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Transcript of sustainable cement plant
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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/
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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