Project details:
Graymont’s Exshaw plant, situated west of Calgary, Alberta, produces a wide range of lime and limestone products, including high-calcium quicklime, hydrated lime, pulverized limestone, and screened limestone. The lime is produced in two rotary preheater kilns.
As part of the operating permit renewal process, the wet scrubber on Kiln #1 needed to be replaced by a baghouse system to meet the standard of “best available control technology”, as required by the Alberta Government.
Challenges:
Project execution within the limited site footprint required an efficient layout. Several options were developed and reviewed with project stakeholders. In the preferred layout, the existing wet scrubber VFDs would need to be relocated in a scheduled kiln shutdown prior to the start of construction.
To limit downtime of the kiln, any new installation would need to be constructed and pre-commissioned as much as possible prior to the kiln shutdown.
Solutions:
Based on the preferred layout, CWA provided preliminary mechanical and structural design and developed an AACE Class 2 capital cost estimate. Upon project approval, CWA completed detailed mechanical and structural design of the infeed and outfeed ducting and supports, dust pneumatic lines and supports, as well as stack and foundations for all equipment. CWA solicited firm quotations for equipment and construction contracts and provided support for Graymont throughout the construction and commissioning of the new baghouse system.
Project Highlights
- Planning and design of a new baghouse system at an operating lime facility.
- Evaluation of conceptual plans, preliminary engineering and development of an AACE Class 2 capital cost estimate for the preferred option.
- Detailed layout and mechanical, structural design.
- Equipment procurement and construction contracting including bid tendering, evaluation, and recommendations.
- Project execution and construction scheduling.
- Home office technical support during construction and commissioning.