New Brazilian cement plant fast into action

February 23, 2017 Steven Miller

Thanks to excellent cooperation between FLSmidth and Margem Campanhia de Mineração, the 3,000tpd greenfield plant in Paraná quickly reached full capacity and met performance guarantees.

Amidst a booming Brazilian economy, the Brazilian company Supremo Cimentos saw the opportunity for a new cement plant in Adrianópolis, a town in the Brazilian state of Paraná. Partnering with the Portuguese company Secil, they formed Margem Campanhia de Mineração to build and operate a 3000 tpd facility.

In 2010, Margem launched a bidding process for the plant design and equipment supply. After a difficult experience with a low-cost equipment supplier, Supremo Cimentos was looking for a Western equipment supplier with local presence. The supplier should offer a combination of the latest technology with the best reliability, local service support after commissioning, and a competitive price. FLSmidth’s name was quickly put on the table, particularly as Secil already had extensive knowledge of FLSmidth's technologies and project capabilities.

One Source supplier
FLSmidth was eventually awarded the contract in March 2012 for engineering and equipment supply for the complete plant from crusher to cement storage. The scope of supply included main equipment, all auxiliary equipment (including conveyors, feeders, fans, dust collectors and similar), plant engineering, automation, and commissioning. FLSmidth’s ability to be a ‘One Source’ supplier for equipment, engineering, and commissioning services played a major role in Margem’s final decision.

FLSmidth was also instrumental in helping Margem to obtain an attractive long-term loan financing of the project.

Global collaboration
The execution of a plant project of this magnitude required excellent communication and coordination. In a truly global effort, Margem and FLSmidth used global engineering and execution resources to bring the new plant to fruition. This included regular meetings and communication sessions involving multiple locations to keep things going smoothly and efficiently during the engineering phase of the project.

The difficult site terrain dictated the need for an ultra-compact layout, and FLSmidth Engineering delivered an extremely efficient design, which has also contributed to energy efficiency. The resulting plant layout demanded close coordination as multiple plant departments were erected in parallel.

Minimising consumption
A cornerstone of Margem’s ambition was state-of-the art equipment with high efficiency and high reliability to deliver sustainable low cost of ownership throughout the plant’s life. To achieve the lowest power consumption possible, all grinding systems include vertical mills. The system is designed to grind OPC as well as multiple blended cements including limestone and slag at different finenesses and conforming to Brazilian cement standards.

The pyroprocessing system included a five-stage low NOx ILC preheater, a two support ROTAX-2® kiln and the latest generation FLSmidth® Cross-Bar® clinker cooler – the first to be commissioned in South America.

The system was designed to achieve low fuel consumption, high availability, and low emissions. Even though it can operate with 100 percent petcoke or 100 percent coal, it is capable of burning alternative waste fuels in the future. In addition, it is designed to achieve the lowest possible levels of gaseous emissions and includes an SNCR (Selective Non-Catalytic Reduction) system to reduce NOx emissions when firing petcoke.

As part of its sustainability and environmental initiatives, 2,000 seedlings were planted along the slopes surrounding the new plant, and most of the equipment is painted in colours to match the surrounding trees, blending in with the surrounding environment.

Outstanding performance
FLSmidth provided an extensive team of about forty engineers to accelerate commissioning. The hard work, collaboration and attention to detail paid off. The plant was commissioned quickly and efficiently with first clinker produced in April 2015. Within one week, the pyro system had its first 24-hour continuous run and within two weeks, the plant had its first 24-hour run above rated capacity. In addition to the pyro system, the grinding systems and storage areas were also commissioned and brought to full capacity within a similarly short time.

By the third week in June, most of the performance guarantee testing had been completed and signed off.

Today, the plant can consistently run at 10 percent above capacity with a total plant power consumption of approximately 84 kWh/t cement.

Margem is a partnership between Brazilian Supremo Cimentos and the Portuguese conglomerate Secil. Supremo Cimentos provided the market expertise and a good understanding of the local contractors and construction requirements, while Secil’s Technical Centre brought the technical know-how and experience from almost 100 years of building and operating cement plants throughout the world, including Europe, Africa, and the Middle East.
*This article is based on an article first published in World Cement, June 2016.

Steven Miller

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