A Warm Welcome to the ETG Sponsored Delegation of Intensive Energy using Industries from India September 2016
Introduction to Siemens Siemens is a well known global brand and a market leader in some sectors, such as renewable energy. It is also a market leader in digitalisation, power engineering, energy networks and control systems and drives. It has significant growth plans for the coming years and as you can see is making progress to meet those targets or exceed them.
Financials – introduction to Fairport Engineering • Major projects in • Cement Industry and Municipal waste recovery • Alternative Fuels expert for Cement, Steel and Lime Industries. • Alternative Energy consultant for a wide range of technologies, including Biomass, AD feedstock preparation, TDF, AF for kilns. • Advanced recycling technology Power Station conversion to biomass • • Staff numbers remained constant • Projected turnover for 2016 is being realised • Fuel conversion of 395MW coal fired powerstation to wood pellet • Scheelite mine design and delivery Spain • New UK nuclear power station aggregate importation facility • Upgrading of the dust filters at Hanson Ketton
Strengths - Study and FEED Assignments
Strengths - Study and FEED Assignments
Scene setting for Cement Industry Of the 24 UK cement sites shown on this map and the 14 cement kilns around the UK, we have supported all but 2 of them through use of our knowledge, expertise and process upgrades. We cover all grades of Cement, from Cem1, Cem 11, Cem 111, Cem1V and Cem V. We cover all aspects of production, from quarrying, Run of Mine, grading, conveying, storage, reclaim, mixing of the Meal, coal mining, coal preparation plants, stockpiling, coal milling, optimisation of the coal mill circuit, Alternative Raw Materials Handling. Kiln combustion with multi-channel burners, low NOx burners, AF combustion, clinker cooling, heat recovery, heavy metal emission control, Chrome VI control, chorine control in kiln by-pass gas flows, grinding energy optimisation, classifier control, storage, blending of slags to make blended cements, handling PFA are some of the things we can advise on. If in doubt ask us!
Top 10 subjects of Interest to Delegation as submitted via ETG 1. Installation of latest Generation Clinker Coolers 2. Energy efficiency in Grinding Systems 3. Use of Multi Channel Burners 4. Increased Renewable Energy Use in Cement Manufacturing 5. Waste Heat Recovery 6. Pre-processing and co-processing technologies for alternate fuels and raw materials (AFR) usage 7. Blended Cements 8. Implementing better and advanced Control Systems 9. Other technology up gradation that the sector can adopt 10. Energy Management information systems
Some Blue Chip Companies we have dealt with – some names no longer exist due to Mergers and Acquisitions.
Smart control systems Upgrade of conveyor Lorry, Rail and Precipitator/ Biomass Fuel Raw & Alternative (ARM) and efficient drives Bagging & and systems drive to Ship Outloading Bypass Plants Materials Handling /electrical generation Palletising High Efficiency Plants Filter System Over 30 years Experience Upgrading Cement Plant Operations & Facilities We have supplied process equipment for Cem 1, 11, 111, 1V and Cem V production. Chrome Reduction Plants Upgrade of pneumatic conveying for energy Storage & Clinker Handling Alternative Fuels efficiency and reliability Recovery Maximisation Filter Upgrades
Some Case Studies –Rugby – Cement Works Turnkey project to design, construct and commission the combined fuel and raw materials handling and storage plant. The plant was designed to receive and reclaim 1500t coal, 1700 t pet coke, 8000t clay, 200t oxide and 1200t sand to provide raw materials to the new kiln. Cement packing plant -3000 x 50kg bags per hour. Cement outloading systems – 6 weighbridges with a wagon turnaround time of 7 mins./bridge. 2 nd Cement packing plant 3,500 x 25 kg bags per hour.
Hanson Cement - Ketton Installation of by-pass filtration system to extract chloride laden dust from kiln gases. Full turnkey project.
Hanson Cement – Padeswood, Ribblesdale and Ketton Works The design, build of 3 Ferrous Sulphate Plants at Hanson’s Padeswood, Ribblesdale and Ketton Cement Works. The process involved the reception, storage and addition of ferrous sulphate to the clinker to reduce Chromium V1 in the finished cement material.
Alternative Fuels Technology Orchid Technology -Stage 1 Stage 2 Possible use for AF - Stage 3 Fuel Properties
AF use in cement production and AF for other industries, plus burner technology Car Frag AF PSP TDF Orchid SRF Secondary Burner Primary Burner Orchid +30mm SRF Orchid SRF pelletised 8mm dia Baled Orchid SRF Orchid SRF -10mm
Blended Cements using Slags, PFA and other extenders New 1.2 MMt/a cement plant Clinker Handling – project included based on blending cement with intake building, intake hopper and dust GBBS – Fairport supplied design extraction, Fairport provided the design, and engineering support services supply, mechanical and electrical for the complete plant installation and commissioning New Blending Plant comprising outloading facility. Blends PFA and OPC, pneumatically conveys to an existing silo or out-loads to tanker. Ferrous Sulphate addition to Installation of by-pass Included 300t PFA silo, control Chromium VI – included filtration system to extract supporting structures, reception, storage and dosing chloride laden dust from weighing systems, civil, supplied to the kiln gases. Full turnkey electrical and control. project Improvements to clinker handling and storage systems including redirecting of major routes to existing storage areas Receipt, transfer, storage and weighing of and creation of new silica, alumina and iron oxide products for import system. metering in preset proportions to the cement milling plant
Renewable energy GA for 12.5 MW(th) or 3.5 Solar Farm at Ketton Cement Works MW(e) Renewable energy facility for Shotton Steel – planned to be first of four identical facilities to deliver 50MW (th) as process heat (steam) or 14MW(e) or any combination. Fuel P&ID for 12.5 MW(th) or 3.5 MW(e) requirement AF of CV Renewable energy facility for Shotton 15MJ/kg boiler 420C @40 – was planned to be first of four barg identical facilities to deliver 50MW (th) or 14MW(e) or any combination Fairport and Siemens can offer state of the art renewable energy power generation solutions, The use of reliable mix of Renewable Energy including: Technologies would reduce your reliance on fossil fuels and thereby increase your gains • Boiler packages and Steam Turbines for Biomass Fuels to generate electricity, heat and against the benchmarked energy levels. Fairport cooling. and Siemens can together supply, manage, control and integrate renewable energy into • Boiler packages and Steam Turbines for Alternative Fuels to generate electricity, heat and your Digital Cement Factory and thereby cooling. maximise your gains under the PAT scheme. • Solar Systems and the control equipment • Wind power generation technology • Biogas engine installations running from Anaerobic Digester Methane.
Looking to the future Emerging Technologies (i.e. non-BAT) 1. Use of waste materials as reactants (e.g. ammonia -> sewage sludge, hydrated lime -> CKD) 2. Concrete recycling (as aggregate only - not currently advanced to include reactivation of cementitious component even on the lab scale) 3. Oxy-combustion (i.e. pure oxygen instead of air = more efficient combustion, less gas volume and no thermal NOx) 4. Carbon Capture and Storage (CCS) 5. More use of Waste Heat Recovery for Electricity Co-generation especially from Clinker Cooling 6. Revolving disc clinker cooler (claimed to be higher efficiency and require much less cooling air – more concentrated waste heat source) 7. Geopolymer Cements (remove the CaCO 3 decarbonation issue from the cement production by using alternative cementitious components) 8. Nano Cement materials to enhance the properties and weather resistance of the cement or concrete – small amounts of materials give disproportionally significant changes in concrete properties. Subject of most funded researched area globally currently. 9. Step change in grinding energy is overdue, last significant steps were the introduction of HPGR to enhance the VRM even further. We are currently investigating two different technologies currently used for different non cement applications, watch this space! 17
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