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    Lafarge DEC Presentation December 2010

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    LafargeRavenaFacts
    The document describes Lafarge's plan to modernize its cement plant in Ravena, NY from a wet to a dry production process. This will involve building new facilities like a raw mill, preheater/precalciner tower, kiln and baghouse collectors. It will eliminate wastewater discharges and reduce energy usage compared to the existing wet process. The modernization is expected to provide economic and environmental benefits for the region through greater efficiency, reduced emissions and sustainable energy production.

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    Download as PDF, TXT or read online from Scribd

    Lafarge DEC Presentation December 2010

    Uploaded by

    LafargeRavenaFacts
    4K views16 pages
    The document describes Lafarge's plan to modernize its cement plant in Ravena, NY from a wet to a dry production process. This will involve building new facilities like a raw mill, preheater/precalciner tower, kiln and baghouse collectors. It will eliminate wastewater discharges and reduce energy usage compared to the existing wet process. The modernization is expected to provide economic and environmental benefits for the region through greater efficiency, reduced emissions and sustainable energy production.

    Original Description:

    Lafarge Cement's presentation at DEC meeting in Ravena on December 8, 2010

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    The document describes Lafarge's plan to modernize its cement plant in Ravena, NY from a wet to a dry production process. This will involve building new facilities like a raw mill, preheater/precalciner tower, kiln and baghouse collectors. It will eliminate wastewater discharges and reduce energy usage compared to the existing wet process. The modernization is expected to provide economic and environmental benefits for the region through greater efficiency, reduced emissions and sustainable energy production.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    4K views16 pages

    Lafarge DEC Presentation December 2010

    Uploaded by

    LafargeRavenaFacts
    The document describes Lafarge's plan to modernize its cement plant in Ravena, NY from a wet to a dry production process. This will involve building new facilities like a raw mill, preheater/precalciner tower, kiln and baghouse collectors. It will eliminate wastewater discharges and reduce energy usage compared to the existing wet process. The modernization is expected to provide economic and environmental benefits for the region through greater efficiency, reduced emissions and sustainable energy production.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 16
    At a glance
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    The presentation discusses Lafarge's plan to modernize its cement plant in Ravena, NY by transitioning from a wet to a dry production process and upgrading its facilities and emissions controls.

    Facilities retained include the quarry, conveyors, administration building, and storage silos. Facilities removed include the raw mills, coal mills, slurry basins, kilns, and clinker coolers.

    In the wet process, raw materials are mixed with water and fed directly to the kiln, requiring extra fuel. In the dry process, materials are preheated and fed to the kiln dry, saving substantial energy. The kiln is also shorter.

    1 Modernization: Economic Benefits | Greater Efficiency | Jobs | Sustainable Energy | Improved Air Quality

    slide 1 of 16
    Agenda

      Introductions
      Project Description
      Facilities Retained
      Wet to Dry Process
      Key Areas Examined
    in DEIS
      Schedule

    www.lafargeravenafacts.com

    2
    slide 2 of 16
    Lafarge Team

      Martin Turecky, Lafarge


    Plant Manager, Ravena Plant

      John Reagan, Lafarge


    Environmental Manager,
    Ravena Plant

      Bill Voshell, Lafarge


    Regional Environmental Manager

      Marc Desimone, Lafarge


    Engineering Manager
      Elena Barnett, HDR
    Vice President
      Jim Brown, HDR
    Senior Vice President

    3
    slide 3 of 16
    The Ravena Process
    Today: Wet Process

    Wet Process
    (1950-60’s Technology)
      Raw materials are mixed with water and
    ground in slurry mills. Slurry is stored and
    homogenized in large slurry basins.
      Slurry mixture is fed directly to the kiln
    without preheating.
      A large amount of extra fuel is used in
    evaporating the water.
      A larger kiln is needed, because much of the
    kiln’s length is used up for the drying proces.
      In 1962, the Ravena cement plant’s nearly
    600-foot long kiln was the largest piece of
    moving industrial equipment in the world.

    4
    slide 4 of 16
    The Ravena Process
    Tomorrow: Dry Process

    Dry Process
    Pre-heater/pre-calciner kiln line
    (State-of-the-art Technology)
      Raw materials are ground, mixed, and fed to a
    kiln in a dry state. Ground dry material is
    preheated in a preheater tower.
      The preheater tower is a tall vertical structure in   Reduced process waste.
    which the dry kiln feed enters at the top of the
    tower and is heated by kiln exhaust gas entering   ZERO process wastewater discharges through
    at the bottom of the tower. re-use and recycling.

      Preheating of the ground dry material prior to   Minimization of Impacts to Hudson River:
    entering the kiln results in substantial energy •  Achieves objectives of Hudson River
    savings compared to the energy required to heat Estuary Program.
    the wet slurry mixture.
    •  Flow minimization through reuse/recycle
      The Rotary kiln length of approximately 200 ft. is of wastewater and use of non-Hudson
    much shorter than the wet kilns. River water sources.
      New emissions control technology includes: •  DEC approved best technology available
    scrubber, SNCR, state-of-the-art dust collectors for water intake from the Hudson River
    and CEMS. to minimize impacts to
    aquatic organisms.

    5
    slide 5 of 16
    Facilities

    Facilities Retained Facilities Removed


      Quarry facilities   Raw Mills (2)
      Conveyors   Coal Mills (2)
      Administration building   Slurry Basins (2)
      Laboratory   Kilns (2)
      Maintenance facilities   Electrostatic
      Cement Storage Silos Precipitator Building

      Wharf facilities   Clinker Coolers (2)


      Most supporting infrastructure   Associated drives, fans
    and ancillary equipment
      Stack

    6
    slide 6 of 16
    New Facilities

    Phase l
      Secondary crusher   Scrubber
      Raw mill storage bins   SNCR—selective non-
      Raw mill catalytic reduction
      Alkali bypass   Baghouse dust collectors
      Coal mill   Fans, drives and ancillary equipment
      Prehemogenization silo   Continuous Emissions Monitors
    (CEMs): NOx, SO2, PM, Hg, CO/CO2,
      Kiln
    THC and HCl
      Preheater precalciner tower
      Clinker cooler

    Phase ll
      Power generating system
      Finish mill
      Clinker storage Ravena’s Quarry
      Preblending system

    7
    slide 7 of 16
    Wet vs. Dry

    Raw Milling
      Horizontal configuration to vertical
      Same raw materials except water

    8
    slide 8 of 16
    Wet vs. Dry

    Kiln Feed Storage


      Dry storage silo
      12 hour storage
      Extraction and transport of powder

    9
    slide 9 of 16
    Wet vs. Dry

    Wet Process Dry Process

    10
    slide 10 of 16
    Lafarge Ravena Plant
    Proposed Plant Modernization Project

    Key Areas Examined


      Land Use and Zoning
      Solid Waste
      Noise
      Traffic
      Visual Impact
      Water and Coastal
    Resources
      Natural Resources
      Socioeconomic
      Air Quality
      Energy Resources

    11
    slide 11 of 16
    DEIS: Water, Energy & Waste
    Comparison: Modernized Facility & Existing Plant

    12
    slide 12 of 16
    Existing vs. New Plant
    Emissions from modernized plant compared to existing plant

    13
    slide 13 of 16
    The Future
    Modernization Project Timeline

    State-of-the-Art New Facility

    14
    slide 14 of 16
    Modernization Benefits

    15
    slide 15 of 16
    Lafarge Ravena Plant Modernization Project
    Information and Updates

    Learn more and get project updates online at:


    lafargeravenafacts.com

    16
    slide 16 of 16

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