FCT COMBUSTION NEWSLETTER: March 2022
BURN AFTER READING
Dear Friends,
I hope this newsletter finds you well, and that you have enjoyed an excellent start to 2022! It is my great wish that you will all enjoy a happy, healthy, and prosperous year ahead, and I look forward to meeting many of our customers and associates again as borders continue to open.
With this in mind, we have recently opened a new office location to ensure our valued customers can access local sales, service, and support in their region. In addition to our offices in Australia, the USA, Brazil, and Austria, we now have an office in Nanjing, China, with an additional licensed workshop located in Bengbu. We are delighted to announce the opening of this office, in partnership with local air pollution control solutions company EETC. The new office has local staff to support the customers in a timely manner.
The most important aim at FCT is to ensure we are always striving to deliver the best solutions and technologies for our customers. For this reason, we have a dedicated R&D center based in Australia where we continue to improve and innovate our product offerings. Lately, much of our R&D work has been focused on decarbonization, and how we can better support our customers to reduce their emissions while maintaining great quality and production output.
As many will know, we are involved in various academic and industry led decarbonation initiatives, including Hydrogen, Clay Calcining and Alternative Fuels, a field that we are present and leading for many years. For instance, we have already the ability to safely utilize Hydrogen for different processes, with some of our customers already using a hydrogen percentage in their plants. Our continued research aims to reach 100% hydrogen firing capability for those who are interested in converting their operations to this fuel, which are already part of jobs that FCT is performing to clients in several countries
In some instances, and for many plants, hydrogen is not yet the most viable fuel since it involves many considerations and practicalities, mainly where and how to source the hydrogen. For these customers, we have successfully been converting plants from traditional fuels toward high levels of alternative fuel firing, or natural gas, for decades. We have several specialized burners and equipment that may or may not be customized, to ensure optimized performance and best outcomes, and our experienced team of engineers have a wealth of experience in doing this across various environments, fuels, industries, and processes worldwide.
In addition, we also offer our flash and rotary kiln calcining technologies for calcining clay for low carbon ‘green’ cement. More information can be found on the method, technologies, and equipment selection by clicking here . In the clay calcining plants area, we have joined forces with IKN to offer complete solutions to the market. A dedicated clay calcining team with several years of hands-on experience in clay calcination is located in our Fort Lauderdale, USA office to give support to the clay initiatives around the world.
I hope that you will enjoy reading our latest newsletter, and please do not hesitate to contact our team anytime if we can be of help. You can contact us via our contact page or follow us on LinkedIn
Wishing you all the best,
Adriano Greco
FCT Group CEO
PROJECTS ACROSS THE GLOBE
RECENTLY COMPLETED OR CURRENTLY ACTIVE PROJECTS ACROSS FCT COMBUSTION INCLUDE:
AUSTRALIA: BHP Olympic Dam
FCT is delivering an oxy-fuel burner package for BHP’s flash smelting furnace at Olympic Dam in South Australia. The upgrade will extend the life of the furnace, reducing waste and reducing emissions associated with manufacture. In addition to the custom burners for both the North and East walls of the Settler Bath, accompanying burner management systems, valve trains, oxygen analysers and ancillaries are also included within the scope.
AUSTRALIA: SIMEC Mining, Whyalla
FCT is conducting a CFD Study as part of the modernisation of the Whyalla Steelworks green steel plant. The CFD study follows a prefeasibility study conducted by FCT regarding the conversion of a grate-kiln burner from coke oven gas to 100% natural gas, as well as investigating the possibility of using hydrogen as a clean alternative fuel in the plant.
AUSTRALIA: Graymont, New South Wales
FCT has delivered a new burner system in support of Graymont’s restart of its lime plant in Charbon, New South Wales.
AUSTRALIA: Albermarle, Kemerton
FCT has delivered and is commissioning the combustion system and gas analyses to Metso: Outotec’s lithium plant in Kemerton, WA.
BRAZIL: Vale, Vitoria
FCT has been awarded a contract to supply a set of 90 burners for Vale’s iron ore pelletizing plant in Vitoria. The scope also included valve trains, flame sensors, igniters, gas analysers, flow meters and various other equipment to convert the kilns to natural gas and improve operational safety.
BRAZIL: Vale, Vitoria
As a continuation of the natural gas conversion and operational safety upgrade of Vitoria’s plant, FCT has been awarded a contract to supply a set of 106 burners for Kilns 5, 6, and 7 to the iron ore pelletizing plant in Vitoria. The scope also includes the necessary valve trains, flame sensors, igniters, gas analyses, flow meters, and various other components.
Burners and valve trains being manufactured for Vale in Brazil
BRAZIL: Icon Máquinas, Criciuma
FCT has been awarded the contract to supply 3 new hot gas generators to Icon Máquinas in Criciuma, for which the final customer is Vale’s New Steel project. Two of the natural gas fired Hot Gas Generators will be installed in the Vitoria plant, and the third Multi-Fuel equipment will be installed in Vargem Grande, MG. All Hot Gas Generators will be supplied in partnership with Icon, who will integrate the equipment to their dryers.
BELGIUM: Cimenterie CBR, Lixhe
FCT recently delivered a hot gas generator with accessories and control system. The hot gas will be used to preheat raw material as part of an expansion of the EU H2020 Leilac (Low Emissions Intensity Lime & Cement) Pilot for CO2 emission reduction.
CANADA: Undisclosed client
FCT has been awarded the contract to supply a new hot gas generator in Canada. The supply comprises the complete hot gas generator including the burner, valve train, igniter system and the components to safely operate the system. The new HGG will combust natural gas to generate hot gases at controlled temperatures to supply thermal energy to a rotary dryer.
CAMEROON: Undisclosed client
FCT has recently delivered a complete fuel oil system for a calciner and a hot gas generator, from truck unloading pumps to valve trains inlet. The scope includes tanks, filtering, pumping and heating stations. Commissioning is expected for 2022.
GERMANY: HeidelbergCement, Burglengenfeld
FCT is currently commissioning a Turbu-Flex™ burner for HeidelbergCement’s Burglengenfeld plant. The targets of the project are to maximise the use of alternative fuels as well as to improve combustion control. The supply includes the accessories and add-on to the burner, as well as igniter, flame sensor, fans, blowers, BMS, and spare parts.
A recently commissioned Turbu-Flex™ burner is showing positive signs of increasing alternative fuels usage at the HeidelbergCement plant in Burglengenfeld.
GERMANY: HeidelbergCement, Hannover
FCT has been awarded a contract to deliver a Turbu-Flex™ burner for HeidelbergCement’s Hannover plant. The targets of the project are to maximise the use of alternative fuels as well as to improve combustion control. The supply includes Accessories and Add-ons to the Burner as well as Igniter, Flame Sensor, Fans, Blowers, BMS and spare parts. Commissioning is expected for mid 2022.
A Turbu-Flex™ burner was recently delivered to HeidelbergCement’s Hannover plant.
HONG KONG: Green Island Cement
FCT is supplying a burner to Green Island Cement, which will increase the plant’s alternative fuel firing capabilities for reduced emissions, alongside coal firing.
JAPAN: Sumitomo Mining & Metals
FCT has delivered a burner to Sumitomo Mining & Metals (SMM) in Japan, for ferro-nickel reduction application. The burner will ensure a high degree of flexibility in heat flux profile to allow for scale-up in the future as the client’s needs change and grow.
NAURU: Republic of Nauru Phosphate Corporation (RONPHOS)
RONPHOS has two rotary dryers for drying phosphate rock, each with its own hot gas generator. FCT has delivered a combustion system including one oil burner, a primary air fan, an oil pumping skid, an oil valve train, and Burner Management System. The combustion system is designed to utilise both waste oil and diesel.
OMAN: Vale, Sohar
FCT will supply a Gyro-Therm™ burner for iron ore pelletizing grate-kiln application, to be installed at Vale’s plant in Sohar, Oman.
FCT has delivered a Gyro-Therm™ burner to Vale’s iron ore pelletizing plant in Oman.
USA: Ash Grove Cement, Chanute KS
FCT has been awarded a contract to supply a new multi-fuel burner for the cement kiln in Chanute Plant. The new Turbu-Jet™ burner system will be able to fire up to 100% coal/petcoke, natural gas and 40% liquid waste.
USA: US Silica, Vale OR
FCT has been awarded the contract to supply a safety system upgrade for kiln 1 installed in US Silica’s plant in Oregon. The project aims to update the existing natural gas valve train to comply with the latest NFPA safety requirements, including new ignition system. A new burner management system will also be installed.
UNDISCLOSED COUNTRY/CLIENT
FCT delivered a set of 20 natural gas burners for an iron ore pelletizing plant in early 2022. The scope also includes valve trains, flame sensors, igniters, flow meters, fans, local control boxes and spare parts.
FCT has delivered combustion equipment for an iron ore pelletizing plant.
UNDISCLOSED COUNTRY/CLIENT
FCT recently delivered 11 Gyro-Therm™ burners for an undisclosed client. The burners were commissioned across 6 of the client’s cement plants, with the main target being to reduce specific fuel consumption. The burners are designed to fire natural gas and solid alternative fuels. Control systems, igniters, igniter valve trains, flame sensors, and accessories were also included within the scope.
PEOPLE OF FCT
At FCT, we know that our continued success is largely due to our team’s commitment to providing the best products, service, and expertise across all our offices. We are pleased to announce the newest additions and changes within our team:
Michael Zhu, CEO, FCT/EETC China
We are pleased to introduce Michael as the CEO of the joint FCT/EECT office in China. Michael has been involved with businesses across the energy and environmental sectors for many years, having managed multiple engineering, manufacturing, and trading companies in the USA and China.
Michael moved from China to the USA in his youth, and is a graduate of the Maryland Business School, of Smith Business School, and holds an EMBA from Rutgers. In 1993, Michael travelled back to manage the China operations of US public company, Environmental Elements Corporation. He took ownership of EEC’s China subsidiary in 2004 with a management buyout and has expanded it through the establishment of other companies to service the growing need for environmental equipment in China, as well as to fulfill the desire of international companies to source engineered products.
For more information about FCT’s presence in China, please click here.
Fernando Libonati, Head of Business Development, Asia-Pacific and Middle East
We are delighted to introduce Fernando as the Head of Business Development for FCT within the Asia Pacific and Middle East regions.
With more than 21 years of technical sales experience for prominent companies including Bühler, AUMUND, and Thermo Fisher Scientific, Fernando has experience across a variety of global markets from having lived and worked in Australia, Hong Kong, China, Germany, and Brazil.
Fernando holds a Mechanical Engineering degree, as well as a Business Administration degree, from the Fundação Armando Alvares Penteado (FAAP) University in Brazil.
CONFERENCES & EVENTS
FCT will exhibit at the IEEE-IAS/PCA Cement Industry Technical Conference in Las Vegas from May 1st to 5th. Come meet our friendly team at Booth 402!
FCT joins forces with EETC in China
FCT Combustion is pleased to announce a formal alliance with the Enelco Environmental Technology Co., Ltd (EETC)
FCT is the worldwide leading supplier of combustion system for iron ore, cement, lime and minerals industries. EETC is a leading supplier of air pollution control equipment systems for the utilities, pulp and paper, steel and related industries.
FCT and EETC are joining forces to support the Chinese steel, cement, glass and other industries with innovative combustion equipment solutions to ensure production safety, conserve energy and control emissions.
EETC is the exclusive representative of FCT Combustion in China. EETC extensive capabilities, and resources shall be shared with FCT to service our valued Chinese customers.
The joint office is based in Nanjing, with an additional workshop based in Bengbu. From these facilities, FCT and EETC are forming teams to offer local technical support, engineering, and procurement capabilities to our valued customer base within China.
Michael Zhu, President of EETC, will become FCT’s China CEO and believes the alliance demonstrates a shared commitment to support the local market.
“We are delighted to have reached this agreement between FCT and EETC. Together, we are committed to delivering high performance solutions, which are proven to reduce emissions while maintaining high levels of quality and production output. China is the largest producer of both steel and cement worldwide, and we look forward to delivering state-of-the-art technologies and solutions to support the continued growth of these industries,” he said.
Adriano Greco, FCT Group CEO, believes the new office will improve the customer experience.
“We have great respect for our growing customer base within China and believe that it is important to establish a locally based business unit, so we can deliver the best outcomes and customer experiences, providing customer service and engineering according to the local culture and language as well as local procurement to offer the most cost-effective solution” he said.
The office based in Nanjing, China will join FCT’s existing network of international offices, which are located in the USA, Brazil, Austria, and Australia.
FCT Combustion公司很高兴宣布，与艾尼科环保技术有限公司 (EETC) 正式结盟。
FCT 是拥有先进技术的全球燃烧系统供应商，产品主要应用于铁矿石、水泥、石灰和矿物业。
EETC 专注于大气污染颗粒物控制技术，为全球电力、造纸、冶金、建材、化工等领域提供高性价比的除尘解决方案与设备。
FCT 和 EETC将联手为中国的球团、水泥、玻璃等行业提供成熟的高性能燃烧解决方案和设备，保障安全生产，实现节能减排。
EETC作为FCT在中国的总代表，将分享其在中国的市场资源、设计制造能力和售后服务体系，携手为FCT的中国客户提供优质服务。
FCT中国总代表处将设在EETC南京分部，负责销售与服务；EETC位于蚌埠的生产基地将为FCT提供制造和调试服务。FCT与EETC将在两地组建团队，为中国客户提供本地技术支持、工程服务和采购服务。
EETC 公司总裁朱合目先生，将出任FCT中国业务首席执行官，相信结盟后的本地化服务系统可以更好地支持中国市场。
他表示：“非常高兴 FCT和 EETC 达成结盟协议，我们可以携手为中国客户提供高性能且技术成熟的燃烧器解决方案，帮助他们节能减排的同时，保证产量与品质。中国是全球最大的钢铁和水泥生产国，希望我们的先进技术和本地化的优质服务能够支持这些行业的持续增长，为他们带来更优质的燃烧器使用体验。”
FCT 集团首席执行官 Adriano Greco 相信，中国总代表处的设立，将提升客户体验。
他强调： “我们非常重视FCT在中国不断增长的客户群，而且相信成立中国总代表处至关重要。提供基于当地文化和语言的客户服务和技术支持，能为我们的中国客户提供最具性价比的解决方案。”
位于中国南京市的总代表处，将加入 FCT 公司现有的国际服务网络，此前FCT已在美国、巴西、奥地利和澳大利亚设立业务网点，提供本地化的技术支持。
The FCT/EETC team celebrating the lunar New Year 2022. Wishing all the best for our friends and valued customers!
CASE STUDY: MAXIMIZING ALTERNATIVE FUEL WITH CFD
A look at how we increased a customer’s alternative fuel (AF) substitution rate using CFD. When paired with FCT’s extensive industrial experience and comprehensive list of international references for high substitution rate burners, the use of CFD can deliver important insights for customers to further optimise their process.
Kiln and calciner burner systems have a major impact on the bottom-line results for a cement plant, and so customised optimisation of the flame for any given kiln is critical to get the best plant performance. In the quest to increase AF firing capabilities, a burner specialist can assist plants in finding an optimal design and tailored solution for their unique environment.
Computational Fluid Dynamics (CFD) can be a crucial tool in the development of tailored burner design, as it provides insight into flow aerodynamics which may not otherwise be visible to the naked eye. This information can then be used to optimise burner design for improved fuel efficiency, product quality, and production output.
Download our free case study to learn how we utilised CFD to improve a customer’s AF firing capabilities in Europe. This case study was originally published in Global Cement’s “AF Special Issue” in 2021.
