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Plant Mannersdorfin a Nutshell
Umweltbundesamt, 02.12.2016
LafargeHolcim at a Glance
| 2
GartenauGmunden
Kirchdorf
Mannersdorf
Wopfing
Peggau
Rohoznik
Cement Plants in Austria / Vienna market
VIENNA
AUSTRIAAUSTRIAVils
Peggau
Wietersdorf
Retznei
Eiberg
Others Others/LafargeHeidelberger /
RohrdorferCRH
| 3
� First cement production activities on site 1894
� Perlmooser joined Lafarge-Group in 1994
� Current kiln line from 1986Current Kiln Capacity:
Plant Historical Development
Current Kiln Capacity:
� 2.730 t/d ⇒ 860.000 t/y
(1,30 Mt/y)
� Currently (70%AF):
2.360 t/d ⇒ 750.000 t/y
(1,13 Mt/y)
� 2 Quarries: � Limestone (42 years reserves)
� Clay (proven 3 years – probable 34 years) – today, 50% natural clay replaced by clay-
bricks
| 4
� Health & Safety� Member of Lafarge H&S
Excellence Club
� 1004 days without LTI
� Last LTI: Eye injury at
bypass dust handling
� Market
Key facts
� Market � excellent plant position
to Vienna market
� HR / Lean Organization � 92 Employees
� 10 Apprentices
� 10 permanent Contractors
� Supervisor / Foreman: mainly recruited locally and developed through dual
education system
| 5
� Plant is Sold Out� 1,15 Mt cement / a
� Kiln UF at ~ 88%
� 9 Cement Types� 90% Bulk /10% Bag
� Dispatch
Key facts
� Dispatch� Truck and Train
� Environment / Stakeholders� Continuous Emission Monitoring:
NOx, SO2, Dust, Hg, TOC
� NOx: First semi-dust SCR installed
in Lafarge (2012)
� Contract with local stakeholders
ensuring wide range of AF-permits
| 6
Cement = ground clinker + gypsum +….
� Hardening under water or under air and giving high
final strenght
� Clinker composition (CS phases):
A hydraulic binder
Oxide
SiO2
Symbol
S
Content
20 to 25 %
Maj
or
elem
ents
7April 2016 |
Al2O3
Fe2O3
CaO
MgO
SO3
Alkalies
Free CaO
A
F
C
M
SK2ONa2O
KN
2 to 7 %
1 to 4,5 %
64 to 70 %
2 %
1%
0,9%
0,5 to 3 %
Maj
or
elem
ents
Min
or
elem
ents
Limestone Quarry
� Mobil crusher� O&K
� Av. Output 700 t/h
� „Load & Carry“
� Komatsu WA 800
8
Komatsu WA 800� 13 m³ bucket capacity
� >95 % CaCO3
� 1 Mio t / yr !
|
...und natürliche
Suksession
Clay pit - Mining, mixing with bricks & recultivation
9
Suksession
05/12/201610
Plant Mannersdorf – Aerial Perspective from North
Clinker Silos
CM 7 & 8
Limestone Quarry
Cement Silos
Offices
11|
Cooler Kiln Preheater
Raw Mill
Offices
AF storage
Kiln and Pre-heater Tower
� Preheater Tower� 2 Strings
� 5 Stages
� Separateline Calciner
� Inline Calciner under
12|
Inline Calciner under construction
� SCR in old PreheaterTower
Locations of fuel input
Riser Duct:
SSW (plastics)
13
raw mill
filter
co
al m
ill
2 calciner burners:
Petcoke, Coal, SSW (plastics), Sunflower shells, ISF (Impr. Solid Fuel), HCF (High Cal. Fuel)
Main burner:
Petcoke, Coal, Sunflower shells, Animal meal, SSW (plastics)
SSW (plastics)
|
Alternative Fuel – Storage Hall
Capacity4.500 m³ (700 t)
3 compartments,
1.500m³ each
14
Automatic Craneproviding 2 weigh-feeders &
belt-conveyors:
� Calciner (up to 10 t/h)
� Main-burner (up to 5 t/h)
|
Solid Shredded Waste
Sunflower Shales
17
Floor +37,3m (4)
17. Oktober
Calciner : 5 m diameter / 1500 m³ / height: 80 m
19
Description of the SCR
� 2 field ESP operated at 300 to 350°C
� Rectangular SCR reactor (4*6 m)
integrated in the old preheater tower
� 2 layers equipped with catalyst and
soot blowers, total of 43 m³ catalyst
� Gas conditioning tower below the SCR
reactor
20|
SCR Mannersdorf - Features
� UREA injection on top
cyclone inlets
� SNCR remains stand by
� Preheat circuit with filter and
electrical heater
UREA
� Filtered and preheated fresh
air for purge
� Catalyst cleaning with
preheated compressed air
� Downcomer water injection
stand by
21|
Operation Results
� NOx target of 200 mg/Nm³ at stack reached from
the beginning
� Positive effect on VOC (~ minus 50 to 75%)
� Hg: almost complete oxidation
� CO: no direct effect, but reduction due to� CO: no direct effect, but reduction due to
stopping SNCR
� Start and stop without impacting the kiln
� Due to carbon fibers in flue gas and high dust
resistivity, the ESP performance is at 15 to 20
g/Nm³ versus planned 2 g/Nm³
22|
Catalyst
• 75-80% TiO2 as carrier
• 8-10% glas fibers
• 5-10% tungsten
• 1-3% V2O5 as active component
23
NOx Emissions: Kiln/Raw Mill Exhaust gas
Emission Monitoring: NOx (kiln exhaust gas)
24
SCRNOx-Reduction through
Selective Catalytic Reaction
� Commissioning in April 2012
� First in Lafarge, first in
Austria, 4th Worldwide
|
Emissions Monitoring
� Continuous Monitoring of:
� NOx, CO, CO2, NH3, VOC, SO2, Dust, Hg
� Discontinuous Monitoring of:
� Heavy Metals� Heavy Metals
� HCl, HF
� Dioxine/Fourane
� PCDD/F, PAH
25|
Dust Emissions: Kiln/RawMill Exhaust Gas
Emission Monitoring: DUST (kiln exhaust gas)
DUST
26
Bag-Filter(installed in 2000)
|
VOC Emissions: Kiln/RawMill Exhaust Gas
Emission Monitoring: VOC (kiln exhaust gas)
27|
SO2 Emissions: Kiln/Raw Mill Exhaust gas
Emission Monitoring: SO2 (kiln exhaust gas)
DUST
28
Managed through blending clay with waste-clay-bricks
DUST
AWG
|
Mercury Emissions: Kiln/Raw Mill Exhaust gas
Emission Monitoring: Hg (kiln exhaust gas)
29
Managed through Active Carbon
Dosing System
|
Discontinuous Emission Monitoring
� Kiln Exhaust gas after Raw-Mill
� 2 times per year
� Measured by TÜV Austria
� Measurements include heavy metals as well as other emissions:
30
mg/Nm³
HCl HF Cd Tl HgSb, As, Pb, Cr, Co, Cu, Mn, Ni, V, Sn gesamt
Dioxine / Furane [ng/Nm³]
Limit: 10 0,7 0,05 0,05 0,05 0,5 0,05
Ø 2012: 0,9 0,125 0,001 0,001 0,029 0,042 0,001
Ø 2013: 1,0 0,07 0,002 0,001 0,014 0,045 0,004
Ø 2014: 2,9 0,15 0,004 0,001 0,019 0,088 0,001
Ø 2015: 2,0 0,100 0,001 0,001 0,013 0,075 0,003
|
Emission Limit Values
Grenzwert (GW)
HMW TWM JMW
NOx 200 (500*) 200 (500*) 200 (500*) mg/Nm³
NH3 - 30 (40**) 30 (40**) mg/Nm³
SO2 350 350 350 mg/Nm³
mg/Nm³, dry at 10% O2
SO2 350 350 350 mg/Nm³
Staub 20 20 20 mg/Nm³
CO - - - mg/Nm³
TOC 120 120 120 mg/Nm³
Hg - 0,050 0,030 mg/Nm³
31
* Without SCR
** Without SCR or RM
|
Cement Grinding
� Clinker Storage Capacity: 135.000 t
(4 clinker silos)
� 2 Cement Mills: ~60 t/h and
~115 t/h
(incl. Slag Dryer)
32|
(incl. Slag Dryer)
� Cement Storage Capacity: 10 cement silos:
54.000 t
ZM 8 ---- 4,6 m diameter / 16,4 m length
2 * 3 MW
340 t grinding balls
33|
Product-Portfolio
34