The Fives FCB sustainable cement plant

FICEM APCAC XXIX Congreso Tcnico Costa Rica - San Jos 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

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

Combined with the Fives Pillard Precalciner burner

A low-NOx high performance burner

(in Hoang Mai/Vietnam cement plant)

FICEM APCAC 05/09/2012

The Fives FCB Zero-NOx Precalciner: a proven technology

Hoang Mai (Vietnam)

Umm Bab (Qatar)

Holcim-Apasco (Mexico)

100% low volatile anthracite coal (< 8%) 5.6 m capacity 4,000 t/d Residence time: 4.5 seconds

Natural gas 5.2 m capacity 5,000 t/d

Residence time: 3 seconds

100% petcoke & ASF 5.6 m capacity 3,500 t/d

Residence time: 5 seconds

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FICEM APCAC 05/09/2012

The Fives FCB Horomill: an advanced technology

FICEM APCAC 05/09/2012

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

Horomill: a worldwide proven technology

2 2

3
2+4 1+2 2+2

3
2

Plants with both raw and cement grinding

Cement grinding Twin cement grinding Raw grinding

Slag or mineral grinding Twin slag grinding Not erected

56 HOROMILLS
FICEM APCAC 05/09/2012

More than 1.5 millions hours of operation

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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 emissions

mg/Nm
550 500 450 400 350 300 250 200 150 100
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

HOURLY NOx EMISSIONS AT CHIMNEY STACK

Less than 500 mg/Nm3 NOx at preheater exhaust

and less than 100 ppm CO with 100% petcoke

No need of SNCR system in most cases

TOTAL NOx (mg/Nm @ 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 t/h kW kWh/t kWh/t kWh/t kWh/t kWh/t CEM II/B-P 3 600 130 2 047 15,7 0,5 0,8 4,2 21,3 CEM II/B-P t/h kW kWh/t kWh/t kWh/t kWh/t kWh/t kWh/t 12,4 37% 3 800 121 3 600 29,8 0,3 0,4 3,3 33,7 Slag / CEM III/A/B 4 000 67 1 880 28,1 1,5 1,3 8,5 39,4 Slag / CEM III/A/B 4 000 53 3 600 67,9 0,6 0,8 6,3 75,7 36,3 48% CEM I / CEM II/A-L 3000 / 3500 115 1 900 16,5 0,5 0,9 3,7 21,6 CEM I / CEM II/A-L 3200 / 3700 115 3 600 31,3 0,2 0,4 2,6 34,5 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%

Ball Mill
Blaine Capacity Ball mill Ball mill TSV Elevator Fan Total Savings

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 230 t/h - 12% R90 Absorbed Power Mill Separator Elevator Fan Auxiliaries Total abs. Power kW Specific energy kWh/t Savings (% ) Vertical mill 1 820 60 30 1 880 60 3 850 16.7 Horomill 1 820 30 160 770 50 2 830 12.3 -26.5%

Cement grinding 115 t/h CEM II A/P - 3900 Blaine Vertical mill 1 850 135 30 930 60 3 005 26.1 Horomill 1 850 55 105 450 50 2 510 21.8 -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

The Fives FCB sustainable plant High clinker substitution: stability & flexibility
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
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

Trino SMA Cimentas Darica Karsdorf Tepetzingo 3 & 4 Cizkovice Tepetzingo 1 & 2 RCC Denizli 3 & 4 Maxit Confidential 1 Confidential 2 Konya

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

FICEM APCAC 05/09/2012
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Ho ro m sit ill es

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 Common stack Booster fan

HE cyclones

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