FIVES NEWSLETTER FCB...cement manufacturers as a general contractor able to design and supply...
2
4 www.fivesgroup.com www.fivesgroup.com Driving progress 1 FIVES F E B R U A R Y / 2 0 1 0 N E W S L E T T E R FCB GOOD NEWS FOR YOU EDITO Fives FCB has been serving the cement manufacturing industry for over 70 years. With references in Central America, Asia and the Middle East, Fives FCB is recognized by the major world cement manufacturers as a general contractor able to design and supply complete cement plants equipped with innovative technologies, while respecting their guaranteed delivery time and performances. After the successful execution of the Umm Bab line no.2 and no.3 projects, Fives FCB has obtained the Provisional Acceptance Certificate on July 9 th , 2009, for the complete Umm Bab line no.4, with a capacity of 5,000 tpd. In 2009, Fives FCB’s successful comple- tion of several upgrading or moderni- zation projects, along with the major complete plants contracts awarded by Vinaincon in Vietnam, Titan in Egypt and Holcim/Cementos Apasco in Mexico, were all opportunities to demonstrate our ability to manage large projects throughout the world. In 2010, as the first signs of recovery are observed in the cement industry, after a difficult economic period, Fives FCB continues to invest in R&D programs to extend its range of innovative technolo- gies in order to meet the new challenges and evolving needs of its customers regarding sustainable development. Furthermore, Fives FCB belongs to Fives, a large industrial engineering group, which has opened new offices in Russia, India, Turkey and Brazil, thus allowing us to strengthen our international presence and to be closer to our customers all over the world. We are pleased to communicate with our customers and partners through our newsletter and we will continue to keep you informed of our latest FIVES FCB GOOD NEWS. Alain Cordonnier, CEO Fives FCB Umm Bab line 4 A long term co-operation with Qatar National Cement Company Only 17 months after the order was brought into effect, in April 2008, Fives FCB obtained the provisional acceptance for the first cement grinding plant. The second grinding plant was started up in June 2008, three months ahead of the contractual schedule. In May 2009, the burning line reached the end of the industrial production tests and since then, the line is producing continuously under stable operation. Further to achievement of industrial tests, the Provisional Acceptance Certificate was signed on July 9 th , 2009. This is the third order awarded to Fives FCB by QNCC, thus crowning almost 15 years of co-operation: • A first contract was signed in 1995 for the construction of a Greenfield turnkey 2,000 tpd cement plant, line no.2, which was commis- sioned in 1998 and has been operating at full capacity ever since. • In 2004, QNCC renewed its confidence in Fives FCB by entrusting it with a turnkey 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: Jacques-Olivier Bou, Gilles Cojean, Hervé Cordier, Jean Pierre Cornille, Serge Jorget, Etienne Simon – Writers: Hélène Bachellerie, Chrystelle Lucidarme – Thanks for their collaboration: Philippe Benoit, Jean-François Bonhomme, Serge Jorget, David Kotrys, Loïc Pottier, Etienne Simon – Execution: Christophe Cocquet – Printing: LCI - 10 bd Louise Michel - ZAC des Aunettes II - 91030 EVRY Cedex – Registration of copyright and ISSN: in progress. Printed in 1,000 numbers. EQUIPMENT AND UPGRADING In early 2009, Titan Cementara Kosjeric ad, the Serbian affiliate of the Greek cement producer Titan, commissioned a third generation TSV™ classifier supplied by Fives FCB to modernize their cement grinding mill. The customer wished to increase the plant’s capacity while optimizing the additives’ contents in the cement. The main challenge was to overcome the very limited space available in the existing building. During the preliminary stage of the project, Titan and Fives FCB‘s teams agreed to build a Following comprehensive kiln audits perfor- med by Fives FCB on four kilns which had originally been delivered in the 1970’s, SLN awarded Fives FCB a contract to revamp them. In fulfilling this contract, Fives FCB delivered four kilns to SLN in New Caledonia between 2006 and 2009. In order to minimize the shutdown period and to decrease the overall maintenance and ope- rating costs of the two aerofall grinding mills, which have been working almost continuously in very hard conditions since their original delivery by Fives FCB in the 1980’s, SNIM and The scope included the supply of the main equipment: shell, girth gear, drive system, inlet and outlet sealing - as well as a detailed erection study and the supervision of the execution. The erection study was used by SLN as a tender document to select a company for this phase and as the guide during its Fives FCB signed an agreement for assistance in the maintenance of this equipment in 2008. Some regular audit and supervision activities are carried out in the plant so as to better monitor the critical issues and provide updated technologies for its operation. execution. Thanks to the high quality of these studies, the shutdown period was reduced. From the expertise phase to the commissio- ning, Fives FCB successfully provided SLN a complete solution for a mechanical revamping guaranteeing long-term optimum kiln availa- bility. two-line circuit with cyclones, and to upgrade the existing bag filter in order to operate it as a mill dedusting filter and as a classifier circuit dedusting filter. Titan’s scope covered the revamping of the filter and the associated fan, thus Fives FCB was responsible for the classifier and its circulating fan. To cope with the very limited space, a lateral air inlet type TSV™ 3600 HF was used allowing for the complete classifier circuit to be located inside the existing building. Furthermore, a specific volute design was implemented to operate with dusty air. The erection took place during the winter shutdown, and the start-up was achieved prior to the kiln firing. The classifier is now in operation and has fully met the customer’s expectations. The plant now produces CEM II/A-M(P-Q) 42,5 with R45µ<5% whereas before it was R45µ=10%. Thus, the capacity has been subs- tantially increased and ball mill specific energy lowered by more than 10%. To further take advantage of the accuracy of the TSV™, the next step will be to increase the cement/ clinker ratio while keeping the cement quality constant. KOSJERIC – TITAN CEMENTARA KOSJERIC (SERBIA) Grinding mill modernization SLN – ERAMET (NEW CALEDONIA) Rotary kilns mechanical revamping SNIM (MAURITANIA) Contract for maintenance assistance The Egyptian cement manufacturer Assiut Cement Company, an affiliate of the leading cement producer CEMEX, selected the Fives FCB-designed 3 rd generation TSV™ classifier for the conversion of their cement grinding plant no.5 from an open circuit to a closed circuit. For this project, Fives FCB supplied a TSV™ 4000 HF classifier and all the necessary associated equipment, including the bucket elevator, fans, bag filter, airslides and impact flow meter. The local fabrication was performed by the customer with Fives FCB’s technical support and expertise. The purpose of the modernization was to increase the production capacity of OPC cement from 115 tph to 145 tph, a 26% increase of the grinding plant’s capacity. The commissioning of the modernized installation was performed in the 3 rd quarter of 2009 and the new equipment fully fulfils the customer’s expectations. With more than 200 references, the TSV™ classifier is renowned for its unrivalled perfor- mance thanks to its patented rotor blades and antivortex system. The high efficiency of the TSV™ results in a minimal by-pass, a particularly steep slope of the Tromp curve, a very low pressure drop and an extremely low level of power consumption. ASSIUT – ASSIUT CEMENT COMPANY (EGYPT) Cement grinding plant modernization contract to supply the new production line no.3 with a capacity of 4,000 tpd, installed near the first cement plant at Umm Bab, on the western side of the Qatari peninsula. The cement grinding plant was started up early, at the end of 2005, in order to respond to the huge demand for cement on the Qatari market. The other plants, including the clinker burning line were commissioned at the end of 2006. The three Umm Bab production lines supplied by Fives FCB make it one of the largest and most modern cement plants in the Gulf region, producing up to 15,000 tpd of cement (5 million tpy of cement). It has to be noted that thanks to the unique Fives FCB Zero-NOx precalciner, these plants are among the most environmentally-friendly plants with reduced NOx emissions meeting the most stringent environmental regulations. These contracts attest to the confidence that QNCC has in Fives FCB. ■ Driving progress I n May 2009, the industrial tests on the 5,000 tpd turnkey clinker production line built by Fives FCB for QNCC were successfully completed. By the end of 2009, the total production of the line surpassed 1 million tonnes.
Transcript of FIVES NEWSLETTER FCB...cement manufacturers as a general contractor able to design and supply...
4 www.fivesgroup.com www.fivesgroup.comDriving progress 1
F I V E S
F E B R U A R Y / 2 0 1 0
N E W S L E T T E R
F C BGOOD NEWSFOR YOU
EDITO
Fives FCB has been serving the cement manufacturing industry for over 70 years.With references in Central America, Asia and the Middle East, Fives FCB is recognized by the major world cement manufacturers as a general contractor able to design and supply complete cement plants equipped with innovative technologies, while respecting their guaranteed delivery time and performances. After the successful execution of the Umm Bab line no.2 and no.3 projects, Fives FCB has obtained the Provisional Acceptance Certificate on July 9 th, 2009, for the complete Umm Bab line no.4, with a capacity of 5,000 tpd. In 2009, Fives FCB’s successful comple-tion of several upgrading or moderni- zation projects, along with the major complete plants contracts awarded by Vinaincon in Vietnam, Titan in Egypt and Holcim/Cementos Apasco in Mexico, were all opportunities to demonstrate our ability to manage large projects throughout the world. In 2010, as the first signs of recovery are observed in the cement industry, after a difficult economic period, Fives FCB continues to invest in R&D programs to extend its range of innovative technolo-gies in order to meet the new challenges and evolving needs of its customers regarding sustainable development.Furthermore, Fives FCB belongs to Fives, a large industrial engineering group, which has opened new offices in Russia, India, Turkey and Brazil, thus allowing us to strengthen our international presence and to be closer to our customers all over the world.We are pleased to communicate with our customers and partners through our newsletter and we will continue to keep you informed of our latest FIVES FCB GOOD NEWS.
Alain Cordonnier, CEOFives FCB
Umm Bab line 4A long term co-operation with Qatar National Cement Company
Only 17 months after the order was brought into effect, in April 2008, Fives FCB obtained the provisional acceptance for the first cement grinding plant. The second grinding plant was started up in June 2008, three months ahead of the contractual schedule.In May 2009, the burning line reached the end of the industrial production tests and since then, the line is producing continuously under stable operation.
Further to achievement of industrial tests, the Provisional Acceptance Certificate was signed on July 9 th, 2009.
This is the third order awarded to Fives FCB by QNCC, thus crowning almost 15 years of co-operation: • A first contract was signed in 1995 for the construction of a Greenfield turnkey 2,000 tpd cement plant, line no.2, which was commis-sioned in 1998 and has been operating at full capacity ever since.
• In 2004, QNCC renewed its confidence in Fives FCB by entrusting it with a turnkey
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: Jacques-Olivier Bou, Gilles Cojean, Hervé Cordier, Jean Pierre Cornille, Serge Jorget, Etienne Simon – Writers: Hélène Bachellerie, Chrystelle Lucidarme – Thanks for their collaboration: Philippe Benoit, Jean-François Bonhomme, Serge Jorget, David Kotrys, Loïc Pottier, Etienne Simon – Execution: Christophe Cocquet – Printing: LCI - 10 bd Louise Michel - ZAC des Aunettes II - 91030 EVRY Cedex – Registration of copyright and ISSN: in progress. Printed in 1,000 numbers.
EqUIpmENT AND UpGRADING
In early 2009, Titan Cementara Kosjeric ad, the Serbian affiliate of the Greek cement producer Titan, commissioned a third generation TSV™ classifier supplied by Fives FCB to modernize their cement grinding mill. The customer wished to increase the plant’s capacity while optimizing the additives’ contents in the cement. The main challenge was to overcome the very limited space available in the existing building. During the preliminary stage of the project, Titan and Fives FCB‘s teams agreed to build a
Following comprehensive kiln audits perfor-med by Fives FCB on four kilns which had originally been delivered in the 1970’s, SLN awarded Fives FCB a contract to revamp them.In fulfilling this contract, Fives FCB delivered four kilns to SLN in New Caledonia between 2006 and 2009.
In order to minimize the shutdown period and to decrease the overall maintenance and ope-rating costs of the two aerofall grinding mills, which have been working almost continuously in very hard conditions since their original delivery by Fives FCB in the 1980’s, SNIM and
The scope included the supply of the main equipment: shell, girth gear, drive system, inlet and outlet sealing - as well as a detailed erection study and the supervision of the execution. The erection study was used by SLN as a tender document to select a company for this phase and as the guide during its
Fives FCB signed an agreement for assistance in the maintenance of this equipment in 2008. Some regular audit and supervision activities are carried out in the plant so as to better monitor the critical issues and provide updated technologies for its operation.
execution. Thanks to the high quality of these studies, the shutdown period was reduced. From the expertise phase to the commissio-ning, Fives FCB successfully provided SLN a complete solution for a mechanical revamping guaranteeing long-term optimum kiln availa-bility.
two-line circuit with cyclones, and to upgrade the existing bag filter in order to operate it as a mill dedusting filter and as a classifier circuit dedusting filter. Titan’s scope covered the revamping of the filter and the associated fan, thus Fives FCB was responsible for the classifier and its circulating fan.
To cope with the very limited space, a lateral air inlet type TSV™ 3600 HF was used allowing for the complete classifier circuit to be located inside the existing building. Furthermore, a
specific volute design was implemented to operate with dusty air.The erection took place during the winter shutdown, and the start-up was achieved prior to the kiln firing. The classifier is now in operation and has fully met the customer’s expectations.The plant now produces CEM II/A-M(P-Q) 42,5 with R45µ<5% whereas before it was R45µ=10%. Thus, the capacity has been subs-tantially increased and ball mill specific energy lowered by more than 10%. To further take advantage of the accuracy of the TSV™, the next step will be to increase the cement/ clinker ratio while keeping the cement quality constant.
KOSJERIC – TITAN CEMENTARA KOSJERIC (SERBIA)Grinding mill modernization
SLN – ERAMET (NEw CALEDONIA)Rotary kilns mechanical revamping
SNIM (MAURITANIA)Contract for maintenance assistance
The Egyptian cement manufacturer Assiut Cement Company, an affiliate of the leading cement producer CEMEX, selected the Fives FCB-designed 3rd generation TSV™ classifier for the conversion of their cement grinding plant no.5 from an open circuit to a closed circuit.For this project, Fives FCB supplied a TSV™ 4000 HF classifier and all the necessary associated equipment, including the bucket elevator, fans, bag filter, airslides and impact flow meter. The local fabrication was performed by the customer with Fives FCB’s technical support and expertise. The purpose of the modernization was to increase the production
capacity of OPC cement from 115 tph to 145 tph, a 26% increase of the grinding plant’s capacity. The commissioning of the modernized installation was performed in the 3rd quarter of 2009 and the new equipment fully fulfils the customer’s expectations. with more than 200 references, the TSV™ classifier is renowned for its unrivalled perfor-mance thanks to its patented rotor blades and antivortex system. The high efficiency of the TSV™ results in a minimal by-pass, a particularly steep slope of the Tromp curve, a very low pressure drop and an extremely low level of power consumption.
ASSIUT – ASSIUT CEMENT COMPANy (EGyPT)Cement grinding plant modernization
contract to supply the new production line no.3 with a capacity of 4,000 tpd, installed near the first cement plant at Umm Bab, on the western side of the Qatari peninsula. The cement grinding plant was started up early, at the end of 2005, in order to respond to the huge demand for cement on the Qatari market. The other plants, including the clinker burning line were commissioned at the end of 2006.
The three Umm Bab production lines supplied by Fives FCB make it one of the largest and most modern cement plants in the Gulf region, producing up to 15,000 tpd of cement (5 million tpy of cement).
It has to be noted that thanks to the unique Fives FCB Zero-NOx precalciner, these plants are among the most environmentally-friendly plants with reduced NOx emissions meeting the most stringent environmental regulations.
These contracts attest to the confidence that QNCC has in Fives FCB. ■
Driving progress
In may 2009, the industrial tests on the 5,000 tpd turnkey clinker production line built by Fives FCB for qNCC were successfully completed.By the end of 2009, the total production of the line surpassed 1 million tonnes.
2 www.fivesgroup.com FIVES FCB GOOD NEWS FOR YOU 3
COmplETE CEmENT plANTS FOCUS
Having made its name in the Vietnamese cement industry with the commissioning of the 4,000 tpd Hoang Mai cement plant in 2002, Fives FCB won a new contract, awarded by Vietnam Industrial Construction Corpora-tion (Vinaincon) for a complete cement plant in Vietnam.This new project included the supply of a 4,000 tpd complete plant equipped with the latest processes and equipment developed by Fives FCB: a 4,000 tpd single line preheater featuring the latest generation of low pressure drop cyclones; a Zero-NOx precalciner burning 100% Vietnamese anthracite coal with low volatile content; and a 240 tph cement grin-ding plant implementing Fives FCB recently developed Twin Horomill® technology, which
A n updated Fives FCB techno-logy, the OpTIKIlN, for burning line control process systems,
enables automatically controlled ope-ration as well as automatic start and production raise.
The updated OPTIKILN uses linked and independent optimization modules for the different controlled parameters. Each one is using a specific modelling based on the experience of several operating plants. The choice is given to optimize a specific para- meter (clinker cooler blowing, kiln speed, calcination temperature, preheater draught, etc.) or all of them. This tech-nology provides high flexibility and stability.For example, the calcination temperature can be stabilized within a range of ±2°C over the course of several days.
Optimization modules have also been asso-ciated to create automatic production start programs for the burning line in any condition – either cold or warm – and for the alkali bypass.
From the cold start to the nominal production level, the line raises production over a number of hours and automatically adapts precalciner operation, preheater draught and clinker cooler operation. Though some operators may be a
Thanks to a long list of refe-rences marking the achieve-ments of recent years, Fives FCB secured a contract with Holcim for the delivery of a complete Greenfield cement plant with a capacity of 3,500 tpd in Mexico.
This new plant will feature the latest technologies developed by Fives FCB to reduce the
allows to increase the grinding units capacity by associating two identical Horomill® grin-ding units, operating simultaneously along with a large-sized TSV TM classifier. A high proportion of mechanical and elec- trical equipment (75% by weight) has been
whole installation’s energy consumption and NOx emis-sions, including the Zero-NOx precalciner which allows for the use of alternative fuels without emitting NOx at this stage of the process. The grinding plant will also be equipped with three Horo-mill® grinding mills, the most energy efficient technology, and which represents a huge
advantage in the arid Mexican State of Sonora where the cement plant is being constructed as it does not require any water injection.
The plant is due to be commissioned by the end of the first semester 2010.
This contract follows the supply, in 2004, of the new 3,000 tpd production line for the Holcim cement plant in Costa Rica and strengthens Fives FCB’s status as an essential partner for major cement manufacturers.
manufactured under Fives FCB’s supervision in Vietnam by the customer, Vinaincon, a corporation made up of twenty-one firms operating in the fields of building, manu- facturing and implementation of industrial projects.Thai Nguyen organised the plant’s inaugu- ration ceremony on December 25th, 2009. The Prime Minister and other Vietnamese government representatives were in atten- dance. The commissioning and performance tests will be completed in early 2010.
THAI NGUyEN - VINAINCON (VIETNAM):Fives FCB is recognized as a general contractorall over the world
OPTIKILN for efficient control of the burning line
HERMOSILLO - HOLCIM/CEMENTOS APASCO - (MEXICO) Fives FCB is delivering a complete 3,500 tpd cement plant
Beni Suef Cement Co., an Egyptian company set up by Titan, the biggest Greek cement manufacturer, has entrusted Fives FCB with the construction of a new 4,000 tpd production line with a 170 tph cement grinding plant on a site located 120 km from Cairo where it already operates its first cement production line.
The contract, which also covers modifi- cations to the existing no.1 production line, includes Fives FCB-designed equipment, optimised to comply with energy consump-
tion and environment protection requirements. This ultra-modern plant shall meet not only Egyptian but also European environmental standards.
The first clinker was produced on November 10 th, 2009. Industrial tests on the cement grinding plant had already been completed on October 8 th 2009, as well as on the burning line on December 7 th, 2009.
The whole plant is now running at full capacity.
BENI SUEF - TITAN (EGyPT)Fives FCB has been chosen by Egyptian company Beni Suef Cement Co. for the turnkey construction of a new 4,000 tpd production line
little reluctant to give up their manual opera-tion of the line, experience has shown that they are quickly convinced of the efficiency of the system.
Fives FCB has implemented its OPTIKILN Burning Line Optimization System on the new 5,000 tpd QNCC cement plant, in Qatar. The burning line is very stable, and since its start-up, no interruption has ever been encountered because of a CO peak or “unburnt” material.
In 2009, two other production plants supplied by Fives FCB were commissioned: the Quang Son 4,000 tpd plant (Thai Nguyen, Vietnam)
and the Titan 4,000 tpd plant in Beni Suef (Egypt). They both benefit from the OPTIKILN control system, which will also
be used at the Holcim-Apasco 3,500 tpd plant, in Hermosillo, Mexico, the next major project to be started-up for Fives FCB. ■
EqUIpmENT AND UpGRADING
The choice is given to optimize a specific parameter or all of them.
Jiujiang & Xinyu -Jingye in ChinaOn October 28 th, 2009, a contract was signed between Jianhuan Technology & Trade Co. Ltd. (Jingye) and Fives FCB for the supply of two new slag grinding plants in China. These plants will be located at the Jiujiang and Xinyu sites, in Jiangxi province, in the East of the country.Each slag grinding plant will be equipped with 1 Horomill® 3800 and 1 TSV™ 4500 separator. Equipment delivery will take place in 2 phases. The first plant will be supplied within 12 months after the coming into force of the contract; the second, within 16 months.
Buzzi Unicem in the USA In May 2009, Buzzi Unicem USA awarded Fives FCB with two contracts for the supply of Horomill® 3800 to be installed in the plants of Maryneal, Texas, and Hercules Cement, Stockertown, Pennsylvania. At the end of 2009, the equipment was dispatched to the sites. These two Horomill® will enable Buzzi Unicem USA to increase energy savings while reducing CO2 emissions in its plants in the United States.
Cementos moctezuma in mexico Following the ten Horomill® delivered to Cementos Moctezuma since 1994, the three Horomill® 3800 (1 raw mill & 2 cement mills) ordered in 2007 are under erection in the Apazapan plant, near Vera Cruz. Commissioning is scheduled for 2010.Including the three Horomill® ordered by Holcim/Cementos Apasco, as part of the Hermosillo complete plant project, Fives FCB totalized 16 identical machines installed in Mexico, with unique performance and efficiency levels on raw meal, Portland and pouzzolana cements.
Calcination temperature control (sampling time: 1 min)
