into bag filters presented by Jens Lange & Ralf Esser

Transcription

1 Intensiv-Filter GmbH & Co. KG 15 TH ARAB-INTERNATIONAL CEMENT CONFERENCE AND EXHIBITION NOVEMBER CAIRO, EGYPT Conversion of electrostatic precipitators into bag filters presented by Jens Lange & Ralf Esser 85 Years - Innovation is our Tradition

2 Agenda 15 TH ARAB-INTERNATIONAL CEMENT CONFERENCE AND EXHIBITION 2008 in Cairo 1. Company Profile of Intensiv-Filter GmbH & Co. KG 2. Advantages of Intensiv-Filter bag filters (versus Electrostatic Precipitators) 3. Benefits for ESP conversions & retrofits made by Intensiv-Filter 4. Different concepts of ESP conversions executed by Intensiv-Filter 5. Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant 6. Summary 7. Intensiv - Filter 3

3 Company Profile of Intensiv-Filter GmbH & Co. KG Intensiv-Filter at Velbert Langenberg, Germany Managing Board Dipl.-Kfm Thomas Blüggel Dipl.-Ing. Konrad Meyr Foundation 1922 by Theodor Hansen Dedusting Solutions for Cement Lime Gypsum Industries Food Industries Power Plants & Incinerators Steel -/ Iron- & Non Ferrous Industries Glass - & Chemical Industries 4

4 Company Profile of Intensiv-Filter GmbH & Co. KG Intensiv - Filter Group Intensiv-Filter GmbH & Co. KG Vlb Velbert, tgermany Intensiv-Filter Austria GmbH Grieskirchen, Austria Filtres Intensiv S.a.r.l. Bouzonville, France Intensiv-Filter (UK) Ltd. West Midlands, England Intensiv-Filter do Brasil Ltda. Sao Paulo, Brasil Intensiv-Filter Korea Ltd. Seoul, Korea Intensiv-Filter India Pvt. Ltd. Pune, India Subsidiary Companies Infastaub Bad Homburg, Germany Nuisance Filters < m³/h Solidux Billerbeck, Germany Noise Abatement Equipment 400 employees world wide Group Turn over appr. 70 million Euros 5

5 Reasons for ESP conversions & retrofits Stricter emission regulation by the authorities Use of secondary fuels Reduction of operation costs 6

6 Advantages of Intensiv-Filter bag filters (versus ESP s) Lower and constant clean gas dust emissions for the use of secondary fuels as kiln fuel to meet strict authority regulations Performance is independent on changing parameters and operating modes (e.g. compound & direct mode) Precipitation is not pending on moisture and chemistry of the gas & dust No CO trips for kiln dedusting applications Online Maintenance possibilities and easy maintenance access (from the clean gas side) 7

7 Benefits for ESP conversions & retrofits made by Intensiv-Filter Lower clean gas dust emissions (constantly) compared to the ESP operation Economical i l bag filter design using low pressure off-line cleaning in combination with bag length up to 8m can be foreseen for ESP conversions, to decrease the pressure drop across the bag filter and to increase the bag life time. Re-use of existing casing, duct work, steel support, dust transport and auxiliary equipment Flexible and pre-assembled filter head module design reduces down time to a minimum and enables the plant to execute ESP conversions during regular plant shutdown times Low cost solution (compared to a new installation) 8

8 Different Concepts of ESP conversions executed by Intensiv-Filter Pre- assembled filter head modules (incl. new penthouse) on top of ESP casing 9

9 Different Concepts of ESP conversions executed by Intensiv-Filter Pre-assembled casing on top of existing ESP hoppers 10

10 Different Concepts of ESP conversions executed by Intensiv-Filter Pre- assembled filter head modules inside ESP casing upper casing used as penthouse 11

11 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Design Data Process Original ESP Supplier Gas Volume Design Kiln- / Raw Mill - bag-filter ELEX / Switzerland up to Am³/h Gas Temperature Range up to 240 C Intensiv-Filter Type IF PJM 136/ / Installed Filtration Area Filter Media Shut down time for Retrofit Clean gas dust load m² gross Glass fibre with PTFE Membrane < 6 weeks 2 mg/nm³ 12

12 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Process at Deuna 1. Rotary kiln 5. Raw meal grinding plant Cyclone preheater 6. Pro-Jet mega bag filter 3. ESP for alkali bypass 7. Exhaust fan 4. Gas conditioning tower 8. Stack 13

13 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant ESP before conversion in

14 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Start of work by the end of January

15 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Removing of ESP internals and gas outlet hood February

16 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Frame installation for new bag filter head modules February

17 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Closed backside back wall / new clean gas duct installation

18 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant New filter head modules incl. sleeve bottom plate and 8m bags

19 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Re-connected clean gas duct / installed compressed air vessels False air dilution system

20 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant View inside penthouse 21

21 Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant Complete installation today 22

22 Operation Data & Results at Dyckerhoff Zement s Deuna plant Filter Description Intensiv-Filter Type IF PJM 136/ / Filter Media 8 m Glass fibre with PTFE Membrane Operation Data Gas Volume Design up to Am³/h Gas Temperature up to 240 C Clean gas load Differential pressure Cleaning Mode less than 2 mg/nm³ 12hPa Semi Off-line Cleaning pressure appr. 1,3 up to 3,4bar 23

23 Summary Low clean gas dust emissions (constantly) independent from gas & dust properties Economical bag filter design can be foreseen for ESP conversions, to decrease the pressure drop across the bag filter and to increase the bag life time Re-use of existing equipment Reduced down time, enables the execution of the conversion during regular plant shutdown times Short amortisation time due to low invest cost solution 24

24 New Filter Generation ProJet mega Volumes up to 2 Mio. M³/h 25

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