the environment of manufacturing refractory …
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THE ENVIRONMENT OF MANUFACTURING REFRACTORY PRODUCTS AND ITS APPLICATIONS 23. INTERNATIONAL INDUSTRIAL MINERALS CONGRESS AND EXHIBITION MARRIOT HOTEL, PRAGUE, CZECH REPUBLIC
15th of June 2016
Roman Hubálek
OVER 125 YEARS OF EXPERTISE & INNOVATION New millennium
South America, Africa, Asia & Russia
LHOIST WORLDWIDE PRESENCE
The 90’s Further development to Western & Eastern Europe
The 80’s Crossing the Atlantic (US, Canada)
1926 First expansion to France
1889 Foundation of the Group in Belgium
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KEY FIGURES
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TURNOVER
€ 2 bn
Europe Other Regions
Corporate North America
South America 6 000
1 R&D CENTER
4 CUSTOMER TECHNICAL SERVICE CENTERS
> 25 COUNTRIES
100 PLANTS NATIONALITIES 40
MAIN PRODUCTS
MINERALS Limestone
Dolomite
Clay and others
CALCINED PRODUCTS Quicklime
(pebble, ground, milled)
Burnt dolomite (soft-/hard-/overburnt)
Hydrated lime
SPECIALTY PRODUCTS Milk of lime
Fluidised lime
Low dust emission lime
High porosity hydrated lime
Formulated products
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DIVERSITY OF APPLICATIONS
All mentioned trademarks are trademarks of Lhoist Recherche et Développement S.A.
Iron and steel Non-ferrous metals Pulp and paper
Glass Civil engineering Building
Drinking water Water and sludge Flue gas treatment
Agriculture Chemicals Biofuels
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Lhoist in the Czech Republic
• since 1992
• 2 companies: Vápenka Čertovy schody a. s.
Velkolom Čertovy schody a. s. (50% of HBZ)
burnt products 350 kt
ground limestone 410 kt
crushed limestone 700 kt
• 102 employees
LHOIST Central Europe
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BU Czech Republic and Slovakia
quarry West Vápenka
Čertovy schody a.s. plant
quarry East
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BU Czech Republic and Slovakia
Production process
Quarry
Primary
crusher Secondary
crusher
Screening
tower
Stock
piles
Grinding
and milling
plant
Milled
limestone
Lump
limestone
Stone for
kilns
Raw stone
Dispatch of lump limestone Dispatch of milled limestone 9
BU Czech Republic and Slovakia
Production process - lime
Stone for
kilns
Fuels dosing
technology
Pebble lime
Pebble lime Milled lime Hydrated lime Sorbacal SP
Lime crusher
Shaft kilns PFR kiln MAERZ
Lime mills
Hydration plant and
Sorbacal SP production
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Quarry West
Quarry East
Quarry Plesivec
Quarry Homolak
Lime Plant VCS
Mining area
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Koneprusy/ Suchomasty Deposit Hard compact limestone
FMS kiln Main kiln aggregate
CaCO3 input 90 – 125 mm
Nominal performance
600 T/d
Two- shafts PFR kiln MAERZ - FMS
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BU Czech Republic and Slovakia
FMR kiln New kiln commisioned during 1.Q 2016
CaCO3 input 50 – 90 mm
Nominal performance 300 T/d
Two rectangular shafts PFR kiln MAERZ - FMR
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BU Czech Republic and Slovakia
FCV4 and FCV5
CaCO3 input 30 % mixture 50 – 90 mm
70 % mixture 90 – 125 mm
Nominal performance 150 T/d
Normal shaft kilns IPZ - FCV
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Hydrator PFFEIFER
Main equipments
Hazemag Crusher
Hydrator Pffeifer
Air Classifier OSEPA
Hammer Mill NEA
Hydrator PFFEIFER
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Sorbacal® SP
Main equipments
Hazemag Crusher
Continuous mixer EMT
Heater ECLIPSE
Cage mill
Continuous mixer EMT
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Environmental status - full compliance with all legal requirements
• Certificate of Environmental Management System based on ISO 14001 since 2013
• VCS plant location at the border of the landscape protected area (LPA) Czech Karst,
• All quarries inside the LPA border , close to the Koneprusy Caves
- many limitations, requires close co-operation with authorities
Environmental management • Automatic continuous immission monitoring station (CAPEX and OPEX by VCS) in the Czech
official air quality monitoring system network is situated 2 km West from the plant since 2009
• Periodical measurement of dust, NOx and noise in all 3 neighbouring villages and in other surroundings
• Monitoring of: nitrogen deposition, flora composition and development, butterflies occurrence, fungi occurrence, hydrogeology, seismic monitoring in Koneprusy Caves
Environment
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Strong environmental orientation
Lhoist in the Czech Republic
LHOIST Central Europe (PL,CZ,SK)
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- FGD/FGT Flue gas compound to treat: - acid compounds : SO2, SO3, HF, HCl - PCDD/F, heavy metals Fly ash mechanical performance stabilisation
- Water Neutralization of acidic compounds
Precipitation of harmful cations and anions:
- heavy metals, sulphates, phosphates, fluorides etc.
Flocculation and coagulation of colloidal particles
Technologies: Wet CaCO3, CaO Power units (above 100 MW )
Semi-wet, Fluid.S-W and Dry (CDS) CaO, Milk of lime, Hydrated lime Power, heating units (50-100 MW)
FBB CaCO3 Power units (above 100 MW )
Dry and combined technologies Sorbacal SP (Special hydrated lime ) Industry, small heating units (0-50 MW)
Segment: FGD, FGT Key drivers : EU air pollution directive National transition plan High sulphur content in lignite ( 0,5 -2,0 S% )
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Dry technologies Sorbacal® SP, SPS
- High reactive sorbent - High pore volume and specific surface
Sorbacal® SP◄ Comparison► standard Ca(OH)2
Technology for product application
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Injecto-Matic®
Dosing device for direct injection of dry sorbents into flue gas stream. 40 m3 silo or Big Bag station
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Actherm Chomutov
Referencies
3 x 80 t /h boilers , lignite, bag filter, 140-160 C
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Example of middle size industry and municipal heating plant
Till 2015 DeSOx Removal needs : max. 40%, Sorbacal® SP CDS technology since 2016 ( new limit: 400 mg / Nm3 ), Sorbacal® H – National Transition Plan impact
Plzeňská teplárenská plant
Referencies
2x granulation boilers, 1x fluid boiler,
1x biomass, 1x Municipal Incinerator plan
Central heat supply net in Pilzen city
Circulation Desulphurisation FGD unit
Local hydratation unit, Fabric filtr
Full range supply of : Sorbacal® C Sorbacal® Q Sorbacal® H/SP Sorbacal® AC Q (blended)
Example of large size industry and municipal heating plant
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Referencies
AGC Flat Glass Czech a.s., Retenice plant Limestone is used for glass batch composition.
Float glass is soda-lime-silicate flat glass. Float line R1 Coloured float glass, 1,6 – 10mm Automotive and Architectural Float line R2 Clear float glass 3 - 12mm Architectural
Float line R3 Coloured float glass 1,6 - 6mm Automotive
The largest float plant in Central Europe ( more than 2 000 T/day )
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AGC Flat Glass Czech a.s., Retenice plant
Referencies
All float lines are built as The Best Available Technologies (BAT ) Anti-pollution control units (APC) to clean gas emissions from dust, sulphur dioxide and nitrogen oxides. Sorbacal® SP product is used as SO2 absorbing agent in two of three APCs.
DeSOx Removal needs : max. 50%
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Johns Manville, plant Trnava Significant producer of glass fibers in Europe Visucal® Q 90 - Low ferromagnetic particle quicklime is used for glass production.
Referencies
Sorbacal® product is used as SO2 , HF and HCl absorbing agent in anti-pollution control units.
Acids Removal needs : 90%
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Segment: Water
Key drivers: EU and CSN directives ( ČSN EN 12518 CaO, 1018 – CaCO3 )
CZ Ministery of Helth Notice 409/2015 Sb.
Technologies : Neutralization units of waste and mine water Drinking Water Treatment plant Proces water preparation plants Municipal waste water treatment plants
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Technology for Milk of lime production
Duwa-Matic®
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15 units installed during last decade in Czech Rep.
Batch/Continous process and Capacity size
Wide range of dosing on different customer sites:
Small units DM 650 : 50 – 300 kg CaO/h
Giant units: 3,2 – 6,4 t CaO/h
Silo capacity range: 40 – 180 m3
Only 1 small unit is using Big-Bags
95 % of units operate continuously
Technology for Milk of lime production
Duwa-Matic®
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Automatic operation on customer sites:
95 % automatized, unit operation via PC in control room
Feeding lime systém: 100% Hethon feeder
Only giant unit feeding hoppers equiped with tensiometer
Neutralac® 90 - High reactive milled quicklime
DIAMO s. p. Key state company responsible for remediation of old mines: uranium, metal and coal
Location Stráž pod Ralskem
Underground chemical leaching of uranium ore during 1968 – 1996
Area: 628 hectare with 15 000 injection points
Chemicals injected into sandstones: > 4000 kt of H2SO4
300 kt of HNO3
120 kt of NH3
Referencies
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Total quantity of uranium mined: 15 862 t
DIAMO s. p.
Location Stráž pod Ralskem
Long-term treatment of contaminated water due to danger for drinking water sources
Total contamination is spread almost on 27 km2
Water volume affected : > 400 mio m3
Quantity of soluted sulphuric anions: > 11 mio t
Main contaminats: SO4, NH4, and Al ions
New Remediation technology units in operation since 2010
Referencies
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DIAMO s. p. Status 2016
Referencies
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Referencies
DIAMO s. p.
