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 FLSmidth - eHighlights - December 2009
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| December 2009 |
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Corporate New contracts Product news Projects in progress Services
| FLSmidth Airtech’s flexibility a huge success for CemexWhen a cement company constructs a new plant, it needs reliable partners who can guarantee quality equipment and timely execution. Cemex got all this from FLSmidth Airtech who supplied the air pollution control (APC) system for the company’s new Broceni plant in Latvia.
On the banks of the Cieceres Upe River in Southern Latvia, Brocêni sits on a large limestone deposit, making it an ideal location for cement production. When Cemex, one of the world’s leading cement manufacturers, decided to build a cement plant there, the company decided to work with multiple suppliers. This meant Cemex could balance proposals and get the best possible plant for its budget; but it also meant the project management was more complex than when dealing with just one turnkey supplier. A flexible proposal process In a project of this size, there are many factors to consider. Cemex knew the amount of money they wanted to spend on the plant as a whole. With regard to the APC equipment they needed to: 1) stay within budget 2) get the best value for money 3) ensure the equipment would meet stringent environmental requirements 4) install the equipment in a timely fashion. Potential APC equipment suppliers were invited to quote a number of scenarios, from a full turnkey project to supplying just the design and key parts of the equipment. In the end, Cemex asked FLSmidth Airtech to supply the complete dedusting set-up, from design and manufacturing to erection and commissioning. Not only could FLSmidth Airtech supply state-of-the-art equipment, the company also met another key criterion: flexibility. Complete design and testing FLSmidth Airtech’s design team analysed all the factors that might affect the filter process at the plant, including the gas and dust distribution, the jet pulse cleaning sequence and the filtration material. The result was a FabriClean™ baghouse utilising seven-metre long filter bags made of fibreglass with PTFE membrane, and with a cleaning pressure below three bar. Another key feature of the FLSmidth Airtech solution is simple maintenance. The Brocêni FabriClean incorporates individual compartment design, which makes it possible for operators to carry out maintenance while the plant is in operation. This was an important feature for Cemex. The design allows personnel to perform inspections and preventive maintenance, including repair or replacement of filter bags without impacting cement production. The world as a workshop
With FLSmidth Airtech coordinating the manufacture of the fabric filter equipment, Cemex were guaranteed a solution that meets the highest quality standards. “We completed the technical specifications and the drawings for the manufacturing and installation at our facilities in Denmark and India,” says Henrik Vitrup Pedersen, Global Fabric Filter Product Manager for FLSmidth Airtech. “We then picked the best suppliers around the world to manufacture the parts. We have ISO Quality Control Procedures in place to ensure quality – and our Quality Control Inspectors checked and tested every piece of equipment before it left each workshop to ensure it met our high quality standards.”
The bags themselves were manufactured at FLSmidth Airtech’s state-of-the-art manufacturing facility in the US, where FLSmidth Airtech uses years of experience to fit the bags perfectly to their cages. This prevents premature flex fatigue and allows the filter media to clean efficiently, ensuring a lower differential pressure across the fabric filter system – and guaranteeing a lifetime of at least five years. Supply and commission, on time and on budget In such a complex project with many suppliers delivering different aspects of a plant, any delay can affect the entire project, so there’s no room for set-backs. FLSmidth Airtech hired two local sub-contractors to carry out the erection, closely supervising their work to make sure it ran according to plan and on schedule. In all, the erection took just over one year to complete. In the winter, temperatures plunged to as low as -15°C, and in the spring and autumn heavy rains turned the site to mud. But despite the tough conditions, the project ran smoothly from start to finish. And the results? The plant was hot commissioned in May 2009. Egon Skytte Jensen, FLSmidth Airtech’s Project Site Supervisor, stated, “It has been a big challenge to be part of this project. There are always obstacles to overcome with a project of this size. When a problem would arise, it was addressed constructively with the end goal in mind; and with the qualified support from the FLSmidth Airtech project group and a very competent client. The positive site atmosphere throughout the construction and commissioning was a big benefit for the project.” The dedusting equipment The equipment supplied by FLSmidth Airtech to the Brocêni plant totals 1,100 tonnes. It includes:
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