Lafarge recently announced the launch of a project to modernize its Joppa, Ill., cement plant. When the $415 million modernization is complete in 2010, the plant will have a 2 million-ton production capacity. The construction effort is part of the company's major emphasis on cost reductions, and the changes also will enhance the plant's environmental performance significantly in terms of alternative fuels and emission control.

Jean-Marc Lechene, the company's president of cement in North America, said this strategic investment will decrease the company's need to import cement to meet demand. The modernization includes a new kiln, which will use the most up-to-date processes and will allow Lafarge to maintain highly competitive positions in terms of safety, product quality, and production costs.

“The expansion of the Lafarge Joppa facility is part of our long-term strategy to strengthen our market position in North America by building high-efficiency, low-cost operations. It significantly improves our ability to service our customers in a competitive manner by improving product quality,” said Lechene.

The Illinois Environmental Protection Agency (IEPA) issued an air permit for this project in July. Lafarge is committed to operating the facility in compliance with all applicable IEPA and U.S. EPA regulatory requirements in a manner that is protective of human health and the environment.

“This is an important victory for southern Illinois and Massac County, where a world-class company is continuing to invest in Illinois. Businesses certainly have many choices for where they want to locate, and this is another good example of a business choosing to keep jobs right here in Illinois. By creating a business climate that encourages innovation and investment, we are helping many companies like Lafarge remain competitive, while putting more people to work,” Illinois Governor Rod R. Blagojevich said of the Joppa facility, which has been a major employer in the area for more than 40 years.

Lafarge has awarded FLSmidth a contract for the new Joppa line, along with two additional finish grinding facilities, and will use the most modern processes and allow Lafarge to maintain highly competitive positions in terms of safety, product quality, and production costs. In addition, this project will help enhance the plant's environmental performance significantly in terms of alternative fuels and emission control.

During contract discussions, the Lafarge and FLSmidth project teams collaborated on developing a plant layout that optimizes reliability, ease of maintenance, and long-term, trouble-free operations. In addition to engineering services, project management, and commissioning, all major machines and auxiliary equipment are included:

• FRM (Fuller Roller Mill) 59/575 for raw grinding;
• CF (Controlled Flow) homogenization blend silo with storage capacity of 10,000 tons;
• Three-support, 7,200-tpd kiln, 5.60 meters diameter × 84 meter long;
• 2-string, 5-stage preheater, with a ILC (In-Line Calciner) with low-NOx designed for coal, natural gas, or petcoke;
• Duoflex kiln burner;
• Multi-Movable Cross-Bar with mid-cooler heavy duty roller breaker;
• ATOX 25.0 for solid fuel grinding;
• OK 42-4 Mill vertical roller mill for finish grinding; and
• Complete jet-pulse bag filter packages, including FabriClean, DuoClean, and nuisance filters.

Many of FLSmidth's companies and divisions will be represented in the project, including Pfister, Airtech, Pneumatic Transport, and FLSmidth Airloq.

To achieve savings in the initial construction, the height of the preheater tower and kiln piers were minimized by the use of both a compact, twin-string preheater and the horizontal design of the Multi-Movable Cross-Bar cooler. Future operating cost savings also will be attained with the chosen preheater configuration; the selected design offers an optimal solution with respect to heat economy and power consumption given the moisture content of the raw materials.

To ensure compliance with the strict emission limits and provide flexibility for the future, an SNCR (selective non-catalytic reduction) system will be incorporated in the preheater. Flexibility also is offered in regards to fuel costs. The design allows for the addition of a Hotdisc reactor. Therefore, the line can easily be modified to use bulky waste/alternative fuels.