Schenck Process was approached by The A TEC Group, working on behalf of LAFARGE Cement Hungary Ltd. LAFARGE were looking to install a new alternative fuel concept at a Királyegyháza cement plant, near Pécs in Hungary. As the global leader in building materials and construction solutions, LAFARGE has the ambition to lead the industry in reducing carbon emissions and moving towards low carbon construction – this is underpinned through a strategy 2025 called “Accelerating Green Growth”.
A TEC Group, an Austrian engineering and technologies company which focuses on improvement of efficiencies in cement plants, has worked with Schenck Process for around 8 years. For this project, A TEC needed to work with an organisation that they could trust to supply the systems for the main burner line in a timely and efficient manner for their client, as well as meeting specific levels of performance. This is why they invited Schenck Process to submit a tender response. The key focus for the A TEC Group and the client LAFARGE, was to deliver a compact, economical and highly sustainable solution.
Compact solutions for custom installation
Owned by LAFARGE, the Királyegyháza cement plant is a plant with state-of-the-art manufacturing equipment and a focus on elevated environmental performance. It has been working with most modern available technology since 2011 and has become one of the major producers of cement with its solutions for the construction industry. Schenck Process successfully designed and proposed a customised solution that aligned closely with its customer’s goals and objectives.
The large capacity plant is responsible for a substantial amount of the delivery of high-quality cement in Hungary; however, its limited footprint posed some unique challenges. Space was restricted and Schenck Process was conscious of the issues this could raise. Schenck Process’s design support capabilities were, as always, focused on meeting the customers’ needs, no matter how complex.
Quick fitting modular design delivers on alternative fuel handling flexibility
Schenck Process supplied and installed an array of integrated equipment, ranging from the Multiflex NG Feeder to the Multicell AF Blow Through Rotary Valve; both of which contribute towards improved handling of alternative fuels, in addition to the following technologies:
- Reception stations EcoDock with agitators
- Chain conveyors MoveMaster C
- Magnetic drum separator (positioned externally)
- Collecting screw conveyor MoveMaster SC
- Pneumatic conveying line
- Double hydraulic unit (positioned externally)
Schenck Process fully engineered its holistic approach to the installation to meet the customer specification.
Supply of the Multiflex NG Feeder has provided a more effective alternative fuel feeding solution. By engineering a modular system with a high degree of accuracy, flexible processing abilities and high feeding consistency, the Multiflex NG can maintain stable conditions within the rotary kiln. By choosing the Multiflex NG, LAFARGE could also utilize the machinery to turn plastic into energy, removing it from land and sea; thus keeping their focus on high environmental performance at the forefront of their activities.
The inclusion of the Multicell AF Rotary Valve allowed its patented air distribution system to maintain consistent feed rates by aerodynamically blowing through materials. The anti-blocking technology ensured a reduced need for cleaning cycles and will extend the overall operation period, maximizing the capacity of the Királyegyháza cement plant.
Ease of maintenance facilitates focus on environmental performance
Implementing the new alternative fuel main burner line system with its product stability and heavy-duty design ensures greater longevity. Schenck Process’s machinery requires minimum maintenance effort; the ability to easily access and rapidly exchange wear parts on the Multicell AF will result in longer life performance of the equipment.
The reliability and longevity of Schenck Process’s technologies have been proven through extensive testing at their dedicated, globally accessible Test and Innovation Center based in the Czech Republic. The reduction in energy consumption and increase in process efficiency combine a cost-effective and environmental solution with an installed end-to-end process which has proven invaluable to the customer.
“The building sector has an essential role to play to accelerate our world’s transition to net zero. The Holcim Group, which is represented by LAFARGE Cement Hungary Ltd., was the first company to have its near and long term CO2 targets validated by the Science Based Targets initiative for all scope, setting the reference for our industry,” With the Schenck Process solution we get closer to reach our net zero target in Scope 1. It means that we can increase the rubber-textil consumption on a more effective way, and in this way we are able to minimize our CO2 emission during the cement production.”
Explained Tamás Hoffmann, Country Manager of LAFARGE Cement Hungary Ltd. about the cooperation.
“Our installation has supported LAFARGE with the flexible processing of a variety of materials and helped them progress towards their sustainability goals. The installation, user support and aftersales care demonstrate the Schenck Process approach to working in partnership. Our team is proud of their ability to provide a such a full service to the customer.”Ondrej Kozel, Head of Sales, Alternative Fuels EMEA, added