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Increasing Efficiency While Keeping Costs Low
Against the backdrop of the current economic situation, the cement industry has put investments for new or replacement equipment on hold. Instead, preference is being given to the cost-effective optimization of existing plants under the aspect of reducing operating costs through conversions or modernization. The focus of these targeted measures is on the overall optimization of crude gas processes involving all exhaust gas flows. Much can be achieved with just a small budget, including a return on investment (ROI) of less than two years.
Savings Potential
In the case of bag filtration plants, optimization measures can lower operating costs in the following areas:
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Pressure loss in the pipe system
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Pressure loss resulting from filter bag geometry
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Pressure loss via the filter bags
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Modernization and/or optimization of the cleaning system
Whether it be dust and gas handling in general, or the cooling of gas using better systems such as gas conditioning towers, heat exchangers and fresh air cooling systems, the accelerated development of heat extraction systems, or measures to increase the efficiency of fans, filters, and material discharge and transport systems, including screw- and valve-based systems, optimization of the dedusting complex results in a substantial performance increase in the primary process.
Today, supposedly “functioning filtration systems” are found in the cement industry all around the world. While these systems do comply with the emission limits, closer examination reveals that they are far removed from what can be considered to be an energy-saving mode of operation. The reason for this often lies in the fact that the underlying volume of air or the crude gas temperature assumed by the original design of the bag filtration plant can no longer be maintained because of process-related changes in which higher volume flows occur as the result of improved performance of the kiln system or changes in fuel composition. A significantly higher differential pressure (delta P up to 20 mbar and higher) leads to an extreme shortening of the service lifetime of filter bags and drives operating costs drastically higher.
Cost Example Filter Bag Geometry
Older chamber-type filters with the ability to shut down individual filter chambers exhibit pressure losses of 6-8 mbar under actual operating conditions. Improvements in pressure loss can be achieved through CFD simulations of the crude gas inlet point and interior pre-separation surfaces and gas distribution plates and, when used in combination with flow-optimized clean gas flaps instead of disk valves, clear savings with respect to pressure loss can be achieved.
The cost example below, which is based directly on actual experience, makes clear how five-figure savings (EURO) can be achieved with low modification costs.
Sample Cost Calculation:
Kiln/Raw mill filter: 480,000 Bm3/h flow rate
Savings pressure loss: 3-5 mbar through optimization
Savings power requirements: 50 – 83 kW on fan unit
Electricity costs (kWh): EUR 0.08 (8 Euro-Cent)
Total annual savings: EUR 32,000,- to 53,120,- based on 8,000 Bh/a.
Conclusion
Backed by years of experience, Scheuch has the expertise and competence to use its detailed understanding of customer processes to implement measures to increase efficiency at a justifiable cost. Working hand in hand with the customer, Scheuch experts use a detailed assessment and analysis of the current situation and a simultaneous economic assessment (cost-benefit analysis) to determine the required measures. A comprehensive pool of services that includes measurement technology, engineering, design, and modern CFD simulation software supports this process. When implementing the design, Scheuch has at is disposal its own in-house manufacturing program, which reliably delivers the required materials and services, including assembly and commissioning.
Picture 2 - Example project:
An increase in kiln performance led to higher flow speeds in the crude gas line, thus causing uneven gas distribution in the filter.
As the result of CFD flow optimization, the dust discharge problems could be eliminated using retrofitted guide plates.
