Filter Technology: The Optimal Operating Point Has A ...€¦ · dust and pollutants (primary ... Wood Processing Industry Wood Based Panel Industry. Metals Industry. Industrial Minerals

FICEM 2010

Filter Technology:The Optimal Operating Point Has A

Decisive Influence On Life Cycle CostsAlois Hermandinger

Scheuch GmbHAurolzmünster / Austria

FICEM 2010

Content of presentation

Scheuch Company Profile

Case Study Macuspana

Other References in South-America

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EMC – The Benchmark

EMC – Minimum Operating Costs

EMC – Lowest Life Cycle Costs

EMC – Minimum Investment Costs

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Collection and extraction of dust and pollutants (primary and secondary)

Ventilation and Environmental Technologyfor Industrial Production Processes

Filtration of dust and pollutants

Separation and transportation of bulk materials

Heat recovery and cooling

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The Best Solution -Technically and Economically

Highest Availability Low Life Cycle Costs Guaranteed Fulfillment of Performance

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Ownership: Family Scheuch

Managing Herbert KendlerDirectors: Stefan Scheuch

Turnover: more than 150 million EURO

Export share: 80 %

Expense R&D: 3 million EURO p.a.

Staff: 640 (Company headquarters)780 (Scheuch Group)

Scheuch GmbHFigures and Facts

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Wood Processing Industry

Wood Based Panel Industry

Metals Industry

Industrial Minerals

Energy Industry

Five Main Business SegmentsSynergies – Multi-sector know-how

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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.

Coal grinding plantKiln / raw mill Clinker cooler

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Filter Technology

SCHEUCH Products for the Cement Industry

3,000 fans per year

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SCHEUCH dust loaden fans with wear protection

(up to 600.000Am³/h, up to 20.000Pa)

Filter Technology 9


SCHEUCH dust loaden fans with wear protection

Filter Technology

Screw conveyors

Rotary valves

Double pendulum flaps

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Filter Technology

Air slides integrated in the filter hopper

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Scheuch filters for cement industry

Crude material transport and treatmentCrude material transport and treatment

Transport and crude material dumpingTransport and crude material dumping

Kiln and raw mill dedustingKiln and raw mill dedusting

Gas conditioning towerGas conditioning tower

Chlorine bypass dedustingChlorine bypass dedusting

Coal mill dryingCoal mill drying

Heat exchangerHeat exchanger

Clinker cooler dedustingClinker cooler dedusting

Clinker transport – dumpingClinker transport – dumping

Cement mill and separating plantsCement mill and separating plants

Packing plants and loading systemsPacking plants and loading systems

Cement transport and dumpingCement transport and dumping

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Our Success FactorsComplete Product and Service Program

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MarketsInstalled Plants Worldwide

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Scheuch customer reference list (extraction)

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The advanced bag cleaning system

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Comparison: Online / Offline

Online OfflineAdvantages • Constant filter differential

pressure• Small filter differential pressure

(cleaning without counter-pressure)• Small cleaning pressure and

compressed air demand• Higher lifetime of the filter bags

Disadvantages • Constant increasing filter differential pressure

• Early ageing of the filter bags

• High energy demand for the cleaning process

• High variation of the filter differential pressure

• Negative effects on primary processes and product quality

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Online OfflineAdvantages • Constant filter differential

pressure• Small filter differential pressure

(cleaning without counter-pressure)• Small cleaning pressure and

compressed air demand• Higher lifetime of the filter bags

Disadvantages • Constant increasing filter differential pressure

• Early ageing of the filter bags

• High energy demand for the cleaning process

• High variation of the filter differential pressure

• Negative effects on auf primary processes and product quality

EMC = Advantages of Online + Offline

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Filtration principle

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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

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On 25th April 2003 under no. AT 410403 the Austrian patent, and on 6th Oktober 2004 under no. EP 1404431 the European patent of Scheuch GmbH, Aurolzmünster/Österreich, for EMC cleaning technology was issued.

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EMC: Patented switching sequence

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Advantage: Patented switching sequence

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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

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The Benefits of EMC:

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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

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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

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EMC: Performance data and application

Volumetric flow: up to 3,000,000 Am³/h Dust load: up to 1,000 g/m³ Cleaning pressure: 0.8 – 3 bar Types of application:

Kiln-/Raw millAlkali Bypass Clinker coolerCement millCement separator

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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.

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Minimum Operating CostsEMC Filter for kiln dedusting

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Minimum Operating CostsEMC Filter for cement mill

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Minimum investment costsdepending 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)

[m/min]

100%

79%

66%

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Minimum investment costsdepending 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%

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Customer:HOLCIMThi 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 Am3/hm = 322 g/m³m = 200 t/h

Start-up:2004

Benefit: Less investment costsComparison 6 m 8 m

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Filter length: 6 m

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Savings

due to 8 m

Technology


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Lowest Life Cycle Costs

Minimal operating costs Energy saving Utilization of process heat

The operating costs aremany times higherthan the investmentcosts

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low operating costs high investment costs low investment costs high operating costs

Lowest Life Cycle Costs

Optimum ?

[m/min]

100%

79%

66%

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Lowest Life Cycle CostsComparison kiln dedusting of Online and EMC

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Life Cycle CostsComparison mill dedusting of Online and EMC

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Lowest Life Cycle Costsconclusio

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.

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Cementos Apasco S.A. de CVPlant „Macuspana“

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Macuspana dedusting plantFacts

Customer: Cementos Apasco, S.A. de CVMacuspana, Mexico

Application: Clinker grate cooler dedusting

Design data: Kiln performance: 2600 t/d Air ratio at normal operation conditions: 310,000 Am³/h @ 350 °C Air ratio at upset operation conditions: 310,000 Am³/h @ 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

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Macuspana dedusting plantErection (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

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Macuspana dedusting plantErection (2)

Erection of the filter penthouse Installation of the Scheuch fan

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Macuspana dedusting plantVideo

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Macuspana dedusting plantComparison actual / nominal values

Air/air-Heat exchanger Designnormal operation

Measures aftertwo months operation

Air volume cooler inlet 310,000 368,335 Am³/h*Gas temperature inlet 350 377 °CAir volume cooler outlet 195,000 240,000 Am³/h*Gas temperature outlet 120 145 °CPower consumption of the axial fans 34.0 17.8 kWLoss of pressure 2.5 1.0 mbar

EMC-Filter Designnormal operation

Measures aftertwo months operation

Air volume filter inlet 195,000 217,700 Am³/hGas temperature filter outlet 120 110 °CFilter surface load 0.82 0.916 m³/m²minLoss of pressure over the whole filter 10 3,5 mbarCompressed air consumption 60 7.0 Nm³/hCleaning pressure 0.8 – 3.0 1.9 BarClean gas dust content 10 < 2.0 mg/Nm³

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Holcim Ecuador S.A.Plant „Cerro Blanco“

Customer:Holcim Group Support, Inc.US-Miamifor Holcim Ecuador S.A.Plant „Cerro Blanco“EC-Guyaquil

Application:Clinker cooler dedustingLine 1 + 2

Air ratio:2 x 310,500 Am3/h

Start-up:2007 + 2010

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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 Am3/h

Start-up:2006

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Cementos Catatumbo C.A.

Customer:Cementos Catatumbo C.A.VEN-Maracaibo

Application:Clinker cooler dedusting


Start-up:2008

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Cementos Bío Bío S.A.

Customer:Loesche GmbH, Germanyfor Cementos Bío Bío S.A.CHILE-Curico

Application:Cement mill dedusting


Start-up:2007

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CUSTOMER END USER APPLICATION CAPACITY Am³/h DELIVERYClaudius Peters AG, Germany Acominas, Brasil Hard coal grinding mill 165,000 1999Loesche GmbH, Germany San Antonio, Chile Cement mill dedusting 199,749 2007

Christian Pfeiffer GmbH, Austria San Juan, Chile Cement mill dedusting 1 x 35,0001 x 10,000 2008

Christian Pfeiffer GmbH, Germany Riobamba, Ecuador Cement mill dedustingSeparator and dryer

1 x 73,5001 x 41,5001 x 30,000

2003

Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Kiln dedusting 45,000 2004Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Lime dedusting 45,000 2007Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Kiln dedusting 75,500 2009Grenzebach-BSH GmbH, Germany Queretaro, Mexico Gypsum mill calcination 95,000 2002

Grenzebach-BSH GmbH, Germany Tecoman, Mexico Gypsum mill calcination 96,500 2006

Christian Pfeiffer GmbH, Austria Cementos Panama (Cemex) Coal grinding plant 100,000 2008

Polysius AG, Germany Panarol, Panama Cement mill dedusting 275,000 2008

Holcim Miami, USA Cementos de El Salvador Kiln-/Raw mill dedustingClinker cooler dedusting

1 x 150,0001 x 295,000 2008

Polysius AG, Germany Urumincom, Uruguay Petrol coke grinding plant 32,000 2002

Inteco GmbH, Austria Minera Loma, Venezuela Kiln dedusting 110,000 1999Mannesmann Demag, Germany Minera Loma, Venezuela Kiln dedusting 250,000 1999Polysius AG, Germany Lomared, Venezuela Nickel ore processing plant 50,000 1999Holcim Miami, USA Holcim Venezuela C.A. Kiln dedusting, ESP Retrofit 493,000 2007Ehdasse Sanat, Iran Cerro Azul Cement, Venezuela Cement mill dedusting 2 x 470,000 2007

Ehdasse Sanat, Iran Cerro Azul Cement, Venezuela Kiln-/Raw mill dedustingClinker cooler dedusting

1 x 647,0001 x 390,000 2009

Cementos Argos Rioclaro Plant Colombia Coal grinding plant 30.500 2010

Further Scheuch filter plants in Latin America

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Thank you for yourattention!

Filter Technology: The Optimal Operating Point Has A ...€¦ · dust and pollutants (primary ... Wood Processing Industry Wood Based Panel Industry. Metals Industry. Industrial Minerals

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