The contract between FLSmidth and Holcim for the modernisation of the Rohoznik cement plant in Slovakia became effective in April 2003. Modernisation projects are always challenging. They often require new designs and solutions, and constant changes to the project have to be dealt with.
In May 2001, Holcim invited FLSmidth to make a proposal for a package solution comprising machinery, technical assistance and commissioning for an upgrading project at their plant in Rohoznik. The aim was to upgrade and modernise the Portland Cement Kiln Line 2.
The existing plant consisted of two grey cement production lines each with a capacity of 2,000 tonnes per day. The modernisation project entails upgrading one of the two lines from 2,000 to 3,500 tonnes per day while closing the other one. A small production line for white cement continues to operate unchanged.
FLSmidth's scope of supply included plant design and the following major additions and modifications
- New ATOX raw mill
- New 5-stage preheater/precalciner to replace the existing shaft preheater
- Replacement of the existing mill/kiln precipitator with bag filter
- Changing the 4-support kiln to 3 supports and modifying the kiln drive
- Replacing the planetary cooler with an SF Cross-Bar cooler
- New dedusting facility including heat exchanger
- Upgrading of the gas conditioning system
- New clinker conveying system up to conveyor feeding of existing clinker silo
- Technical assistance and commissioning services
- A subsequent order for a HOTDISC
- Expansion of the raw material storage, adding new LHO bridge reclaimer and upgrading the existing LHO reclaimer
In a total of 177 calendar days all major departments were modified and 5,470 tonnes of equipment installed
The project included a total redesign of the preheater to incorporate a HOTDISC waste burning reactor. It also came to include a new kiln section delivered within 4½ weeks to replace one that had been damaged during transport.
By upgrading one production line from 2,000 tpd to 3,500 tpd
- The new line will be able to handle all the production of grey cement.
- The production will be much more cost-effective and efficient.
- Rohoznik will meet the stringent EU standards for noise, emissions and safety.
