An offer which ranges from design to supply and turnkey delivery of process equipment, grinding plants (cement and minerals) and complete cement plants through to associated services.
Fives and Qatar National Cement Company have signed the provisional acceptance certificate, thus finalizing the implementation, on an EPC basis, of the Umm Bab line 5 with a 5,000 tpd clinker capacity.
The project included the design and supply of all equipment, from raw material preparation to cement dispatch, including a 440 tph raw meal grinding plant, a 2 x 115 tph cement grinding plant and the burning line. Fives has completed four of the five Umm Bab cement plant production lines, which has a production capacity of 16,000 tpd of clinker.
Construction work for the 5th cement production line has started at the Lagunas site in Mexico.
Fives was awarded a turnkey contract for the engineering, supply, construction and commissioning of a 300 tph FCB Horomill® raw grinding plant.
Cooperativa La Cruz Azul SCL awarded Fives another turnkey contract to supply the 280 tph FCB Horomill® grinding plant on the new clinker production line at its Hidalgo site, as well as an order for coke grinding at the two sites.
After successfully completing all performance tests on the Tula production line (3,300 tpd of clinker), Fives has obtained the final acceptance certificate from Cementos Fortaleza which concludes this turnkey capacity extension project.
The new line includes three identical FCB Horomill® grinding mills: one for the raw meal grinding plant, and the two others for the cement grinding plant, offering flexibility and low energy consumption. The tests reported an overall energy consumption of 63.8 kWh per ton of cement for the entire production line.
To meet market needs, Fives has developed a flexible and modular grinding unit which combines the best FCB technologies in terms of grinding, drying and classification:
the FCB Horomill®, the FCB Flash dryer and the FCB TSVTM Classifier. Its standard design allows fast delivery and start-up whilst its modular concept, with pre-assembled modules, minimizes on-site work and associated costs. The FCB FLAGTM station features all the benefits of the FCB Horomill® grinding plant whilst adapting production to market changes with reduced investment and operating costs.
Fives has completed several service contracts for kilns: in France at the EQIOM site in Lumbres and the LafargeHolcim site in Val d’Azergues to replace kiln shells, and in Morocco to refurbish the LafargeHolcim kiln girth-gear in Bouskoura thanks to the patented FCB Nova-Gear® industrial on-site machining solution.
This project was carried out in automatic mode, and allowed to recover the initial profile of girth gear teeth active flanks, on site with no dismantling required. Finally, Fives obtained an order from Breedon Cement to replace the entire no. 1 ball mill drive system at its Hope cement plant in the United Kingdom.
To offer its clients the technical assistance and services needed to successfully operate their facilities and to reduce operating costs, Fives has created a new entity dedicated to services in Dubai, the United Arab Emirates.
The Group has also opened a new office in the United States to offer a better response to the requirements of the US market and promote its FCB range of equipment and its expertise in modernization and supply of complete production lines.
FCB Rhodax® 4D, mineral crushing technology applied to the deconstruction sector
FCB Rhodax® is a vibrating cone crusher developed by Fives which allows material interparticle bed crushing. The FCB Rhodax® was subject to innovation and became Rhodax® 4D (4 Drives): the mechanical systems were replaced with patented electronic synchronization, provided by four engines equipped with controllers.
In 2018, DCX Chrome from the Delachaux Group granted a contract to Fives to modify its chrome-corundum grinding plant for its Marly site in France.
The project includes the supply and refurbishment of a second-hand FCB Rhodax® 1000 MP 4D crusher, modernization of the existing FCB Rhodax® crusher by equipping it with the electronic synchronization system, and installation of a maintenance gantry.
FCB Rhodax® 4D - already used for crushing mineral materials - now has a potential new application in processing deconstruction waste. It can be used to process concrete to separate aggregates from cement and reuse this aggregate, and to recover fines from crushing for addition at cement plants.