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    Fives

    FICEM APCAC XXIX Congreso Tcnico Costa Rica - San Jos 05/09/2012

    Driving Progress

    The Fives FCBsustainable

    cement plant

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    FICEM APCAC 05/09/2012 2

    The Fives FCB sustainable plant in figures

    Less than 500 mg/Nm3 of NOx (equivalent NO2 dry @ 10%O2) at stack

    Up to 70% of AFR substitution at precalciner (on thermal load)

    Thanks to the combination of the Fives FCB precalciner & Fives Pillard burner

    Less than 80 kWh/t of cement

    High clinker substitution factor

    Thanks to the Fives FCB Horomill & Fives FCB TSVTM

    Zero water consumption

    Thanks to the combination of the Fives FCB Horomill & common filter

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    A combination of advanced proven technologies

    Low emissions

    Low power consumptionHigh alternative fuels substitution

    Zero water consumption

    High clinker substitution

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    The Fives FCB Zero-NOx Precalciner: an advanced technology

    The Concept: a real COMBUSTION CHAMBER

    Downward High-Performance Burner: Creating a Hot Spot For successful ignition & efficient

    combustion Staged Combustion in reducing conditions Zero-NOx

    Air and Meal injection: Through a ring without cycloning Creating a meal curtain Protection of lining Progressive and efficient mixing

    Designed to burn difficult solid fuelsand a high rate of alternative solid fuelswith Zero-NOx emission

    Low-NOx burner with

    central channel for ASF

    Meal feed

    Direct flow

    Ring-shaped injection

    Distribution chamber

    FICEM APCAC 05/09/2012

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    The Fives FCB Zero-NOx Precalciner: an advanced technology

    Hot spot forcomplete burn-out

    Centered flame

    Protected lining

    FICEM APCAC 05/09/2012

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    Combined with the Fives Pillard Precalciner burner

    A low-NOx high performance burner

    (in Hoang Mai/Vietnam cement plant)

    FICEM APCAC 05/09/2012

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    The Fives FCB Zero-NOx Precalciner: a proven technology

    Hoang Mai (Vietnam)

    100% low volatile anthracite coal (< 8%)

    5.6 m capacity 4,000 t/d

    Residence time: 4.5 seconds

    Umm Bab (Qatar)

    Natural gas

    5.2 m capacity 5,000 t/d

    Residence time: 3 seconds

    Holcim-Apasco (Mexico)

    100% petcoke & ASF

    5.6 m capacity 3,500 t/d

    Residence time: 5 seconds

    FICEM APCAC 05/09/2012

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    The Fives FCB Horomill: an advanced technology

    FICEM APCAC 05/09/2012

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    The Fives FCB Horomill: an advanced technology

    FICEM APCAC 05/09/2012

    Grinding layer centrifugation

    Control of grinding actions

    Control of material advance

    Simple concept

    Continuous adaptations

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    3

    2+4

    1+2

    2+2

    2

    2

    2

    2

    3

    2

    Twin cement grinding

    Cement grinding

    Raw grinding

    Plants with both raw

    and cement grinding

    Slag or mineral grinding

    Twin slag grinding

    Not erected

    56 HOROMILLS

    Horomill: a worldwide proven technology

    10

    More than 1.5 millions hours of operation

    FICEM APCAC 05/09/2012

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    A combination of advanced proven technologies

    Low emissions

    Low power consumption

    High alternative fuels substitution

    Zero water consumption

    High clinker substitution

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    The Fives FCB sustainable plant

    Low emissions

    Cartago (Holcim Costa Rica) NOx Emissions hourly average in mg/Nm3 @ 10%O2 dry

    Less than500 mg/Nm3

    NOx atpreheaterexhaust

    No need ofSNCR system

    in most cases

    HOURLY NOx EMISSIONS AT CHIMNEY STACK

    100

    150

    200

    250

    300

    350

    400

    450

    500

    550

    00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00

    TOTAL NOx (mg/Nm @ 10%O2, dry fumes) on 15th to 19th October 2007

    and less than 100 ppm CO with 100% petcoke

    mg/Nm

    FICEM APCAC 05/09/2012

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    A combination of advanced proven technologies

    Low emissions

    Low power consumption

    High alternative fuels substitution

    Zero water consumption

    High clinker substitution

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    The Fives FCB sustainable plant

    High alternative fuels substitution

    Cartago (Holcim Costa Rica) : up to 70% coarse ASF(thermal load) can be fed directly in the precalcinerburner (ASF made of rubber, plastics and papers)

    ppm kg/

    FICEM APCAC 05/09/2012

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    The Fives FCB sustainable plant

    High alternative fuels substitution

    Alternative

    FuelsHermosillo (Holcim Apasco)

    A quick and efficient ignition

    A good burn-out & low CO

    50% of shredded tyres

    (thermal load)

    FICEM APCAC 05/09/2012

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    A combination of advanced proven technologies

    Low emissions

    Low power consumption

    High alternative fuels substitution

    Zero water consumption

    High clinker substitution

    Th Fi FCB t i bl l t

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    The Fives FCB sustainable plant

    Low power consumption

    Horomill3800 CEM II/B-PSlag /

    CEM III/A/B

    CEM I /

    CEM II/A-LCEM I

    Blaine 3 600 4 000 3000 / 3500 4 000

    Capacity t/h 130 67 115 72

    Horomill kW 2 047 1 880 1 900 1 880

    Horomill kWh/t 15,7 28,1 16,5 26,1

    TSV

    kWh/t 0,5 1,5 0,5 1,5

    Elevator kWh/t 0,8 1,3 0,9 1,3

    Fan kWh/t 4,2 8,5 3,7 6,7

    Total kWh/t 21,3 39,4 21,6 35,5

    Ball Mill CEM II/B-P Slag /CEM III/A/B

    CEM I /CEM II/A-L

    CEM I

    Blaine 3 800 4 000 3200 / 3700 4 200

    Capacity t/h 121 53 115 78

    Ball mill kW 3 600 3 600 3 600 3 600

    Ball mill kWh/t 29,8 67,9 31,3 46,2

    TSV

    kWh/t 0,3 0,6 0,2 0,6

    Elevator kWh/t 0,4 0,8 0,4 0,6

    Fan kWh/t 3,3 6,3 2,6 4,1

    Total kWh/t 33,7 75,7 34,5 51,4

    Savings kWh/t 12,4 36,3 13,0 15,9

    37% 48% 38% 31%

    Large energy savings compared to the ball mill

    FICEM APCAC 05/09/2012

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    Horomill : the lowest energy consumption

    but also substantial energy savings compared with the vertical mill

    Absorbed Power Vertical mill Horomill Vertical mill Horomill

    Mill 1 820 1 820 1 850 1 850

    Separator 60 30 135 55

    Elevator 30 160 30 105

    Fan 1 880 770 930 450

    Auxiliaries 60 50 60 50

    Total abs. Power kW 3 850 2 830 3 005 2 510

    Specific energy kWh/t 16.7 12.3 26.1 21.8

    Savings (%) -26.5% -16.5%

    Raw meal grinding Cement grinding

    230 t/h - 12% R90 115 t/h CEM II A/P - 3900 Blaine

    FICEM APCAC 05/09/2012

    which can represent more than 1 MUSD in annual operation cost

    The Fives FCB sustainable plant

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    The Fives FCB sustainable plant

    Low power consumption

    Cement plant consumption: 80 kWh/ton of cement

    Example of cement plants fully equippedwith Fives FCB Horomill

    Tepetzingo (Mexico): 2 lines with 1 Horomillfor raw grinding and 1 Horomill for cement

    Cerritos (Mexico): 2 lines with 1 Horomillfor raw grinding and 2 Horomill for cement

    Apazapan (Mexico):1 line with 1 Horomillfor raw grinding and 2 Horomill for cement

    Typical cement produced: CEM I / CEM II-A/P @ 4200 Blaine

    FICEM APCAC 05/09/2012

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    A combination of advanced proven technologies

    Low emissions

    Low power consumption

    High alternative fuels substitution

    Zero water consumption

    High clinker substitution

    The Fives FCB sustainable plant

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    The Fives FCB sustainable plant

    High clinker substitution: stability & flexibility

    the Horomill installed at Lafarge Karsdorf (Germany) produces up to 7 different recipes

    FICEM APCAC 05/09/2012

    Horom

    ill

    sites CEM

    I

    CE

    MII/

    A-L

    CE

    MII/

    A-P

    CE

    MII/

    B-P

    CE

    MII/

    B-S

    CE

    MIII/A

    CE

    MIII/B

    CE

    MV

    /A

    Raw

    meal

    Slag

    Lim

    estone

    Anh

    ydri

    te

    Dol

    omit

    e

    Trino 2

    SMA 1

    Cimentas 1

    Darica 3

    Karsdorf 7Tepetzingo 3 & 4 2

    Cizkovice 2

    Tepetzingo 1 & 2 1

    RCC 1

    Denizli 3 & 4 3

    Maxit 1

    Confidential 1 1

    Confidential 2 1Konya 1

    7 2 4 2 2 1 1 1 1 1 1 2 1

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    A combination of advanced proven technologies

    Low emissions

    Low power consumption

    High alternative fuels substitution

    Zero water consumption

    High clinker substitution

    The Fives FCB sustainable plant

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    The Fives FCB sustainable plantZero water consumption: the Fives FCB common filter

    FICEM APCAC 05/09/2012

    Example of zero water burning line equipped with Fives FCB common filter: Holcim Hermosillo

    Air/Air Heat exchanger

    Mixing chamberwith dilution

    Common stack

    Common filterwith PTFE bagsHE cyclones

    Booster fan

    Preheater downcomerwithout water injection

    The Fives FCB sustainable plant

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    The Fives FCB sustainable plantZero water consumption: the Fives FCB Horomill

    FICEM APCAC 05/09/2012

    Example of zero water cement grinding equipped with Fives FCB Horomill: Holcim Hermosillo

    No need of water for grinding

    Centrifugation of the layer

    procuring grinding stability

    No need of water thermal balance

    External recirculation

    with cooling in the classifier loop

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    FICEM APCAC 05/09/2012 25

    The Fives FCB sustainable plant in figures

    Less than 500 mg/Nm3 of NOx (equivalent NO2 dry @ 10%O2) at stack

    Up to 70% of AFR substitution at precalciner (on thermal load)

    Thanks to the combination of the Fives FCB precalciner & Fives Pillard burner

    Less than 80 kWh/t of cement

    High clinker substitution factor

    Thanks to the Fives FCB Horomill & Fives FCB TSVTM

    Zero water consumption

    Thanks to the combination of the Fives FCB Horomill & common filter

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    Thank you for your attention