THE ENVIRONMENT OF MANUFACTURING REFRACTORY PRODUCTS AND ITS APPLICATIONS 23. INTERNATIONAL INDUSTRIAL MINERALS CONGRESS AND EXHIBITION MARRIOT HOTEL, PRAGUE, CZECH REPUBLIC

15th of June 2016

Roman Hubálek

OVER 125 YEARS OF EXPERTISE & INNOVATION New millennium

South America, Africa, Asia & Russia

LHOIST WORLDWIDE PRESENCE

The 90’s Further development to Western & Eastern Europe

The 80’s Crossing the Atlantic (US, Canada)

1926 First expansion to France

1889 Foundation of the Group in Belgium

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KEY FIGURES

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TURNOVER

€ 2 bn

Europe Other Regions

Corporate North America

South America 6 000

1 R&D CENTER

4 CUSTOMER TECHNICAL SERVICE CENTERS

> 25 COUNTRIES

100 PLANTS NATIONALITIES 40

MAIN PRODUCTS

MINERALS Limestone

Dolomite

Clay and others

CALCINED PRODUCTS Quicklime

(pebble, ground, milled)

Burnt dolomite (soft-/hard-/overburnt)

Hydrated lime

SPECIALTY PRODUCTS Milk of lime

Fluidised lime

Low dust emission lime

High porosity hydrated lime

Formulated products

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DIVERSITY OF APPLICATIONS

All mentioned trademarks are trademarks of Lhoist Recherche et Développement S.A.

Iron and steel Non-ferrous metals Pulp and paper

Glass Civil engineering Building

Drinking water Water and sludge Flue gas treatment

Agriculture Chemicals Biofuels

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Lhoist in the Czech Republic

• since 1992

• 2 companies: Vápenka Čertovy schody a. s.

Velkolom Čertovy schody a. s. (50% of HBZ)

burnt products 350 kt

ground limestone 410 kt

crushed limestone 700 kt

• 102 employees

LHOIST Central Europe

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BU Czech Republic and Slovakia

quarry West Vápenka

Čertovy schody a.s. plant

quarry East

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BU Czech Republic and Slovakia

Production process

Quarry

Primary

crusher Secondary

crusher

Screening

tower

Stock

piles

Grinding

and milling

plant

Milled

limestone

Lump

limestone

Stone for

kilns

Raw stone

Dispatch of lump limestone Dispatch of milled limestone 9

BU Czech Republic and Slovakia

Production process - lime

Stone for

kilns

Fuels dosing

technology

Pebble lime

Pebble lime Milled lime Hydrated lime Sorbacal SP

Lime crusher

Shaft kilns PFR kiln MAERZ

Lime mills

Hydration plant and

Sorbacal SP production

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Quarry West

Quarry East

Quarry Plesivec

Quarry Homolak

Lime Plant VCS

Mining area

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Koneprusy/ Suchomasty Deposit Hard compact limestone

FMS kiln Main kiln aggregate

CaCO3 input 90 – 125 mm

Nominal performance

600 T/d

Two- shafts PFR kiln MAERZ - FMS

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BU Czech Republic and Slovakia

FMR kiln New kiln commisioned during 1.Q 2016

CaCO3 input 50 – 90 mm

Nominal performance 300 T/d

Two rectangular shafts PFR kiln MAERZ - FMR

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BU Czech Republic and Slovakia

FCV4 and FCV5

CaCO3 input 30 % mixture 50 – 90 mm

70 % mixture 90 – 125 mm

Nominal performance 150 T/d

Normal shaft kilns IPZ - FCV

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Hydrator PFFEIFER

Main equipments

Hazemag Crusher

Hydrator Pffeifer

Air Classifier OSEPA

Hammer Mill NEA

Hydrator PFFEIFER

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Sorbacal® SP

Main equipments

Hazemag Crusher

Continuous mixer EMT

Heater ECLIPSE

Cage mill

Continuous mixer EMT

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Environmental status - full compliance with all legal requirements

• Certificate of Environmental Management System based on ISO 14001 since 2013

• VCS plant location at the border of the landscape protected area (LPA) Czech Karst,

• All quarries inside the LPA border , close to the Koneprusy Caves

- many limitations, requires close co-operation with authorities

Environmental management • Automatic continuous immission monitoring station (CAPEX and OPEX by VCS) in the Czech

official air quality monitoring system network is situated 2 km West from the plant since 2009

• Periodical measurement of dust, NOx and noise in all 3 neighbouring villages and in other surroundings

• Monitoring of: nitrogen deposition, flora composition and development, butterflies occurrence, fungi occurrence, hydrogeology, seismic monitoring in Koneprusy Caves

Environment

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Strong environmental orientation

Lhoist in the Czech Republic

LHOIST Central Europe (PL,CZ,SK)

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- FGD/FGT Flue gas compound to treat: - acid compounds : SO2, SO3, HF, HCl - PCDD/F, heavy metals Fly ash mechanical performance stabilisation

- Water Neutralization of acidic compounds

Precipitation of harmful cations and anions:

- heavy metals, sulphates, phosphates, fluorides etc.

Flocculation and coagulation of colloidal particles

Technologies: Wet CaCO3, CaO Power units (above 100 MW )

Semi-wet, Fluid.S-W and Dry (CDS) CaO, Milk of lime, Hydrated lime Power, heating units (50-100 MW)

FBB CaCO3 Power units (above 100 MW )

Dry and combined technologies Sorbacal SP (Special hydrated lime ) Industry, small heating units (0-50 MW)

Segment: FGD, FGT Key drivers : EU air pollution directive National transition plan High sulphur content in lignite ( 0,5 -2,0 S% )

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Dry technologies Sorbacal® SP, SPS

- High reactive sorbent - High pore volume and specific surface

Sorbacal® SP◄ Comparison► standard Ca(OH)2

Technology for product application

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Injecto-Matic®

Dosing device for direct injection of dry sorbents into flue gas stream. 40 m3 silo or Big Bag station

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Actherm Chomutov

Referencies

3 x 80 t /h boilers , lignite, bag filter, 140-160 C

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Example of middle size industry and municipal heating plant

Till 2015 DeSOx Removal needs : max. 40%, Sorbacal® SP CDS technology since 2016 ( new limit: 400 mg / Nm3 ), Sorbacal® H – National Transition Plan impact

Plzeňská teplárenská plant

Referencies

2x granulation boilers, 1x fluid boiler,

1x biomass, 1x Municipal Incinerator plan

Central heat supply net in Pilzen city

Circulation Desulphurisation FGD unit

Local hydratation unit, Fabric filtr

Full range supply of : Sorbacal® C Sorbacal® Q Sorbacal® H/SP Sorbacal® AC Q (blended)

Example of large size industry and municipal heating plant

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Referencies

AGC Flat Glass Czech a.s., Retenice plant Limestone is used for glass batch composition.

Float glass is soda-lime-silicate flat glass. Float line R1 Coloured float glass, 1,6 – 10mm Automotive and Architectural Float line R2 Clear float glass 3 - 12mm Architectural

Float line R3 Coloured float glass 1,6 - 6mm Automotive

The largest float plant in Central Europe ( more than 2 000 T/day )

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AGC Flat Glass Czech a.s., Retenice plant

Referencies

All float lines are built as The Best Available Technologies (BAT ) Anti-pollution control units (APC) to clean gas emissions from dust, sulphur dioxide and nitrogen oxides. Sorbacal® SP product is used as SO2 absorbing agent in two of three APCs.

DeSOx Removal needs : max. 50%

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Johns Manville, plant Trnava Significant producer of glass fibers in Europe Visucal® Q 90 - Low ferromagnetic particle quicklime is used for glass production.

Referencies

Sorbacal® product is used as SO2 , HF and HCl absorbing agent in anti-pollution control units.

Acids Removal needs : 90%

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Segment: Water

Key drivers: EU and CSN directives ( ČSN EN 12518 CaO, 1018 – CaCO3 )

CZ Ministery of Helth Notice 409/2015 Sb.

Technologies : Neutralization units of waste and mine water Drinking Water Treatment plant Proces water preparation plants Municipal waste water treatment plants

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Technology for Milk of lime production

Duwa-Matic®

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15 units installed during last decade in Czech Rep.

Batch/Continous process and Capacity size

Wide range of dosing on different customer sites:

Small units DM 650 : 50 – 300 kg CaO/h

Giant units: 3,2 – 6,4 t CaO/h

Silo capacity range: 40 – 180 m3

Only 1 small unit is using Big-Bags

95 % of units operate continuously

Technology for Milk of lime production

Duwa-Matic®

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Automatic operation on customer sites:

95 % automatized, unit operation via PC in control room

Feeding lime systém: 100% Hethon feeder

Only giant unit feeding hoppers equiped with tensiometer

Neutralac® 90 - High reactive milled quicklime

DIAMO s. p. Key state company responsible for remediation of old mines: uranium, metal and coal

Location Stráž pod Ralskem

Underground chemical leaching of uranium ore during 1968 – 1996

Area: 628 hectare with 15 000 injection points

Chemicals injected into sandstones: > 4000 kt of H2SO4

300 kt of HNO3

120 kt of NH3

Referencies

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Total quantity of uranium mined: 15 862 t

DIAMO s. p.

Location Stráž pod Ralskem

Long-term treatment of contaminated water due to danger for drinking water sources

Total contamination is spread almost on 27 km2

Water volume affected : > 400 mio m3

Quantity of soluted sulphuric anions: > 11 mio t

Main contaminats: SO4, NH4, and Al ions

New Remediation technology units in operation since 2010

Referencies

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DIAMO s. p. Status 2016

Referencies

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Referencies

DIAMO s. p.

Thank you for your attention.

E-mail: roman.hubalek@lhoist.com, prodej@lhoist.com GSM: +420 602 495 376