Successful Cement VRM Projects

Successful Cement VRM Projects
Review of Companhia Siderurgica Nacional (CSN)
Volta Redonda Plant
Dois (2) OK 39-4
FICEM – APCAC, September 2011
John Terembula, Product Manager – Milling, FLSmidth
Luiz Magno Paixão Silva, Gerência Geral, CSN Cimentos S.A.
Agenda
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Project Background
Engineering & Design
Layout
Construction
Start-up
Operation & Maintenance
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Localização da Moagem de Cimento na UPV - VR
Área CSN - UPV
Área CSN Cimentos
Trajeto Caminhões
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fundo
• Planta concebida para utilização da escória da UPV
• Sinergia com a UPV com fornecimento de calcário,
malha ferroviária, porto, energia elétrica, etc.
• Próximo dos 2 maiores mercados consumidores de
cimento SP/RJ
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Engenharia e Design
• Nº de operários envolvidos na obra – 1.800
colaboradores;
• Civil – Consócio Contern/Cetenco e Paranasa;
• EletroMecanica – Daltec
• Projeto e Equipamentos – FLS
• Perfil :
60% Importado
40% Nacional
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Moagem de Cimento – Layout
8-Galpão das Paletizadoras
Descarga Rodoviária
5-Moinhos e
Filtros
2- Galpão de
M.Prima
1-Descarga
Ferroviária
7- Prédio das
Ensacadeiras
6- Silos de Cimento
3- Silo de
Clinquer
4- Silos
Dosadores
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Seleção de Equipamentos
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Equipamentos de Plantas
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Construção
Construção da planta em 02/12/08
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Construção
Start up da planta em abril de 2009
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Matérias-primas
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5-8, 2011
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Transportador de Alimentação
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5-8, 2011
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Materiais em Iniciar
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
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Operação
• Operação de 100% de Escória:
• Blaine de 4.500 a 4.800 cm²/g
• Finura 45µ (#325) - 2,5% a 3,5%
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Operação
Moinho 1
Guaranteed Production
• 171 MTPH a CPIII
• 4500 blaine
Moinho 2
Guaranteed Production
• 171 MTPH a CPIII
• 4500 blaine
Max production
• 207 t/h CPIII
Max production
• 193 t/h CPIII
First Shutdown
15 Dec 2009
First Shutdown
19 Oct 2010
Total hours of operation
91% Cimento
9% Escória-Moída
Total hours of operation
95% Cimento
5% Escória-Moída
3.200:17h TOTAL
1.497:55h TOTAL
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Operação e Manutenção
1ª Parada MOINHO 1 - 15 a
21/12/2009
Horas Operação: 2.195:12h
Horas Cimento: 90%
Horas Escoria: 10%
2ª Parada MOINHO 1 – 05 a
12/07/2010
Horas operação: 2.552:29h
Horas cimento: 72%
Horas Escoria: 28%
Total Geral Produzido:
360.207
Total Geral Produzido:
416.958
Enchimento realizado:
2.360 kg
Desgaste:
Mesa 60mm
Rolos 40mm
Enchimento realizado:
3.134 kg
Desgaste:
Mesa 60mm
Rolos 30mm
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Cronograma
Moinho 2
First Start
19 Apr 2010
Moinho 1
First Start
24 Apr 2009
Guaranteed production
28 Apr 2009
Guaranteed production
20 May 2010
Max production
207 t/h (seca)
Max production:
193 t/h (seca)
First Shutdown
12 Dec 2009
First Shutdown
19 Oct 2010
Total hs of operation
3.200:17 h (falhas)
Total hs of operation
1.497:55 h (falhas)
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Experiência
Positivas
• Moinho apresenta resposta rápida aos ajustes de
processo
• Possibilita a obtenção de blaines elevados
• Apresenta baixo consumo energético
• Baixa vibração e ruído durante a operação
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Experiência
Oportunidades
•
Operação com 100% de escória gera impregnação nas
transferencias
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Diferença de umidade entre os materiais a moagem
alternada entre cimento e escória gera
•
A eliminação de metais da alimentação
•
O equipamento Belt Wall requer know how de
manutenção ainda não totalmente disponível no Brasil
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Custos - Peças de desgaste de moinhos de bolas
Ball charge
60 g/t
0.06 $/t
Liners Compartment 1
Shell + head +
diaphragm grate
0.06 $/t
Liners Compartment 2
Shell + diaphragm
liner + outlet grate
0.04 $/t
TOTAL
0.16 $/t
No labor included
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Custos – Peças de desgaste moinho OK
Roller tire
5 year
0.05 $/t
Table track
5 year
0.05 $/t
Hardface
2 g/t with labor
0.10 $/t
TOTAL
0.15 $/t
Contractor labor
included for Hardfacing
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Total de Custos de Manutenção
Equipment in Same Plant
($/t)
OK Mill
0.54
Ball Mill + HRP
0.78
Ball Mill
0.48*
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Custos - Energia
Ball Mill System
42.0 kWh/t
5.04 $/t
OK Mill System
28.5 kWh/t
3.42 $/t
TOTAL SAVINGS
1.62 $/t
0.12 $/ kWh
Economia de energia são maiores
do que os custos de manutenção!
Energy savings are greater than
maintenance costs !
23
FICEM--APCAC Conference ● Sao Paulo, Brasil ● September 5FICEM
5-8, 2011
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Obrigado!
Gracias!
Thank you!