the fives fcb sustainable cement plant
DESCRIPTION
The Fives FCB sustainable cement plant. FICEM APCAC – XXIX Congreso Técnico – Costa Rica - San José – 05/09/2012. Driving Progress. Fives . The Fives FCB sustainable plant in figures. Less than 500 mg/Nm3 of NOx (equivalent NO2 dry @ 10%O2) at stack - PowerPoint PPT PresentationTRANSCRIPT
Fives
FICEM APCAC – XXIX Congreso Técnico – Costa Rica - San José – 05/09/2012
Driving Progress
The Fives FCBsustainable
cement plant
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
A combination of advanced proven technologies
Low emissions
Low power consumption
High alternative fuels substitution
Zero water consumption
High clinker substitution
4
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 fuels and a high rate of alternative solid fuels with 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
5
The Fives FCB Zero-NOx Precalciner: an advanced technology
Hot spot for complete burn-out
Centered flame
Protected lining
FICEM APCAC – 05/09/2012
6
Combined with the Fives Pillard Precalciner burner
A low-NOx high performance burner (in Hoang Mai/Vietnam cement plant)
FICEM APCAC – 05/09/2012
7
The Fives FCB Zero-NOx Precalciner: a proven technology
Hoang Mai (Vietnam)• 100% low volatile anthracite coal (< 8%)• Ø 5.6 m – capacity 4,000 t/d• Residence time: 4.5 seconds
Umm Bab (Qatar)• Natural gas• Ø 5.2 m – capacity 5,000 t/d• Residence time: 3 seconds
Holcim-Apasco (Mexico)• 100% petcoke & ASF• Ø 5.6 m – capacity 3,500 t/d• Residence time: 5 seconds
FICEM APCAC – 05/09/2012
8
The Fives FCB Horomill: an advanced technology
FICEM APCAC – 05/09/2012
9
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
32+4
1+2
2+2
2
2
2
2
3
2
Twin cement grindingCement grinding
Raw grinding
Plants with both rawand cement grinding
Slag or mineral grindingTwin slag grindingNot erected
56 HOROMILLS
Horomill®: a worldwide proven technology
10
More than 1.5 millions hours of operation
FICEM APCAC – 05/09/2012
A combination of advanced proven technologies
Low emissions
Low power consumption
High alternative fuels substitution
Zero water consumption
High clinker substitution
12
The Fives FCB sustainable plantLow emissions
Cartago (Holcim Costa Rica) NOx Emissions hourly average in mg/Nm3 @ 10%O2 dry
Less than500 mg/Nm3
NOx atpreheaterexhaust
No need ofSNCR systemin 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/Nm³ @ 10%O2, dry fumes) on 15th to 19th October 2007
… and less than 100 ppm CO with 100% petcoke
mg/Nm³
FICEM APCAC – 05/09/2012
A combination of advanced proven technologies
Low emissions
Low power consumption
High alternative fuels substitution
Zero water consumption
High clinker substitution
14
The Fives FCB sustainable plantHigh alternative fuels substitution
Cartago (Holcim Costa Rica) : up to 70% coarse ASF (thermal load) can be fed directly in the precalciner burner (ASF made of rubber, plastics and papers)
ppm kg/h
FICEM APCAC – 05/09/2012
15
The Fives FCB sustainable plantHigh alternative fuels substitution
Alternative Fuels
Hermosillo (Holcim Apasco)
A quick and efficient ignition
A good burn-out & low CO
50% of shredded tyres (thermal load)
FICEM APCAC – 05/09/2012
A combination of advanced proven technologies
Low emissions
Low power consumption
High alternative fuels substitution
Zero water consumption
High clinker substitution
17
The Fives FCB sustainable plantLow power consumption
Horomill® 3800 CEM II/B-P Slag /CEM III/A/B
CEM I /CEM II/A-L CEM I
Blaine 3 600 4 000 3000 / 3500 4 000Capacity t/h 130 67 115 72Horomill® kW 2 047 1 880 1 900 1 880Horomill® kWh/t 15,7 28,1 16,5 26,1TSV™ kWh/t 0,5 1,5 0,5 1,5Elevator kWh/t 0,8 1,3 0,9 1,3Fan kWh/t 4,2 8,5 3,7 6,7Total 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 200Capacity t/h 121 53 115 78Ball mill kW 3 600 3 600 3 600 3 600Ball mill kWh/t 29,8 67,9 31,3 46,2TSV™ kWh/t 0,3 0,6 0,2 0,6Elevator kWh/t 0,4 0,8 0,4 0,6Fan kWh/t 3,3 6,3 2,6 4,1Total kWh/t 33,7 75,7 34,5 51,4
Savings kWh/t 12,4 36,3 13,0 15,937% 48% 38% 31%
Large energy savings compared to the ball mill …
FICEM APCAC – 05/09/2012
18
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% R90µ 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
19
The Fives FCB sustainable plantLow power consumption
Cement plant consumption: 80 kWh/ton of cement
Example of cement plants fully equipped with Fives FCB Horomill
Tepetzingo (Mexico): 2 lines with 1 Horomill®
for raw grinding and 1 Horomill® for cement
Cerritos (Mexico): 2 lines with 1 Horomill®
for raw grinding and 2 Horomill® for cement
Apazapan (Mexico):1 line with 1 Horomill®
for raw grinding and 2 Horomill® for cement
Typical cement produced: CEM I / CEM II-A/P @ 4200 Blaine
FICEM APCAC – 05/09/2012
A combination of advanced proven technologies
Low emissions
Low power consumption
High alternative fuels substitution
Zero water consumption
High clinker substitution
21
The Fives FCB sustainable plantHigh clinker substitution: stability & flexibility
the Horomill® installed at Lafarge Karsdorf (Germany) produces up to 7 different recipes
FICEM APCAC – 05/09/2012
Trino 2SMA 1Cimentas 1Darica 3Karsdorf 7Tepetzingo 3 & 4 2Cizkovice 2Tepetzingo 1 & 2 1RCC 1Denizli 3 & 4 3Maxit 1Confidential 1 1Confidential 2 1Konya 1
7 2 4 2 2 1 1 1 1 1 1 2 1
A combination of advanced proven technologies
Low emissions
Low power consumption
High alternative fuels substitution
Zero water consumption
High clinker substitution
23
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
24
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
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
Thank you for your attention