Filter Technology: The Optimal Operating Point Has A Decisive Influence On Life Cycle Costs. Alois Hermandinger Scheuch GmbH Aurolzmünster / Austria

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1 Filter Technology: The Optimal Operating Point Has A Decisive Influence On Life Cycle Costs Alois Hermandinger Scheuch GmbH Aurolzmünster / Austria FICEM 2010

2 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

3 Ventilation and Environmental Technology for Industrial Production Processes Collection and extraction of dust and pollutants (primary and secondary) Filtration of dust and pollutants Separation and transportation of bulk materials Heat recovery and cooling FICEM

4 The Best Solution - Technically and Economically Highest Availability Low Life Cycle Costs Guaranteed Fulfillment of Performance FICEM

5 Scheuch GmbH Figures and Facts Ownership: Managing Directors: Turnover: Family Scheuch Herbert Kendler Stefan Scheuch more than 150 million EURO Export share: 80 % Expense R&D: Staff: 3 million EURO p.a. 640 (Company headquarters) 780 (Scheuch Group) FICEM

6 Five Main Business Segments Synergies Multi-sector know-how Wood Processing Industry Wood Based Panel Industry Metals Industry Industrial Minerals Energy Industry FICEM

Industrial Minerals Exhaust and dedusting

and the recycling of construction waste.

7 Industrial Minerals Exhaust and dedusting plants, process filters in the cement, limestone and gypsum industries, the basic material and building material industries, and the recycling of construction waste. Kiln / raw mill Clinker cooler Coal grinding plant FICEM

protection (up to 600.000Am³/h, up to 20.

8 SCHEUCH Products for the Cement Industry SCHEUCH dust loaden fans with wear protection (up to Am³/h, up to Pa) 3,000 fans per year Filter Technology 8

9 SCHEUCH Products for the Cement Industry SCHEUCH dust loaden fans with wear protection Filter Technology 9

10 SCHEUCH Products for the Cement Industry Screw conveyors Rotary valves Double pendulum flaps Filter Technology 10

11 SCHEUCH Products for the Cement Industry Air slides integrated in the filter hopper Filter Technology 11

Scheuch filters for cement industry Crude material transport and treatment Kiln and raw mill dedusting Chlorine bypass dedusting Heat exchanger Cement transport and dumping Clinker transport

12 Scheuch filters for cement industry Crude material transport and treatment Kiln and raw mill dedusting Chlorine bypass dedusting Heat exchanger Cement transport and dumping Clinker transport dumping Gas conditioning tower Transport and crude material dumping Coal mill drying Clinker cooler dedusting Cement mill and separating plants Packing plants and loading systems FICEM

13 Our Success Factors Complete Product and Service Program FICEM

14 Markets Installed Plants Worldwide FICEM

15 FICEM Scheuch customer reference list (extraction)

16 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

17 FICEM The advanced bag cleaning system

18 Comparison: Online / Offline Advantages Disadvantages Online Constant filter differential pressure Constant increasing filter differential pressure Early ageing of the filter bags High energy demand for the cleaning process Offline Small filter differential pressure (cleaning without counter-pressure) Small cleaning pressure and compressed air demand Higher lifetime of the filter bags High variation of the filter differential pressure Negative effects on primary processes and product quality FICEM

differential pressure (cleaning without counter-pressure) Small cleaning pressure and compressed air demand Higher lifetime of the

19 EMC = Advantages of Online + Offline Advantages Disadvantages Online Constant filter differential pressure Constant increasing filter differential pressure Early ageing of the filter bags High energy demand for the cleaning process Offline Small filter differential pressure (cleaning without counter-pressure) Small cleaning pressure and compressed air demand Higher lifetime of the filter bags High variation of the filter differential pressure Negative effects on auf primary processes and product quality FICEM

20 Filtration principle FICEM

21 EMC The decisive difference At the EMC cleaning process, the filter modules are cleaned alternately The module, which is taken out of the gas flow, is recovered in flowless condition Due to the patented, diametrically opposed switching, the active filter area stays constantly, and also the filter differential pressure remains roughly constant FICEM 2010 On 25th April 2003 under no. AT the Austrian patent, and on 6th Oktober 2004 under no. EP the European patent of Scheuch GmbH, Aurolzmünster/Österreich, for EMC cleaning technology was issued. 21

22 FICEM EMC: Patented switching sequence

23 Advantage: Patented switching sequence FICEM

24 Advantage: Cleaning under flowless condition Efficient and soft cleaning because there appears no counter-pressure Less cleaning pressure and small compressed air demand Decrease of the cleaning frequency Less mechanical load of the filter bags Noticeably longer bag lifetimes FICEM

25 FICEM Advantage: Cleaning under flowless condition

26 Advantage: Cleaning under flowless condition FICEM

27 Advantage: Cleaning under flowless condition FICEM

the bag lifetime up to 80 % less compressed-air

28 The Benefits of EMC: less investment costs plant availability > 99 % up to 30 % less fan power doubling of the bag lifetime up to 80 % less compressed-air consumption low outlet dust concentration lower sound emission FICEM

29 Story of sucess 2001: First EMC filter installed in Lafarge Mannersdorf / AT 2003: Scheuch got patent for EMC technology 2004: Saving effects practically confirmed 2005: EMC makes 8m filter bags possible (standard today) 2007: 100. EMC filter sold 2008: Research project for 10m bags finalized 2009: New controller: EMC-PulseMaster Today: more than 150 EMC filters with 60 Mio. Am³/h sold FICEM

30 EMC: Performance data and application Volumetric flow: Dust load: Cleaning pressure: Types of application: up to 3,000,000 Am³/h up to 1,000 g/m³ bar Kiln-/Raw mill Alkali Bypass Clinker cooler Cement mill Cement separator FICEM

31 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

32 Minimum Operating Costs due to optimum operating point and correct filter design 3 main cost factors: Fan power consumption Filter bag costs and Compressed air costs cost factors: behave interdependently dependently on filter pressure difference. FICEM

33 Minimum Operating Costs EMC Filter for kiln dedusting FICEM

34 FICEM Minimum Operating Costs EMC Filter for kiln dedusting

35 FICEM Minimum Operating Costs EMC Filter for kiln dedusting

36 FICEM Minimum Operating Costs EMC Filter for kiln dedusting

37 FICEM Minimum Operating Costs EMC Filter for kiln dedusting

38 FICEM Minimum Operating Costs EMC Filter for cement mill

39 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

40 Minimum investment costs depending on filter area loading A higher filter area loading enables: Reduction of the filtration area Less size of the filter unit Less secondary investment costs (filter support construction or building, form works) 100% 79% 66% [m/min] FICEM

41 Minimum investment costs depending on filter bag length Longer filter bags enables: Less size of the filter unit Less secondary investment costs (filter support construction or building, form works) 100% 83% 77% FICEM

grinding with high dust load and 6,000 mm filter bag length Technical

42 Benefit: Less investment costs Comparison 6 m 8 m Customer: HOLCIM Thi Vai / Vietnam Application: Dedusting of a vertical mill for cement grinding with high dust load and 6,000 mm filter bag length Technical data: V = 622,000 Am 3 /h m = 322 g/m³ m = 200 t/h Start-up: 2004 FICEM

43 Benefit: Less investment costs Comparison 6 m 8 m Filter length: 6 m FICEM

44 FICEM Benefit: Less investment costs Comparison 6 m 8 m

45 Benefit: Less investment costs Comparison 6 m 8 m Savings due to 8 m Technology FICEM

46 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

47 Lowest Life Cycle Costs The operating costs are many times higher than the investment costs Minimal operating costs Energy saving Utilization of process heat FICEM

48 Lowest Life Cycle Costs low operating costs high investment costs low investment costs high operating costs Optimum? 100% 79% 66% [m/min] FICEM

49 FICEM Lowest Life Cycle Costs Comparison kiln dedusting of Online and EMC

50 FICEM Life Cycle Costs Comparison mill dedusting of Online and EMC

51 Lowest Life Cycle Costs conclusio draw attention to the interactive design parameters of filter area loading and pressure drop, which have to be put into an optimum relationship when designing optimum adaptation to the correct operating point depending on the upstream process Filter system should able to follow the variable modes of operation and performs continuous adjustment to the optimum mode of operation. Scheuch therefore developed the EMC-PulseMaster controller specially for controlling the cleaning of process filters. FICEM

52 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

53 Cementos Apasco S.A. de CV Plant Macuspana FICEM

54 Macuspana dedusting plant Facts Customer: Cementos Apasco, S.A. de CV Macuspana, Mexico Application: Clinker grate cooler dedusting Design data: Kiln performance: 2600 t/d Air ratio at normal operation conditions: 310, C Air ratio at upset operation conditions: 310,000 temporary up to 525 C Raw gas dust load: max. 20 g/nm³ Clean gas dust content: max. 10 mg/nm³ Special conditions: Kiln stoppage time: 16 days (for dismantling of existing electrostatic precipitator including ducts and fan, erection and start-up of the new Bag filter dedusting plant) Tight local installation situation Small area for the pre-assembling works FICEM

of dismantling the electro filter The EMC filter is

55 Macuspana dedusting plant Erection (1) Pre-assembling of the tube bundle for the air/air-heat exchanger Start of dismantling the electro filter The EMC filter is mounted with pre-assembled construction units FICEM

56 Macuspana dedusting plant Erection (2) Erection of the filter penthouse Installation of the Scheuch fan FICEM

57 FICEM Macuspana dedusting plant Video

58 Macuspana dedusting plant Comparison actual / nominal values Air/air-Heat exchanger Design Measures after normal operation two months operation Air volume cooler inlet 310, ,335 Am³/h* Gas temperature inlet C Air volume cooler outlet 195, ,000 Am³/h* Gas temperature outlet C Power consumption of the axial fans kw Loss of pressure mbar EMC-Filter Design Measures after normal operation two months operation Air volume filter inlet 195, ,700 Am³/h Gas temperature filter outlet C Filter surface load m³/m²min Loss of pressure over the whole filter 10 3,5 mbar Compressed air consumption Nm³/h Cleaning pressure Bar Clean gas dust content 10 < 2.0 mg/nm³ FICEM

59 Content of presentation Scheuch Company Profile EMC The Benchmark EMC Minimum Operating Costs EMC Minimum Investment Costs EMC Lowest Life Cycle Costs Case Study Macuspana Other References in South-America FICEM

60 Holcim Ecuador S.A. Plant Cerro Blanco Customer: Holcim Group Support, Inc. US-Miami for Holcim Ecuador S.A. Plant Cerro Blanco EC-Guyaquil Application: Clinker cooler dedusting Line Air ratio: 2 x 310,500 Am 3 /h Start-up: FICEM

61 Cemex Colombia S.A. Plant Caracolito Customer: Cemex Colombia S.A. Plant Caracolito CO-Ibagué Application: Retrofit electrostatic precipitator to EMC-bag filter Air ratio: 250,000 Am 3 /h Start-up: 2006 FICEM

62 Cementos Catatumbo C.A. Customer: Cementos Catatumbo C.A. VEN-Maracaibo Application: Clinker cooler dedusting Air ratio: 296,311 Am 3 /h Start-up: 2008 FICEM

63 Cementos Bío Bío S.A. Customer: Loesche GmbH, Germany for Cementos Bío Bío S.A. CHILE-Curico Application: Cement mill dedusting Air ratio: 360,000 Am 3 /h Start-up: 2007 FICEM

64 Further Scheuch filter plants in Latin America CUSTOMER END USER APPLICATION CAPACITY Am³/h DELIVERY Claudius Peters AG, Germany Acominas, Brasil Hard coal grinding mill 165, Loesche GmbH, Germany San Antonio, Chile Cement mill dedusting 199, Christian Pfeiffer GmbH, Austria San Juan, Chile Cement mill dedusting 1 x 35,000 1 x 10, Christian Pfeiffer GmbH, Germany Riobamba, Ecuador 1 x 73,500 Cement mill dedusting 1 x 41,500 Separator and dryer 1 x 30, Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Kiln dedusting 45, Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Lime dedusting 45, Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Kiln dedusting 75, Grenzebach-BSH GmbH, Germany Queretaro, Mexico Gypsum mill calcination 95, Grenzebach-BSH GmbH, Germany Tecoman, Mexico Gypsum mill calcination 96, Christian Pfeiffer GmbH, Austria Cementos Panama (Cemex) Coal grinding plant 100, Polysius AG, Germany Panarol, Panama Cement mill dedusting 275, Holcim Miami, USA Cementos de El Salvador Kiln-/Raw mill dedusting Clinker cooler dedusting 1 x 150,000 1 x 295,000 Polysius AG, Germany Urumincom, Uruguay Petrol coke grinding plant 32, Inteco GmbH, Austria Minera Loma, Venezuela Kiln dedusting 110, Mannesmann Demag, Germany Minera Loma, Venezuela Kiln dedusting 250, Polysius AG, Germany Lomared, Venezuela Nickel ore processing plant 50, Holcim Miami, USA Holcim Venezuela C.A. Kiln dedusting, ESP Retrofit 493, Ehdasse Sanat, Iran Cerro Azul Cement, Venezuela Cement mill dedusting 2 x 470, Ehdasse Sanat, Iran Cerro Azul Cement, Venezuela Kiln-/Raw mill dedusting Clinker cooler dedusting 1 x 647,000 1 x 390,000 Cementos Argos Rioclaro Plant Colombia Coal grinding plant FICEM

65 Thank you for your attention! FICEM 2010

Conversion of electrostatic precipitators into bag filters

Intensiv-Filter GmbH & Co. KG 7 TH ARAB INTERNATIONAL CONFERENCE & EXHIBITION ON ENVIROMENTAL PROTECTION in CEMENT 10-12 NOVEMBER 2009 - BEIRUT, LIBANON Conversion of electrostatic precipitators into bag