Lafarge DEC Presentation December 2010
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Transcript of Lafarge DEC Presentation December 2010
1 Modernization: Economic Benefits | Greater Efficiency | Jobs | Sustainable Energy | Improved Air Quality slide 1 of 16
2
Introductions Project Description Facilities Retained Wet to Dry Process Key Areas Examined
in DEIS Schedule
www.lafargeravenafacts.com
Agenda
slide 2 of 16
3
Martin Turecky, Lafarge Plant Manager, Ravena Plant
John Reagan, Lafarge Environmental Manager, Ravena Plant
Bill Voshell, Lafarge Regional Environmental Manager
Marc Desimone, Lafarge Engineering Manager
Elena Barnett, HDR Vice President
Jim Brown, HDR Senior Vice President
Lafarge Team
slide 3 of 16
4
The Ravena Process Today: Wet Process
Wet Process (1950-60’s Technology) Raw materials are mixed with water and
ground in slurry mills. Slurry is stored and homogenized in large slurry basins.
Slurry mixture is fed directly to the kiln without preheating.
A large amount of extra fuel is used in evaporating the water.
A larger kiln is needed, because much of the kiln’s length is used up for the drying proces.
In 1962, the Ravena cement plant’s nearly 600-foot long kiln was the largest piece of moving industrial equipment in the world.
slide 4 of 16
5
The Ravena Process Tomorrow: Dry Process
Raw materials are ground, mixed, and fed to a kiln in a dry state. Ground dry material is preheated in a preheater tower.
The preheater tower is a tall vertical structure in which the dry kiln feed enters at the top of the tower and is heated by kiln exhaust gas entering at the bottom of the tower.
Preheating of the ground dry material prior to entering the kiln results in substantial energy savings compared to the energy required to heat the wet slurry mixture.
The Rotary kiln length of approximately 200 ft. is much shorter than the wet kilns.
New emissions control technology includes: scrubber, SNCR, state-of-the-art dust collectors and CEMS.
Dry Process Pre-heater/pre-calciner kiln line (State-of-the-art Technology)
Reduced process waste.
ZERO process wastewater discharges through re-use and recycling.
Minimization of Impacts to Hudson River:
• Achieves objectives of Hudson River Estuary Program.
• Flow minimization through reuse/recycle of wastewater and use of non-Hudson River water sources.
• DEC approved best technology available for water intake from the Hudson River to minimize impacts to aquatic organisms.
slide 5 of 16
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Facilities Retained Quarry facilities Conveyors Administration building Laboratory Maintenance facilities Cement Storage Silos Wharf facilities Most supporting infrastructure
Facilities Removed Raw Mills (2) Coal Mills (2) Slurry Basins (2) Kilns (2) Electrostatic
Precipitator Building Clinker Coolers (2) Associated drives, fans
and ancillary equipment Stack
Facilities
slide 6 of 16
7
Ravena’s Quarry
New Facilities
Phase ll Power generating system Finish mill Clinker storage Preblending system
Secondary crusher Raw mill storage bins Raw mill Alkali bypass Coal mill Prehemogenization silo Kiln Preheater precalciner tower Clinker cooler
Scrubber SNCR—selective non-
catalytic reduction Baghouse dust collectors Fans, drives and ancillary equipment Continuous Emissions Monitors
(CEMs): NOx, SO2, PM, Hg, CO/CO2, THC and HCl
Phase l
slide 7 of 16
8
Raw Milling Horizontal configuration to vertical Same raw materials except water
Wet vs. Dry
slide 8 of 16
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Kiln Feed Storage Dry storage silo 12 hour storage Extraction and transport of powder
Wet vs. Dry
slide 9 of 16
10
Wet Process Dry Process
Wet vs. Dry
slide 10 of 16
11
Lafarge Ravena Plant Proposed Plant Modernization Project
Land Use and Zoning
Solid Waste
Noise
Traffic
Visual Impact
Water and Coastal Resources
Natural Resources
Socioeconomic
Air Quality
Energy Resources
Key Areas Examined
slide 11 of 16
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DEIS: Water, Energy & Waste Comparison: Modernized Facility & Existing Plant
slide 12 of 16
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Existing vs. New Plant Emissions from modernized plant compared to existing plant
slide 13 of 16
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The Future Modernization Project Timeline
State-of-the-Art New Facility
slide 14 of 16
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Modernization Benefits
slide 15 of 16
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Lafarge Ravena Plant Modernization Project Information and Updates
Learn more and get project updates online at: lafargeravenafacts.com
slide 16 of 16