Conversion of electrostatic precipitators into bag filters Egypt

Conversion of electrostatic precipitators into bag filters Egypt 2017

Agenda 1. Advantages of Intensiv-Filter bag filters (versus Electrostatic Precipitators) 2. Benefits for ESP conversions & retrofits made by Intensiv-Filter 3. Different concepts of ESP conversions executed by Intensiv-Filter 4. Project Dyckerhoff Geseke, Germany 5. Project Dyckerhoff Deuna, Germany 6. Project Dyckerhoff Cementownia Nowiny (Poland) plant 7. Further IF References 8. Conclusion 2

Reasons for ESP conversions & retrofits ü Stricter emission regulation by the authorities ü Reduction of operation costs 3

Advantages of Intensiv-Filter bag filters versus ESP’s ü Lower and constant clean gas dust emissions for the use of secondary fuels as kiln fuel to meet strict authority regulations ü Performance is independent on changing parameters and operating modes (e. g. compound & direct mode) ü Precipitation is not pending on moisture and chemistry of the gas & dust ü No CO – trips for kiln dedusting applications ü Online Maintenance possibilities and easy maintenance access (from the clean gas side) 4

Benefits for ESP conversions & retrofits made by Intensiv-Filter ü Lower clean gas dust emissions (constantly) compared to the ESP operation ü Economical bag filter design using low pressure off-line cleaning in combination with bag length up to 8 m can be foreseen for ESP conversions, to decrease the pressure drop across the bag filter and to increase the bag life time. ü Re-use of existing casing, duct work, steel support, dust transport and auxiliary equipment ü 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 ü Low cost solution (compared to a new installation) 5

Different Concepts of ESP conversions executed by Intensiv-Filter Pre-assembled filter head modules on top of ESP casing 6

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Pre-assembled casing on top of existing ESP hoppers 7

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Design Data Process Kiln- / Raw Mill- bag-filter Original ESP Supplier KHD / Germany Gas Volume Design up to 240. 000 Am³/h Gas Temperature Range up to 230°C Intensiv-Filter Type IF JCC 85 / 13 - 7000 Eco Installed Filtration Area 4. 010 m² gross 3. 701 m² net (semi off-line cleaning) Filter Media Glass fibre with PTFE Membrane Shut down time for Retrofit 5 weeks 8

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Simplified flow sheet of Geseke’s new bag filter Legend for the flow sheet: 1. Rotary kiln with cyclone preheater 2. Raw meal grinding plant 3. Gas conditioning tower 4. Eco. Jet-Filter 5. Exhaust fan 9

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Disassembling of ESP Internals / Casing 16. 01. 2007 23. 01. 2007 10 10

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Disassembling of ESP Casing & parallel pre-assembling of Bag Filter 30. 01. 2007 25. 11. 2009, AUSTROPLAN 11

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant 06. 02. 2007 12

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Lifting of pre-assembled Bag Filter 09. 02. 2007 13

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Complete Installation incl. new ductwork, Fan & Silencer Today 14

Kiln bag-filter conversion at Dyckerhoff Zement’s Geseke plant Operation Data & Results Clean gas dust load less than 10 mg/Nm³ Differential pressure less than 10 h. Pa Cleaning pressure appr. 2, 5 bar Compressed air consumption less than 45 Nm³/h Cleaning Mode Semi Off-line 15

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Pre-assembled filter head modules inside ESP casing, upper casing used as penthouse 16

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Design Data Process Kiln- / Raw Mill - bag-filter Original ESP Supplier ELEX / Switzerland Gas Volume Design up to 550. 000 Am³/h Gas Temperature Range up to 240°C Intensiv-Filter Type IF PJM 136/6 + 119/12 - 8000 Installed Filtration Area 9. 274 m² gross Filter Media Glass fibre with PTFE Membrane Shut down time for Retrofit < 6 weeks Clean gas dust load 2 mg/Nm³ 17

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Process at Deuna 1. 2. 3. 4. Rotary kiln Cyclone preheater ESP for alkali bypass Gas conditioning tower 5. Raw meal grinding plant 1 + 2 6. Pro-Jet mega bag filter 7. Exhaust fan 8. Stack 18

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant ESP before conversion in 2007 19

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Start of work by the end of January 2008 20

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Frame installation for new bag filter head modules – February 2008 21

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant New filter head modules incl. sleeve bottom plate and 8 m bags 03. 2008 22

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Re-connected clean gas duct / installed compressed air vessels False air dilution system 10. 03. 2008 23

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Complete installation today 24

Kiln bag-filter conversion at Dyckerhoff Zement’s Deuna plant Filter Description Intensiv-Filter Type IF PJM 136/6 + 119/12 – 8000 Filter Media 8 m Glass fibre with PTFE Membrane Operation Data Gas Volume Design up to 550. 000 Am³/h Gas Temperature up to 240°C Clean gas load less than 2 mg/Nm³ Differential pressure 12 h. Pa Cleaning Mode Semi Off-line Cleaning pressure appr. 1, 3 up to 3, 4 bar 25

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant Simplified flowsheet of Cementownia Nowiny 26

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant Design Data Process Kiln- / Raw Mill - bag-filter Original ESP Supplier ELWO (Lurgi Type) / Poland Line 1 (2009) Line 2 (2005) Gas Volume Design 430. 000 Am³/h 270. 000 Am³/h Gas Temperature Range 120°C Intensiv-Filter Type IF JCN 85/ 18 – 8000 IF JCN 85/ 18 – 6000 Installed Filtration Area ~ 6. 400 m² ~ 4. 800 m² Filter Media Polyacrylnitril 120°C 27

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant Conversion Concept of Cementownia Nowiny 28

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant before retrofit 2005 after retrofit of Line 2 29

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant ESP top view before retrofit of Line 1 in 2009 30

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant New penthouse Inside new penthouse Safety air damper 31

Kiln bag filter conversion at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant Line 1 after successful commissioning in 2009 32

Operation Data & Results at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant Operation Data Line 1 (2009) Intensiv-Filter Type IF JCN 85/ 18 – 8000 Filter Media 8 m Polyester / Polyacrylnitril mix felt Gas Volume Design up to 430. 000 Am³/h with up to 40 g/Am³ dust load Gas Temperature up to 120°C Clean gas load less than 10 mg/Nm³ Differential pressure 7 h. Pa Cleaning Mode Off-line Cleaning pressure appr. 3, 0 bar Compressed air consumption 72 Nm³/h 33

Operation Data & Results at Dyckerhoff Cement’s Cementownia Nowiny (Poland) plant Operation Data Line (2009) Residual dust content old ESP Residual dust content new Intensiv-Filter bag filter 34

Further IF Retrofit References - 2002 Cementerie Aldo Barbetti Sp. A, Gubbio (PG), Kiln ESP - 2002 2 x Lafarge Ciment Medgidia Romania, Cement Mill ESP - 2003 Villiers au Bouin, Frankreich, Kiln ESP - 2007 2 x Lafarge Ciment Medgidia Romania, Cement Mill ESP - 2008 2 x Carpartcement, Bicaz, Romania, Kiln ESP - 2008 Carpartcement, Bicaz, Romania, Cement Mill ESP - 2009 National Cement, United Arab Emirates, Bypass ESP - 2011 Italcementi, Kiln ESP - 2012 4 x Arabian Cement, Cement Mill ESP - 2013 Manglam Cementg, Buthan, Cement Mill ESP - 2015 7 x Shree cement, India, Rawmeal Kiln ESP (6 x 588. 000 m³/h; 1 x 885. 000 m³/h) 35

Conclusion ü Low clean gas dust emissions (constant) independent from gas & dust properties ü 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 ü Re-use of existing equipment ü Reduced down time, enables the execution of the conversion during regular plant shutdown times ü Short amortisation time due to low invest cost solution 36

www. intensiv-filter. com 37