A Warm Welcome to the ETG Sponsored Delegation of Intensive Energy using Industries from

India

September 2016

Introduction to Siemens

Siemens is a well known global brand and a market leader in some sectors, such as renewable energy.It is also a market leader in digitalisation, power engineering, energy networks and control systems and drives.It has significant growth plans for the coming years and as you can see is making progress to meet those targets or exceed them.

• Major projects in• Cement Industry and Municipal waste

recovery• Alternative Fuels expert for Cement, Steel

and Lime Industries.• Alternative Energy consultant for a wide

range of technologies, including Biomass, AD feedstock preparation, TDF, AF for kilns.

• Advanced recycling technology• Power Station conversion to biomass

• Staff numbers remained constant• Projected turnover for 2016 is being realised

• Fuel conversion of 395MW coal firedpowerstation to wood pellet

• Scheelite mine design and delivery Spain• New UK nuclear power station aggregate

importation facility• Upgrading of the dust filters at Hanson

Ketton

Financials – introduction to Fairport Engineering

Strengths - Study and FEED Assignments

Strengths - Study and FEED Assignments

Scene setting for Cement Industry

Of the 24 UK cement sites shown on this map and the 14 cement kilns around the UK, we have supported all but 2 of them through use of our knowledge, expertise and process upgrades.We cover all grades of Cement, from Cem1, Cem 11, Cem 111, Cem1V and Cem V.We cover all aspects of production, from quarrying, Run of Mine, grading, conveying, storage, reclaim, mixing of the Meal, coal mining, coal preparation plants, stockpiling, coal milling, optimisation of the coal mill circuit, Alternative Raw Materials Handling. Kiln combustion with multi-channel burners, low NOx burners, AF combustion, clinker cooling, heat recovery, heavy metal emission control, Chrome VI control, chorine control in kiln by-pass gas flows, grinding energy optimisation, classifier control, storage, blending of slags to make blended cements, handling PFA are some of the things we can advise on.

If in doubt ask us!

Top 10 subjects of Interest to Delegation as submitted via ETG

1. Installation of latest Generation Clinker Coolers

2. Energy efficiency in Grinding Systems

3. Use of Multi Channel Burners

4. Increased Renewable Energy Use in Cement Manufacturing

5. Waste Heat Recovery

6. Pre-processing and co-processing technologies for alternate fuels and raw materials (AFR) usage

7. Blended Cements

8. Implementing better and advanced Control Systems

9. Other technology up gradation that the sector can adopt

10. Energy Management information systems

Some Blue Chip Companies we have dealt with – some names no longer exist due to Mergers and Acquisitions.

Raw & Alternative (ARM) Materials Handling

Plants

Storage & Recovery Filter Upgrades

Biomass Fuel Plants

Lorry, Rail and Ship Outloading Bagging &

Palletising

Clinker HandlingAlternative Fuels Maximisation

Precipitator/ Bypass

Filter System

Chrome Reduction Plants

Over 30 years Experience

Upgrading Cement Plant Operations &

Facilities

Upgrade of conveyor and systems drive to High Efficiency

Upgrade of pneumatic conveying for energy efficiency and reliability

Smart control systems and efficient drives /electrical generation

We have supplied process equipment for Cem 1, 11, 111, 1V and Cem V production.

Some Case Studies –Rugby – Cement Works

Turnkey project to design, construct and commission the combined fuel and raw materials handling and storage plant. The plant was designed to receive and reclaim 1500t coal, 1700 t pet coke, 8000t clay, 200t oxide and 1200t sand to provide raw materials to the new kiln.

Cement packing plant -3000 x 50kg bags per hour.Cement outloading systems – 6 weighbridges with a wagon turnaround time of 7 mins./bridge.2nd Cement packing plant 3,500 x 25 kg bags per hour.

Hanson Cement - Ketton

Installation of by-pass filtration system to extract chloride laden dust from kiln gases.

Full turnkey project.

Hanson Cement – Padeswood, Ribblesdale and Ketton Works

The design, build of 3 Ferrous Sulphate Plants at Hanson’s Padeswood, Ribblesdale and Ketton Cement Works.

The process involved the reception, storage and addition of ferrous sulphate to the clinker to reduce Chromium V1 in the finished cement material.

Orchid Technology -Stage 1 Stage 2

Possible use for AF - Stage 3 Fuel Properties

Alternative Fuels Technology

AF use in cement production and AF for other industries, plus burner technology

Primary Burner Secondary Burner

TDF PSP Car Frag AF

Orchid SRF

Orchid +30mm SRF Baled Orchid SRF Orchid SRF -10mm Orchid SRF pelletised 8mm dia

Blended Cements using Slags, PFA and other extenders

New 1.2 MMt/a cement plant based on blending cement with GBBS – Fairport supplied design and engineering support services for the complete plant

Clinker Handling – project included intake building, intake hopper and dust extraction, Fairport provided the design, supply, mechanical and electrical installation and commissioning

Ferrous Sulphate addition to control Chromium VI – included reception, storage and dosing supplied to

Receipt, transfer, storage and weighing of silica, alumina and iron oxide products for metering in preset proportions to the cement milling plant

Installation of by-pass filtration system to extract chloride laden dust from the kiln gases. Full turnkey project

New Blending Plant comprising outloading facility. Blends PFA and OPC, pneumatically conveys to an existing silo or out-loads to tanker.Included 300t PFA silo, supporting structures, weighing systems, civil, electrical and control.

Improvements to clinker handling and storage systems including redirecting of major routes to existing storage areas and creation of new import system.

Renewable energy

Solar Farm at Ketton Cement Works

P&ID for 12.5 MW(th) or 3.5 MW(e) Renewable energy facility for Shotton – was planned to be first of four identical facilities to deliver 50MW (th) or 14MW(e) or any combination

GA for 12.5 MW(th) or 3.5 MW(e) Renewable energy facility for Shotton Steel –planned to be first of four identical facilities to deliver 50MW (th) as process heat (steam) or 14MW(e) or any combination. Fuel requirement AF of CV 15MJ/kg boiler 420C @40 barg

Fairport and Siemens can offer state of the art renewable energy power generation solutions, including:

• Boiler packages and Steam Turbines for Biomass Fuels to generate electricity, heat and cooling.

• Boiler packages and Steam Turbines for Alternative Fuels to generate electricity, heat and cooling.

• Solar Systems and the control equipment

• Wind power generation technology

• Biogas engine installations running from Anaerobic Digester Methane.

The use of reliable mix of Renewable Energy Technologies would reduce your reliance on fossil fuels and thereby increase your gains against the benchmarked energy levels. Fairport and Siemens can together supply, manage, control and integrate renewable energy into your Digital Cement Factory and thereby maximise your gains under the PAT scheme.

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Looking to the future

Emerging Technologies (i.e. non-BAT)

1. Use of waste materials as reactants (e.g. ammonia -> sewage sludge, hydrated lime -> CKD)2. Concrete recycling (as aggregate only - not currently advanced to include reactivation of cementitious component even

on the lab scale)3. Oxy-combustion (i.e. pure oxygen instead of air = more efficient combustion, less gas volume and no thermal NOx)4. Carbon Capture and Storage (CCS)5. More use of Waste Heat Recovery for Electricity Co-generation especially from Clinker Cooling6. Revolving disc clinker cooler (claimed to be higher efficiency and require much less cooling air – more concentrated

waste heat source)7. Geopolymer Cements (remove the CaCO3 decarbonation issue from the cement production by using alternative

cementitious components)8. Nano Cement materials to enhance the properties and weather resistance of the cement or concrete – small amounts of

materials give disproportionally significant changes in concrete properties. Subject of most funded researched area globally currently.

9. Step change in grinding energy is overdue, last significant steps were the introduction of HPGR to enhance the VRM even further. We are currently investigating two different technologies currently used for different non cement applications, watch this space!

Fairport Engineering together with Siemens are unique in their experience and capability in partnership

• Energy Generation by Captive Power Plants, Co-Generation, Pure Power Plants up to MW capacity.

• Energy Generation by installation of WHR based on ORC, Kalina or Waste Heat Recovery Systems.

• Energy Generation by Renewable Energy methods, solar, wind , hydro.

• Utilisation of Waste Heat from within existing operations, either for process heat or WHR and generation.

• Multi Fuel Burners – replacement or upgrading – staged combustion

• Reduction in NOx – various technologies

• Reduction in SOx – various technologies

• Reduction Heavy Metals and other emissions – Chromium IV, Chlorine from bypass gas streams, etc.

• Reduction in process plant water usage

• Process Optimisation by Flow Analysis, Intelligent Automation, Big Data Acquisition, and Computer Flow Modelling

• Energy Efficiency in Electrical Systems

• Opportunities for Wider social integration with local communities by planting of Alternative Energy Biomass Crops and its use in Trigeneration and Power Generation

• Alternative Raw Materials Handling plants

Thank you for your attention. If you have any questions we will be happy to discuss those with you later either in person or by email.

rwoosnam@fairport.co.uk+44 1257 484000

Mobile +44 7979 745 836