Plant Mannersdorf in a Nutshell. Umweltbundesamt,

Transcription

1 Plant Mannersdorf in a Nutshell Umweltbundesamt,

2 LafargeHolcim at a Glance 2

3 Cement Plants in Austria / Vienna market Rohoznik Kirchdorf VIENNA Mannersdorf Vils Gartenau Eiberg AUSTRIA Gmunden Peggau Wopfing Retznei Wietersdorf Heidelberger / Rohrdorfer Others Others/Lafarge CRH 3

4 Plant Historical Development First cement production activities on site 1894 Perlmooser joined Lafarge-Group in 1994 Current kiln line from 1986 Current Kiln Capacity: t/d t/y (1,30 Mt/y) Currently (70%AF): t/d 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 claybricks 4

5 Key facts Health & Safety Member of Lafarge H&S Excellence Club 1004 days without LTI Last LTI: Eye injury at bypass dust handling 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

6 Key facts Plant is Sold Out 1,15 Mt cement / a Kiln UF at ~ 88% 9 Cement Types 90% Bulk /10% Bag 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

7 Cement = ground clinker + gypsum +. A hydraulic binder Hardening under water or under air and giving high final strenght Clinker composition (CS phases): Oxide Symbol Content Major eleme ents SiO 2 Al 2 O 3 Fe 2 O 3 CaO S A F C 20 to 25 % 2 to 7 % 1 to 4,5 % 64 to 70 % Minor elements MgO SO 3 Alkalies Free CaO K 2 O Na 2 O M S K N 2 % 1% 0,9% 0,5 to 3 % April

8 Limestone Quarry Mobil crusher O&K Av. Output 700 t/h Load & Carry Komatsu WA m³ bucket capacity >95 % CaCO3 1 Mio t / yr! 8

9 Clay pit - Mining, mixing with bricks & recultivation...und natürliche Suksession 9

10 10 05/12/2016

11 Plant Mannersdorf Aerial Perspective from North Limestone Quarry CM 7 & 8 Clinker Silos Cement Silos Offices AF storage Cooler Kiln Preheater Raw Mill 11

12 Kiln and Pre-heater Tower Preheater Tower 2 Strings 5 Stages Separateline Calciner Inline Calciner under construction SCR in old Preheater Tower 12

13 Locations of fuel input Riser Duct: SSW (plastics) coal mill 2 calciner burners: Main burner: filter raw mill Petcoke, Coal, SSW (plastics), Sunflower shells, ISF (Impr. Solid Fuel), HCF (High Cal. Fuel) Petcoke, Coal, Sunflower shells, Animal meal, SSW (plastics) 13

14 Alternative Fuel Storage Hall Capacity m³ (700 t) 3 compartments, 1.500m³ each Automatic Crane providing 2 weigh-feeders & belt-conveyors: Calciner (up to 10 t/h) Main-burner (up to 5 t/h) 14

15 Solid Shredded Waste

16 Sunflower Shales

17 17

18 Floor +37,3m (4) 17. Oktober

19 Calciner : 5 m diameter / 1500 m³ / height: 80 m 19

20 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

21 SCR Mannersdorf - Features UREA injection on top cyclone inlets UREA SNCR remains stand by Preheat circuit with filter and electrical heater Filtered and preheated fresh air for purge Catalyst cleaning with preheated compressed air Downcomer water injection stand by 21

22 Operation Results NO x 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 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

23 Catalyst 75-80% TiO2 as carrier 8-10% glas fibers 5-10% tungsten 1-3% V2O5 as active component 23

24 Emission Monitoring: NOx (kiln exhaust gas) NOx Emissions: Kiln/Raw Mill Exhaust gas SCR NOx-Reduction through Selective Catalytic Reaction Commissioning in April 2012 First in Lafarge, first in Austria, 4th Worldwide 24

25 Emissions Monitoring Continuous Monitoring of: NOx, CO, CO2, NH3, VOC, SO2, Dust, Hg Discontinuous Monitoring of: Heavy Metals HCl, HF Dioxine/Fourane PCDD/F, PAH 25

26 Emission Monitoring: DUST (kiln exhaust gas) Dust Emissions: Kiln/RawMill Exhaust Gas DUST Bag-Filter (installed in 2000) 26

27 Emission Monitoring: VOC (kiln exhaust gas) VOC Emissions: Kiln/RawMill Exhaust Gas 27

28 Emission Monitoring: SO2 (kiln exhaust gas) SO2 Emissions: Kiln/Raw Mill Exhaust gas DUST AWG Managed through blending clay with waste-clay-bricks 28

29 Emission Monitoring: Hg (kiln exhaust gas) Mercury Emissions: Kiln/Raw Mill Exhaust gas Managed through Active Carbon Dosing System 29

30 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: mg/nm³ HCl HF Cd Tl Hg Sb, 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 30

31 Emission Limit Values mg/nm³, dry at 10% O2 * Without SCR ** Without SCR or RM Grenzwert (GW) HMW TWM JMW NOx 200 (500*) 200 (500*) 200 (500*) mg/nm³ NH3-30 (40**) 30 (40**) mg/nm³ SO mg/nm³ Staub mg/nm³ CO mg/nm³ TOC mg/nm³ Hg - 0,050 0,030 mg/nm³ 31

32 Cement Grinding Clinker Storage Capacity: t (4 clinker silos) 2 Cement Mills: ~60 t/h and ~115 t/h (incl. Slag Dryer) Cement Storage Capacity: 10 cement silos: t 32

33 ZM ,6 m diameter / 16,4 m length 2 * 3 MW 340 t grinding balls 33

34 Product-Portfolio 34