Displaying items by tag: Plant
Votorantim Cimentos installs chlorine bypass at Vidal Ramos plant
14 December 2022Brazil: Votorantim Cimentos has installed a chlorine bypass at its integrated Vidal Ramos plant in Santa Catarina. The US$10m upgrade is intended to allow the unit to process more alternative fuels such as plastics, fabrics and personal protective equipment. The company says it is the first such installation in the country. It will allow the plant to increase its co-processing volumes by 62% to 73,000t/yr from 45,000t/yr. In 2021 the plant used 65,000t of petcoke. This is expected to fall to 53,000t/yr with the addition of the chlorine bypass, reducing CO2 emissions by 5% or 12,200t.
Halla Cement awards upgrade project to KHD
30 August 2022South Korea: Halla Cement has awarded a supply and engineering contract to Germany-based KHD Humboldt Wedag for an upgrade of line 2 at Okke plant. KHD will supply a new Pyroclon R type calciner, with a Pyrotop type mixing chamber, and a 4.2m x 15m Pyrorotor type combustion reactor. Other equipment being provided includes: a Pyrobox type coal firing system for process start-up and operation balancing; replacement of stage five cyclones with new high-efficiency cyclones; and a new kiln inlet chamber with orifice. Erection and commissioning of the modernised production line is scheduled for the first quarter of 2024.
This latest project marks the second installation of a Pyrorotor at Halla Cement’s Okke plant. The installation of line 3 at the site is currently ongoing with commissioning scheduled for the first quarter of 2023. Overall, this will be KHD’s ninth installation of a Pyrorotor in South Korea.
The Pyrorotor has been promoted to cement plants as a way of using low-quality alternative fuels with minimal pre-processing. It offers a thermal substitution rate of over 85% and will also allow the Okke plant to reduce its NOx emissions. The installation of the new Pyroclon R type calciner and the high-efficiency cyclones in the lowest preheater stages will also provide the production line with an increase in efficiency due to an overall pressure drop reduction in the entire preheater.
UK: Mexico-based Cemex has inaugurated the Climafuel unit at Rugby cement plant. Climafuel is a waste derived fuel which is made using domestic and commercial waste. The upgrade is intended to allow the cement plant to operate at a 100% alternative fuels (AF) substitution rate. This is the first Cemex plant to be able to do this.
Sergio Menéndez, the President of Cemex Europe, Middle East, Africa & Asia, said, “With the completion of this considerable development, we have set new records in alternative fuel substitution, the highest of any of our plants and eventually expect to phase out completely the usage of fossil fuels at the plant. We expect the Rugby plant to be a model for other Cemex cement plants around the world.”
ABB to launch ProKiln inlet gas sampling system
01 June 2022Switzerland: Switzerland-based ABB is launching the ProKiln inlet gas sampling system to help cement producers reduce the volatility associated with using higher levels of alternative fuels (AF) and allow kilns to run for longer. The product offers probe cleaning with increased mechanical strength, which includes a dual probe retraction system to ensure no sampling interruption.
The supplier says that its product uses an extractive filter in the tip of the probe which separates sample gas from the dust load to reduce problems faced with scaling of material when gathering data. It also uses two air blasters to clean the tip to maintain a sample path for analysis. A three-dimensional printed stainless steel nozzle is intended to ensure that no blockages at the tip of the probe occur and the system is mounted on a buggy running on a retractor which carries the probe in and out of the kiln allowing it to be cleaned automatically. Measuring 3m long, the gas probe is water cooled with an extractive filter placed at the sample and flow is maintained by the blasters. A cooling system also provides recirculating water for temperature control.
The ProKiln has been tested for six months at Holcim’s Lägerdorf site in Germany, a cement plant that has an AF substitution rate of over 80%.
Dulsco commissions refuse-derived fuel plant in Dubai
13 April 2022UAE: Dulsco has commissioned a 70,000t/yr refuse-derived fuel (RDF) plant at the Expo 2020 Dubai site in Dubai. RDF from the plant will be used by local cement producers and other industries. The project follows the UAE’s Circular Economy Policy 2021 - 2031. Dulsco’s business interests cover waste management, outsourcing, recruitment and workshop and fabrication services.
Kuwait: Kuwait City Cement has received government approval for its plan to establish a municipal solid waste (MSW) plant. The Al Qabas newspaper has reported that, when commissioned, the plant will supply refuse-derived fuel to the country’s cement industry.
Kuwait cement previously applied for a licence to burn municipal waste fractions at its Shuaiba, Ahmadi, cement plant in 2019.
HeidelbergCement India commissions alternative fuels processing line at Narsingarh clinker plant
12 January 2022India: HeidelbergCement India has commissioned an alternative fuel (AF) receiving, storage and feeding system at its Narsingarh clinker plant in Madhya Pradesh. United News of India has reported the company’s investment in the facility’s construction as US$2.16m. It says that it will give the Narsingarh plant an AF substitution rate of 5%, reducing its carbon footprint by 42,000t/yr. The company plans to raise its substitution rate to over 10% ‘in the coming years.’
Norway: Norcem plans to invest up to Euro8m on upgrades at its integrated Kjøpsvik cement plant to improve its receiving, handling and feeding of alternative fuels. The project will be implemented by 2023. The work will include installing new storage and dosing systems for waste oil, FAB pellets and bone meal.
Punjab Renewable Energy Systems to supply biofuel lines for three UltraTech Cement cement plants
13 October 2021India: UltraTech Cement has signed a memorandum of understanding with Punjab Renewable Energy Systems for the installation of biomass processing lines to produce cement fuel at three of its Indian integrated cement plants. The supplier will also build a sustainable supply chain of agricultural waste for the plants. The companies say that the deal will help to dispose of the waste, which is normally burnt in the open, and reduce the cement plants' Scope 1 and 2 emissions. Currently, the plants rely on imported coal. Additionally, it will augment incomes in local farming communities.
Poland: Lafarge Poland has laid the foundation stone for the Euro100m new kiln line at its Małogoszcz cement plant. The replacement of the three existing kilns and installation of an alternative fuel (AF) line aims to reduce the plant’s CO2 emissions by 20% and its energy consumption by 33%. The company, a subsidiary of Switzerland-based Holcim, aims to make the cement plant into one of the EU’s most modern. China National Building Material (CNBM) subsidiary Nanjing Kisen International Engineering will carry out the work, which is scheduled for completion in early 2023.
Project director Krzysztof Byczyński said “One of the three kilns has already been demolished and in its place a new kiln will be built with the necessary installations. Preparatory works for the construction of a new kiln are currently underway.”