ste genevieve plant tour worlds largest single kiln line cement plant jeff ouhl vice president plant manager september 14 2010 holcim ltd

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Ste Genevieve Plant Tour

World’s largest single kiln line cement plant

Jeff Ouhl – Vice President / Plant Manager

September 14, 2010

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1 Site specific safety training – 10 minutes

2 Quick summary “the making of cement” – 5 minutes

3 Ste Genevieve plant preview – 40 minutes

4 Plant tour – approximately 60 minutes

5 Questions & answers

6 Depart for hotel at 17:15

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Summary – site specific safety training

Safety first

• Holcim believes that the safety and health of all

personnel working at our plant is our number one

priority

• We also believe that zero accidents is achievable and the only acceptable goal

• You are responsible for staying with your escort and

following the directions of your escort at all times

• If you are unsure about a situation, please stop and get clarification 90% of all workplace accidents are the

result of a poor or uninformed decision

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Quick summary – cement and concrete

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Cement plant Process Flow

Kiln System

“Burning”

ACE ACE

Grinding Distribution Raw Mills

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Agenda

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Ste Genevieve plant project goals – simple and clear

No fatalities; no serious accidents

No tolerance for unsafe conditions, behaviors, design

Meet scheduled start-up dates

Meet capital investment commitment

Meet operational commitments = volume & costs

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Zero accidents is achievable!

• Qualified contractors – must meet minimum requirements to bid

work

• ALL construction workers must have

10/30 hours safety training

4 hours site specific training

• Zero tolerance for certain unsafe acts/conditions

• Financial penalties and rewards to contractors

• Tight access control

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• > 40 Environmental studies completed

• 8 state and federal regulatory agencies with jurisdiction

• Final permits received – June 2004

• Administrative and legal appeals to issued permits

Defended 3 appeals cases up to September, 2004

Settlement of permit appeals – October 2004

MDNR §401 Water Quality Certificate

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3,900 acre site, 2,200 acre conservation easement area, 61 acres of new wetlands created

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Environmental control – best available control technology (BACT) used

• NOx reduction – multi stage combustion & SNCR

• SO2 reduction – lime injection system when raw mills down

• PM10 reduction

Latest technology fabric filters

Covered storage for material storage areas

Covered belts for material transport

Road paving throughout plant

Haul road watering, paved road washing, truck washing

• Opacity monitors on stacks

• Continuous emission monitoring of combustion exhaust points

• One of the most energy efficient cement plants in the US

• Selective quarrying in combination with mining plan

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Cement manufacturing process

The key operational areas of a cement plant are:

• Raw material extraction

• Kiln feed preparation

• Kiln operations – “burning” clinker

• Cement grinding

• Cement shipping

• Quality control

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Limestone is the main component

plant raw mix is limestone

calcium, a lesser percentage

of silica, and possibly small amounts of alumina and iron

mix

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Typical quarry operation

limestone

waste

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Raw mills (2) for kiln feed preparation

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Preheater Precalciner Kiln

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Ste Genevieve preheat tower

except bottom stage is

dual 8.5 meter ø

retention time

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Ste Genevieve three support kiln system

6.6 Meter Dia X 93 Meter L 3.6 RPM Nominal, 5.0 RPM Max

Tangential

suspension Semi-rigid

supports

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Kiln station, refractory installation and kiln firing, July 2009

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New generation MMC 23x123 clinker cooler

• Cools the clinker from the kiln for transport & storage

• Recovers heat from clinker for firing in kiln and

improves thermal efficiency

• 80 deg + ambient clinker

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Coal/petcoke grinding (2) ATOX 27.5 mills

• 37 t/h petcoke or,

• 70 t/h coal

• 740 kW each

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Cement grinding – (4 mills)

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Huge investment in quality control – consistent supply automated lab

is key to meeting our goal

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Product quality assurance and control – highly automated for quick

response

• Fully automated lab system (Robolab – FLS)

Sampling, transport to lab, preparation of pressed tablets,

analysis, mix control

• 2 PGNAA Cross Belt Analyzers

• New Omni Generation by Thermo Fisher

Remote displays in Quarry Mobile Equipment

• XRF and backup XRF (main oxide analysis) (Panalytical)

• XRD with Rietveld capability (fast free-lime; phase analysis)

(Panalytical)

-• Particle Size Analyzer (Sympatec)

• Cross-belt moisture analyzer for incoming raw materials and coal

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Ste Genevieve plant story

480 days without a LTA (Holcim and Contractors)

employees – validated by performance!

Plant staff working extremely diligently to solve startup issues and optimize the plant

High degree of ownership and therefore performance

Achieved goal of high availability first (mills and kiln)

Mill rates running above design, kiln rate now increased

markets

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Our strength is our people – recruiting process was a resounding

success!

team

Hired all employees First for “Attitude and Aptitude”

Multi-skilled organizational design

Mechanical / electrical skills important

Soft skills, leadership skills, and team-building skills

Basic technical skills – welding, hydraulics, pneumatics, etc

Specific technical skills – electrical switchgear, FLS equipment

commissioned and started-up with:

No major injuries or equipment damage

Excellent OEE on start up

High degree of ownership

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Startup First Clinker (assumes July 4 th startup)

Startup after Kiln Bearing Issues (assumes August 13 th Startup)

Months of operation

Ste Geneviève Average 13 Kilns

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GV product is approved for use by DOT’s in the entire river market

Trident

Ada Portland

Approved Jul 7

OHDOT Approved Aug 31

IADOT Approved Jul 24 IDOT

Approved Jul 7 MoDOT Approved Jul 10

LaDOT Approved Sept 22

MIDOT Approved Oct 12 INDOT Approved Oct 12

KYDOT Approved Oct 12 TDOT Approved Sept 21

NDDOT Approved Jul 24

TxDOT Approved Sept 1

ARDOT Approved Aug 27 MSDOTApproved Oct 5

KSDOT Approved Oct 14

GV primary shipping destinations

SDDOT Approved Nov 5

NBDOT Approved Nov 19

GV secondary shipping destinations (no approval applied for yet)

NYDOT Tentative Approval

OKDOT Approved Apr/2010

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Meeting or exceeding all quality targets

STE GENEVIEVE Competitor 1 Competitor 2 Competitor 3

Competitor 4 Competitor 5 Competitor 6 Competitor 7

HCA-MISSISSAUGA (Holly Hill)

GV Target 2500 psi

GV Target 6500 psi

Ste Geneviève 1- and 28-days Strength

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Although no real maintenance costs realized to date, operating costs are better than anticipated

Mothballed/Closed

US Plants Full Year

Specific Power Consumption

(excl shipping) [kWh/t cem]

TOTAL Specific Cash Cost

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Thermal energy (fuel) efficiency continues to improve – MTBF

improvement is main driver

3,000 3,050 3,100 3,150 3,200 3,250 3,300 3,350 3,400 3,450 3,500 3,550

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Environmental – stack tests completed and in compliance with all

requirements

0.0 200.0 400.0 600.0 800.0 1000.0 1200.0 1400.0 1600.0

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Port capabilities & river access

Key element of success for this plant is river access

& unloading

Coal, Petcoke, Gypsum, Fly ash

barge line agreements for transportation

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Slack-water harbor on Mississippi River for loading/unloading up to 6Mt/y of materials

North Fleeting Area - 60

barges

South Fleeting Area

-23 barges Inbound Unloading

Cement Loading

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Harbor cross section

Harbor accommodates >16 m water level fluctuation

Loading silos

Inbound material unloading station Barge loading station

Rail loading

station

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Harbor water level at normal operating depth with no flooding and all modes of distribution available

September 2007

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Harbor depth at above normal level with no affect to any mode of

distribution

April 2008

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Harbor above flood levels with all rail traffic terminated barge loading and unloading is not impacted

June 2008

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Agenda

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Agenda

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Disclaimer

Cautionary statement regarding forward-looking statements

This presentation may contain certain forward-looking statements relating to the Group’s future business, development and economic performance

Such statements may be subject to a number of risks, uncertainties and

other important factors, such as but not limited to (1) competitive pressures; (2) legislative and regulatory developments; (3) global, macroeconomic and political trends; (4) fluctuations in currency exchange rates and general

financial market conditions; (5) delay or inability in obtaining approvals from authorities; (6) technical developments; (7) litigation; (8) adverse publicity

and news coverage, which could cause actual development and results to

differ materially from the statements made in this presentation Holcim

assumes no obligation to update or alter forward-looking statements whether

as a result of new information, future events or otherwise.

As part of Holcim's global commitment to compliance with competition laws, please note that this presentation has been comprehensively reviewed by

counsel in both the United States and Switzerland.

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Strength Performance Passion.

Tiêu đề	Ste. Genevieve Plant Tour World’s Largest Single Kiln Line Cement Plant
Người hướng dẫn	Jeff Ouhl – Vice President / Plant Manager
Trường học	Holcim Ltd
Chuyên ngành	Construction / Cement Industry
Thể loại	Presentation
Năm xuất bản	2010
Thành phố	Ste. Genevieve

Định dạng
Số trang	46
Dung lượng	1,9 MB