Part 2 CCT Overview
Iron Making and General Industry Technologies (General Industry Technologies)

3B1. Fluidized-bed Advanced Cement Kiln System (FAKS)
Technology overview

1. Features
The Fluidized-bed Advanced Cement Kiln System (FAKS)
efficiently combusts low-grade coal, significantly reduces NOxemissions, and increases the heat recovery efficiency between
solids and gases discharged from the process. This isaccomplished by leveraging the advantages of the fluidized-bedprocess, including the combustion efficiency, and the heattransfer efficiency, as well as the particle dispersion andgranulation features. Thus, the ultimate objectives of thedevelopment are to contribute to global environmental
conservation, energy conservation, and to fulfill demands forvarious types and/or special grades of cement.

Cement clinker

Fluidized-bed kiln

Rotary kiln

Photo 1 Clinker produced from a fluidized-bed kiln

Photo 2 Overview of 200 t/day plant

2. Technology overview
A FAKS includes a fluidized-bed cement kiln and a two-stage

Gas

cooler. The fluidized-bed cement kiln reduces the raw material toa specific size for melting it into high quality cement, and thenC1 Cyclone

sinters the granulated raw material at a high temperature. The
two-stage cooler combines a quenching cooler and a packedbed, slow-cooling cooler to increase the heat recovery efficiency.

Raw material
For C2 Cyclone

The most important technology in the system is the granulation

Air lock damper

control technology. Compared with conventional technology,
which required that seed clinker be fed from the outside andwhich required control of the granulation process thus allowing
high temperature raw material powder to adhere and accumulate

FCK: Fluidized-bed
cement kiln

to the seed clinker, FAKS employs a first-ever "self-granulation"
process. Self-granulation is the process where granule cores are

Pulverized coal

generated through the agglomeration of a portion of the raw
material, allowing the rest of the raw material to adhere and grow

Air

PBC: Packed-bed
coolerFBQ

on the core in order to control granulation. The fluidized-bed
cement kiln furnace integrates two major technologies to control

FBQ: Fluidized-bed
quenching cooler

Airthe granulation: a raw material injection unit, and a bottom
classification and discharge unit.
Air

Cement clinker

Fig. 1 FAKS process flowchart

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Clean Coal Technologies in Japan

3. Demonstration site and application
1) 200 t/day demonstration[1] Demonstration site: Sumitomo Osaka
Cement Co., Ltd.’s Tochigi plant

Bottom classifying
discharge system

Fluidized-bed cement kiln
Raw material

Primaryclassifying[2] Application: Cement production[3] Development period: 1996 to 1998

Air2) 1,000 t/day demonstration

Secondaryclassifying[1] Demonstration site: Shandong Paoshan Biological Building

Raw material
injection device

Materials Co., Ltd.
Liubo City, Shandong Province, China

Special distributor
with center cone

[2] Application: Cement production[3] Development period: 2005 to 2007

AirClinker granules

Fig. 2 Key technology

4. Demonstration site and application
A basic study of FAKS technology was originally launched inoperation. The basic planning and design of a 200 t/d plant were1984 as a voluntary project by Kawasaki Heavy Industries, Ltd.

jointly undertaken by Japan Coal Energy Center, and the Japanand Sumitomo Osaka Cement Co., Ltd. Based on the results ofCement Association in April 1993. This scaled-up plant was put

the study, research and development have been sponsored since

into test operation for commercialization in February 1996. After1986 under a Coal Production and Utilization Technology

the system was validated, test operations of the plant werePromotion Grant project of the Agency of Natural Resources andcompleted at the end of December 1997.

Energy of the Ministry of International Trade and Industry. In June

NEDO also launched a joint demonstration project for a 1,000 t/dof 1989, a 20 t/d pilot plant was constructed jointly by Japan Coal

FAKS plant at Shandong Paoshan Biological Building Materials

Energy Center, Kawasaki Heavy Industries, Ltd., and SumitomoCo., Ltd. in Liubo City, Shandong Province, China, as an

Osaka Cement Co., Ltd. The plant was subsequently put into test

International Coal Utilization Project in May 2005.

5. Issues
A performance comparison between the conventional technology

below. FAKS is expected to be commercially adopted as anand FAKS for a 1,000 t/d commercial plant is shown in the Table 1

innovative, alternative cement production technology.

Table 1 Comparison of environmental improvement effects of FAKS vs. a rotary kiln type process at a 1,000 t/d plant
Discharge quantity
NO2
1% N and10% O2 content in coalEmissions Rotary Kiln & AQC FAKS
CO2*depends on electric power
and fuel consumption

Rotary Kiln & AQC

FAKS

Emissions (mg/Nm3)

708

476

Annual emissions(tons-NO2/year)

341

233

Emissions (g/Nm3)

245

220

Annual emissions(tons-CO2/year)

118x103108x103tons-clinker/day

1,000

1,000

tons-cement/day

1,050

1,050

330

330

3,411x103

2,993x103

Basis of calculation
Production capacity
Annual operating timedays/year

Heat consumption

kJ/ton-clinker

Power consumption

kWh/ton-clinker

2736

Exhaust gas specific quantity

Nm3/kg-clinker

1.46

1.49

Lower calorific value of coalkJ/kg-coal

25,11625,116*Based on IPCC: Guideline for National Greenhouse Gas Inventories, Reference Manual Carbon Emission Coefficient/Basic Calculation;Carbon Emission Factor = 26.8 tC/TJ, Fraction of Carbon Oxidized = 0.98

Reference1) Isao Hashimoto, Tatsuya Watanabe, et al., Development of Fluidized Bed Advanced Cement Kiln Process Technology (Part 9),
The 8th Coal Utilization Technology Congress, Japan, September 1998.
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