The title ‘cement plant with the lowest emissions in the world’ is not awarded every day. However, Kirchdorfer Zement spares no effort in the search for the best environmental protection. Here, it presents the development of emissions abatement systems at the plant, with a focus on the recent commissioning of a DeCONOx system from Scheuch GmbH.
Around 60% of a cement plant’s CO2 emissions are from the calcination step. Received wisdom in the sector is that such emissions cannot be avoided and reduction of combustion CO2 through dry processing, alternative fuels, waste heat recovery or other advanced solutions has historically been preferred. However, the Direct Separation Reactor from Australian firm Calix, which will be used in the Low Emissions Intensity Lime and Cement (LEILAC) project, will tackle the issue of CO2 emissions from calcination head on. The technology has already been used commercially in the magnesite calcining industry. Peter Edwards spoke to key staff from Calix about the technology and its potential for the cement and lime sectors.
Cement producers around the world are under greater pressure than ever to maintain margins in light of difficult conditions in many markets. Once any apparent technical process solutions have been implemented, what else can be done to improve the performance of cement producers in terms of operational costs, suppliers, staff attitudes and management approaches? Here, we hear about the work of Alexander Proudfoot, a management consulting company with wide experience in the global cement industry, from Angus Maclean, the firm’s Executive Vice President for Client Delivery, Europe.
During 2015 the Austrian cement manufacturer Schretter & Cie GmbH & Co KG modernised its grinding process. The former system with a high pressure grinding roll (HPGR) working in a pre-grinding mode was upgraded to a grinding circuit with an HPGR in semi-finish grinding mode. A compact 2-Stage Koesep air classifier, the latest development of Köppern, based in Germany, was installed. The new combined air classifier was implemented during ongoing operation with total plant downtime of just 40hr. One year after re-commissioning of the grinding system it can be noted that the modernisation improved production, stabilised the process and reduced energy consumption. This article reflects experiences made throughout the first year of operation and shows effects with regard to production and energy consumption.
The Cemex South Ferriby plant has stood proudly on the Humber Estuary in North Lincolnshire, UK for nearly 80 years. Over the years, the river has been a vital lifeline for the plant to bring in raw materials and export cement. However, in December 2013 the plant was completely overwhelmed by a tidal surge, leaving it with major damage. Here, key plant staff describe the damage, the renovation and the plant’s unusual semi-dry Lepol grate production process.
