Our Client: Lafarge, a world leader in building materials and a major player in the cement, aggregates and concrete industries.
Our project management team delivered the project from contract to commissioning in a mere 9 months. This included having 1,100 tons of steel fabricated for a heavy-duty stack.
Our Contract: This was a complete turnkey upgrade solution to further reduce air emissions while increasing filtration efficiency throughout the entire line.
Our Solution: We replaced two existing electrostatic precipitators with one large 1.5 million m3 Bag Filter. The new system reduced the amount of dust to less than 10 mg/m3. We disassembled the existing kiln and clinker cooler lines, replacing the components with new, highly efficient ones. We converted the existing conditioning tower into a Mixing Chamber and provided new ducts, a new fan and integrated all new portions into the existing automation system of the plant.
Our Challenges: The stack required to optimize emission reduction was impressive, measuring 4.1 m wide and 80 m high (13 ft x 263 ft). We had it delivered in two pieces and assembled on site. During the peak of activities, this required 120 workers. In addition, the timeline was tight. We completed the entire project, from the awarding of the contract to commissioning, in 9 months. This included having 1,100 tons of steel fabricated for the external and internal components. We were able to achieve this record time by doing a design-build and overlapping activities.