French start-up company is going to realized a clay calcining plant in Saint-Maximin, in the Oise Department, Picardy region in Northern France. The company will use a flash calcining system with an activated clay capacity of around 0.1 Mta, ready to produce about 1 Mta of low-carbon concrete. The plant shall be operational in the 2025. While the capacity of the plant may be expanded the company is targeting 5 production sites by 2030/32 in France and other European countries.
To produce the cement, the company will use a flash calcination process, whereby the clay is crushed, dried and heated to 750˚C. It is then mixed with clinker and limestone and no longer needs to be reheated.
The plant will provide employment for around 20 people. It represents an investment of EUR23m and is mainly financed by a consortium of regional institutional investors and Bpifrance. There is also land available to double production capacity at a later date. For now, it is expected that the new line will be commissioned in the 2025.
For this purpose BSP was commissioned for the construction of 1 silo of 1.000 tons of calcined clay and 1 silo of 1200 tons of grind clay both equipped with a planetary extraction system and loading and unloading handling.
CALCINATED CLAY SILO
SPIRAL SILOS
BSP will realized a special type of silo for the storing of the calcinated clay
It will be a flat bottom, 13m diameter, Double walled silo, equipped with Rotobox screw reclaimer and N°2 truck loading stations integrated.
Double wall type consists in a sort of hybrid solution steel/concrete.
BSP erect the first cylinder skin through its special double folding system technology that allow the creation of cylinders profiling and folding rolled steel coils directly on site thanks to special automated former machines. While the first cylinder is growing a steel panel mesh layer is directly assembled over the external side of the wall. Once the first wall is completed, former machines have moved 25-30cm outside and start the erection of the second skin that works as a form work. Later, BSP or the client itself, provides the injection of concrete between 2 layers.
Double walled design avoids the welding of internal vertical rigid bars, reducing operations on site and speeding up assemblig times. The concrete gap allows an internal flat wall built in GALVANIZED STEEL providing a natural insulation against the creation condense.
EXTRACTION & HANDLING
ROTOBOX SCREW EXTRACTOR CAP. 100TON/H
LOADING BUCKET ELEVATOR CAP. 40TON/H
LOADING SCREW CONVEYOR CAP. 40TON/H
ROOF ACCESS SPIRAL STAIR
The ROTOBOX tunnel beam allows the maintenance operations even with full silo :
The planetary screw extractor collects the product from the whole flat bottom surface of the silo and conveys it towards the central outlet at the rate of 100tph avoiding air injection inside the product. The Archimedes screw floated in the product moves radially around the vertical axis of the silo (sweeping rotation) while rotating on itself.
TRUCK LOADING STATION
The automatic and compartmentalized loading stations are equipped with weighbridges.
Sophisticated scheduling software allows drivers to book the exact loading time in order to streamline operations and avoid unnecessary queues and delays on site.
A special mobile loader with bidirectional auger allows the truck to remain stationary during loading operations.
GRIND CLAY SILO
GRIND CLAY SILO : DIAM. 9M – CAP.1.000TON
ROTOBOX SCREW EXTRACTOR CAP. 70TON/H
LOADING BUCKET ELEVATOR CAP. 70TON/H
LOADING SCREW CONV. CAP 40TON/H
ROOF ACCESS SPIRAL STAIR
REALIZATION
GRIND CLAY SILO ERECTION
In a very short time an expert a BSP site responsible can start the automated production process by himself.
- After anchoring the mounting ring, a steel coil is placed on the uncoiler reel.
- The steel coil enters the profiling machine, which bends the tape in accordance with the desired diameter of the silo.
- When part of the cylindrical body is erected (2 meters high), the spiral process is stopped to install the roof (as well as outlets, filters, piping, walkways, when foreseen).
- The erection operation starts again and the silo arises up to the desired height.
- When the assembly is finished, the machine turns in the opposite direction, the silo is demounted by the supporting ring and laid down at ground.
- Installing of eventual unloading metallic hoppers or handling equipment.
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The complete assembly is achieved very quickly and all the operations are executed at ground level without the employ of dangerous scaffolding.
CONCLUSION
BSP is increasingly involved in the cement field on the international market, especially in the creation of more sustainable low-carbon emission plants, thanks to its precious know-how and technologies, its fifty years of experience in the field and the professional skills it has at its disposal