Fives FCB selected by Rohrdorfer Zement for the supply of a new clay calcination unit in Bavaria

Rohrdorfer Zement was looking for the installation of an integrated clay calcination unit within the clinker production line to test various clay sources and qualities with the ultimate goal of reducing CO₂ emissions linked to cement production, targeting net zero emissions in 2038.

Reducing the proportion of clinker in cement – notably by using fired clay – can cut CO₂ emissions in the cement production process by 40% making clinker substitution one of the most important levers for decarbonising cement.

Dr. Helmut Leibinger, Managing Director of Net Zero Emission Labs GmbH, explained, "After a detailed technical review of the various existing technologies available on the market, we have decided that the flash calciner with an integrated clay calcination unit from Fives FCB was the best solution in terms of reliability, efficiency, and colour control. We are confident that the offered clay calcination unit will be essential to move forward on our pathway to net zero."

A unique design providing the full activation of clays

The solution developed by Fives FCB is a flash calcination process. Its unique design with five independent process stages offers multiple advantages, and enables full activation of a wide range of clays by controlling particle size distribution, temperature and residence time of the material in the circuit.

The absence of material contact with the flame ensures homogenous calcination and therefore excellent product quality.

In addition, the FCB patented colour control process, which reduces iron oxides in a separate decolorisation step after calcination, efficiently produces the 'traditional' grey colour required by cement manufacturers without generating pollutants.

The pilot plant will feature Fives' proprietary technologies in pyroprocess, such as:

• A 3-stage FCB preheater.
• FCB Flash Calciner.
• FCB Colour control system.

Efficient project management

To better support Rohrdofer Zement in the execution of this project with respect to quality, deadlines and performances, Fives FCB will provide its experience and know-how as a supplier of high-performance installations on EPC basis worldwide.

Read the article online at: https://www.worldcement.com/europe-cis/11062024/fives-fcb-selected-rohrdorfer-zement-for-the-supply-of-a-new-clay-calcination-unit-in-bavaria/