12/02/15

New bag house filtration for improved emission control

An Egyptian case study: Salvatore Gallo, Boldrocchi (Italy)

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I. Pulse Jet Bag Filter Principles

II. High Dust Bag Filters Boldrocchi Technology

III. Case Study: Suez Helwan Plant (Egypt)

IV. Boldrocchi Group Profile

V. Boldrocchi In The World

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.pulse jet bag filter principles

PARAMETERS:

- Air To Cloth Ratio

1 m3/m2

- Can Velocity
Kiln and raw mill <1,3 m/s
Clinker cooler <1,3 m/s
Integrated <1,3 m/s
Coal mill <1,0 m/s
Bypass <1,0 m/s
Cement mill <1,3 or 1,0 m/s

-  Inlet Flange
Gas Velocity <12 m/s

-  Hopper Flange
Gas Velocity <5 m/s

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.pulse jet bag filter principles

CFD Simulation
Computational Fluid Dynamics

- 3D Modeling Design

- Iteration Steps

- Architectural Modify

TAYLORMADE DESIGN

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.content

I. Pulse Jet Bag Filter Principles

II. High Dust Bag Filters Boldrocchi Technology

III. Case Study: Suez Helwan Plant (Egypt)

IV. Boldrocchi Group Profile

V. Boldrocchi In The World

.high dust bag filters boldrocchi technology

THE IMPORTANT OF BAGS

LENGTH: 6 – 8 – 10 – 12 mt ?
WHAT’S REALLY IMPORTANT ?

WE CAN CHOOSE
MOST IMPORTANT IS ANY LENGHT.
HOW MUCH EACH THAT’S NOT THE
BAG WORKS DURING MOST IMPORTANT
OPERATION AND
CLEANING CYCLE !

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OPTIMIZATION OF GAS DISTRIBUTION THROUGH ALL BAGS

Basic design of this bag filter model:

 
-  double feeding of dusty gas to bags
-  due to the length of the bags, it is needed to feed
gas both from bottom to top, rising from hopper
-  from side, in higher part of bags.
-  Filter is designed to optimize the repartition of
total gas among compartments and between
lateral side and bottom-top direction.

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OPTIMIZATION OF GAS DISTRIBUTION THROUGH ALL BAGS

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OPTIMIZATION OF GAS DISTRIBUTION THROUGH ALL BAGS

HALF FILTER SECTION GAS INLET

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OPTIMIZATION OF GAS DISTRIBUTION THROUGH ALL BAGS

BOTTOM APPROACH SIDE APPROACH

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OPTIMIZATION OF GAS DISTRIBUTION THROUGH ALL BAGS

BOTTOM GAS EXIT SIDE GAS EXIT

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.high dust bag filters boldrocchi technology

SPECIAL VENTURI DESIGN FOR AIR PULSE JET

VENTURI SPECIAL BOLDROCCHI DESIGN VISCOSITY FRICTION

100% COMPRESSED AIR SUCTION

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RESULTS OF DISTRIBUTION

BOLDROCCHI technology
and research with CFD has
permitted to reach around
60% of gas from bottom to
top and 40% through side

ADVANTAGES OF DOUBLE SIDE GAS APPROACH AND VENTURI DESIGN

- Less DP through the filter - Power saving at exhaust Fan

- 100% filtration surface working - Low emission level and cost saving
- Longer bag’s life
- Less compressed air consumption - Power saving for Compressors

LOW OPERATION COST

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.content

I. Pulse Jet Bag Filter Principles

II. High Dust Bag Filters Boldrocchi Technology

III. Case Study: Suez Helwan Plant (Egypt)

IV. Boldrocchi Group Profile

V. Boldrocchi In The World

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.case study: Suez Helwan Plant (Egypt)

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.case study: Suez Helwan Plant (Egypt)

The Project: Egyptian Pollution Abatement Project (EPAP)
LOCATION
Helwan Cement Line #1 & #2
Total Production: 11.000 TPD

SCOPE OF WORKS
-  Dismantling existing ESP’s
-  Installation of new Bag Filters, fans,
stacks
-  Turn-key Job

DESIGN DATA (Special Compound)

-  Application: Kiln & Raw Mill
-  Gas Flow: 1.106.000 m3/h (each line)
-  Temp: 120 °C (max 250 °C)
-  Dust inlet: 286 g/Nm3

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.case study: Suez Helwan Plant (Egypt)

The Project: Egyptian Pollution Abatement Project (EPAP)
Bag Filters Characteristics (each line)
-  Installed bags: 5.184 q.ty
-  Bags length: 8.000 mm
-  Filtration surface: 19.804 m2
-  Collected dust: 213.600 Kg

Bags & Cages material

-  FiberGlass with PTFE Membrane
-  Cages in carbon steel with cataphoresys
special surface painting treatment

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.case study: Suez Helwan Plant (Egypt)

Existing ESP’s on Line #1 & #2

Dismantling  of  exis:ng  ESP’s  and  inlet/outlet  ducts  

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New Bag Filter Design

Hoppers  
deflectors  

Baffles pipes and plates installed

inside hoppers and casing, after CFD
analysis and getting results

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.case study: Suez Helwan Plant (Egypt)

New Bag Filter Design

Special baffles plates installed to achieve

gas side approach through the bags

Installed  baffles  
plates  
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Mechanical Erection

Pre-assembly of hoppers

LiJ  and  Erec:on  

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Mechanical Erection

Clean  Air  Plenum  

assembled  on  ground  

Assembled  Casing  LiJ  

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Final Assembly and Installation

Installa:on  without  
modifica:on  on  exis:ng  
concrete  builing  

Complete  erec:on  

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Numbers of Boldrocchi Egypt Success

Project  Schedule:      10  months  

Kiln  shut-­‐down  dura:on:    38  days  
Total  Installed    steel/equipment:  1.740  tons  
Workers  peak  involved:    130  no.  
Biggest  Crane  used:    750  tons  

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Performances

                           Guaranteed                  Measured  
Dust  emission  level:        <      10      4,8  mg/Nm3  
Pressure  drop  total:                              12    10,4  mbar  
Compressed  air  consump:on:        ≤    187    142  Nm3/h      
Power  consum:on  at  fan  (each)                980    870  KW  

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HEIDELBERG HANNOVER PLANT

LOCATION
Hannover - Germany
Production: 2.500 TPD

SCOPE OF WORKS
-  ESP Conversion into Bag Filter
-  Turn-key Job

DESIGN DATA
-  Application: Kiln & Raw Mill
2 Fans System
-  Gas Flow: 570.000 m3/h
-  Temp: 125 °C
-  Dust inlet: 800 g/Nm3

Visit our booth B48

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.content

I. Pulse Jet Bag Filter Principles

II. High Dust Bag Filters Boldrocchi Technology

III. Case Study: Suez Helwan Plant (Egypt)

IV. Boldrocchi Group Profile

V. Boldrocchi In The World

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.Boldrocchi Group Profile

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.Boldrocchi Group Profile

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.Boldrocchi Group Profile

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.Boldrocchi Group Profile

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.content

I. Pulse Jet Bag Filter Principles

II. High Dust Bag Filters Boldrocchi Technology

III. Case Study: Suez Helwan Plant (Egypt)

IV. Boldrocchi Group Profile

V. Boldrocchi In The World

32

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.Boldrocchi in the World

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Boldrocchi Group!

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