Another step forward for Mannok’s decarbonization plans
New satellite burner installation to see CO2 emissions reduced by 23,000 tonnes annually
MANNOK’s ongoing decarbonization plans in the cement production process took another step forward recently with the installation of a new satellite burner – phase 1 of a two-phase project to upgrade the pyro kiln system.
The company, which has been manufacturing cement for more than 30 years, producing approximately 1.4 million tonnes annually and supplying customers across the UK and Ireland, is committed to manufacturing cement more sustainably.
Mannok’s sustainability goals are laid out in the Mannok 2030 Vision – the company’s long-term strategic plan that roadmaps the progress it will make towards a carbon-zero future up to the end of the decade, while paving the way for net-zero emissions by no later than 2050.
The installation of the satellite burner, in conjunction with FL Smidth, will aid Mannok’s progress toward these goals, allowing the introduction of SRF (solid recovered fuel) as a coal replacement to the kiln pyro system for the first time.
The completion of the €2.5 million project for Phase 1 has enabled Mannok to substitute coal by up to 30% in the kiln, whilst an added benefit will see 23,000 tonnes of CO2 emissions reduced annually.
Phase 2 is an upgrade of the main burner to a new Jetflex burner. On completion of this two-phase upgrade, Mannok should achieve 65–70% substitution of kiln coal throughout the pyro system.
This current project follows the successful implementation of a FuelFlex pyrolyzer in 2022, also in conjunction with FL Smidth. This world-first combustion system has almost eliminated the use of fossil fuel in the most carbon-intensive stage of cement production – the pre-calcination stage – at Mannok’s plant, reducing 240 tonnes of CO2 emissions per day, and significantly reducing NOx emissions.
Paul Carron, Mannok’s engineering manager for decarbonization, said: ‘The satellite burner is the latest instalment in our decarbonization plan, as laid out by our Mannok 2030 Vision to decarbonize the cement plant. The satellite burner will introduce SRF to the kiln pyro system for the first time. It’s part of a two-phase project where we will be deploying a new Jetflex burner in January.’
The installation of this first phase of the new system includes the satellite burner, Pfister feeder dosing system, and a double docking station for walking-floor articulated trailers, which will be used for SRF storage for the system.
