CREATING A PRE-ASSEMBLED

MONSTER
OF A BAG FILTER

GIULIAMARIA MERIGGI, REDECAM GROUP, ITALY, OUTLINES THE

COMPANY’S SEARCH FOR INNOVATIVE SOLUTIONS AT ITS BRAZILIAN
CLIENTS’ CEMENT PLANTS.

O
ver the past few years, Redecam Group has put Redecam on the path to find a number of local
expanded its number of contracts in Brazil, during Brazilian suppliers to perform precise work on a very
which time it has created an interesting precedent large quantity of enormous pieces of equipment. It also
in terms of product offering. In 2014, Redecam created a new product offering.
commissioned a project that marked the first time
they supplied and transported a heavy duty bag filter Bag Filter in 14 parts
(baghouse) pre-assembled in a mere 14 parts, leaving In 2013, Redecam was contracted to find solutions for a
the crew to put together what looked like a giant new – and fifth – mill line at one of its Brazilian clients’
Rubik’s Cube on site. What’s more, most parts for these cement plants. The project was commissioned in 2014.
recent projects, including the Rubik’s Cube bag filter, Redecam provided a large bag filter, a cyclone and
were manufactured in Brazil creating jobs, contributing dedusting filters for this project.
to the local economy, reducing costs for their customers The innovation came in the form of a large
and making the pre-assembled monster of a bag filter DPM-Model Bag Filter, suitable for high flow rates
a success. It proved to be a worthwhile challenge and (above 1.5 million m3/h or 883 000 ACFM) and high
 inlet dust burden applications (up to 1000 g/Nm3 or
0.44 gr/ft3). Redecam’s large DPM-Models are standard
with a big central hopper, but this one was completely
re-designed without one. The client had already
defined their layout, leaving a limited footprint for a
baghouse and the idea was to try to reduce weight.
Weight reduction is a common goal in the pursuit of
baghouse perfection, although the ideal often proves
challenging due to custom part thicknesses or specific
standards imposed by the client.
The big challenge was providing a modular
solution. Although Redecam is used to pre-assembling
equipment, it usually means splitting a part simply to
make it fit into a container. Producing and transporting
a baghouse in 14 parts may not sound that difficult, but
All 14 modules were pre-assembled with tailor-made the list of challenges was impressive:
lifting lugs installed in-factory for easy installation. 1. The baghouse was non-compartmented, meaning
there were no walls inside to form perform
straightforward ‘cuts’ to create a module.
Engineers had to re-think every part. They had to
innovate a way to allow each module to be lifted
and transported despite not having walls to hold
the structure. They succeeded in creating what
looked like a giant Rubik’s Cube: 16 m long x 16 m
wide and almost 15 m tall, divided into 14 pieces
weighing a total of 230 t.
yy Every big lateral compartment was 16 m long x
almost 5 m wide x 5 m tall.
yy The central compartments were 16 m x 3 m x 5 m.
yy The hoppers were nearly 16 m x 16 m x 15 m.
2. The project was developed in 3D Cad-Cam
Software and executed with CNC machines to avoid
mistakes on the final assembly. The modules being
so large, some usual procedures were impossible,
such as pre-assembling the entire bag filter in the
workshop. A large crane would have been needed
in the workshop twenty-four seven. It meant the
Installation took about half the time and much less calculations, 3D design and CNC cuts had to be
space on site. exact, with no room for error.
3. Once the modules were assembled, they needed to
be sandblasted and painted. It required the team to
find an extremely large paint cabin, which they did.
4. Transporting this monster of a baghouse by
road offered another challenge. The 14 modules
needed to be brought 450 km from the workshop
to the site in record time. “I drove the entire trip
myself to ensure the trucks wouldn’t face a dead
end,” laughs Redecam’s Brazil Country Manager
Felipe Abraham. “We even measured every bridge
clearance and every potential obstacle to be sure
the trucks had clearance.” A specific route was
chosen because it was quiet, not because it was
smooth. “At times the trucks were rolling at a
mere 30 km/h in a procession with two police cars.
We certainly did not need a speedway to go that
slowly!”
5. The team was on a very tight timeline, roughly
Redecam engineers succeeded in creating what
120 days to get all equipment designed and
looked like a giant Rubik’s Cube: 16 m long X 16 m
produced, which is much tighter than usual. The
wide and almost 15 m tall, divided into 14 pieces
Rubik’s Cube was only possible because of the
weighing a total of 230 t. engineering team’s innovation and hard work, how

Reprinted from June 2016

\ World Cement
 they developed the project, the local workshop
hired for the job and because the project was
nearly completely supplied locally (only specialised
components like Redecam’s proprietary Bi-Jet Bag
Cleaning System and other such components were
brought in from Redecam’s own workshop in Italy).
“This modular system wouldn’t have been possible
if we had tried to ship it from abroad,” admitted
Abraham.

The big goal: Savings for the client

Both the client and the installation company saved on
numerous fronts due to the modular approach:

ll Money. They saved money on welding,

pre-assembling on the ground (most modules were
dropped-off trucks directly to their final positions) The Modular Filter saved the clients money, space and
and repainting. time while increasing on site safety.
ll Space. The customer also saved space on site as
field pre-assembly was eliminated. Usually, an
empty space as big as two baghouses placed
side-by-side (sometimes even larger) is needed to
pre-assemble the modules on site. In many cases,
the client must have a solid concrete base poured
to support the baghouse’s pre-assembly ‘table,’
which is as big as the filter itself.
ll Time. The Redecam team developed a precise
logistics and delivery schedule. Some parts arrived
on site earlier than others in order to avoid a rush
once the last pieces were ready. The erection of
the bag filter began once half the modules had
arrived. “The result was superb,” commented
Abraham. “Our client saved a lot of time,
compared to the normal installation process. I’d say The 14 modules needed to be brought 450 km from
we cut installation time by more than half.” the local workshop to the site in record time.
ll Safety. Bigger pieces are usually not appreciated
by the ground crew. The on site installation said Abraham. In this second Rubik’s Cube contract, the
team usually views them as heavy and difficult baghouse was smaller but it was designed based on its
to manoeuvre. It was crucial that the contractor ‘bigger brother’s’ concept.
already have his cargo weight and rigging “In this second contract, the company also saved
plan done. Every part arrived with its own quite a lot on installation costs. The company that did
custom-designed lifting lug pre-assembled on
the erection was the same company that manufactured
the part in the workshop. Redecam ensured each
the smaller Rubik’s Cube, so they knew exactly what
lifting lug was properly designed for the weight,
shape and size of the piece it was to fit upon needed to be done on site – almost nothing, really,”
and oversaw the manufacturing process and its continued Abraham.
installation. When on-site installation began, a
large crane was needed only for a short time and Conclusion
the process was quite fast and safe. In effect, That project was a first and a learning experience for
safety was augmented doing installation this many at Redecam and amongst their subcontractors.
way. Erecting this equipment the ‘traditional’ way “Despite the challenges, I offer this solution now
means handling numerous pieces and creating lugs anytime I can,” stated Abraham. “It is true that the
on site that are not as perfectly adjusted.  Rubik’s Cube concept is not one that can be used for
The modular concept worked so well that Redecam all projects and plants. But when it can be done, the
re-created it on a smaller scale for five SP-Model savings in terms of money, space, time and safety make
Nuisance Filters (each customised for its use and space) it a winning solution.”
and a cyclone for this customer. Some dedusting filters “We now have Brazilian subcontractors with
were supplied in one large piece, others were divided experience manufacturing this type of concept for us
into three main ‘modules’: the structure, the hopper, as well, making us confident about closing more similar
and the casing and plenum together. deals in this country,” he concluded.
“Our Lego-type concept really worked so well that Redecam has since created its ‘Modular Filters’ as
we closed another Brazilian contract for a leading a general concept that they have begun offering to
cement manufacturer with the same concept of supply,” customers all over the globe.

Reprinted from June 2016

World Cement /