FPE Global helps Hanson to clean up

FPE Global helps Hanson to clean up

The way that we effect the environment at both a national and global level is a hot topic. Hardly a week goes by without a media driven story warning us of a previously unconsidered effect of global warming. The fact remains though, that at an industrial level, significant improvements in the way that we process the unfortunate bi-products from such industries as energy generation and cement manufacture have had a positive impact on the environment.

The Hanson cement plant at Ketton in Rutland is pioneering the concept of sustainable cement production with an increasing use of non-fossil fuels for heating the kilns. The range of combustible products which engineers are using to replace coal includes paper and plastic which would otherwise end up as landfill. As a result, the company’s carbon footprint is dropping year on year.

Now, in a move to further reduce harmful emissions, a new lime dosing system has just been delivered, installed and successfully commissioned by FPE Global. Over the past thirty years, FPE Global have developed considerable knowledge and a fine reputation for lime injection systems capable of delivering carefully metred amounts of lime in precisely targeted patterns.

The system we supplied included a 40 tonne capacity mild steel silo to provide the bulk storage of lime on site. To allow for the safe filling of the silo by road tankers, the silo is fitted with a filter/venting unit and pressure relief valve in line with the latest HSE guidelines. There is also a silo auto shut off mechanism designed to protect both the environment and the silo from being over pressurised or over filled. Compression type load-cells are fitted to the silo to continuously monitor and measure the inventory within the silo.

To assist in product discharge and eliminate bridging at the silo outlet a rotating mechanical discharger has been fitted to the base of the silo.

As with any pneumatically conveyed delivery system, when handling hydrated lime, a great deal of care is needed at the planning stage to ensure that the system operates as reliably as possible. A possible problem can be caused when hydrated lime enters the pneumatic conveying air stream. A chemical reaction can occur where the lime releases CO2 and picks up moisture from the conveying air.

This is known as “calcining”. This release of moisture means that the hydrated lime will adhere to the surface that the moisture condenses upon. This chemical reaction is unavoidable however, using our 30+ years of pneumatic conveying experience, we designed a conveying system that will perform to the best of its ability and will operate with minimal maintenance.

We supplied a turnkey project to Hanson including the civils, design, project management, supply, manufacture, delivery and mechanical installation with Hanson providing the electrical control panel and electrical wiring.

“It was very important that we invested wisely in equipment to reduce stack emissions of HCl”, explains, Senior Project Manager for Hanson Cement.

“Margins are tighter than ever in the cement business so we needed equipment that was good value for money.’’

“The mechanical installation was carried out safely over a 5 day period. I was impressed by the quality of workmanship and organisation of the site team. The commissioning of the equipment went well and after quickly correcting a couple of snags we have been handed over a very capable system. The site process engineer is very impressed with the solution we have presented him. We have a system that can control the levels of HCl automatically without having to make compensations elsewhere in the process. I will not hesitate in considering FPE Global for future projects within Hanson Cement. Their experience has been invaluable in making this project a success.”

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