WFRLD CEMENT April 2021 2021 COMING SOON Reeni ot oe te eau rt ITY sa GATENLY = SERV! VIBRATION AANAGS = SUSTAINABILITY a li GE B Q M esi a mes J fe ier et g nt “Eg “HO? ip i Optimisation of automation processes especially for sand and gravel for shorter gate to gate times. > Development and implementation of a special ‘all in one’ mask for faster manual handling of trucks. > Development and implementation of a wheel loader application for the online and offline case. ‘One of the top priorities in the project was to integrate the three challenges mentioned above into the software solution in the best possible way. Another priority was the harmonious integration, successful synchronisation and ‘synergy utilisation of the two divisions, cement and aggregates, This was achieved by means of a VAS template. Due to restrictions on handling in 2020, the project team had to deal thoroughly with the following challenge: “How can we take all sand ‘and gravel plants into operation without being on site whilst guaranteeing that everything runs well at the end?” ‘As part of the further digitisation and. optimisation of HeidelbergGement AG, an integrated material flow management system will be introduced to achieve significant ‘savings in logistics costs throughout the group. Based on the existing development process, HeidebergCement AG was able to provide remote access, which enabled all plants to go live ‘smoothly. Various plants worldwide in the cement, aggregates (sand & gravel) and cement business areas are currently being equipped with the VAS solution from Axians IAS GmbH. UltraTech chooses AUMUND India as equipment supplier for ‘Project Spring" expansion UttraTech has chosen AUMUND India to ‘supply a. comprehensive equipment package comprising 22 chain bucket elevators, 46 bolt bucket elevators, six pan conveyors and 11 Samson® material feeders for its “Project Spring’ expansion. The order is one of the largest to date for AUMUND India. The expansion project includes three integrated ‘cement production units, each with capacities ‘of up to 10 000 tpd. For these kiln lines, AUMUND India will supply the critical clinker cooler extraction conveyors, well known for their reliability and availabilty, as well as the transfer conveyors to the clinker silos. {In addition to the clinker production lines in Madhya Pradesh, Rajasthan and Chhattisgarh, six cement grinding plants in various locations in India are part of the capacity expansion plans. The order won by AUMUND India includes raw ‘material handling bucket elevators, critical kiln feed bucket elevators with heights up to 187 m, and roller press recirculation bucket elevators with capacities up to 2200 tph, as well as clinker and cement handling bucket elevators of various sizes. ‘At the end of 2020, UltraTech decided to increase its current consolidated productionoN DIARY Hannover Messe - Digital Edition 12~ 16 April, 2021 Hannover, Germany www.hannovermesse.de Sehmeer ENVIROTECH 2021 20-21 Apri, 2021 An interactive online conference focusing on reducing the cement industry's environmental footprint. For more information, oF to rogiter for fre, head over to: swww.worldcement.com! ‘envirotech2021 IEEEIAS/PCA Cement Conference 2021 24-28 May, 2021 www.cementconference.org Semarr OPTIMISATION 2021 16 ~ 17 June, 2021 www.worldcement.com/ optimisation2021 BULKEX21 12-18 October, 2021 Chestord Grange, ‘Warwickshire, UK secretary@mhea.co.uk ‘wrw.mbea.co.uk capacity of 116.8 million tpy by 12.8 million tpy with a mix of brownfield and groonfiold expansions in the eastern, contral and northern parts of India. The completion of these capacity additions will further reinforce the position of UitraTech as the third largest cement producer in the world outside of China, Starlinger bags fit the national standard for cement packaging in China AAs China is modernising its cement production, the government has also set up a national standard, defining types and specifications of bags used for packaging cement. One of the three bag types, permitted in the Chinese Standard GB/T 9774-2020 ‘Sacks for Packing Cement’, which was officially released in October 2020, are block bottom valve bags made of woven polypropylene tape fabric. This type of bag was invented in 1995 by the Austrian engineering company Starlinger & Co. GmbH and patented under the brand name AD'STAR. ‘With the AD'STAR bag, Starlinger, specialised in machinery C for woven plastic packaging, created a sustainable and efficient \ packaging solution for cement and all kinds of dry bulk goods. ‘The idea behind it was to combine the advantages of a paper bag - its brick shape and suitability for automatic handling ~ with the tightness and flexibility of a PE film bag, and the strength and resistance of a woven PP bag. The result: A laminated one-layer block bottom valve bag made of stretched and woven polypropylene tapes. The main assets of AD*STAR bags are their extremely low breakage rate and excellent protection against moisture. Especially in countries like China, transport and storage of cement in bags is widespread and involves a lot of transhipping and long-term storage. Loss of cement due to bag rupture or hardening in humid conditions is a big issue. Packaging cement in AD"STAR bags offers substantial savings potential in this respect: low breakage rates and good moisture protection mean that significantly less cement is lost in the logistic chain. Consequently, not only environmental pollution is reduced, but also less cement needs to be produced to replace these losses, which in turn saves CO, emissions. An independent Life Cycle Analysis carried out in 2015 showed that due to these characteristics, AD'STAR cement bags have lower global warming potential than multilayer paper cement bags and are currently the most environmentally friendly packaging for cement. ‘AD'STAR bags are produced on Starlinger ad°starKON block bottom conversion lines and are available in a wide range of sizes. The company's focus on research and development ensures that AD'STAR bags and AD'STAR production technologies are continuously improved and adapted to the needs of the market. Technological advancements and new product features such as easy-open closure or handles for carrying make the bags even more versatile and usable in different applications. World CementBCT Meter aielg MAXIMIZE SEWAGE SLUDGE UTILIZATION Drying sewage sludge with preheated raw meal PAY E ¥ 4 Ny == 1 Say ea ae Compact and Low Cost Easy Operation Safe and Clean Not convinced? There is more. Find out directly from us: overseas_sales@taiheiyo-eng.co.jp www.taiheiyo-eng.co.jp/en/ | TaiheiyoEngineeringg Currently, around 15.7 billion AD*STAR sacks are produced each year on more than 550 Starlinger conversion lines installed on five continents. ‘The new Chinese Standard for cement packaging applies to cement bags holding Up to 50 kg and lists the above mentioned laminated woven plastic bags (made of one layer of laminated plastic fabric or with additional paper liner), paper bags (three-layer, three-layer with PE liner, fourlayer bags), as well as paper plastic composite bags (paper bags with plastic liner) as possible packaging options. All three types of bags must be designed as block bottom valve bags. The standard specifies the dimensions as well 1s physical and mechanical requirements of the cement bags. Regarding break resistance, for example, a cement bag has to survive a drop from a 1'm height a minimum of six times before it breaks. Furthermore, printing and marking, general bag appearance, testing methods, and rules for quality inspection during bag manufacture are established in the standard. It also stipulates that each bag must be provided with a certificate betore selling. By recommending woven polypropylene block bottom bags in the new National Standard, the Chinese government has adopted a future-oriented approach that aims for more sustainability in the cement industry. It curbs unnecessary loss of cement during production, transport and storage, reduces environmental impacts, improves working conditions for ‘operators on the cement filing lines, and generally makes the handling of cement in 50kg or smaller units more efficient Itaiso means that the formerly widely used sewn woven plastic bags which were irregular in shape, often leaking, and problematic for automatic filing and handing, will no longer be permitted as cement packaging in China. ‘Cement companies are given a transition period until 31 March 2022 to adapt to the new standard. Due to this time limit, Starlinger's AD'STAR conversion lines are currently high in demand in China. The company expects to deliver and install machines for an additional production capacity of more than 2 billion AD"STAR bags on the Chinese market in 2021 and 2022 IKN makes progress on Kiln Line No. 8 for Marker Cement New projects always begin with a frst step. ‘When looking at the construction site at Marker Cement, the first series of steps is already quite visible. Both the solid concrete basis for the preheater and the first kiln pier have almost reached their full heights. Foundation works for the cooler building are in progress, showing the future footprint. The new kiln line No. 8 is being built right next to the existing production line which it will replace after commissioning. The start of this important project directly in the heart of Germany and during the difficult COVID-19 times shows the commitment of Marker Cement towards the plant, its employees, and the region. Cimprogetti receives orders for multiple lime hydration plants Htaly-based engineering firm, Cimprogetti, which supplies vertical kilns for the calcination of limestone and dolomite and complete quicklime hydration units, has received several orders for hydration plants. Rheinkalk, a subsidiary of Belgium's Lhoist, has placed an order to Cimprogetti for two hydration plants with a 10 tph nominal capacity for its lime plants at Regensburg (Walhalla plant) and, Efringen-Kirchen (Istein plant). The Walhalla Plant features a CIM-HYDRAX-4G hydrator mod, the fourth generation of Cimprogetti hydrator, with a customised fiter. The Istein Plant features instead the CIM-HYDRAX-4G MAX hydrator mod, with an independent premixing stage. The hydration plants have been ordered as part of a renovation programme. Cimprogett also received an order from a leading Chinese Group for a 10 tph hydrating plant featuring the 5:shaft hydrator Cim-Hyrdax-TG-600. The calcium hydroxide will be used as absorbent for the FGD device located in Haimen Port area (Jiangsu Province). The use of Ca(OH), sorbent allows for a reduction in the concentration of acid gases in different industrial sectors; average of 18 ~ 30% for HCI, 50 - 90% for SO, and 80% for HF in certain process conditions (temperature and pressure). World CementDON’T GET TRAPPED 4 Analysis Complete, Replace PowerCore® Today BHA’ TotalPleat” raceme a eer - Low Pressure Drop ee eee eee ponerse eet peers eas eaten ec cee es Suc ae ‘get trapped in TotalPleat airflow ee cea drop, giving longer useful fiter life as ER www.parker.com/totalpleat Sd ere tsi) Ree eee ee eeWang Lan, China Building Materials Academy, discusses the installation and operation of a moderate temperature SCR Reactor for ChangXing Southern Cement Company.EVERYTHING \China's Cement Industry Emission Standard of Air Pollutants (GB4815-2013) set up limitation values for NOx emissions at 320 mg/m? and 400 mg/m? from cement kilns in different areas. However, several local governments have issued more stringent requirements, outlining that NOx emissions from cement kilns must be below 50 mg/m? and NH, slip below 5 mg/m? it ammonia is used as reducing agent. The best available technologies for DeNOx operations include primary measures and secondary measures. The former are based ‘on the principle of reducing the excess oxygen levels and the peak flame temperature in cement kilns, for example by using a low nitrogen burner and staged combustion, However, the DeNOx efficiency of the primary measures cannot exceed 50% without interfering with cement kiln operation. The latter includ SNGR (selective non catalytic reduction) and SCR (selective catalytic reduction) technologies, and they often use ammonia or other nitrogen-containing compounds with the chemical reaction: NH, + NOx —+ N, + H,0. Usually, DeNOx efficiency of SNCR is controlled at 60%, otherwise it could lead to more NH, slip, e.g, high emissions of unreacted ammonia. Compared to SNR, SCR can achieve DeNOx efficiency of up to 85% and it cause less NH, slip, as the NH, to NOx molar ratio can be controlled as 1:1, In order to limit NOx emissions 10 a low level of 50 mg/m, the use of the SCR technique is necessary. Development of a moderate temperature SCR technique The key setup of the SCR technique involves a ‘SCR reactor, which is a high tower with several layers of catalyst modules installed inside. Flue gas from the cement kiln mixed with injected ammonia is drawn into the reactor, where NH, reacts with NOx quickly when passing through the channels of the catalyst element (Figure 1). The temperature of flue gas exiting 710000 (WG) the top of the preheater about 320% and the dust oan? 0,108 content of the nom 0,108 flue gas is about 0.10% 120 g/m’. When exiting the waste heat boiler, the Figure 2. The layout of a moderate temperature SCR reactor. 12 temperature of the flue gas is reduced to about 200°C, and the dust content is reduced to about 60 g/m’. The SGR reactors can be placed before the waste heat boiler (high temperature configuration’) or after the ‘waste heat boiler (‘mode temperature configuration’). The ‘high temperature configuration’ can also be classi as a ‘high dust’ layout or a‘low dust’ layout. The ‘high dust" layout has litle effect on the efficiency of the waste heat boi but has a high impact on the service life of catalyst material and on the DeNOx efficiency of the SCR reactor. The ‘low dust’ layout requires ‘a dust collector installed in front of the SCR reactor to lower the dust content of the flue {gas to about 56 g/m’. This not only reduces the efficiency of the waste heat boiler significantly, bbut also complicates the SCR reactor system and increases the potential stoppage of the entire system. “Moderate temperature configuration’ refers to the SCR reactor being arranged betw: the high temperature fan and the raw material mill system, as shown in Figure 2. It has the advantages of both ‘high temperature” layouts. This SGR reactor has no effect on the efficiency of the waste heat boiler. Due to the natural ‘separation in the waste heat boiler, the presence of dust in the flue gas decreases from 120 g/m? to 60 g/m® betore the flue gas enters the SCR reactor. Moderate temperatures will also result in a smaller volume of flue gas, thus allowing for ‘smaller dimensions of the reactor, and in turn for lower construction investment and lower costs of the SCR reactor system. In order to develop moderate temperature SCR techniques, research has been Figure 3. The semi-scale SCR reactor. conducted into the raising of DeNOx activity of the traditional SCR catalyst. Some strong absorptive materials have been added to the catalyst to reinforce its adsorption of NH, and NOx. Trace transition metals, such as W,0,, have been added to the catalyst to promote its moderate temperature activity After that, a semi-scale SCR reactor installed with +1 catalyst for the examination ‘of the function of the newly developed catalyst ‘materials, as chown in Figure 3. In this semi-scale PACKAGING fee Cuma x SOR ney ry So om od FUTUR ecg eee Me See ad (MOVE) as well as a dual-stacking unit. | Rene ean Uz : PSone noe ra | Tare Pu ee es on Ee ed eet tat)SCR reactor, each layer of catalyst has only one Catalyst module. Flue gas of 10.000 m*/h from the cement kiln is drawn into the reactor and its ‘The inital storage tank of ammonia for 'SNCR was used and two new ammonia, pumps ware added. Meteretting ‘A now sat of moters were added and modules to control the dosage ‘of ammonia were devered. A now ‘ammonia evaporator with 125% capacity was added. Four catalyst layers were installed, and a ith layer was added as a backup. Dust blowing Fake teeth blowers and acoustic soot blowers with compressed air were sed. ‘Two new compressors were added, with one in operation and one an standoy. Connected ducts and pipes [Now baffios wore sot up for orignal ducts and pipes. Dust dolvery ‘Ascrow tooder to star feeder was, ‘added below the dust bucket. Electrical & controling ‘Connections were made to the central ‘control room and DCS system. 1“ temperature and the dust content are 200°C and 60 g/m’, respectively. The NOx concentration in the flue gas from the cement kiln has been detected as up to 300 mg/m?, and due to the unreacted ammonia ‘of SNCR in kiln system, its NH, content has also been tested up to 120 mg/m?. In this case, a certain amount ‘of ammonia has been added and injected into the SCR reactor to maintain the molar ratio of NH, to NOx of 1:1, The semi-scale SCR reactor has been in operation for nearly two years, with DeNOx efficiency up to 90%. This research work has confirmed the feasibility of the moderate temperature SCR technique, Application of the moderate 2.6300 tpd cement clinker production fine with a rotary kiln of 04.8 72m, a TDF precalciner and a waste heat boiler. ‘A breakdown of the flue gas from the waste heat boiler is listed in Table 1. The production fine has been added with the SNCR system, using ‘up 350 hr of ammonia (20% concentration), and reducing NOx ‘emissions to about 280 mg/m*. Considering the stnngent upcoming requirements to lower the emissions of NOx to less than World Cement ov 20250 mg/m? and NH, slip to less than 5 mg/m?, the cement company decided to make use of SCR techniques — the moderate temperature configuration was chosen for the plant design. The designed SCR reactor (Figure 4) was placed alter the waste heat boiler, with a Section area of 64 m:, height of 34 m, and the whole tower of 350 t. Inside the SCR reactor, 4+1 catalyst layers were installed, and each layer has 48 modules. The whole volume of the catalyst used is about 200 m?. Around and above each catalyst layer, acoustic soot blowers and rack teeth blowers were fitted to avoid the accumulation of the dust on the catalyst layer and to help convey the dust to a hopper at the bottom of the reactor CFD simulation analysis was conducted for the design of connected pipes to the reactor in order to optimise their arrangements. Deflectors Were set up in suitable positions inside the pipes in order to improve the uniformity of the flue gas and to prevent the creation of deviant dust currents, as deviant dust currents may cause severe abrasion of the catalyst materials and block up the cells of the catalyst The SCR reactor was equipped with meters and gauges to detect and measure the pressures, temperatures and compositions of the flue gas, and to send all this data to the newly added DCS system for remote monitoring and daily start-stop of the reactor. The SCR reactor was attached to the ammonia injection system and can perform DeNOx by itself. It can also utilise NH, slip from the SNCR system to perform DeNOx. The economy of both operation methods is under review based on the DeNOx efficiency, the consumption of ammonia, the NH, slip and the power consumption of the entire system. Major equipment and setups of the SCR reactor are listed in Table 2. The construction duration of the SCR reactor (Figure 5) took around 100 days and the kiln was shut down for a week to integrate the SCR reactor. Since then, it has been in steady operation alongside the kiln for nearly cone year. The results of the long-term operation indicate that when operating with SNCR, the consumption of ammonia is 2.2 kg/t-clinker with NOx emissions of less than 40 mg/m? and NH, slip of less than 5 mg/m’; whereas when operating by SCR itself, the consumption of ammonia is 2.0 kg/t-clinker, with NOx emission less than 30 mg/m? and NH, slip less than 5 mg/m’. The pressure drops of the SCR reactor and entire SCR system are 320 Pa and 1100 Pa, respectively, and the power consumption of the entire SCR system is about 3 kWh/t-clinker, fully meeting the requirements of the plant design proposed by ChangXing Southern Cement ‘Company. World Cement Figure 5. The moderate temperature SCR reactor tower. Conclusions NN Controlling NOx emissions is one of the most important tasks for the cement industry to deal with, and achieving low emissions of less than 50 mg/m’ isthe top priority of China's cement industry for the near future. DeNOx techniques, such as low NOx burners, staged combustion and SNCR can reduce NOx emissions to a certain extent, but SCR carries out DeNOx operations much more efficiently. Compared to “high temperature configuration’, the ‘moderate temperature configuration’ technique offers some obvious advantages, such as low investment, jow operation cost, and long-term steady operation After nearly one year of operation of the full-scale ‘moderate temperature configuration’ the SCR reactor for ChangXing Southern Cement Company has confirmed its technical feasibility and low operation cost. This technique is imperative for China's cement plants to realise their NOx ultra-low emissions and green development goals, « About the author ‘Wang Lan is a professor at China Building Materials Academy, Chair of China Cement Engineering Technology Committee, and consultant for China Cement Association. The principal areas of research in which the author has worked are energy saving and emissions reduction of cement production, especialy flue gas DeNOx with SCR technology.