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The Fives FCB sustainable cement plant

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

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The Fives FCB sustainable cement plant

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  1. The Fives FCBsustainablecement plant FICEM APCAC – XXIX Congreso Técnico – Costa Rica - San José – 05/09/2012 Driving Progress Fives

  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 FICEM APCAC – 05/09/2012

  3. Low emissions • High alternative fuels substitution A combination of advanced proven technologies • Low power consumption • High clinker substitution • Zero water consumption

  4. The Fives FCB Zero-NOx Precalciner: an advanced technology Low-NOx burner with central channel for ASF Distribution chamber Ring-shaped injection Direct flow Meal feed • 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 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 • Simple concept • Continuous adaptations • Grinding layer centrifugation • Control of grinding actions • Control of material advance FICEM APCAC – 05/09/2012

  10. Horomill®: a worldwide proven technology 2 2 2 2 3 3 2+4 1+2 2 2+2 3 Plants with both raw and cement grinding Cement grinding Slag or mineral grinding Twin cement grinding Twin slag grinding Raw grinding Not erected • More than 1.5 millions hours of operation • 56 HOROMILLS FICEM APCAC – 05/09/2012

  11. Low emissions • High alternative fuels substitution A combination of advanced proven technologies • Low power consumption • High clinker substitution • Zero water consumption

  12. The Fives FCB sustainable plantLow emissions mg/Nm³ • Less than500 mg/Nm3NOx atpreheaterexhaust • … and less than 100 ppm CO with 100% petcoke • No need ofSNCR systemin most cases • Cartago (Holcim Costa Rica) NOx Emissions hourly average in mg/Nm3 @ 10%O2 dry FICEM APCAC – 05/09/2012

  13. Low emissions • High alternative fuels substitution A combination of advanced proven technologies • Low power consumption • High clinker substitution • Zero water consumption

  14. The Fives FCB sustainable plantHigh alternative fuels substitution ppm kg/h • 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) 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

  16. Low emissions • High alternative fuels substitution A combination of advanced proven technologies • Low power consumption • High clinker substitution • Zero water consumption

  17. The Fives FCB sustainable plantLow power consumption • 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 which can represent more than 1 MUSD in annual operation cost FICEM APCAC – 05/09/2012

  19. The Fives FCB sustainable plantLow power consumption • 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 Cement plant consumption: 80 kWh/ton of cement FICEM APCAC – 05/09/2012

  20. Low emissions • High alternative fuels substitution A combination of advanced proven technologies • Low power consumption • High clinker substitution • Zero water consumption

  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

  22. Low emissions • High alternative fuels substitution A combination of advanced proven technologies • Low power consumption • High clinker substitution • Zero water consumption

  23. The Fives FCB sustainable plantZero water consumption: the Fives FCB common filter Example of zero water burning line equipped with Fives FCB common filter: Holcim Hermosillo Preheater downcomer without water injection Air/Air Heat exchanger Mixing chamber with dilution Common filter with PTFE bags HE cyclones Common stack Booster fan FICEM APCAC – 05/09/2012

  24. The Fives FCB sustainable plantZero water consumption: the Fives FCB Horomill 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 FICEM APCAC – 05/09/2012

  26. Thank you for your attention

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