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Fives FCB has been serving the cement manufacturing industry for over 70 years. Its double expertise as process mecha-nical equipment supplier and turnkey general contractor leads Fives FCB to provide complete solutions integrating proprietary equipment that combines innovation and efficiency in the pro-duction of high quality products in environmentally-friendly conditions.As a driver of sustainable industrial progress, Fives FCB follows through in its active policy in the field of Research & Development in order to support its clients in their objectives of reducing energy consumption and polluting emissions.Fives FCB’s technologies, such as the Horomill® and the TSV™ classifier, have once again enjoyed tremendous success in 2010 within the context of cement or mineral grinding plants construction or refurbishment projects.While new regulations limit NOx emis-sions, Fives FCB’s innovation efforts have focused on the development of a new proprietary solution, the D-Nox system, which can equip the Zero-NOx precalci-ner to reduce the kiln’s nitrogen oxides emissions.The signing of the Final Acceptance Certificate for the Umm Bab no.4 pro-duction line in Qatar, the commissio-ning of the complete cement plant at Thai Nguyen in Vietnam, the smooth running of the Hermosillo project in Mexico, and the outstanding safety results obtained at the Beni Suef cement plant in Egypt, all constitute proof of Fives FCB’s ability to design and supply complete cement plants all over the world, achieving gua-ranteed delivery times and performances.Backed by these successes and relying on the Fives group’s facilities throughout the world, especially in India, Brazil and China, Fives FCB remains your reference partner for all your projects for the cement industry and the mineral grin-ding applications.

Alain Cordonnier, CEOFives FCB

Beni Suef - Titan (Egypt)Success right across the board

Fives FCB achieved all the contractual objectives while respecting the deadlines and success-fully passing the industrial and performance tests. It even exceeded the client’s objectives by the end of the first year of clinker and cement production. Besides the global success of this project, one exceptional result should be taken into account: 6.5 million hours spent on site under optimal safety conditions: the construction, assembly and the start-up of the plant were carried out without any lost time injuries.These results were obtained thanks to carefully working out procedures, training and raising the awareness of sub-contractors to safety constraints, plus the implementation of a dedicated team.The project’s success was recognized by the American company DuPont, one of the world leaders in the field of safety and prevention of industrial accidents, which, in October 2010,

FIVES FCB GOOD NEWS FOR YOU, the newsletter of Fives FCB – Fives FCB – 50 rue de Ticléni – B.P. 376 – 59666 Villeneuve d’Ascq Cedex – France – Phone: +33 (0)3 20 43 77 77 – Director of publication: Alain Cordonnier – Editor: Jean-Pierre Cornille – Editorial committee: Samir Bekkaoui, Jacques-Olivier Bou, Gilles Cojean, Hervé Cordier, Jean-Pierre Cornille, Serge Jorget – Writers: Hélène Bachellerie, Chrystelle Lucidarme – Thanks for their collaboration: Jean-François Bonhomme, Frank Chambord, Dominique Lemarié, Philippe Benoit, Sébastien Devroe, Serge Jorget, Jérôme Portal – Graphics and layout: Christophe Cocquet – Printing: VMV - 3 Allée des 3 Lions - Parc du Lion - 59223 Roncq – ISSN number: 2106-9883. 500 copies printed.

EQUIPMENT & UPGRADING

awarded the prestigious DuPont Safety Award to Titan for the remarkable completion of the Beni Suef plant.After an identical performance in Tula, Mexico, it is now evident that safety is a fundamental parameter, fully mastered by Fives FCB during the realization of its projects. ■

In December 2010, Fives FCB was selected by RENEVIS, a subsidiary of EDF in Wroclaw, Poland, to find a solution for drying, grinding and selecting fly ash.The order concerned providing a core process including a flash dryer tube, a disagglome- rator, a TSVTM 2000 BF classifier and a cyclone. The installation will process 39 tph of fly ash and slag at 18 % humidity.It will produce 30 tph of fly ash while comp-lying with European standards of use as an additional component to concrete.For over fifteen years, similar installations have been operating at Hornaing and Carling in France and demonstrate that Fives FCB fully masters these processes.

RENEVIS (POLAND)Drying and classifying plant

Driving progress

After starting production in November 2009, commissioning of the new 4,000 tpd production line was completed at the beginning of 2010 with a demonstration of all the contractual achievements.

Elpion, a South-Korean company and subsi-diary of the OCI Group, wished to produce powdered silicon.In this context, Elpion consulted Fives FCB to

carry out grinding tests of different materials in their laboratory. Satisfied with the results of these tests, in March 2010 Elpion awarded Fives FCB with a contract for the design,

manufacture and supply of a Rhodax® 600 HP, as well as a TSVTM 800 classifier and itsauxiliary equipment.

ELPION (SOUTH KOREA)Silicon grinding plant

SACEM (Société Chérifienne d’Etudes Minières, a mining company) in Morocco, asked BHIL SA (France) for the refurbishment of its grinding and selecting plant for manganese ore located at Imini, near Ouarzazate.Within this framework, Fives FCB supplied BHIL with a TSVTM 1 400 HF classifier coupled to an aerodecanter to dry and select the product. The installation will handle an output

of 10 tph of manganese ore at 92% of MnO2

purity.Manganese is used mainly in the production of alloyed steels and bronzes, saline batteries and pigments.By using the testing station at its Research Centre (CRCM) Fives FCB demonstrated the feasibility of the project and its equipment’s performance.

BHIL FOR SACEM (MOROCCO)Grinding plant refurbishment

In March 2010, Fives FCB completed the refur-bishment of the kiln for Rio Tinto Alcan on its site located in Gardanne, in France. The contract concerned the replacement of the tyre and the kiln supporting shell after a kiln audit including a hot kiln alignment and a mechanical expertise. The material was delivered on site in November 2009. The preparation works and replacement were carried out from mid-February to mid-March 2010.

RIO TINTO ALCAN (FRANCE)Kiln refurbishment

The Ciments d’Oum El Khelil (Ciok) awarded Fives FCB with a contract for the expertise of a ball mill supplied during the 1980’s, which had started vibrating. Vibration measurements were carried out to determine the reasons for the deterioration and to offer a solution that would allow the ball mill to operate reliably

once again. Following this analysis, Fives FCB proposed and supplied a new driving mecha-nism (2 pinions and a girth gear) and realized the supervision as well as the assembly and assistance during start up.After this intervention, the ball mill was able to operate again normally.

CIOK (TUNISIA)Ball mill refurbishment

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COMPLETE CEMENT PLANTS

EQUIPMENT & UPGRADING

FOCUS

At the beginning of 2008, Holcim Apasco awarded Fives FCB with a contract for the engineering and supply of a 3,500 tpd complete cement plant, equipped with the la-test technology developed by Fives FCB to reduce its energy consumption and NOx emissions.By the beginning of 2010, studies in the mechanical, electrical, civil engineering works and steel structures, representing over 10,000 plans and documents, were finalized. Mecha-nical and electrical equipment, weighing 8,500 tonnes in total and coming from Europe or the United States were delivered to the site.

In October 2010, Fives FCB received an order from the Saudi White Cement Co. for the revamping and the increasing of capacity from 700 to 1,000 tpd for the white cement pro-duction line no.1 on the Muzahmiyah site, lo-cated at 75 kilometres from Riyadh, in Saudi Arabia.This contract concerned the addition of Kaolin and Gypsum crushing plant, the increasing of capacity of the raw and cement grinding plants, which will each be equipped with a ball

Final Acceptance Certificate for the Umm Bab 4 production line (5,000 tpd) in QatarOn October 6th 2010, Fives FCB signed the Final Acceptance Certificate with Qatar National Cement Company for the Umm Bab production line no.4, with a capacity of 5,000 tpd.

General Acceptance Certificate for the complete cement plant of Thai Nguyen (4,000 tpd) in Vietnam.On November 16th 2010, Fives FCB received the General Acceptance Certificate from Vinaincon for the 4,000 tpd complete cement plant at Thai Nguyen.

MORE FROM FIVES FCB

In the context of reducing polluting emissions, the new regulations regarding NOx require limiting rejects to a level lower than 200 mg/m3(n) (e.g. NO2 @ 10 % O2 for dry fumes).Until now, complying with such limits forced producers to install a secondary air pollution control device, called SCR, which is costly to install as well as to ope-rate and, under certain conditions, may be energy-consuming. A global approach to the NOx issue led Fives FCB, after computer-assisted modelling, to perfect the operation of the Zero-NOx precalciner and modify its design to integrate and optimize the Fives Pillard’s (another company belonging to the Fives

N ew regulations require produ-cers to limit NOx emissions at their new plants. To comply

with this requirement, Fives FCB has developed an innovative proprietary solution with the objective of redu-cing to a minimum the investment and operating cost of the solution of denitrification.

The first months of 2010 saw the finalization of the automation studies, as well as the local manufacture of steel structures and boilers, representing 13,000 tonnes of material. By the end of the first six months of 2010, as the mechanical and electrical assembly of the upstream section of the cement plant had been fully completed, Fives FCB was able to supervise the no-load tests of these facilities and then bring them into production. The last few months of 2010 were dedicated to the successful start-up of all the other facilities of the cement plant.

Performance tests carried out on the kiln line and the coal grinding plant, as well as the industrial production tests performed on the Horomill® n°3 cement grinding plant, fulfilled the contractual objectives entirely.The cement plant was inaugurated on March 10th 2011. ■

mill alongside the existing grinding mills, as well as a TSVTM classifier. It also included the modification of the preheater tower including a new precalciner, the replacement of the downstream seal of the kiln, the modification of the clinker cooler as well as the installation of a 10,000 tonne silo for cement storage.The deadline for carrying out modifications on the existing equipment will be very short as the shutdown period, starting in March 2012, will not exceed three months.

HERMOSILLO-HOLCIM/CEMENTOS APASCOStart-up of the cement plant in Mexico

SAUDI WHITE CEMENT CO. (SAUDI ARABIA)Fives FCB signed a contract for increasing the capacity of a white cement production line to 1,000 tpd

D-NOx system: an innovativeapproach to reducing nitrogen oxide

group) SNCR denitrification solution (Selec-tive Non Catalytic Reduction), which cost is 7 times less than traditional SCR solutions.In order to limit to a minimum the reactive consumption of the SNCR, the NOx emissions must be reduced prior to injecting the ammo-niac solution. The Fives FCB Research Centre has defined the optimal conditions of air dis-tribution which would enable reaching this objective.The operating principle of the D-NOx system is based on a deep air staging with the addi-tion of post-combustion air which represents around 20% of tertiary air.Extension of the length of the goose neck

duct increases the residence time in the precalciner which allows for complete com-bustion of difficult fuels while ensuring the efficacity of Fives Pillard’s SNCR solution. Therefore, the objectives fixed by the new regulations may be achieved or even

exceeded, all with moderate reactive consumption.Compared with traditional SCR solutions, the Fives FCB technology allows for a return on investment of 3 million Euros for a 3,000 tpd production line.

EQUIPMENT & UPGRADING

Extension of the length of the goose neck duct increases the residence time in the precalciner, enabling to obtain optimal conditions for the SNCR solution.

Lafarge CimentIn November 2010, Lafarge Ciment once again showed its confidence in Fives FCB by awarding it with a contract for the supply of a TSVTM 1 000 THF classifier for treating 4 tph of specific products at one of its European sites.

Lalitha Cement (India)In April 2010, Fives FCB signed a contract with Lalitha Cement for the supply of two Horomill® 3 800 with a capacity of 225 tph each for raw grinding.The assembly of both of these Horomill® started in February 2011 on the Andhra Pradesh site.

Bunge Maroc Phosphore In the frame of the implementation of a complete fertilizers production plant, the company Bunge Maroc Phosphore awarded Fives FCB with an order for the supply of a phosphate grinding plant with a capacity of 30 tph. This contract included the plant’s design, the supply of all the mechanical and electrical equipment, including a ball mill and a TSVTM BF 2 400 classifier, as well as their supervision, erection and commis-sioning. The client was responsible for the civil engineering works, the steel structures and the assembly.When the studies were completed, all the material (partly imported and partly supplied locally) was delivered on site for assembly beginning of March 2011. Start-up should begin in June 2011.