conversion of electrostatic precipitators into bag filters · operation data & results at...
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![Page 1: Conversion of electrostatic precipitators into bag filters · Operation Data & Results at Dyckerhoff Zement’s Cementownia Nowiny (Poland) plant 17 Operation Data Line 1 (2009) Intensiv-Filter](https://reader033.vdocument.in/reader033/viewer/2022042111/5e8bda29400ce1338f110ac0/html5/thumbnails/1.jpg)
Intensiv-Filter GmbH & Co. KG
7TH ARAB INTERNATIONAL CONFERENCE & EXHIBITION ON ENVIROMENTAL PROTECTION in CEMENT
10 - 12 NOVEMBER 2009 - BEIRUT, LIBANON
Conversion of electrostatic precipitators into bag filterspresented by Ralf Esser & Dr. Ahmed Yehia
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Agenda
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 Cementownia Nowiny (Poland) plant
6. Conclusion
7. Contact @ Intensiv-Filter
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7TH ARAB-INTERNATIONAL CEMENT
CONFERENCE AND EXHIBITION 2009 in BEIRUT
Intensiv-Filter_7th_arab_2009_rev1
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Company Profile of Intensiv-Filter GmbH & Co. KG
Intensiv-Filter Group www.intensiv-filter.com
Intensiv-Filter GmbH & Co. KG Velbert-Langenberg, Germany
Intensiv-Filter Austria GmbH Grieskirchen, Austria
Filtres Intensiv S.a.r.l. Bouzonville, France
Intensiv-Filter (UK) Ltd. West Midlands, Great Britain
Intensiv-Filter do Brasil Ltda. Sao Paulo, Brasil
Intensiv-Filter Korea Ltd. Seoul, Korea
Intensiv-Filter India Pvt. Ltd. Pune, India
Infastaub Bad Homburg, Germany Series-produced small filters < 30.000 m³/h
Solidux Billerbeck, Germany Solutions for sound insulation
More than 400 employees world wide - Group Turn over appr. 70 million Euros
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Reasons for ESP conversions & retrofits
Stricter emission regulation by the authorities
Use of secondary fuels
Reduction of operation costs
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Advantages of Intensiv-Filter bag filters versus ESP’s
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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 operatingmodes (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)
Intensiv-Filter_7th_arab_2009_rev1
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Benefits for ESP conversions & retrofits
made by Intensiv-Filter
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Lower clean gas dust emissions (constantly) compared to the ESP operation
Economical 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)
Intensiv-Filter_7th_arab_2009_rev1
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Different Concepts of ESP conversions
executed by Intensiv-Filter
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Pre-assembled filter head modules on top of ESP casing
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Different Concepts of ESP conversions
executed by Intensiv-Filter
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Pre-assembled casing on top of existing ESP hoppers
Intensiv-Filter_7th_arab_2009_rev1
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Pre-assembled filter head modules inside ESP casing, upper casing used as penthouse
Different Concepts of ESP conversions
executed by Intensiv-Filter
Intensiv-Filter_7th_arab_2009_rev1
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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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 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 Polyacrylnitril
Intensiv-Filter_7th_arab_2009_rev1
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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Simplified flowsheet of Cementownia Nowiny
Intensiv-Filter_7th_arab_2009_rev1
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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Conversion Concept of Cementownia Nowiny
Intensiv-Filter_7th_arab_2009_rev1
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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before retrofit 2005 after retrofit of Line 2
Intensiv-Filter_7th_arab_2009_rev1
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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ESP top view before retrofit retrofit of Line 1 in 2009
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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Inside new penthouse
Safety air damper
New penthouse
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Kiln bag filter conversion at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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Line 1 after successful commissioning in 2009
Intensiv-Filter_7th_arab_2009_rev1
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Operation Data & Results at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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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 40g/Am³ dust load
Gas Temperature up to 120°C
Clean gas load less than 10 mg/Nm³
Differential pressure 7 hPa
Cleaning Mode Off-line
Cleaning pressure appr. 3,0 bar
Compressed air consumption 72 Nm³/h
Intensiv-Filter_7th_arab_2009_rev1
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Operation Data & Results at Dyckerhoff Zement’s
Cementownia Nowiny (Poland) plant
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Operation Data Line (2009)
Residual dust content old ESP Residual dust content new
Intensiv-Filter bag filter
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Conclusion
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Low clean gas dust emissions (constant) 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
Intensiv-Filter_7th_arab_2009_rev1
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New Intensiv-Filter Bag Filter Generation –
ProJet mega© Volumes up to 2 Mio. m³/h
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Contact
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Intensiv-Filter GmbH & Co. KG
Voßkuhlstraße 63
42555 Velbert-Langenberg
Deutschland / Germany
Tel.: +49 2052 910-623
Fax: +49 2052 910-602
www.intensiv-filter.com
Intensiv-Filter GmbH & Co. KG
Dr.-Ing. Ahmed Yehia
P.O. Box 72256
Sharjah
United Arab Emirates
Tel.: +97 150 282 1500
www.intensiv-filter.com
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www.intensiv-filter.com
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