Displaying items by tag: Upgrade

Germany: Zement- und Kalkwerke Otterbein plans to invest Euro10m in upgrades to its Otterbein cement plant to increase the sustainability of cement production there. The new equipment will include a hot gas filter SCR catalytic converter system. The producer says that this will install the facility as one of the lowest-CO₂ cement plants in the world. Local press has reported that, after commissioning the new system, the company plans to increase its approved substitution of biomass as fuel to 100% from 60%.

Russia: Eurocement says that its subsidiary Peterburgcement’s Slantsy cement plant in Leningrad Oblast is undergoing an upgrade in order to co-process 100,000t/yr of alternative fuel (AF) in its cement production. The group claims that the upgrade will improve the efficiency of the 1.9Mt/yr plant and reduce its consumption of natural gas by 25%. The purported cost of the upgrade is US$1.77m.

Eurocement previously implemented the same technology at another of its cement plants in the Republic of Mordovia.

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.”

Switzerland: 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%.

Germany: Australia-based FCT Combustion has successfully delivered a new Turbu-Flex burner to replace the existing burner at HeidelbergCement’s Hanover, Lower Saxony, cement plant. FCT Combustion will also supply burner accessories and add-ons, an igniter, a flame sensor, fans, blowers and spare parts. The project aims to improve combustion control and maximise alternative fuel (AF) use in the plant’s cement production.

India: 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.’

Peru: FLSmidth has secured a contract for the supply of a new pyro line for Cementos Pacasmayo’s Pacasmayo cement plant near Lima. The new line will give the plant an additional production capacity of 0.6Mt/yr. The supplier says that it plans to install a Cross-Bar cooler, low-NOx calciner, Jetflex burner, equipment for dosing and feeding and process automation. FLSmidth says that the upgrade will reduce the plant’s energy consumption and open new opportunities for the use of alternative fuel (AF).

FLSmidth’s head of projects and upgrades and senior vice president Anders Josefsen said “We are very excited to work with Cementos Pacasmayo on this project – not only on growing the business, but doing it in a sustainable way. The new line will be equipped with a state-of-the-art pyro system including several of our MissionZero solutions. With this, Pacasmayo makes a significant investment in future-proofing its production.” He added “The Pacasmayo project is a prime example of our capabilities within process design: ensuring the integration to an existing plant, while also demonstrating our ability to deliver equipment that meets demands for energy and fuel efficiency.”

France: Germany-based ThyssenKrupp has won a contract for the installation of a new 4000t/day clinker line at Ciments Calcia’s Airvault cement plant in Poitou-Charentes. The supplier expects the new line to double the plant’s clinker capacity while also reducing its CO₂ emissions. It is intended to replace the two existing lines at the site.

ThyssenKrupp will supply a 1200t/hr double-shaft hammer crusher, a longitudinal blending bed, a 370t/hr Quadropol QMR² 45/23 type vertical roller mill and a 10,000t tangential blending silo to process raw materials for the line. A single-string, five-stage Dopol type cyclone preheater with integral calciner will be supplied that is suitable to use with alternative fuels, with the possibility of conversion to oxyfuel in future. ThyssenKrupp plans to preassemble the preheater, reducing anticipated construction time ‘by several months.’ The plant also includes a Polytrack clinker cooler, a solid recovered fuel (SRF) preparation line and dedusting systems. Commissioning is scheduled for mid-2024.

No value for the project has been disclosed by Ciments Calcia or ThyssenKrupp. However, Ciments Calcia previously announced a proposed investment of Euro300m in January 2021.

India: UltraTech Cement plans to increase the production capacity at its Maihar cement plant by 50%. FLSmidth will carry out the expansion project, which also involves the installation of a new calciner and JetFlex burner along with other pyroprocessing equipment. The supplier says that the upgrade will facilitate greater alternative fuel substitution at the plant in Madhya Pradesh.

FLSmidth’s cement president Carsten Riisberg Lund said “We are pleased to continue our long-lasting collaboration with UltraTech Cement. With the new upgrades to the pyro sections, installing MissionZero flagship offerings, such as the low-NO_x calciner and JetFlex burner, UltraTech makes a significant investment in future-proofing its sustainable production.”

Indonesia: FLSmidth has won a contract for the supply of a new alternative fuel (AF) line to Indocement’s Tunggal Prakarsa cement plant consisting of a HotDisc-S combustion device and feeding systems. The supplier says that the line will enable AF derived from municipal solid waste (MSW) to replace coal at the plant.

Cement business president Carsten Riisberg Lund said that MSW processing is ‘a growing challenge in many parts of the world.’ He continued, “The cement industry is well-positioned to be part of the solution, and we see more and more cement producers successfully replacing fossil fuels with AF. I am very pleased that we can support Indocement in its sustainability ambitions in Indonesia, particularly at a site we helped to build in 2000.”