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HeidelbergCement entrusts thyssenkrupp with the modernisation of its Airvault cement plant in France

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World Cement,

  • Construction of a new 4000 tpd clinker production line
  • Significantly lower emissions while almost doubling production capacity
  • New assembly concept reduces construction time of preheater by several months
  • Commissioning is planned for mid 2024

The business unit Cement Technologies of thyssenkrupp has received an order from Ciments Calcia S.A, subsidiary of HeidelbergCement Group, for the construction of a turnkey cement production line.

The line, with a production capacity of 4000 tpd of clinker, is to be built at the Airvault site to replace the two existing lines. The aim is to almost double clinker production at the Airvault site. Both parties have agreed not to disclose the contract value.

Pablo Hofelich, CEO of Cement Technologies at thyssenkrupp: "I would like to thank HeidelbergCement and Ciments Calcia for their trust. This is another important step in our long-standing cooperation. In this flagship project, our latest innovations in sustainability and safety are leading the way to a future-proof cement production, with significantly reduced emissions."

By implementing specific processes, the plant’s energy performance will be improved while reducing its thermal and electrical consumption. Thanks to the use of waste as an alternative fuel to fossil energy, the plant's greenhouse gas emissions and carbon footprint will be substantially reduced. The plant is designed to allow for conversion to oxyfuel technology in the future, to efficiently separate carbon dioxide and thereby facilitate carbon capture and storage at a later stage.

The main equipment for the raw material preparation includes a double-shaft hammer crusher with a capacity of 1200 tph, a longitudinal blending bed, a quadropol® QMR² 45/23 vertical roller mill with a throughput of 370 tph and a tangential blending silo with a storage capacity of 10 000 t for the raw meal. The kiln line consists of a single-string, 5-stage dopol® cyclone preheater with integral calciner suitable for the use of alternative fuels and a 3-support rotary kiln, followed by a last generation polytrack® clinker cooler. The plant also includes a preparation workshop for alternative fuels (SRF - Solid Recovered Fuels) as well as proven and reliable dedusting systems.

A new construction method is being implemented for the erection of the preheater tower at the Airvault plant. The preheater modules, including brickwork and electric systems, are preassembled in parallel and almost entirely at ground level.

The Airvault cement plant, scheduled to start-up by mid 2024 will become a benchmark plant in terms of decarbonisation and environmental protection.

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