Intensiv-Filter GmbH & Co.

KG

15TH ARAB
ARAB-INTERNATIONAL
INTERNATIONAL CEMENT
CONFERENCE AND EXHIBITION
18-20 NOVEMBER 2008 - CAIRO,
CAIRO EGYPT

Conversion of electrostatic precipitators

into bag filters presented by Jens Lange & Ralf Esser
85 Years - Innovation is our Tradition
Agenda 15TH ARAB-INTERNATIONAL CEMENT
CONFERENCE AND EXHIBITION 2008 in Cairo

1. Company Profile of Intensiv-Filter GmbH & Co. KG

g of Intensiv-Filter bag
2. Advantages g 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 Deuna plant
6. Summary
7. Contact @ Intensiv - Filter

3
Company Profile of Intensiv-Filter GmbH & Co
Co. KG

Intensiv-Filter
Intensiv Filter at Velbert – Langenberg,
Langenberg Germany
Managing Board
Dipl. Kfm Thomas Blüggel
Dipl.-Kfm
Dipl.-Ing. Konrad Meyr

Foundation
1922 by Theodor Hansen

Dedusting Solutions for

− Cement Lime Gypsum Industries
− Food Industries
− Power Plants & Incinerators
− Steel -/ Iron- & Non Ferrous
Industries
− Glass - & Chemical Industries

44
Company Profile of Intensiv-Filter GmbH & Co
Co. KG

Intensiv - Filter Group www.intensiv-filter.de

I t
Intensiv-Filter
i Filt GmbH
G bH & Co. C KG V lb t Germany
Velbert, G
Intensiv-Filter Austria GmbH Grieskirchen, Austria
Filtres Intensiv S.a.r.l. Bouzonville, France
Intensiv-Filter (UK) Ltd. West Midlands, England
Intensiv-Filter do Brasil Ltda. Sao Paulo, Brasil
Intensiv-Filter Korea Ltd
Ltd. Seoul Korea
Seoul,
Intensiv-Filter India Pvt. Ltd. Pune, India

Subsidiary Companies
Infastaub Bad Homburg, Germany Nuisance Filters < 30.000 m³/h
Solidux Billerbeck , Germanyy Noise Abatement Equipment
q p

400 employees world wide

G
Group Turn
T over appr. 70 million
illi Euros
E
5
Reasons for ESP conversions & retrofits

9 Stricter emission regulation by the authorities

9Use of secondary fuels

9Reduction of operation costs

6
Advantages of Intensiv-Filter bag filters (versus ESP’s)
ESP s)

9Lower and constant clean gas dust emissions for the use of
secondary fuels as kiln fuel to meet strict authority regulations

9Performance is independent on changing parameters and

operating modes (e.g. compound & direct mode)

9Precipitation is not pending on moisture and chemistry of the

gas & dust

9No CO – trips for kiln dedusting applications

9Online Maintenance possibilities and easy maintenance access

(from the clean gas side)

7
Benefits for ESP conversions & retrofits made by Intensiv-Filter

9Lower clean gas dust emissions (constantly) compared to the

ESP operation
9Economical
9E i l bag
b filter
filt design
d i using
i low
l pressure off-line
ff li cleaning
l i in
i
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.
time
9Re-use of existing casing, duct work, steel support, dust transport
y equipment
and auxiliary q p
9Flexible 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
9Low cost solution (compared to a new installation)

8
Different Concepts of ESP conversions executed by Intensiv-Filter

Pre- assembled filter head modules (incl. new penthouse)

on top of ESP casing

9
Different Concepts of ESP conversions executed by Intensiv-Filter

Pre-assembled casing on top of existing ESP hoppers

10
Different Concepts of ESP conversions executed by Intensiv-Filter

Pre- assembled filter head modules inside ESP casing

upper casing used as penthouse

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Design Data

Process Kiln- / Raw Mill - bag-filter

Original ESP Supplier ELEX / Switzerland

Gas Volume Design up to 550.000 Am³/h

Gas Temperature Range up to 240

240°C
C

Intensiv-Filter Type IF PJM 136/6 + 119/12 - 8000

Installed Filtration Area 9.274 m² gross

Filter Media Glass fibre with PTFE Membrane

Shut down time for Retrofit < 6 weeks

Clean g
gas dust load 2 mg/Nm³
g

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Process at
Deuna

1. Rotary kiln 5. Raw meal grinding plant 1 + 2

2. Cyclone preheater 6. Pro-Jet mega bag filter
3. ESP for alkali bypass 7. Exhaust fan
4
4. Gas conditioning tower 8 Stack
8.

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

ESP before conversion in 2007

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Start of work by the end of January 2008

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Removing of ESP internals and gas outlet hood – February 2008

16
Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Frame installation for new bag filter head modules – February 2008

17
Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Closed backside back wall / new clean gas duct installation

19 02 2008
19.02.2008 26 02 2008
26.02.2008

18
Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

New filter head modules incl. sleeve bottom plate and 8m bags

03.03.2008

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Re-connected clean gas duct / installed compressed air vessels

False air dilution system

y

10.03.2008
20
Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

View inside penthouse

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Kiln bag filter conversion at Dyckerhoff Zement’s
Zement s Deuna plant

Complete installation today

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Operation Data & Results at Dyckerhoff Zement’s
Zement s Deuna plant

Filter Description

Intensiv-Filter Type IF PJM 136/6 + 119/12 – 8000

Filter Media 8 m Glass fibre with PTFE Membrane

Operation Data

G Volume
Gas V l Design
D i up to 550.000
0 000 A
Am³/h
³/h

Gas Temperature up to 240°C

Clean gas load less than 2 mg/Nm³

Differential pressure 12hPa

Cleaning Mode Semi Off-line

Cleaning pressure appr 1

appr. 1,3
3 up to 3
3,4bar
4bar

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Summary

9Low clean gas dust emissions (constantly) independent from

gas & dust properties

9Economical 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

9Re-use of existing equipment

9Reduced down time, enables the execution of the conversion during

regular plant shutdown times

9Short amortisation time due to low invest cost solution

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New Filter Generation – ProJet mega Volumes up to 2 Mio.
Mio M³/h

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www.intensiv-filter.de