting unit
• Raw meal transport and homogenisation silo unit
• Kiln feed system
• Gas conditioning tower unit
• Preheater tower (cyclones, dip tubes, flap valves, etc)
• Precalciner
• RDF utilisation
• Rotary kiln (inlet & outlet seals, tyres & rollers, hydraulic thrust, etc)
• AD damper
• Clinker cooler
• Clinker cooler de-dusting unit (heat exchanger + bag filter or ESP).

Dal Teknik Makina has conducted two audits for mechanical and process point of view to the Norm Cement Plant to figure out the bottlenecks of the pyro line together with the cement grinding unit in order for the Norm Cement Plant to increase its production capacity and decrease the energy consumption. In addition to detailed production figures inspection, mechanical inspection has been conducted for both steel parts and mechanical equipment to figure out the reasons for corroded and weared out parts at the pyro line and two cement mills. Dal Teknik Makina has prepared a detailed report pointing out the required improvements the plant has to carry out in order to fulfill their capacity increase concerns.

The goal of the project CIMSA Mersin Cement Plant wants to improve its 1st clinker production line by changing the 1st and 2nd stage cyclones for both two strings. Dal Teknik Makina offers “turnkey” replacement of cyclones. The modification project will allow electrical and a slight heat energy reduction by reducing pressure drop and improving separation efficiency of the cyclones.

The main equipment and design offered will be as follows:

• Modification of 1st and 2nd stage cyclones and riser ducts

• Downcomer ducts modification

• Dip tubes, pendulum flaps, meal pipes, splash boxes of the modified cyclones

• Accessories (manholes, poke holes,measuring points etc.)

• Dismantling and erection of the scope mentioned above

• Refractory procurement, demolishing and installation

Dal Teknik Makina has conducted a process audit for both clinker production lines of Isparta Cement Plant to figure out the bottlenecks of the pyro line in order for Isparta Cement Plant to burn alternative fuels without decreasing its production capacity. Technical inspection covered clinker production line measurements together with the ball type raw mill mechanical inspection for the 1st kiln line. After evaluating the current situation of the plant, together with the measurement results and documents given by the plant, Dal Teknik Makina has prepared a detailed report pointing out the needed improvements the plant has to carry out in order for them to burn alternative fuel and fuel injection points, which was the main concern of the plant.

Chairman of DAL, Mr. DAL, together with Senior Directors Mr. Adnan CAN and Mr. Demircan KÖSE, held a high level meeting with the Deputy Prime Minister and Minister of Investment and Foreign Trade of Uzbekistan, Mr. S. Umurzakov.

The meeting was also attended by Deputy Minister Mr. L. Kudratov and the Ambassador of Uzbekistan to Turkey, Mr. A. Azamhocayev. The discussion focused on ongoing activities of DAL within Uzbekistan, where the company continues to advance industrial execution spanning automation, engineering, heavy manufacturing, and turnkey solutions.

Both sides reviewed the progress of current projects and explored new areas for collaboration that support Uzbekistan’s national industrial development goals. Uzbek officials expressed their full support for deeper cooperation, and DAL reaffirmed its commitment to expanding its presence and contributing to economic development through strategic investments and long term partnerships.