The Fives FCB
sustainable
cement plant
FICEM APCAC – XXIX Congreso Técnico – Costa Rica - San José – 05/09/2012
Fives
Driving Progress
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
2
A combination of advanced proven technologies
Low emissions
High alternative fuels substitution
Low power consumption
High clinker substitution
Zero water consumption
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
Low-NOx burner with
central channel for ASF
Distribution chamber
Ring-shaped injection
Direct flow
Meal feed
Designed to burn difficult solid fuels
and a high rate of alternative solid fuels
with Zero-NOx emission
FICEM APCAC – 05/09/2012
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The Fives FCB Zero-NOx Precalciner: an advanced technology
 Hot spot for
complete 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%)
Ø 5.6 m – capacity 4,000 t/d
Residence time: 4.5 seconds
FICEM APCAC – 05/09/2012
Umm Bab (Qatar)
Holcim-Apasco (Mexico)
•
•
•
•
•
•
Natural gas
Ø 5.2 m – capacity 5,000 t/d
Residence time: 3 seconds
100% petcoke & ASF
Ø 5.6 m – capacity 3,500 t/d
Residence time: 5 seconds
7
The Fives FCB Horomill: an advanced technology
FICEM APCAC – 05/09/2012
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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
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Horomill®: a worldwide proven technology
2
2
2
2
3
3
2+4
1+2
2
2+2
Plants with both raw
and cement grinding
Cement grinding
Twin cement grinding
Raw grinding
56 HOROMILLS
FICEM APCAC – 05/09/2012
Slag or mineral grinding
Twin slag grinding
Not erected
More than 1.5 millions hours of operation
10
A combination of advanced proven technologies
Low emissions
High alternative fuels substitution
Low power consumption
High clinker substitution
Zero water consumption
The Fives FCB sustainable plant
Low emissions
mg/Nm³
HOURLY NOx EMISSIONS AT CHIMNEY STACK
550
Less than
500 mg/Nm3
NOx at
preheater
exhaust
500
450
400
350
300
250
200
… and less than 100 ppm CO with 100% petcoke
150
100
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
No need of
SNCR system
in most cases
TOTAL NOx (mg/Nm³ @ 10% O2, dry fumes) on 15th to 19th October 2007
Cartago (Holcim Costa Rica) NOx Emissions hourly average in mg/Nm3 @ 10%O2 dry
FICEM APCAC – 05/09/2012
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A combination of advanced proven technologies
Low emissions
High alternative fuels substitution
Low power consumption
High clinker substitution
Zero water consumption
The Fives FCB sustainable plant
High 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
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The Fives FCB sustainable plant
High 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
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A combination of advanced proven technologies
Low emissions
High alternative fuels substitution
Low power consumption
High clinker substitution
Zero water consumption
The Fives FCB sustainable plant
Low power consumption
Horomill® 3800
Blaine
Capacity
Horomill ®
Horomill ®
TSV™
Elevator
Fan
Total
CEM II/B-P
3 600
130
2 047
15,7
0,5
0,8
4,2
21,3
t/h
kW
kWh/t
kWh/t
kWh/t
kWh/t
kWh/t
Ball Mill
CEM II/B-P
Blaine
Capacity
Ball mill
Ball mill
TSV™
Elevator
Fan
Total
t/h
kW
kWh/t
kWh/t
kWh/t
kWh/t
kWh/t
Savings
kWh/t
3 800
121
3 600
29,8
0,3
0,4
3,3
33,7
12,4
37%
Slag /
CEM III/A/B
4 000
67
1 880
28,1
1,5
1,3
8,5
39,4
CEM I /
CEM II/A-L
3000 / 3500
115
1 900
16,5
0,5
0,9
3,7
21,6
Slag /
CEM III/A/B
4 000
53
3 600
67,9
0,6
0,8
6,3
75,7
CEM I /
CEM II/A-L
3200 / 3700
115
3 600
31,3
0,2
0,4
2,6
34,5
36,3
48%
13,0
38%
CEM I
4 000
72
1 880
26,1
1,5
1,3
6,7
35,5
CEM I
4 200
78
3 600
46,2
0,6
0,6
4,1
51,4
15,9
31%
Large energy savings compared to the ball mill …
FICEM APCAC – 05/09/2012
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Horomill® : the lowest energy consumption
Raw meal grinding
Cement grinding
230 t/h - 12% R90µ
115 t/h CEM II A/P - 3900 Blaine
®
®
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%
… 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
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The Fives FCB sustainable plant
Low 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
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A combination of advanced proven technologies
Low emissions
High alternative fuels substitution
Low power consumption
High clinker substitution
Zero water consumption
Ho
ro
m
sit ill
es
CE
M
I
CE
M
II
CE / A-L
M
II
CE / A-P
M
II /
BCE
P
M
II /
BS
CE
M
III/
A
CE
M
III/
B
CE
M
V/A
Ra
w
me
al
Sla
g
Lim
es
ton
e
An
hy
dr
ite
Do
lom
ite
The Fives FCB sustainable plant
High clinker substitution: stability & flexibility
Trino
SMA
Cimentas
Darica
Karsdorf
Tepetzingo 3 & 4
Cizkovice
Tepetzingo 1 & 2
RCC
Denizli 3 & 4
Maxit
Confidential 1
Confidential 2
Konya
2
1
1
3
7
2
2
1
1
3
1
1
1
1
7
2
4
2
2
1
1
1
1
1
1
2
1
the Horomill® installed at Lafarge Karsdorf (Germany) produces up to 7 different recipes
FICEM APCAC – 05/09/2012
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A combination of advanced proven technologies
Low emissions
High alternative fuels substitution
Low power consumption
High clinker substitution
Zero water consumption
The Fives FCB sustainable plant
Zero 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
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The Fives FCB sustainable plant
Zero 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
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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
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Thank you for your attention