View
2
Download
0
Category
Preview:
Citation preview
Successful Cement VRM Projects
Review of Companhia Siderurgica Nacional (CSN)
Volta Redonda Plant
Dois (2) OK 39-4Dois (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
• Project Background
• Engineering & Design
• Layout
• Construction
• Start-up
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
• Start-up
• Operation & Maintenance
Área CSN - UPV
Área CSN Cimentos
Trajeto Caminhões
Localização da Moagem de Cimento na UPV - VR
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The 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
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
• Próximo dos 2 maiores mercados consumidores de cimento SP/RJ
Engenharia e Design
• Nº de operários envolvidos na obra – 1.800 colaboradores;
• Civil – Consócio Contern/Cetenco e Paranasa;
• EletroMecanica – Daltec
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
• EletroMecanica – Daltec
• Projeto e Equipamentos – FLS
• Perfil : 60% Importado
40% Nacional
2- Galpão de M.Prima
Descarga Rodoviária
5-Moinhos e Filtros
8-Galpão das Paletizadoras
Moagem de Cimento – Layout
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
1-Descarga Ferroviária
3- Silo de Clinquer
6- Silos de Cimento
7- Prédio das Ensacadeiras
4- Silos Dosadores
Seleção de Equipamentos
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The 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
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The 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
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The 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
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Matérias-primas
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Transportador de Alimentação
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Materiais em Iniciar
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Operação
• Operação de 100% de Escória:
• Blaine de 4.500 a 4.800 cm²/g
• Finura 45µ (#325) - 2,5% a 3,5%
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
• Finura 45µ (#325) - 2,5% a 3,5%
Operação
Moinho 1
Guaranteed Production
• 171 MTPH a CPIII
• 4500 blaine
Max production
• 207 t/h CPIII
Moinho 2
Guaranteed Production
• 171 MTPH a CPIII
• 4500 blaine
Max production
• 193 t/h CPIII
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
First Shutdown
15 Dec 2009
Total hours of operation
91% Cimento
9% Escória-Moída
3.200:17h TOTAL
First Shutdown
19 Oct 2010
Total hours of operation
95% Cimento
5% Escória-Moída
1.497:55h TOTAL
Operação e Manutenção
1ª Parada MOINHO 1 - 15 a 21/12/2009
Horas Operação: 2.195:12h
Horas Cimento: 90%
Horas Escoria: 10%
Total Geral Produzido:
2ª Parada MOINHO 1 – 05 a 12/07/2010
Horas operação: 2.552:29h
Horas cimento: 72%
Horas Escoria: 28%
Total Geral Produzido:
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Total Geral Produzido: 360.207
Enchimento realizado:
2.360 kg
Desgaste:
Mesa 60mm
Rolos 40mm
Total Geral Produzido: 416.958
Enchimento realizado:
3.134 kg
Desgaste:
Mesa 60mm
Rolos 30mm
Cronograma
Moinho 1
First Start
24 Apr 2009
Guaranteed production
28 Apr 2009
Moinho 2
First Start
19 Apr 2010
Guaranteed production
20 May 2010
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Max production
207 t/h (seca)
First Shutdown
12 Dec 2009
Total hs of operation
3.200:17 h (falhas)
Max production:
193 t/h (seca)
First Shutdown
19 Oct 2010
Total hs of operation
1.497:55 h (falhas)
Experiência
Positivas
• Moinho apresenta resposta rápida aos ajustes de processo
• Possibilita a obtenção de blaines elevados
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
• Apresenta baixo consumo energético
• Baixa vibração e ruído durante a operação
Experiência
Oportunidades
• Operação com 100% de escória gera impregnação nas transferencias
• Diferença de umidade entre os materiais a moagem alternada entre cimento e escória gera
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
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 - Shell + diaphragm
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
No labor included
Liners -Compartment 2
Shell + diaphragm liner + outlet grate
0.04 $/t
TOTAL 0.16 $/t
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
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Contractor labor included for Hardfacing
TOTAL 0.15 $/t
Total de Custos de Manutenção
Equipment in Same Plant ($/t)
OK Mill 0.54
Ball Mill + HRP 0.78
Ball Mill 0.48*
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Ball Mill 0.48*
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
FICEMFICEM--APCAC Conference APCAC Conference ●● Sao Paulo, Sao Paulo, BrasilBrasil ●● September 5September 5--8, 20118, 2011The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
23
0.12 $/ kWh
Economia de energia são maiores do que os custos de manutenção!
Energy savings are greater than maintenance costs !
Obrigado!
Gracias!Gracias!
Thank you!
Recommended