· of solid waste. if leachate is not col-lected the ground as well as the nat-ural water sources...

Newsletter

Summer2013

Completion of the British Airways engine dock

High Alumina Cements

Infrastructure Projects

And much more to read ⋯

WWW.PEGENG.CH

Our solutions for wastemanagement & reycling

PEG S.A. - 4, rue du Lièvre - CP 1411 - 1211 Geneva 26 - SwitzerlandTel +41 (0) 22 544 31 00 Fax +41 (0) 22 544 31 05 www.pegeng.ch [email protected]

Contents

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New Projects

Calcium Aluminates (or High Alumina Cements)

Our Concept of Waste Management and Recycling Complex

Completion of the British Aiways maintenance facility

Activities of the PEG Infrastructure Department

Introducing New Staff Member

PEG Vacancies

Dear reader,

In this first 2013 issue of our Newsletter, you will have an overview of the different sectors of activity where PEG can be found , let it be in the cement industry with a technical article about Alumina Cement, and the environment with a presentation of our energy-self-sufficient waste management and recycling complex. The activities and projects carried out by our Aviation and Infrastructure Departments will also be presented.

As always, we hope you enjoy this newsletter and will continue to read through further editions.

Yours Sincerely,

Geneva water fountain, one of the city’s most famous landmarks

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Marc LambertC.E.O.

PEG S.A. - 4, rue du Lièvre - CP 1411 - 1211 Geneva 26 - SwitzerlandTel +41 (0) 22 544 31 00 Fax +41 (0) 22 544 31 05 www.pegeng.ch [email protected] 2

New projects

Since our last newsletter PEG has signed the following new contracts :

SAUDI ARABIA

- Supervision of contractor’s engineering, control of manufactured equip-ment, supervision of construction and supervision of strat -up and commis-sioning for a brownfield new 5’000 tpd production line (line 3) on a turnkey basis.

- Preparation of tender documents, evaluation of proposals and contract negotiations for a Greenfield cement plant of two production lines of 10’000 tpd clinker each and the relocation of the existing line 7 to the new site on an EPC turnkey contracting basis.

- Services for inspection for a cement plant.

- Preparation of a project technical study for the power supply of lines 1,2,3 and white cement line.

RUSSIA

- Assessment of possible sources of car-bamide concentration in the clinker and ce-ment produced.

- Waste energy feasibility study.

- Grinding plant audit.

MOROCCO

- Feasibility study for a new 1’000’000 tpa cement plant.

- Equipment inspections for three grind-ing stations.

SWITZERLAND

Airports projects:- New rapid exit taxiway “Charlie 2” at Geneva Airport- Modification of the rapid exit taxiway “Bravo” at Geneva Airport- Compliance of Lausanne Airport to allow night landings

JORDAN

- Services for inpection of the raw mill ID fan.



CHEMISTRY

Like Ordinary Portland Cements, Cal-cium Aluminates are composed of oxides of Calcium, Aluminium and Silicon, but in different proportions.

The Alumina (Al2O3) fraction is be-tween 35% and 70%, and the Silica fraction (SiO2) as low as zero or trace. Calcium Aluminates are usually char-acterized as low range, mid range and high range, with the alumina content at 35 – 42%, 48 – 58%, and 65 – 70% respectively. The bulk of the remaining is CaO, with SiO2 from 4% down to zero. Ferrites and oxides of titanium are also present, particu-larly in the low range.

Clearly to achieve this difference in chemistry, quite different raw materials are used.The production of Portland Cements is based on Limestone and varying proportions of clay, shale, bauxite and other potential sources of Silica and ferrites. The production of low and mid range calcium aluminates is based on bauxites of varying purity and high grade limestone. The production of high range calcium aluminates is based on metallur-gical grade alumina and calcined high – grade limestone.

Comparison to portland cement

MINERALOGY

Chemistry is a means to an end, the formation of minerals, crystalline in nature, which when mixed with wa-ter form hydrates constituting the gels which bind aggregates togeth-er in concrete.

In the picture on the left, customary cement “shorthand” is used, with C for CaO, A for Al2O3 etc.

Taking the simplest system shown in the phase diagram, that of high range calcium aluminates, the active minerals formed in the production process are CA (strength and flow) CA2 (not much use) and C12A7 (ear-ly set). CaO or free lime is present in ppm quantities.

4PEG S.A. - 4, rue du Lièvre - CP 1411 - 1211 Geneva 26 - Switzerland

Tel +41 (0) 22 544 31 00 Fax +41 (0) 22 544 31 05 www.pegeng.ch [email protected]


The phase diagram looks neat and tidy, and a cursory look will pro-voke the question as to why you don’t just manage the process so you’re in the CA + C12A7 box.

This can be done, theoretically, at around 65% alumina content, but production tools and raw materials being somewhat less than perfect, if you try it you end up with a lot of liquid phases in the burning zone and block the kiln within minutes. So operators add a bit more alumina, make some CA2 along with the rest, and have a more robust process.

HYDRATION

Without water, cement is of no use whatsoever. What counts are hydrates formed by cement re-acting with water, they are what bind aggregates together to make concrete. Even in the most sim-ple systems the reactions are complex and de-pend a lot on temperature.

Below is a picture of what a hydrate looks like un-der a scanning electron microscope.

Crystals obtained in dilute solution

Hydrates of CAC

CAH10C2AH8

Strength development

And here after you have a sum-mary graph of which hydrates are formed at what temperature, and how they influence strength development in the concrete.



MARKETS AND APPLICATIONS

All ranges of Calcium Aluminates have two principal markets: con-struction chemistry and refractories.

Construction chemistry: Essentially used as an additive in Portland for-mulations, low range Calcium Alu-minates are used as a Portland ac-celerator by jobbing builders. High range Calcium Aluminates are one of 15 – 20 ingredients in self lev-eling floor screeds and tile adhe-sives. The properties of flow, fast setting and high early strength are useful in these applications. 100% low range concretes are used in spe-cial applications, industrial floors, marine works, dam spillways etc, where properties such as sulphate resistance, acid attack resistance, and abrasion resistance are of value.Rapid set and fast strength develop-ment are used in special formulated mixes for road and bridge repairs in avalanche areas, and military run-way repair systems.

Refractories: Calcium Aluminates of all ranges are the principal binders in monolithic refractories and gunnit-ing formulations. The high alumina content brings temperature resist-ance, but this is always mitigated by the lime fraction. In the more exotic refractory formulations, particle size distribution is optimized to improve packing in the matrix, and in order to push temperature resistance as high as possible, the cement content can be as low as 1% - 3%.

The two applications, temperature resistance and structural strength, are combined in examples such as Fire Department training areas,

and missile launch platforms. Minor markets are served by the abil-ity of calcium aluminates to capture sulphates (steel manufacture, efflu-ent treatment) and slow neutrons (reactor civils).

PRODUCTION

The Calcium Aluminate market is very small on a global scale, quite niche, and hence has not attracted the attention of Engineering firms, Turnkey contractors and Equipment suppliers. Design is done in – house, and in order to protect know – how Plants are built on a multi – pack-age basis with the owner perform-ing process design, key equipment selection, automation and general co-ordination.

If the “typical” Portland Plant makes 1 Million tpy, you could say that the “typical” Calcium Aluminates Plant makes 100’000 tpy. With raw materi-al costs and average selling prices of Aluminates an order of magnitude higher than those of Portland, the financial structures of the “typical” plants are quite similar.

The basic processes are in the public domain.

Low range is made in hearth fur-naces, raw materials are presented in block form and gravitate down the vertical section to a “bath” where they are melted at around 1500C, and tapped out continuously via a pan conveyor.

Mid range can use the above process, or a semi-dry rotary kiln process, or even sintered in vertical shaft kilns.

High range can either be sintered in a rotary kiln, or melted in induction crucibles in a batch process. It’s the closest process to the Portland ce-ment process. In general terms the main differences are a greater em-phasis on quality management in Calcium Aluminates, and a greater emphasis on energy efficiency in Portland.

Process detail and industrial perfor-mances are closely guarded secrets.

The Milling process is similar to Port-land, but the very high wear rates obviate the use of Vertical Mills and Roller presses.

Packing and dispatch are similar, the main difference being in quality management e.g. 3mm screens on bulk loading equipment, develop-ment of waterproof Cement bags etc.

Quality management is adapted to the selling prices of up to 1000 Eu-ros / tonne: fractional PSD analysis of the raw material mix, on – line XRD by Rietveld, predictive tests for ap-plication performance on cement etc

If you have any question regarding High Alumina Cement, please do not hesitate to contact us at [email protected]. We will assist you in the realization of all your projects by putting at your disposal our best specialists.


Our Concept of Waste Management and Recycling Complex

PEG which is involved in environ-

mental projects for years, has re-

cently developed its own concept

of waste management and recy-

cling complex, including facilities

for the production en thermal and

electrical energy.

The complex consists of a complete recycling center including the fol-lowing facilities:

Sorting lines for the production of

Refuse Derived Fuel (RDF)

The equipement used for the sorting line can either be electrical or diesel powered, static or mobile, according to client needs.

Plastics, rubber, fabrics, papers and wood will be used to produce RDF which will then be sold to the ce-ment industry as well as other en-ergy intensive industries as a substi-tute to fossil fuel.

General arrangement

Methane gas extraction including a

storage tank

After extraction of the material that constitutes RDF, the remaining waste mainly consists of biodegrad-ables materials which will be land-filled and used for the production of methane. This gas is produced by the breakdown of organic mat-ter and once treated, can generates thermal and electrical energy.

Wastewater treatment stations

It is important to treat the landfill leachate which is a liquid generated by the rainwater mixed with the liq-uid produced from the degradation of solid waste. If leachate is not col-lected the ground as well as the nat-ural water sources of the surround-ings may be contaminated.

In a second phase, a facility for the treatment of municipal waste water can also be integrated within the complex.

Hazardous waste incinerator

Special waste such as hazardous and hospital waste will be incinerated.

Boiler

A methane powered boiler will be used for the production of hot water, which can then be put through ex-changers in order to produce heat-ing, cold air or create electricity.

The waste management and recy-cling complex objective is that once the methanization process is proper-ly running, the complex will become energy-self-sufficient.

Therefore, PEG has developped part-nerships with reputable companies using the the latest technologies and quality equipment that meet all re-quired European standards in order to deliver a waste management and recycling center of high standard.If you wish to receive our complete presentation, please do not hesitate

to contact us at [email protected]. Our team can also provide you with a detailled and personnalized invest-ment file for the reali-zation of such project.


After its presentation in our last newsletter, today PEG is proud to announce the completion of the MRO pro-

ject on Turn-Key Supply of the Innovative Engine docking system suited to service Airbus A319/A320/A321 for

British Airways Maintenance Glasgow (BAMG).

PROJECT HIGHLIGTS:

The whole Project took approxi-mately 1 year to accomplish from the conceptualizing and design un-til putting the Dock into operation at the Glasgow Maintenance and Overhaul facility of British Airways.

The new docking system features numerous customized aspects providing more flexibility and ac-cessibility to the areas to be main-tained or repaired. The dock con-sists of a light aluminum structure, which makes it mobile and easy to install and operate. The high end quality result is achieved through a combination of Swiss engineer-ing and German fabrication, high-est quality craftsmanship, whilst remaining competitively priced.

Completion of the British Airways maintenance facility

The docks design and the project realization were accomplished to the full satisfaction of the client.

DESCRIPTION OF THE ENGINE

DOCK

The maintenance dock consists of two lightweight aluminum mobile platforms, providing access to the engines of the aircraft let it be on wheels or on jacks. Additionally, slid-ing panels covering the entire length of the engines are provided. This al-lows more flexibility and accessibil-ity to the areas to be maintained or repaired. When the platforms are in-stalled around the engine the tech-nicians are able go from one plat-form to the other using the access in the frontal parts of the platforms.


Completion of the British Airways maintenance facility

Each of the two platforms is equipped with a sliding ladder pro-viding access to the engine pylon. The ladder can be moved around the platform and along the engine. This ladder is designed for one person to sit on top whilst performing repairs or inspections to the pylon. When it is not in use, it can be parked on the front side of the platform to enable the opening of the engine cowling. The working platform has the plug-in railings with kick plates fabricated and installed according to EU safety norms.

If you want to entrust PEG Aviation with your next project, please do not hesitate to contact us at [email protected].


Activities of PEG Infrastructure Department

The PEG Infrastructure depart-

ment is currently composed of

7 engineers, technicians and

draftsmen all experienced em-ployees with complementary skills in the fields of electrome-chanical, automation and energy.

The Infrastructure department per-forms all kind of engineering mis-sions ranging from the realization of the feasibility studies, the prepa-ration of technical specifications for tenders, the consultations for public procurement, the negotiation and the contract drafting for procure-ment, the supervision and quality control of works until commissioning.

The PEG Infrastructure depart-ment is particularly active in Swit-zerland and some of our main cli-ents and current projects include:

Geneva International Airport PEG and Geneva International Air-port have developed a tight relation-ship.

PEG is currently working on different projects, among which the provi-sion of engineering services related to the luminous beaconing and the management of the power supply. More precisely, our scope of work consists of the complete renovation and conformance of the visual bea-cons of the runaway and taxi ways.

This project is now coming to its end and was executed all along this past five years but new contracts were awarded to PEG such as the park-ing stand guidance light and the new rapid exit taxiway of Charlie 2.

Federal Roads Office

PEG regularly carries out studies and works related to the facilities and equipment on motorways and in tunnels. These studies or works are varied and can concern the fields of fire safety, light signaling, auto-mation and systems management, CCTV and automatic incident detec-tion, management of maintenance contracts, Auxiliary Control System, etc.

Geneva Industrial Services

The Geneva Industrial Services are the operators of the CADIOM district heating network.

In 2011, PEG was awarded the con-tract related to the heat recovery from the exhaust gas of the 4 boil-ers and using it to heat the water of the heating of administrative build-ing SIG of Lignon and to pre-heat the combustion air of the 4 boilers and the 2 new ones. Currently , PEG is in the completion phase of the first boiler.

This was an overview of some of our current projects. Today, the PEG Infrastructure team is involved in about 20 projects and helps its cli-ents to deploy effective technolo-gies and processes. If you would like to submit us your project, please do not hesitate to contact us.


Introducing New Staff Member

Jens will be responsible for the daily operations of the company in close cooperation with PEG C.E.O., Marc Lambert, and will be providing op-erational and technical assistance to the team whilst staying up to date with the day-to-day business issues.

Jens brings with him a wealth of ex-perience from his past positions in the cement industry, where he used to work for some of the world lead-ing companies.

Jens started his career in 1981 within the Danish group FLSmidth and its af-filiated companies. He first occupied the position of Project Engineer. Jens has evolved rapidly: Managing Director of Danalith UK, Regional Manager at Danogips, Sales Manager at Densit, Managing Director of DEF 1994 and also FLS Aerospace. In 1999, Jens was appointed Director of Sinai White Port-land Cement Company with the mission to establish an Egyptian subsidi-ary of Aalborg Portland and to manage and supervise the construction of the world’s largest white cement plant (1.2 million tons per annum. From 2002, Jens worked as Site Manager for FLSmidth in Algeria and Nigeria. After 24 years working for FLSmidth, Jens gave a new direction to his career. From 2005 to 2011, he worked for the Holcim group and held various positions such as Construction Manager for Holcim Morocco with the main task to manage the sites activities for the realisation of a greenfield cement plant. In 2008 and for the next 3½ years, Jens was at the helm of Ceprocim engineering in Romania. The last position he held before joining PEG was as Project Manager at Holcim Belgium. Jens, who enjoys working with people across cultures and borders, speaks fluent Danish as well as English, French, German and some Arabic and Ro-manian. Moreover, his long career with time shared between office work and site enhances his ability to settle, organize and lead both, office and site ac-tivities. All his new colleagues wish him every success in carrying out his new mis-sion at PEG.

Jens Hedegaard has recently joined PEG as Chief Operations Officer and

we are delighted to welcome him in the team.

If you would like to contact Jens directly, please send an email to: [email protected] or call him on: +41 (0)79 268 77 74.

PUBLICATIONS:

PEG took part, with 4 other con-sultants, to a Q&A article pub-lished by World Cement in his March issue. The questions var-ied from traditionnal issues to more modern topics such as al-ternative fuels.

A full copy of this article is avail-able to download on our website http://www.pegeng.ch/down-loads/articles.php

CALENDAR:

Meet us at the 18th Arab Inter-national Cement Conference and Exhibition which will take place at the Hilton Dead Sea Resort and Spa in Jordan from 11-13th November 2013.

PEG Vacancies

As an ever expanding company, we constantly have new opportunities for experienced engi-neers to become part of our team. Our projects are spread over 5 continents .

We currently have the following positions available:

Site Resident ENGINEERS : Civil, Mechanical, ElectricalYou will be responsible for the supervision of the work on site and be the main contact of the client and the subcontractors.

Expert in AFR / Refuse dump organization and establishment

PEG is looking for someone with experience in the field of recycling and/or waste preparation and in design of waste preparation plants (ability to judge different technical solutions for waste preparation plants).


For a complete profile overview and information about our application procedure, please visit our website

www.pegeng.ch/about/careers

· of solid waste. if leachate is not col-lected the ground as well as the nat-ural water sources...

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