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Portugal: Cimpor Portugal has signed a contract with Germany-based KHD Humboldt Wedag (KHD) for an upgrade to production line 7 at its Alhandra cement plant. The project is intended to increase the production capacity at the plant to 3600t/day from 3000t/day and increase the line’s alternative fuels thermal substitution rate to over 80%. It will also be the first installation of KHD’s Pyrorotor alternative fuel combustion reactor in the country.

The scope of the engineering and supply contract comprises:

• New HKSK 224/335 preheater ID fan
• New downcomer duct
• New preheater with 8064/5-type HEM cyclones
• Pyroclon R calciner with Pyrotop mixing chamber. The Pyroclon R will utilize fine refuse-derived fuel (RDF) and natural gas
• 4m x 10m Pyrorotor alternative fuel combustion reactor
• Pyrobox coal firing system for process start-up and operation balancing
• Shortening of the existing kiln and installation of new kiln inlet chamber with bypass extraction
• New kiln drive station 2 (the existing girth gear and two pinions will be reused)
• New kiln hood and take-off of tertiary air from the cooler roof
• New main kiln burner designed to use more than 50% alternative fuels (but will also be capable of burning natural gas, as well as liquid fossil and alternative fuels)
• New Pyrofloor PFC²829AW cooler with a Pyrocrusher PRC 420-3ES clinker crusher.

KHD will also be supplying its KHD ProMax software product as part of the project.

Matthias Mersmann, chief technology officer at KHD, said “The decision by Cimpor Portugal to opt for KHD pyroprocessing equipment - and especially the Pyrorotor - underlines the leading market position of KHD, as well as the outstanding capability of KHD’s unique alternative fuel-processing solution.”

Project execution will be led by KHD Germany, with support from Humboldt Wedag India and the Turkish branch office of Humboldt Wedag. Commissioning of the upgraded production line is scheduled for 2025.

US: Continental Cement has ordered a Fuelflex Pyrolyzer alternative fuels combustion system from Denmark-based FLSmidth for installation at its Davenport plant in Buffalo, Iowa. The supplier says that its product offers a lower capital expenditure compared to competing systems, can control NOx emissions without the need for ammonia water and can be installed without a long shutdown period. This is the first commercial installation of the Fuelflex Pyrolyzer system following a pre-commercial installation at the Mannok cement plant in Northern Ireland, UK, in 2022.

David Loomes, the president of Continental Cement, said “We’re very excited about what the Fuelflex Pyrolyzer will do for our process.” He added, “We’re planning to achieve 55% fossil fuel replacement across the plant, utilising non-hazardous waste that would otherwise go to landfill or incinerators. The economic and environmental benefits of this technology are very significant and a key element of executing our carbon reduction commitment.” Continental Cement, a subsidiary of Summit Materials, has been incorporating waste materials as fuels for more than 30 years.

Jens Jonas Skov Larsen, Head of Capital Sales at FLSmidth, said “Mannok has called the Fuelflex Pyrolyzer a game-changer for the cement industry.” He continued, “This system effectively rearranges the order of the combustion process to make use of hot preheater meal, which is the heat source for the waste fuel pyrolysis. It’s a more efficient way of burning alternative fuels and it comes with a host of benefits, including reduced emissions and a more stable process.”

The installation at Davenport cement plant is expected to start operation in 2024. The full commercial launch for the system is scheduled by 2025. No value for the order has been disclosed.

Portugal: Secil has ordered a 300m3/hr alternative fuel (AF) pipe conveyor for its Outão cement plant from Italy-based Bedeschi. The conveyor will have a diameter of 250mm and conveying length of 350m. The supplier says that it will enable safe and clean transportation of AF unhindered by the steep incline and curve and the difficulty of the materials.

Austria: Untha has announced the supply of an Untha XR3000C mobil-e primary shredder to Austrian Tyre Processes. The supplier says that the model’s twin 132kW motors produce refuse-derived fuel of a homogenous 50mm size, suitable for further processing into a cement fuel additive.

Its director of global business development Gary Moore said, “With the world’s raw materials rapidly depleting – and businesses and consumers alike demanding more environmentally responsible solutions – this is a fantastic example of clever engineering and innovative thinking coming together to change the face of the industry.”

UK: Tarmac has ordered a solid recovered fuel (SRF) handling system from Saxlund International to increase the capability to utilise alternative fuels at its Dunbar integrated cement plant. The SRF system will be installed in the second half of 2019. It is designed for the reception of trucks and storage of fuel in two bunkers. The new system includes processing of fuel to remove ferrous and oversize particles before weighing and dosing into a pneumatic conveying system for kiln injection. The Dunbar plant will use SRF supplied by Hamilton - Solid Recovered Fuel.

“We are delighted to be involved in the development of this new SRF facility at the Dunbar Cement works. The overall system for the reception, storage and conveying of SRF fuel will help to ensure a highly resilient and robust solution for our client,” said Mark Neal, sales manager at Saxlund International.

Germany: Intercem has been contracted to optimise the secondary fuel dosing system at an unnamed German cement plant. The scope of delivery includes disassembly on site, refurbishment of the trough chain conveyors that will be re-used, construction of a new bunker and installation of the refurbished screws. The engineering, as well as the assembly of the new components and the provision of the necessary cranes, hoists and other equipment, are also included.

Austria: Saubermacher Dienstleistungs has ordered a XR3000C shredder from Untha for the single-stage processing of commercial and household waste at a sorting plant in Vienna. The Styrian-based waste and recycling company produces refuse-derived fuel (RDF) for the cement industry. The company’s main requirement was that the RDF should have a particle size of less than 80mm and be produced by means of a single-stage shredding process, rather than a two-stage shredding process with coarse and fine shredding. Saubermacher Dienstleistungs wanted a machine with a throughput of at least 20t/hr. It also chose the XR3000C model for its energy efficiency.

France: Solid recovered fuel (SRF) manufacturer Environnement 48 has ordered a XR3000C mobil-e shredder from Austria’s Untha. The new unit has an expected production capacity of 10,000t/yr. It will mainly be used to process plastics and wood to a particle size of 80mm. It follows a previous order of an XR Ripper waste shredder by the French company.

Austria: Rohrdorfer Group has awarded an engineering, procurement and construction (EPC) contract to Humboldt Wedag, a subsidiary of KHD, for the modernisation of the kiln line at its cement plant operations in Gmunden. The upgrade will enable the flexible usage of a wide range of waste fractionally pre-treated derived fuels on a high substitution rate.

The modernisation project comprises the design and supply of KHD’s world´s first ever Pyrorotor Cacliner Technology, as well as the replacement of the existing satellite cooler with a new generation Pyrofloor PFC2 clinker cooler. The existing three station rotary kiln will be fitted with a new kiln drive and a new kiln hood as well as kiln inlet and outlet.

With the installation of the new Pyrorotor Cacliner Technology from KHD the Gmunden plant will be able to burn very coarse waste derived fuels including whole rubber tires, which will lead to drastically reduced requirements in regard to waste pre-treatment. Therefore, the kiln modification will also emphasise on pollutant emission reduction.

The contract includes: three new preheater cyclones; a new preheater ID-fan; a tertiary air duct; a Pyrotop compact calciner mixing chamber; Pyrorotor Calciner burning chamber technology, a Pyroclon Calciner Burning System; a new kiln bypass unit; a multi-fuel Pyro-Jet kiln burner for primary and secondary fuels; a new kiln drive and kiln hood; a Pyrofloor PFC2 clinker cooler equipped with a Pyrocrusher roller type clinker crusher; and Simulex plant simulation software.

KHD services include the dismantling of existing equipment parts as well as the engineering, design, supply and erection of new equipment including commissioning services. Commissioning of the new system is scheduled for April 2019.

Japan: Austria’s Untha has agreed a new distribution partnership with Yokohama-based engineering firm Sun Earth. The deal will see Untha’s manufactured shredding technology supplied to a number of waste and alternative fuel production facilities throughout Japan. The agreement was arranged to help Sun Earth cope with demand for a shredding system that can tackle complex production waste, including single-step solid recovered fuel (SRF) manufacturing. Talks between the companies started in mid-2017.

Sun Earth has already placed an order for an Untha XR3000C shredder scheduled for shipment in early 2018.