The business unit Cement Technologies of thyssenkrupp has received an order from Ciments Calcia S.A, a subsidiary of the HeidelbergCement Group, for the construction of a turnkey cement production line. The line, with a production capacity of 4000 t of clinker per day, is to be built at the Airvault site to replace the two existing lines. The aim is to almost double clinker production at the Airvault site. Both parties have agreed not to disclose the contract value.
By implementing specific processes, the plant’s energy performance will be improved while reducing its thermal and electrical consumption. Thanks to the use of waste as an alternative fuel to fossil energy, the plant’s greenhouse gas emissions and carbon footprint will be substantially reduced. The plant is designed to allow for conversion to oxyfuel technology in the future, to efficiently separate carbon dioxide and thereby facilitate carbon capture and storage at a later stage.
The main equipment for the raw material preparation includes a double-shaft hammer crusher with a capacity of 1200 t/h, a longitudinal blending bed, a quadropol® QMR² 45/23 vertical roller mill with a throughput of 370 t/h and a tangential blending silo with a storage capacity of 10000 t for the raw meal. The kiln line consists of a single-string, 5-stage dopol® cyclone preheater with integral calciner suitable for the use of alternative fuels and a 3-support rotary kiln, followed by a last generation polytrack® clinker cooler. The plant also includes a preparation workshop for alternative fuels (SRF – Solid Recovered Fuels) as well as proven and reliable dedusting systems.
A new construction method is being implemented for the erection of the preheater tower at the Airvault plant. The preheater modules, including brickwork and electric systems, are preassembled in parallel and almost entirely at ground level.
The Airvault cement plant, scheduled to start-up by mid 2024 will become a benchmark plant in terms of decarbonization and environmental protection.