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Lafarge Holcim Filters

A new exceptional achievement by Redecam, the replacement of two existing ESPs with two new high performance bag filters, In Lafarge Holcim, South Africa.

“Even if a hard lockdown was determined during the middle of the kiln outage period, we have been able to successfully started up our full Turn-Key (civil, mechanical, electrical) project in LafargeHolcim South Africa Lichtenburg plant. We converted the existing Kiln and Raw Mill n.2 ESPs into Bag Filters, with new outlet and two new exhaust fans. A special thanks goes to all Redecam project and site team that made possible this outstanding job and to well achieve the contractual performances!”

#southafrica #plant #project #filter #team

Read the article and watch the video here

Ready-to-go baghouses

Ready-to-go baghouses

The fast pace of today’s cement markets requires cement companies to deploy production assets such as grinding facilities at short notice to gain the edge on their competitors. The support of equipment manufacturers to deliver modular ‘ready-to-install’ production systems is key in the success of cement producers when entering new markets.
~ by Redecam SpA, Italy

Rapid deployment of production assets is essential in successfully entering new markets. One way of optimising the response to new opportunities in today’s fast-changing cement markets are the recently-developed small grinding stations. Compact and efficient they can be put into operation in just a few weeks.

From modular grinding to modular baghouses

To support such operational flexibility, Redecam Group SpA has designed a
modular baghouse that is easy and fast to install. It has the same features and high performance of the conventional units that have established this Italian company’s legacy of high performance for the last 35 years.

The complete unit of the modular baghouse is pre-assembled in the factory, thus reducing installation time on site by 80 per cent and eliminating any quality issues that can sometimes arise with field assembly. The design allows each fully preassembled module to fit into a standard 40ft shipping container. All modules have bolted flanges that enable fast and accurate assembly into the full unit at site.

The clean air plenum modules are also prepared with a high level of pre-assembly with compressed air tank receivers and solenoid valves already installed.

Following the building of modular grinding units, Redecam has developed a modular baghouse that is easy to deploy.

The supporting structure for the unit is incorporated within the hopper modules in the workshop to lower shipping costs. The structure requires only minimal bolting work to attach to the completed assembly.

Despite the smart design, which minimises steelwork, the baghouse built with the modular concept handles high gas flows while achieving high performance.

The design accommodates bags up to 8m in length. Emission levels are guaranteed to be lower than 5mg/Nm3. To illustrate the unit’s high performance, it is possible to treat gas flow rates up to 235,000m3/h, using only 7m bags, with the baghouse pre-assembled and shipped using only 15 standard 40ft containers.

Costa Rican case study

As an example of this innovative, high-performance system, Redecam recently supplied a modular baghouse to a Costa Rican cement plant, owned by Cementos Fortaleza and Plycem. The company’s client, Gebr Pfeiffer Inc, installed its ready-to-grind system with a VRM 2500 C-4 vertical mill and the Redecam Modular Baghouse with a technical and performance specification as shown in Table 1.

This modular baghouse was designed with the ‘double approach’ system recently developed by Redecam. This system allows the gas to be distributed through both the bottom and the side of the bags. This ensures 100 per cent of the bags’ filtration surface is used in the filtration process, avoiding the underused surfaces common in standard designs. Therefore, the DP across the filter is reduced and the number of cleaning cycles is minimised. As a result, the lifespan of the bags increases drastically. For example, the average lifetime of these bags is around 100,000 cleaning cycles. A typical baghouse works at a rate of five cycles/h and as a result bag life is around 2.5 years. Assuming the new concept baghouse achieves the same performance at a rate of two cycles/h, the bag lifetime is more than doubled. Moreover, this also results in a large reduction in consumption of compressed air, which saves both money and compressed air capacity. The degree of savings in terms of compressed air depends on power costs per kiloWatt, which varies from plant to plant. However, tests run by Redecam show positive results with power cost savings of up to 30 per cent when compared to a traditional baghouse. Therefore, the total savings in operating costs is substantial.

The baghouse provides an easy-to-install solution to control dust from modular grinding units.

Project timeline

In the design phase, the efficient concept of the modular baghouse allows Redecam to finish detailed drawings within just a few weeks of the project start. While the design is somewhat standardised, Redecam engineers are able to quickly tailor the baghouse to meet the specific process requirements of the site. In this way, the baghouse is optimally sized while achieving the extremely low emissions standards typically required.

Once the detailed design is finished, Redecam’s worldwide procurement
expertise is used to quickly obtain the bestquality materials at the optimum price.

Since the design already takes into account the maximum sizes allowed in shipping containers, the baghouse supplier has the flexibility to take advantage of material pricing opportunities all over the world.

The company’s design also allows fast and efficient field erection. All preassembled pieces are equipped with a special sealing gasket that allows the bolted flanges to be mated together quickly and accurately. The gasket means site welds are not necessary, saving considerable time and expense for field erection.

Total assembly time in almost all cases is only two weeks – significantly
shorter when compared with the up to six-week assembly and start-up time of a conventional baghouse. Commissioning also takes only two days. Therefore, the following construction schedule is typical:

• unloading modules from containers – one day
• lifting of modules into place and bolting – five days
• installation of bags and cages – three days
• connection of compressed air pipes – two days
• electrical connections – three days
• cold test, commissioning and start-up – two days.

Flexible baghouse deployment To meet the needs of a rapidly-changing
market, cement producers require easyto- install baghouse solutions to enable an effective deployment of production assets. The Redecam modular baghouse is a perfect fit for the new modular grinding
stations. This combination gives cement producers a flexible, fast and economical tool to manage their grinding needs across their fleet of production facilities.

Redecam and GC Top Technologies start South Africa cooperation

Redecam Group S.p.A. and GC Top Technologies announce the starting of their cooperation agreement for South African market.

The new partnership will extend to all applications of the Redecam portfolio (Bag Filters, ESPs, Conditioning Towers, Heat Exchangers, Waste Heat Recovery, DeSOx and DeNOx technologies) and will cover the South African region. Redecam Group welcomes Mr. Giovanni Carnelli, founder of GC Top Technologies and his team for this new journey together.

Niccolò Griffini, Sales and Business Development Director at Redecam Group: “South Africa is one of the countries where we planned to increase our presence, being the African hub of industrial equipment technology providers and having also an historical basic industry large footprint. We strongly believe that the background of GC Top Technologies team, which has a wide synergic networking with some of the most knowledgeable experts in the industry and a first-hand relation with some of the most accredited international equipment suppliers, will increase our market share, giving to the African customers the possibility to benefit from tailor-made solutions that are part of Redecam DNA”.

Giovanni Carnelli, founder of GC Top technologies: “We are very happy that we have signed the cooperation agreement with Redecam, a trusted partner with an outstanding technology portfolio in the Flue Gas Treatment field. Top Technologies has a strict policy in terms of selection of the Partner Companies, to ensure that the quality of products is always rated world class, and Redecam Group completely fulfils it. We both look forward to work together for mutual success by providing customers with even better solutions than ever before.”

Redecam Group is an Italian leader in the air pollution control industry with innovative and tailor-made solutions executed around the world. Headquartered in Milan, Italy, Redecam delivers engineering, equipment and service flue gas treatment solutions to the entire basic production industry with references in 6 continents. For more information, please visit the Redecam website www.redecam.com

GC Top Technologies connects a group of reliable international suppliers with the South African Customers in need of improved efficiency, enhanced productivity and environmental friendly solutions. These companies are able to provide specifically tailored, dedicated solutions to resolve the daily problems of our customers. For more information, please visit the GC Top Technologies website www.gc-toptechnologies.com

Scrubbing Technology

Scrubbing technology
When it comes to emission-reduction technology, how does a plant know it is selecting the right technology for the job? Redecam believes its DeSOx technology, known as RDS, provides the ideal solution for both the cement and the lime industry. Here it directly compares RDS with wet flue gas desulphurization (FGD). 

Environmental preservation is a global need, involving all countries in the world and all areas of human activity, from agriculture to industry. In terms of industry, there is a tendency to align emission requirements with the best performance achievable by technology. Therefore, it is vital that those companies operating in the industrial sector have as broad a spectrum of possibilities available to them when selecting the best emission-reduction technology for their plants. Several factors have to be taken into account during this selection process, including the possibility of achieving the required emission targets, the technology reliability, the interaction with other gas treatment technologies, technology flexibility (turn-down), byproducts recovery, the specific skills required to operate and maintain the emission reduction plant, as well as the operating and investment cost.

Building on circulating fluidised bed technology
One technology that meets many of these factors is the circulating fluidized bed (CFB) semi-dry reactor from Redecam, known as RDS. CFB scrubbing technology is based on the fluidized bed principle. Hydrated lime and water are injected into a reactor where the powder is suspended and mixed using a high-velocity stream of flue gas entering  from the bottom. The intense mixing between the acid gas, solid reagents and water, and the presence, for a given time, of a liquid phase over the reagent particles, enables SO2 reduction efficiencies of over 95 per cent. The system is also active for the removal of hydrogen chloride (HCl), hydrogen fluoride (HF), mercury and other trace metals, without using reagents other than lime. Once mixed and reacted, the gas flow carries the solids out through the top of the reactor into a fabric filter, which separates the dust from the flue gas. The dust is then recycled back into the  reactor with a recirculation rate in the hundreds with respect to the fresh lime injected, after which the clean flue gas is conveyed to the stack. Since water is injected directly into the reactor, hydrated lime is fed in powder form and no slurry handling is necessary.

Moreover, water is totally evaporated in the reactor, avoiding the need for wastewater treatment. As the final product evacuated from the filter is totally dry, drying equipment is also unnecessary.

The fabric filter is properly designed and sized for this application, due to the high dust load coming from recirculation and the relatively-low operating temperatures (usually 20°C above the dew point). Thanks to the bed mixing, the lime conversion rate is high, even when elevated acid gas reductions are required, so allowing a Ca:S molar ratio of around 1.5 or less.

The final byproduct, even if not usable to replace gypsum as a cement regulator, has a wide range of applications, including as a fertiliser in agriculture, as a building material (additive for the production of screed and mortar, additive for production of building bricks and lime sand brick, fibreboards, etc), in the production of binders, in road construction, in the field of surface and underground mining, for the conditioning of sewage sludge.

Potential benefits to the cement industry
This technology is already widely used in the power and waste-to-energy (WTE) industry, while in other sectors, such as cement and lime, it is not yet present, mainly because the kilns does not usually require DeSOx installations due to their natural scrubbing effect. However, there are several cases where the characteristics of the process, whether for raw materials or fuels, do require DeSOx treatment. Here, RDS technology becomes a competitive option, particularly where high reduction is necessary or where the operating cost of a dry sorbent injection (DSI) technology is not sustainable.

Cost comparison
Tables 1 and 2 compare RDS and wet FGD for a 3000tpd cement kiln where SO2 emissions need to be reduced by 95 per cent.

The operating cost was evaluated starting from a hydrated lime cost of €83/t and a power cost of €41.40/MWh. A higher power cost would further penalise the wet FGD technology, which is the most energy-demanding in this comparison. From a technical point of view, it should be noted that while the byproduct coming from the wet FGD is recoverable in cement grinding in the place of gypsum (the replacement percentage is very low), the byproduct of the RDS can be mixed with the kiln dust and recovered into the raw meal.

The operating cost of the two options is very similar. The higher reagent cost of the RDS is balanced by the higher power and maintenance cost of the wet FGD.

Of course, when the size of the plant decreases, the comparison goes in favour of the RDS, because maintenance cost is not linearly decreasing with plant capacity.

In terms of investment cost, RDS requires around half of the investment typically required for a wet FGD installation. Moreover, its footprint consumption is lower in comparison with a wet FGD as there are no sections for slurry treatment and byproduct drying. In addition,  it does not require specific skills or additional personnel for operation and maintenance.

Finally, due to the necessity to have a specific filter design, RDS is a very interesting option when it is required to improve both SO2 (or heavy metals, HCl, etc) and dust emissions.

A typical application could be when the existing dedusting is carried out by an ESP or old baghouse that has to be revamped.

In this situation, an RDS installed downstream, or in the place of the existing equipment, can solve both gaseous and powder emission issues without requiring heavy investment or big layout modifications. 

Read the article here

Putting the lid on emissions

In many cases the latest round of stringent emission norms requires an upgrade of emissions control technology in which mechanical filtration is able to achieve a higher performance, usually lower than 10mg/Nm3 of dust at the stack. As a result, Redecam has been part of several projects converting electrostatic precipitators (ESPs) into hybrid or bag filters. One such market is India, where many cement plants require such upgrades, leading to the study of specific designs on a case-by-case basis. Often computational fluid dynamics (CFD) are a key tool in optimising gas distribution into existing ESP casings.

Expanding business in India
India has seen a boom in infrastructure and housing projects in recent years and cement producers have expanded their production base accordingly. This drive continues and the country aims to achieve a staggering 600Mta of clinker production by 2022. To improve its service to this key market, Italy-based Redecam Group SpA created with its joint-venture partner Isgec Heavy Industries, a new company, earlier this year a new company with Isgec Heavy Industries called ISGEC Redecam Enviro Solutions Pvt Ltd, which is headquartered in Noida, Delhi. With this joint venture, both partners are geared up to be a complete provider for flue gas treatment systems for the cement, power and metals industries.

“Air pollution is one of the major environmental issues facing India and the rest of Asia today. It is a serious problem with the major sources being industrial emission and biomass burning, vehicle emission and traffic congestion,” said Niccolò Griffini and Suman Jain, board members at Isgec Redecam Enviro Solutions. They added: “In an effort to reduce the country’s air pollution and to help companies to grow with a sustainable development approach, Redecam and Isgec aim to build a strong business in Asia, drawing upon Redecam’s global expertise combined with the skills and knowledge of Isgec, a strong partner headquartered in India.”

ESP-to-baghouse conversion
Case study: Cemex’s Caracolito plant, Colombia

In this case study Cemex required the reuse of the ESP casing to reduce costs of the ESP-to-baghouse conversion project at its Caracolito plant in Colombia. Redecam saw this as an opportunity to provide the customer with a highly-effective yet lowercapex solution.

The existing ESP with capacity of 800,000Am3 /h was transformed into a Redecam DPT model bag filter, including a Simple Pressure System (SPS). The SPS bag fixation system guarantees that the tightness of the casing between the dusty and clean sides is 100 per cent effective. It prevents dust leakage at weak points as a result of two main design features:

1. Individually-punched and -drawn tube sheet holes increase the contact surface area of the bag against the tube sheet by extending and contouring the tube sheet opening. Therefore, the surface contact is not limited to the pure thickness of the plate but is extended to the entire internal surface of the drawn hole.

2. The pressure of the bag collar on the drawn edge of the tube sheet hole is increased, firmly securing the bag’s cloth. The collar is also designed to take advantage of the temperature. The tube sheet is carbon steel and the collar is aluminium, resulting in higher useful pressure being generated on the sealing surface. The filter bag cages were designed to maximise the lifespan of the filter bags. It is crucial that the filter bag fits perfectly around the support cage, because if the bag is too big, it will rub on the cage during cleaning, causing premature wear and tear. The bag cages for this customer were made of carbon steel with cataphoresis painting and were tailored to fit with fibreglass bags with PTFE membrane stitching. The baghouse was engineered to include a jet-pulse Bi-Jet bag cleaning system. This system has a dual venturi arrangement, minimising the dispersion of compressed air during the injection phase and thus increasing the volume of air forced into the bag. In turn, this reduces the quantity of air needed to pulsate the bag and achieves a higher flow velocity than in systems equipped with one venturi. The dual venturi also ensures more accurate air pulses and therefore, less wear on the bags due to misaligned equipment.

Redecam supplied Cemex Caracolito with an online model, which provides less stress on mechanical devices (since there are no compartments to be closed for cleaning operations) and consequently reduces power consumption. The maintenance of a steady pressure drop value across the filter further contributes to reduced mechanical stress on the bag and eliminates a peak of negative pressure over the exhaust fan, which in turn lowers power demand. Redecam also provided and installed the new dust transport and compressed air systems, and revamped the ID fan.

Reducing capex
In addition to transforming the ESP into a baghouse, Redecam designed other parts of the system to reduce costs. The ID fan downstream of the baghouse needed a new impeller, due to the increased pressure drop of the new filtration system. As much of the existing, ductwork was reusable, the existing raw gas duct reaching the baghouse and the existing stack were kept. While this added complexity to the installation, it also reduced its direct costs.

Installation and commissioning
Redecam was instructed by Cemex Colombia to perform an ESP conversion to baghouse filter in 21 days “flame to flame” shutdown time, which gave the Redecam crew 19-20 days to achieve the result. During the kiln outage, Redecam used a 750t crawler crane to perform the ESP dismantling and installation of the new components that conform to the Redecam baghouse filter.

The Redecam team included:

  • 109 full operative workers on site
  • four site engineers from local erection contractor
  • one head of site management
  • one mechanical supervisor
  • one fan engineer
  • one commissioning engineer.

The 50t Clean Gas Plenum lift was executed during a late Sunday afternoon with all the major components already installed and pretested on the ground (dampers, electrical panels, compress air collectors, solenoid valves). Installation of the 3500 bags and cages was achieved in a total of 42h, thanks to a dedicated crew that worked on a 24h basis. Before the first passage of fumes a fluorescent powder test was performed to check the perfect sealing of the clean gas plenum. The kiln start-up was then successfully performed within the guaranteed time.

“All these activities were carried out in the middle of the rainy season,” said Cristian Guadagnin, Redecam’s head of site management, “which affects the schedule due to the impossibility of performing several working tasks such as welding and major lifts. The great effort of the Redecam team with the collaboration of our main contractor was the key to this successful project.”

Since its foundation in the 1980s, Redecam has been committed to providing tailormade solutions to customers’ needs. Being flexible and finding innovative solutions is a must to remain focused on this approach. These projects, which transform underperforming ESPs into bag filters, are perfect examples of saving considerable capex costs, while potentially meeting India’s emissions reduction requirements.

Read the article here: http://www.redecam.com/wp-content/uploads/2018/01/ENVIRONMENTAL-Redecam.pdf

Joint Venture of REDECAM and ISGEC Starts Operations

Redecam Group S.p.A. and Isgec Heavy Engineering Ltd. announce the establishment of their joint venture in the field of Air Pollution Control industry. The new company is named ISGEC REDECAM ENVIRO SOLUTIONS PVT. LTD and is headquartered in Noida, Delhi, India. With this joint venture, both partners are geared up to be a complete provider for flue gas treatment systems for the cement, power and metals industry.

Barry Downing, CEO of Redecam Group: “Air pollution is one of the major environmental issues India and the rest of Asia face today and it is a serious problem with the major sources being industrial emission and biomass burning, vehicle emission and traffic congestion. In the effort to reduce the country’s air pollution, Redecam and Isgec aim to build a strong business in Asia, drawing upon Redecam’s global expertise combined with the skills and knowledge of Isgec, a strong partner headquartered in India.”

Aditya Puri, MD of Isgec: “With air pollution becoming a growing threat in the region, I see great potential for flue gas treatment solutions in Asia. We are very happy that we have signed the joint venture agreement with Redecam, a trusted partner with an outstanding technology portfolio. With Isgec’s vast experience in manufacturing and project execution, we look forward to working together for mutual success by providing customers with even better solutions than ever before.”

Redecam Group S.p.A. is an Italian leader in the air pollution control industry with innovative solutions executed around the world. Headquartered in Milan, Italy, Redecam delivers engineering, equipment and service flue gas treatment solutions to the industry with references in 6 continents. For more information, please visit the Redecam website www.redecam.com

Isgec Heavy Engineering Ltd. is a global engineering company providing engineering products to customers in more than 87 countries across various sectors such as sugar, chemical, textile, IPP, oil and gas & cement. The company has its manufacturing plants and design offices spread across India in the states of Haryana, Uttar Pradesh, Gujarat, Tamil Nadu and Maharashtra. For more  information, please visit the Isgec website www.isgec.com

Read the press release here: http://www.redecam.com/wp-content/uploads/2017/03/Joint-Press-Release.pdf