Fives FICEM APCAC – XXIX Congreso Técnico – Costa Rica - San José – 05/09/2012 Driving Progress The Fives FCB sustainable cement plant

FICEM APCAC – 05/09/ The Fives FCB sustainable plant in figures Less than 500 mg/Nm3 of NOx (equivalent NO2 10%O2) at stack Up to 70% of AFR substitution at precalciner (on thermal load) Thanks to the combination of the Fives FCB precalciner & Fives Pillard burner Less than 80 kWh/t of cement High clinker substitution factor Thanks to the Fives FCB Horomill  & Fives FCB TSV TM Zero water consumption Thanks to the combination of the Fives FCB Horomill  & common filter

A combination of advanced proven technologies Low emissions Low power consumption High alternative fuels substitution Zero water consumption High clinker substitution

4 The Fives FCB Zero-NO x Precalciner: an advanced technology The Concept: a real COMBUSTION CHAMBER Downward High-Performance Burner: Creating a Hot Spot For successful ignition & efficient combustion Staged Combustion in reducing conditions Zero-NO x Air and Meal injection: Through a ring without cycloning Creating a meal curtain Protection of lining Progressive and efficient mixing Designed to burn difficult solid fuels and a high rate of alternative solid fuels with Zero-NO x emission Low-NO x burner with central channel for ASF Meal feedDirect flowRing-shaped injectionDistribution chamber FICEM APCAC – 05/09/2012

5 The Fives FCB Zero-NO x Precalciner: an advanced technology Hot spot for complete burn-out Centered flame Protected lining FICEM APCAC – 05/09/2012

6 Combined with the Fives Pillard Precalciner burner A low-NO x high performance burner (in Hoang Mai/Vietnam cement plant) FICEM APCAC – 05/09/2012

7 The Fives FCB Zero-NO x Precalciner: a proven technology Hoang Mai (Vietnam) 100% low volatile anthracite coal (< 8%) Ø 5.6 m – capacity 4,000 t/d Residence time: 4.5 seconds Umm Bab (Qatar) Natural gas Ø 5.2 m – capacity 5,000 t/d Residence time: 3 seconds Holcim-Apasco (Mexico) 100% petcoke & ASF Ø 5.6 m – capacity 3,500 t/d Residence time: 5 seconds FICEM APCAC – 05/09/2012

8 The Fives FCB Horomill: an advanced technology FICEM APCAC – 05/09/2012

9 The Fives FCB Horomill: an advanced technology FICEM APCAC – 05/09/2012  Grinding layer centrifugation  Control of grinding actions  Control of material advance  Simple concept  Continuous adaptations

Twin cement grinding Cement grinding Raw grinding Plants with both raw and cement grinding Slag or mineral grinding Twin slag grinding Not erected 56 HOROMILLS Horomill®: a worldwide proven technology 10 More than 1.5 millions hours of operation FICEM APCAC – 05/09/2012

A combination of advanced proven technologies Low emissions Low power consumption High alternative fuels substitution Zero water consumption High clinker substitution

12 The Fives FCB sustainable plant Low emissions Cartago (Holcim Costa Rica) NO x Emissions hourly average in mg/Nm 10%O 2 dry Less than 500 mg/Nm 3 NO x at preheater exhaust No need of SNCR system in most cases … and less than 100 ppm CO with 100% petcoke mg/Nm³ FICEM APCAC – 05/09/2012

A combination of advanced proven technologies Low emissions Low power consumption High alternative fuels substitution Zero water consumption High clinker substitution

14 The Fives FCB sustainable plant High alternative fuels substitution Cartago (Holcim Costa Rica) : up to 70% coarse ASF (thermal load) can be fed directly in the precalciner burner (ASF made of rubber, plastics and papers) ppmkg/h FICEM APCAC – 05/09/2012

15 The Fives FCB sustainable plant High alternative fuels substitution Alternative Fuels Hermosillo (Holcim Apasco) A quick and efficient ignition A good burn-out & low CO 50% of shredded tyres (thermal load) FICEM APCAC – 05/09/2012

A combination of advanced proven technologies Low emissions Low power consumption High alternative fuels substitution Zero water consumption High clinker substitution

17 The Fives FCB sustainable plant Low power consumption Large energy savings compared to the ball mill … FICEM APCAC – 05/09/2012

18 Horomill ® : the lowest energy consumption … but also substantial energy savings compared with the vertical mill FICEM APCAC – 05/09/2012 which can represent more than 1 MUSD in annual operation cost

19 The Fives FCB sustainable plant Low power consumption Cement plant consumption: 80 kWh/ton of cement Example of cement plants fully equipped with Fives FCB Horomill Tepetzingo (Mexico): 2 lines with 1 Horomill ® for raw grinding and 1 Horomill ® for cement Cerritos (Mexico): 2 lines with 1 Horomill ® for raw grinding and 2 Horomill ® for cement Apazapan (Mexico):1 line with 1 Horomill ® for raw grinding and 2 Horomill ® for cement Typical cement produced: CEM I / CEM 4200 Blaine FICEM APCAC – 05/09/2012

A combination of advanced proven technologies Low emissions Low power consumption High alternative fuels substitution Zero water consumption High clinker substitution

21 The Fives FCB sustainable plant High clinker substitution: stability & flexibility the Horomill ® installed at Lafarge Karsdorf (Germany) produces up to 7 different recipes FICEM APCAC – 05/09/2012

A combination of advanced proven technologies Low emissions Low power consumption High alternative fuels substitution Zero water consumption High clinker substitution

23 The Fives FCB sustainable plant Zero water consumption: the Fives FCB common filter FICEM APCAC – 05/09/2012 Example of zero water burning line equipped with Fives FCB common filter: Holcim Hermosillo Air/Air Heat exchanger Mixing chamber with dilution Common stack Common filter with PTFE bags HE cyclones Booster fan Preheater downcomer without water injection

24 The Fives FCB sustainable plant Zero water consumption: the Fives FCB Horomill FICEM APCAC – 05/09/2012 Example of zero water cement grinding equipped with Fives FCB Horomill: Holcim Hermosillo  No need of water for grinding Centrifugation of the layer procuring grinding stability  No need of water thermal balance External recirculation with cooling in the classifier loop

FICEM APCAC – 05/09/ The Fives FCB sustainable plant in figures Less than 500 mg/Nm3 of NOx (equivalent NO2 10%O2) at stack Up to 70% of AFR substitution at precalciner (on thermal load) Thanks to the combination of the Fives FCB precalciner & Fives Pillard burner Less than 80 kWh/t of cement High clinker substitution factor Thanks to the Fives FCB Horomill  & Fives FCB TSV TM Zero water consumption Thanks to the combination of the Fives FCB Horomill  & common filter

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