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Kiln exhaust
Gases
Introduction
Ambuja Cements and ACC which are controlled by Holcim
group operate various cement plants all over India. In last few
years monitoring of the manufacturing process impact on the
environment has become the top priority of the company. This
includes the control on Dust emission from various electrostatic
precipitators and process /nuisance bag filters.
• Holcim operates various plants all over the world and are having good
experience of pulse jet bag filter technology for Kiln/Raw Mill.
• Foot print area of pulse jet bag filter is less compared to Reverse Air Bag
House.
• Filter Media of P-84 and Glass with PTFE membrane are proven for very low
emission and this reasonable bag life.
• The plant is located in sensitive area near well known hill station Shimla,
hence the environmental norms needs to be strictly complied with.
Intensiv Filter has supplied Pulse Jet Bag Filter for Kiln/Raw Mill application
from 1994 with excellent results. (Polysius, Holcim, KHD, Equador, Cemex, Lafarge,
Rudniki, Tong-Yang Cements.Italcementi, Dyckerhof, Campulung etc)
Selection of P-84 filter media was due to its capability to Filter gases up to
200°C and to offer emission as low as 10mg/Nm3.(measured values for some
installations are as low as 2-3mg/Nm3)
In July 2007, Intensiv Filter India was entrusted the job and by January 2010
the Bag filter was installed and commissioned successfully.
The new filter is designed for a gas volume of 22, 00,000 m3/hr when raw mill
is down and for a gas volume of 14, 40,000 m3/hr when raw mill is working. This is
the largest bag filter for Kiln/Raw mill application in Cement Sector.
Due to large Volumes and space constraint Intensiv Filter proposed two
parallel streams with Twelve compartments each; Twenty Four totally with two
separate Induced Draught (ID) Fans.
Intensiv Filter offered low pressure cleaning technology with the patented
Jet Bus technology for cleaning. As Intensiv has considerable experience of using
filter bag as long as 8000 mm, it was decided to consider bag length of 8000 mm.
For ease of maintenance Pent House was installed on bag filter and chain
conveyors were considered below bag filter for collection of dust.
Erection Stage
General arrangement
As shown in the layout the dusty gas from Preheater will go either to the raw mill or
to the bag house after dilution. The exhaust gases from raw mill are passed through
the bag filter after set of cyclones and raw mill fan. Thus the bag filter will receive
the dusty gas either from Preheater directly or from Roller Mill. The clean gas from
the bag filter will be exhausted by two ID fans.
The process filter data and the technical specifications are given in Table 2.
Conclusion
The plant was commissioned without any problems in January 2010 and has bettered
the performance parameters stipulated by Ambuja Cements. The Filtering process is
optimized and client is very happy with new filter technology and dust free
environment. Needless to mention that this was the first and largest Pulse Jet Bag
Filter for Kiln/Raw Mill application.