Plant Mannersdorfin a Nutshell

Umweltbundesamt, 02.12.2016

LafargeHolcim at a Glance

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GartenauGmunden

Kirchdorf

Mannersdorf

Wopfing

Peggau

Rohoznik

Cement Plants in Austria / Vienna market

VIENNA

AUSTRIAAUSTRIAVils

Peggau

Wietersdorf

Retznei

Eiberg

Others Others/LafargeHeidelberger /

RohrdorferCRH

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� First cement production activities on site 1894

� Perlmooser joined Lafarge-Group in 1994

� Current kiln line from 1986Current Kiln Capacity:

Plant Historical Development

Current Kiln Capacity:

� 2.730 t/d ⇒ 860.000 t/y

(1,30 Mt/y)

� Currently (70%AF):

2.360 t/d ⇒ 750.000 t/y

(1,13 Mt/y)

� 2 Quarries: � Limestone (42 years reserves)

� Clay (proven 3 years – probable 34 years) – today, 50% natural clay replaced by clay-

bricks

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� Health & Safety� Member of Lafarge H&S

Excellence Club

� 1004 days without LTI

� Last LTI: Eye injury at

bypass dust handling

� Market

Key facts

� Market � excellent plant position

to Vienna market

� HR / Lean Organization � 92 Employees

� 10 Apprentices

� 10 permanent Contractors

� Supervisor / Foreman: mainly recruited locally and developed through dual

education system

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� Plant is Sold Out� 1,15 Mt cement / a

� Kiln UF at ~ 88%

� 9 Cement Types� 90% Bulk /10% Bag

� Dispatch

Key facts

� Dispatch� Truck and Train

� Environment / Stakeholders� Continuous Emission Monitoring:

NOx, SO2, Dust, Hg, TOC

� NOx: First semi-dust SCR installed

in Lafarge (2012)

� Contract with local stakeholders

ensuring wide range of AF-permits

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Cement = ground clinker + gypsum +….

� Hardening under water or under air and giving high

final strenght

� Clinker composition (CS phases):

A hydraulic binder

Oxide

SiO2

Symbol

S

Content

20 to 25 %

Maj

or

elem

ents

7April 2016 |

Al2O3

Fe2O3

CaO

MgO

SO3

Alkalies

Free CaO

A

F

C

M

SK2ONa2O

KN

2 to 7 %

1 to 4,5 %

64 to 70 %

2 %

1%

0,9%

0,5 to 3 %

Maj

or

elem

ents

Min

or

elem

ents

Limestone Quarry

� Mobil crusher� O&K

� Av. Output 700 t/h

� „Load & Carry“

� Komatsu WA 800

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Komatsu WA 800� 13 m³ bucket capacity

� >95 % CaCO3

� 1 Mio t / yr !

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...und natürliche

Suksession

Clay pit - Mining, mixing with bricks & recultivation

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Suksession

05/12/201610

Plant Mannersdorf – Aerial Perspective from North

Clinker Silos

CM 7 & 8

Limestone Quarry

Cement Silos

Offices

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Cooler Kiln Preheater

Raw Mill

Offices

AF storage

Kiln and Pre-heater Tower

� Preheater Tower� 2 Strings

� 5 Stages

� Separateline Calciner

� Inline Calciner under

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Inline Calciner under construction

� SCR in old PreheaterTower

Locations of fuel input

Riser Duct:

SSW (plastics)

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raw mill

filter

co

al m

ill

2 calciner burners:

Petcoke, Coal, SSW (plastics), Sunflower shells, ISF (Impr. Solid Fuel), HCF (High Cal. Fuel)

Main burner:

Petcoke, Coal, Sunflower shells, Animal meal, SSW (plastics)

SSW (plastics)

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Alternative Fuel – Storage Hall

Capacity4.500 m³ (700 t)

3 compartments,

1.500m³ each

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Automatic Craneproviding 2 weigh-feeders &

belt-conveyors:

� Calciner (up to 10 t/h)

� Main-burner (up to 5 t/h)

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Solid Shredded Waste

Sunflower Shales

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Floor +37,3m (4)

17. Oktober

Calciner : 5 m diameter / 1500 m³ / height: 80 m

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Description of the SCR

� 2 field ESP operated at 300 to 350°C

� Rectangular SCR reactor (4*6 m)

integrated in the old preheater tower

� 2 layers equipped with catalyst and

soot blowers, total of 43 m³ catalyst

� Gas conditioning tower below the SCR

reactor

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SCR Mannersdorf - Features

� UREA injection on top

cyclone inlets

� SNCR remains stand by

� Preheat circuit with filter and

electrical heater

UREA

� Filtered and preheated fresh

air for purge

� Catalyst cleaning with

preheated compressed air

� Downcomer water injection

stand by

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Operation Results

� NOx target of 200 mg/Nm³ at stack reached from

the beginning

� Positive effect on VOC (~ minus 50 to 75%)

� Hg: almost complete oxidation

� CO: no direct effect, but reduction due to� CO: no direct effect, but reduction due to

stopping SNCR

� Start and stop without impacting the kiln

� Due to carbon fibers in flue gas and high dust

resistivity, the ESP performance is at 15 to 20

g/Nm³ versus planned 2 g/Nm³

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Catalyst

• 75-80% TiO2 as carrier

• 8-10% glas fibers

• 5-10% tungsten

• 1-3% V2O5 as active component

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NOx Emissions: Kiln/Raw Mill Exhaust gas

Emission Monitoring: NOx (kiln exhaust gas)

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SCRNOx-Reduction through

Selective Catalytic Reaction

� Commissioning in April 2012

� First in Lafarge, first in

Austria, 4th Worldwide

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Emissions Monitoring

� Continuous Monitoring of:

� NOx, CO, CO2, NH3, VOC, SO2, Dust, Hg

� Discontinuous Monitoring of:

� Heavy Metals� Heavy Metals

� HCl, HF

� Dioxine/Fourane

� PCDD/F, PAH

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Dust Emissions: Kiln/RawMill Exhaust Gas

Emission Monitoring: DUST (kiln exhaust gas)

DUST

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Bag-Filter(installed in 2000)

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VOC Emissions: Kiln/RawMill Exhaust Gas

Emission Monitoring: VOC (kiln exhaust gas)

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SO2 Emissions: Kiln/Raw Mill Exhaust gas

Emission Monitoring: SO2 (kiln exhaust gas)

DUST

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Managed through blending clay with waste-clay-bricks

DUST

AWG

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Mercury Emissions: Kiln/Raw Mill Exhaust gas

Emission Monitoring: Hg (kiln exhaust gas)

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Managed through Active Carbon

Dosing System

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Discontinuous Emission Monitoring

� Kiln Exhaust gas after Raw-Mill

� 2 times per year

� Measured by TÜV Austria

� Measurements include heavy metals as well as other emissions:

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mg/Nm³

HCl HF Cd Tl HgSb, As, Pb, Cr, Co, Cu, Mn, Ni, V, Sn gesamt

Dioxine / Furane [ng/Nm³]

Limit: 10 0,7 0,05 0,05 0,05 0,5 0,05

Ø 2012: 0,9 0,125 0,001 0,001 0,029 0,042 0,001

Ø 2013: 1,0 0,07 0,002 0,001 0,014 0,045 0,004

Ø 2014: 2,9 0,15 0,004 0,001 0,019 0,088 0,001

Ø 2015: 2,0 0,100 0,001 0,001 0,013 0,075 0,003

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Emission Limit Values

Grenzwert (GW)

HMW TWM JMW

NOx 200 (500*) 200 (500*) 200 (500*) mg/Nm³

NH3 - 30 (40**) 30 (40**) mg/Nm³

SO2 350 350 350 mg/Nm³

mg/Nm³, dry at 10% O2

SO2 350 350 350 mg/Nm³

Staub 20 20 20 mg/Nm³

CO - - - mg/Nm³

TOC 120 120 120 mg/Nm³

Hg - 0,050 0,030 mg/Nm³

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* Without SCR

** Without SCR or RM

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Cement Grinding

� Clinker Storage Capacity: 135.000 t

(4 clinker silos)

� 2 Cement Mills: ~60 t/h and

~115 t/h

(incl. Slag Dryer)

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(incl. Slag Dryer)

� Cement Storage Capacity: 10 cement silos:

54.000 t

ZM 8 ---- 4,6 m diameter / 16,4 m length

2 * 3 MW

340 t grinding balls

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Product-Portfolio

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