FIVES

equipment and upgrading

N E W S L E T T E R
Kosjeric – TITAN Cementara Kosjeric (Serbia) specific volute design was implemented to

F C B
operate with dusty air.
Grinding mill modernization The erection took place during the winter
shutdown, and the start-up was achieved
In early 2009, Titan Cementara Kosjeric ad, the two-line circuit with cyclones, and to upgrade prior to the kiln firing. The classifier is now in
Serbian affiliate of the Greek cement producer
Titan, commissioned a third generation TSV™
the existing bag filter in order to operate it as
a mill dedusting filter and as a classifier circuit
operation and has fully met the customer’s
expectations. GOOD NEWS
FOR YOU
classifier supplied by Fives FCB to modernize dedusting filter. Titan’s scope covered the The plant now produces CEM II/A-M(P-Q) 42,5
their cement grinding mill. revamping of the filter and the associated with R45µ<5% whereas before it was
The customer wished to increase the plant’s fan, thus Fives FCB was responsible for the R45µ=10%. Thus, the capacity has been subs-
capacity while optimizing the additives’ contents classifier and its circulating fan. tantially increased and ball mill specific energy
in the cement. The main challenge was to lowered by more than 10%. To further take F E B R U A R Y / 2 0 1 0
overcome the very limited space available in To cope with the very limited space, a lateral advantage of the accuracy of the TSV™, the
the existing building.
During the preliminary stage of the project,
air inlet type TSV™ 3600 HF was used allowing
for the complete classifier circuit to be located
next step will be to increase the cement/
clinker ratio while keeping the cement quality
EDITO
Umm Bab line 4
A long term co-operation with
Fives FCB has been serving the cement
Titan and Fives FCB‘s teams agreed to build a inside the existing building. Furthermore, a constant. manufacturing industry for over 70
years.

Assiut – Assiut Cement Company (Egypt)

With references in Central America,
Asia and the Middle East, Fives FCB Qatar National Cement Company
is recognized by the major world

I
Cement grinding plant modernization cement manufacturers as a general n May 2009, the industrial tests on the 5,000 tpd turnkey clinker production
contractor able to design and supply line built by Fives FCB for QNCC were successfully completed.
complete cement plants equipped
The Egyptian cement manufacturer Assiut capacity of OPC cement from 115 tph to
with innovative technologies, while
By the end of 2009, the total production of the line surpassed 1 million tonnes.
Cement Company, an affiliate of the leading 145 tph, a 26% increase of the grinding plant’s
respecting their guaranteed delivery
cement producer CEMEX, selected the Fives capacity. The commissioning of the modernized time and performances.
FCB-designed 3rd generation TSV™ classifier installation was performed in the 3rd quarter After the successful execution of the
for the conversion of their cement grinding plant of 2009 and the new equipment fully fulfils Umm Bab line no.2 and no.3 projects,
no.5 from an open circuit to a closed circuit. the customer’s expectations. Fives FCB has obtained the Provisional
For this project, Fives FCB supplied a TSV™ With more than 200 references, the TSV™ Acceptance Certificate on July 9 th,
4000 HF classifier and all the necessary classifier is renowned for its unrivalled perfor- 2009, for the complete Umm Bab line
associated equipment, including the bucket mance thanks to its patented rotor blades no.4, with a capacity of 5,000 tpd.
elevator, fans, bag filter, airslides and impact and antivortex system. The high efficiency In 2009, Fives FCB’s successful comple-
flow meter. The local fabrication was performed of the TSV™ results in a minimal by-pass, tion of several upgrading or moderni-
by the customer with Fives FCB’s technical a particularly steep slope of the Tromp curve, zation projects, along with the major
support and expertise. The purpose of the a very low pressure drop and an extremely complete plants contracts awarded by
Vinaincon in Vietnam, Titan in Egypt and
modernization was to increase the production low level of power consumption.
Holcim/Cementos Apasco in Mexico,
were all opportunities to demonstrate Only 17 months after the order was brought contract to supply the new production line
our ability to manage large projects into effect, in April 2008, Fives FCB obtained no.3 with a capacity of 4,000 tpd, installed
SLN – Eramet (New Caledonia) throughout the world.
In 2010, as the first signs of recovery are
the provisional acceptance for the first cement near the first cement plant at Umm Bab, on
grinding plant. The second grinding plant was the western side of the Qatari peninsula. The
Rotary kilns mechanical revamping observed in the cement industry, after
started up in June 2008, three months ahead cement grinding plant was started up early,
a difficult economic period, Fives FCB
of the contractual schedule. at the end of 2005, in order to respond to
Following comprehensive kiln audits perfor- The scope included the supply of the main execution. Thanks to the high quality of these continues to invest in R&D programs to
extend its range of innovative technolo- In May 2009, the burning line reached the the huge demand for cement on the Qatari
med by Fives FCB on four kilns which had equipment: shell, girth gear, drive system, studies, the shutdown period was reduced. end of the industrial production tests and market. The other plants, including the clinker
gies in order to meet the new challenges
originally been delivered in the 1970’s, SLN inlet and outlet sealing - as well as a detailed From the expertise phase to the commissio- since then, the line is producing continuously burning line were commissioned at the end
and evolving needs of its customers
awarded Fives FCB a contract to revamp them. erection study and the supervision of the ning, Fives FCB successfully provided SLN a under stable operation. of 2006.
regarding sustainable development.
In fulfilling this contract, Fives FCB delivered execution. The erection study was used by SLN complete solution for a mechanical revamping Furthermore, Fives FCB belongs to Fives,
four kilns to SLN in New Caledonia between as a tender document to select a company guaranteeing long-term optimum kiln availa- a large industrial engineering group, Further to achievement of industrial tests, the The three Umm Bab production lines supplied
2006 and 2009. for this phase and as the guide during its bility. which has opened new offices in Russia, Provisional Acceptance Certificate was signed by Fives FCB make it one of the largest and
India, Turkey and Brazil, thus allowing us on July 9 th, 2009. most modern cement plants in the Gulf
to strengthen our international presence region, producing up to 15,000 tpd of cement
and to be closer to our customers all
SNIM (Mauritania) over the world.
This is the third order awarded to Fives FCB
by QNCC, thus crowning almost 15 years of
(5 million tpy of cement).

Contract for maintenance assistance FIVES FCB GOOD NEWS FOR YOU, the newsletter of Fives FCB
We are pleased to communicate with
our customers and partners through
co-operation: It has to be noted that thanks to the unique
– Fives FCB – 50 rue de Ticléni – B.P. 376 – 59666 Villeneuve-d’Ascq • A first contract was signed in 1995 for the Fives FCB Zero-NOx precalciner, these plants
Cedex – France – Phone: +33 (0)3 20 43 77 77 – Director of Publication:
our newsletter and we will continue
In order to minimize the shutdown period and Fives FCB signed an agreement for assistance construction of a Greenfield turnkey 2,000 tpd are among the most environmentally-friendly
Alain Cordonnier – Editor: Jean Pierre Cornille – Editorial Committee: to keep you informed of our latest
to decrease the overall maintenance and ope- in the maintenance of this equipment in Jacques-Olivier Bou, Gilles Cojean, Hervé Cordier, Jean Pierre Cornille,
FIVES FCB GOOD NEWS. cement plant, line no.2, which was commis- plants with reduced NOx emissions meeting
Serge Jorget, Etienne Simon – Writers: Hélène Bachellerie, Chrystelle
rating costs of the two aerofall grinding mills, 2008. Some regular audit and supervision Lucidarme – Thanks for their collaboration: Philippe Benoit, Jean-François sioned in 1998 and has been operating at full the most stringent environmental regulations.
activities are carried out in the plant so as to Bonhomme, Serge Jorget, David Kotrys, Loïc Pottier, Etienne Simon –
which have been working almost continuously Execution: Christophe Cocquet – Printing: LCI - 10 bd Louise Michel - Alain Cordonnier, CEO capacity ever since.
in very hard conditions since their original better monitor the critical issues and provide ZAC des Aunettes II - 91030 EVRY Cedex – Registration of copyright Fives FCB • In 2004, QNCC renewed its confidence in These contracts attest to the confidence that
and ISSN: in progress. Printed in 1,000 numbers.
delivery by Fives FCB in the 1980’s, SNIM and updated technologies for its operation. Fives FCB by entrusting it with a turnkey QNCC has in Fives FCB. ■

4 www.fivesgroup.com Driving progress www.fivesgroup.com Driving progress 1

 Complete cement plants FOCUS equipment and upgrading

Thai Nguyen - Vinaincon (Vietnam):

Fives FCB is recognized as a general contractor
OPTIKILN for efficient control Jiujiang & Xinyu -
Jingye in China
all over the world of the burning line On October 28 th, 2009, a contract was
signed between Jianhuan Technology &
Having made its name in the Vietnamese allows to increase the grinding units capacity Trade Co. Ltd. (Jingye) and Fives FCB for the
cement industry with the commissioning of by associating two identical Horomill® grin- supply of two new slag grinding plants in
the 4,000 tpd Hoang Mai cement plant in ding units, operating simultaneously along China. These plants will be located at the
2002, Fives FCB won a new contract, awarded with a large-sized TSV TM classifier. Jiujiang and Xinyu sites, in Jiangxi province,
by Vietnam Industrial Construction Corpora- A high proportion of mechanical and elec- in the East of the country.
tion (Vinaincon) for a complete cement plant trical equipment (75% by weight) has been manufactured under Fives FCB’s supervision Each slag grinding plant will be equipped
in Vietnam. in Vietnam by the customer, Vinaincon, a with 1 Horomill® 3800 and 1 TSV™ 4500
This new project included the supply of a corporation made up of twenty-one firms separator. Equipment delivery will take
4,000 tpd complete plant equipped with the operating in the fields of building, manu- place in 2 phases. The first plant will be
latest processes and equipment developed by facturing and implementation of industrial supplied within 12 months after the
Fives FCB: a 4,000 tpd single line preheater projects. coming into force of the contract; the
featuring the latest generation of low pressure Thai Nguyen organised the plant’s inaugu- second, within 16 months.
drop cyclones; a Zero-NOx precalciner burning ration  ceremony on December 25th, 2009.
100% Vietnamese anthracite coal with low The Prime Minister and other Vietnamese
volatile content; and a 240 tph cement grin- government representatives were in atten- Buzzi Unicem
ding plant implementing Fives FCB recently
developed Twin Horomill® technology, which
dance. The commissioning and performance
tests will be completed in early 2010.
in the USA
In May 2009, Buzzi Unicem USA awarded
Fives FCB with two contracts for the supply
of Horomill® 3800 to be installed in the
Beni Suef - Titan (Egypt) plants of Maryneal, Texas, and Hercules

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n updated Fives FCB techno- little reluctant to give up their manual opera- Cement, Stockertown, Pennsylvania. At the
Fives FCB has been chosen by Egyptian company logy, the OPTIKILN, for burning tion of the line, experience has shown that end of 2009, the equipment was dispatched
Beni Suef Cement Co. for the turnkey construction line control process systems, they are quickly convinced of the efficiency to the sites. These two Horomill® will enable
Buzzi Unicem USA to increase energy
of the system.
of a new 4,000 tpd production line enables automatically controlled ope- savings while reducing CO2 emissions in
ration as well as automatic start and its plants in the United States.
Fives FCB has implemented its OPTIKILN
Beni Suef Cement Co., an Egyptian company tion and environment protection requirements. production raise. Burning Line Optimization System on the new
set up by Titan, the biggest Greek cement This ultra-modern plant shall meet not only
manufacturer, has entrusted Fives FCB with Egyptian but also European environmental The updated OPTIKILN uses linked and
5,000 tpd QNCC cement plant, in Qatar. The
burning line is very stable, and since its start-
Cementos Moctezuma
the construction of a new 4,000 tpd production
line with a 170 tph cement grinding plant on a
standards. independent optimization modules for the up, no interruption has ever been encountered in Mexico
different controlled parameters. Each one is because of a CO peak or “unburnt” material.
site located 120 km from Cairo where it already The first clinker was produced on November Following the ten Horomill® delivered to
using a specific modelling based on the
operates its first cement production line. 10 th, 2009. Industrial tests on the cement Cementos Moctezuma since 1994, the three
experience of several operating plants. The In 2009, two other production plants supplied
grinding plant had already been completed on Horomill® 3800 (1 raw mill & 2 cement
choice is given to optimize a specific para- by Fives FCB were commissioned: the Quang
The contract, which also covers modifi- October 8 th 2009, as well as on the burning line mills) ordered in 2007 are under erection
meter (clinker cooler blowing, kiln speed, Son 4,000 tpd plant (Thai Nguyen, Vietnam)
cations to the existing no.1 production on December 7 th, 2009. in the Apazapan plant, near Vera Cruz.
calcination temperature, and the Titan 4,000 tpd
Commissioning is scheduled for 2010.
line, includes Fives FCB-designed equipment, preheater draught, etc.) The choice is given to optimize plant in Beni Suef (Egypt).
optimised to comply with energy consump- The whole plant is now running at full capacity. Including the three Horomill® ordered by
or all of them. This tech- a specific parameter or all of They both benefit from
Holcim/Cementos Apasco, as part of the
nology provides high them. the OPTIKILN control
Hermosillo complete plant project, Fives FCB
Hermosillo - Holcim/Cementos Apasco - (Mexico) flexibility and stability.
For example, the calcination temperature can
system, which will also
be used at the Holcim-Apasco 3,500 tpd plant,
totalized 16 identical machines installed
Fives FCB is delivering a complete 3,500 tpd cement plant be stabilized within a range of ±2°C over the in Hermosillo, Mexico, the next major project
in Mexico, with unique performance and
efficiency levels on raw meal, Portland
course of several days. to be started-up for Fives FCB. ■
and pouzzolana cements.
Thanks to a long list of refe- whole installation’s energy advantage in the arid Mexican State of Sonora
rences marking the achieve- consumption and NOx emis- where the cement plant is being constructed Optimization modules have also been asso-
ments of recent years, Fives sions, including the Zero-NOx as it does not require any water injection. ciated to create automatic production start Calcination temperature control (sampling time: 1 min)
FCB secured a contract with precalciner which allows for programs for the burning line in any condition
Holcim for the delivery of a the use of alternative fuels The plant is due to be commissioned by the – either cold or warm – and for the alkali
complete Greenfield cement without emitting NOx at this end of the first semester 2010. bypass.
plant with a capacity of 3,500 stage of the process.
tpd in Mexico. The grinding plant will also be This contract follows the supply, in 2004, of From the cold start to the nominal production
equipped with three Horo- the new 3,000 tpd production line for the level, the line raises production over a number
This new plant will feature the mill® grinding mills, the most Holcim cement plant in Costa Rica and of hours and automatically adapts precalciner
latest technologies developed energy efficient technology, strengthens Fives FCB’s status as an essential operation, preheater draught and clinker cooler
by Fives FCB to reduce the and which represents a huge partner for major cement manufacturers. operation. Though some operators may be a

2 www.fivesgroup.com FIVES FCB GOOD NEWS FOR YOU 3