THE CEMENT FACTORY
16. DEDUSTING
The Cement factory
16. Dedusting
Table of Contents
16 DEDUSTING...................................................................................................5
16.1 DUST-PRECIPITATION....................................................................................5
16.2 CYCLONES.....................................................................................................6
16.3 BAG FILTERS.................................................................................................7
16.4 CENTRAL JET PULSE FILTERS, TYPE CE.......................................................8
16.5 INSERTABLE JET PULSE FILTERS, TYPE IN....................................................9
16.6 ELECTROSTATIC PRECIPITATION.................................................................10
16.7 PRECIPITATOR DESIGN.................................................................................11
16.8 FLS PRECIPITATOR TYPES...........................................................................12
16.9 MIGRATION VELOCITY AND RESISTIVITY....................................................14
16.10 PULSE-ENERGISED PRECIPITATORS..............................................................15
16.11 RESISTIVITY-REDUCTION WITH SO3............................................................16
16.12 PRECIPITATOR INSTALLATIONS...................................................................17
Page 16.3
Table of Figures
FIGURE 16-1.............................................................................................................................................5
FIGURE 16-2.............................................................................................................................................5
FIGURE 16-3.............................................................................................................................................6
FIGURE 16-4.............................................................................................................................................7
FIGURE 16-5.............................................................................................................................................7
FIGURE 16-6.............................................................................................................................................7
FIGURE 16-7.............................................................................................................................................7
FIGURE 16-8.............................................................................................................................................8
FIGURE 16-9.............................................................................................................................................9
FIGURE 16-10.........................................................................................................................................10
FIGURE 16-11.........................................................................................................................................11
FIGURE 16-12.........................................................................................................................................12
FIGURE 16-13.........................................................................................................................................13
FIGURE 16-14..................................................................................ERROR! BOOKMARK NOT DEFINED.
FIGURE 16-15.........................................................................................................................................14
FIGURE 16-16.........................................................................................................................................14
FIGURE 16-17.........................................................................................................................................15
FIGURE 16-18.........................................................................................................................................15
FIGURE 16-19.........................................................................................................................................15
FIGURE 16-20.........................................................................................................................................16
FIGURE 16-21.........................................................................................................................................16
FIGURE 16-22.........................................................................................................................................17
FIGURE 16-23.........................................................................................................................................17
FIGURE 16-24.........................................................................................................................................18
FIGURE 16-25.........................................................................................................................................19
FIGURE 16-26.........................................................................................................................................19
FIGURE 16-27.........................................................................................................................................20
FIGURE 16-28.........................................................................................................................................20
FIGURE 16-29.........................................................................................................................................21
FIGURE 16-30.........................................................................................................................................21
FIGURE 16-31.........................................................................................................................................22
FIGURE 16-32.........................................................................................................................................22
The Cement factory
16. Dedusting
16 DEDUSTING
16.1 Dust-precipitation
Dust-laden air and smoke gases from cement factories are cleaned before being let
out into the atmosphere for two reasons.
In most countries the laws limiting dust emission in the atmosphere are becoming
increasingly rigorous.
The dust trapped in air and smoke gases normally represents material which can be
re-used in the production.
Gas emission is normally defined as the maximum permissible dust content per cubic
unit of escaping gas or, in some cases, as the maximum total quantity of dust per
hour from a single stack or factory.
The type and size of dedusting device depends on the type, grunlometry and amount
of dust to be handled, and on the moisture and temperature of the carrier air. The
diagram, figure 16.1, shows the commonly used dedusting devices in the cement
factory and their relationships between efficiency and particle size. The efficiencies
of bag filters and electrostatic precipitators is practically identical, but the latter are
able to handle larger volumes of air, at higher temperatures and gas containing
moisture. Cyclones are simple and inexpensive dedusting devices, but ineffective at
particle sizes below 50 .
In a cement factory the main source of pollution is the kiln. Figure 16.2 illustrates the
average size distribution of the dust from kiln operation.
Figure 16-1 Figure 16-2
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16.2 Cyclones
The cyclone consists of a cylindrical part with a conical bottom hopper and a
concentric exhaust pipe protruding into the cylinder from above. The dust-laden air is
drawn through the cyclone by a fan, and the design forces the design forces the gas
flow into a circular movement whereby the particles are subjected to a centrifugal
force. The particles hit the inner cyclone wall and fall to the bottom from where they
are removed through an air sluice.
The cyclone does not need an integrated power source apart from the fan, necessary
for the gas flow. A somewhat high pressure drop must be expected across the
cyclone. The gas flow and thereby the degree of dedusting is regulated by a damper
in the pipe line before the fan.
Figure 16-3
A cyclone is often placed before an electrostatic precipitator, figure 16.4. The
efficiency can be improved by installing a battery of cyclones, figure 16.6, and the
pre-heater for the modern dry process kiln, figure 16.5, is in effect a string of
cyclones.
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Figure 16-4 Figure 16-5 Figure 16-6
16.3 Bag filters
Bag filters are used to clean dry air of temperatures not exceeding approximately
1300C. In principle the filter consists of casing (A) with a battery of porous bags (B)
suspended in a frame (C). The air is drawn through the filter by the fan (D) and
leaves through the exit pipe (G), while the dust collects on the fabric of the bags.
Figure 16-7
At regular intervals the framework is shaken and scavenging air from the pipe (H)
blown through the bags. The loosened dust collects in the conical hopper (F) and is
removed with the screw conveyor (K). During scavenging each filter compartment in
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16. Dedusting
turn in turn is set out of function while being cleaned. Cleaning is effected in a given
time sequence.
Figure 16.8 shows the design of the current FLS bag filter, which is now being
succeeded by the Jet-pulse filter.
Figure 16-8
16.4 Central Jet Pulse Filters, type CE
FLS Central Jet pulse filters are modular bag filters in which the dust-laden air enters
through the base or side of the casing, and is evenly distributed between the filter
bags. The dust is deposited on the outside of the needle-felt bags, while the air passes
through the felt into the clean air chamber at the top.
The bags are cleaned by the injection of an ultra-short burst of air.
The air jet burst cleans each row of bags in turn. The blast is triggered by the
electronic control unit based on the pressure drop across the filter.
The filter module comprises 3, 4 or 5 rows, each with 7 cylindrical bags mounted on
wire cages 3m in length and 120mm in diameter. The filtration area is 1.15 m 2 per
bag.
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Dedusting capacity is 80-180 m3/h per m2 filtration area according to dust type and
operating conditions.
Filters for coal have special features to prevent explosions and fires.
Figure 16-9
16.5 Insertable Jet Pulse filters, type IN
This filters is identical to the central Jet Pulse filter in basic design and operation.
However, Insertable Jet Pulse filters may be fitted directly – vertically or horizontally
– on the source to be dedusted, f.ex. a silo, elevator, screw or other type of conveyor.
The dust dislodged from the outside of the bags falls directly into the silo or into the
conveyor on which the filter is mounted, and is then returned to the production
process.
The filter module comprises 6 rows each with 6 or 9 cylindrical bags mounted on
wire cages 1.5m long and 120mm in diameter. The filtration surface is 0.55m 2 per
bag.
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Dedusting capacity is 90-180m3/h per m2of filtration surface according to dust type
and operating conditions. The filter can operate at air temperature up to 80 oC with a
direct-mounted fan, or up to 200oC with special bags and separate fan.
The type designation is IN (INsertable) or INF (INsertable) with direct-mounted FLS
Fan CQF (40/40) followed by the digits 36 og 54, indicating the number of filter
bags per unit.
Figure 16-10
16.6 Electrostatic precipitation
Electrostatic precipitators are primarily used for cleaning large air quantities from
rotary kilns, clinker grate coolers and grinding mills. Electrostatic precipitation
principles require that the gas contains moisture, giving it a dew point of 50-60 oC.
The principle is shown in figure 16.11 and 16.12.
The gas is cleaned during its passage in an electrical field, between ducts of
electrodes. Rows of earthed collecting electrodes (u) are suspended from the filter
casing, parallel to the gas flow. Discharge electrodes (e) are suspended between the
collecting electrodes. The discharge electrodes are mounted in a framework which is
insulated from the rest of the filter and charged with a negative d.c potential in the
order of 30-70 kV.
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The high potential creates such a powerful electrical field that negative electrons are
detached from the discharge electrodes, and this so called corona effect ionises the
gas around the discharge electrodes. – the ions hit the dust particles and charge them,
and the now negatively charged dust moves towards the positive collecting
electrodes where it is captured. Some positive ions are formed and collected on the
discharge electrode, a phenomenon called back corona.
At predetermined intervals both sets of electrodes are rapped and the loosened dust
falls to the bottom and is removed by drag chain or screw conveyor.
The ion-migration causes an electric current to flow from the e-electrodes to the u-
electrodes. This is the emission current which expresses the efficiency of the
precipitator. It is measured in mA/m2 area of the collection electrodes.
The precipitator efficiency is defined as the relationship between the dust
concentration before and after precipitation. It is for present- day precipitator 95-
99.9%.
Figure 16-11
16.7 Precipitator design
Large precipitators are divided into independent units to allow sectional maintenance
without stopping the entire plant. – In addition, precipitator units are divided into two
or more fields in series, fed from individual high velocity rectifiers. This assures that
the voltage from each rectifier can be adjusted to the operational conditions are
concerned.
The inlet and outlet casings are supplied in many designs, depending on local
conditions. An adjustable system of grates in the inlet ensures an even distribution of
the gas over the cross section of the filter casing. – the bottom structure consists
either of longitudinal, conical hoppers or rows of pyramidal hoppers. The dust is
extracted by screw conveyors, drag chain or pneumatic transport. The figures of
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precipitator types on the following pages illustrates sum of the constructional
alternatives.
The discharge electrodes (2) are spiral-shaped wires, but new designs are being
developed. The collecting electrodes (6) are profiled steel plates provided with top-
hooks for the suspension. – Both electrode systems are rapped by tumbling hammers
at predetermined intervals.
The discharge electrodes (2) are fitted in a framework (1), which for each section is
suspended in 4 steel rods. The rods are led through the roof by insulators (3) in
insulator boxes (4). The boxes are heated in order to heat the temperature above the
dew point. The high tension is introduced through a cable box (5).
The main transformers with rectifier unit and thyristor control system may be
installed either on top of the filter casing or in a separate power station.
Figure 16-12
16.8 FLS precipitator types
FLS electrostatic precipitators are made in three types. Type F, figures 16.13 and
16.14 are used to treat large gas volumes, mainly from rotary kilns, clinker grate
coolers and major coal grinding plants.
Precipitators for coal firing installations are supplied with explosion coves in the roof
besides being equipped with CO2 – injection as an emergency measure in case of
ignition of the coal dust.
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Precipitators of type F for clinker grate coolers have an antechamber in the inlet in
order to precipitate the coarsest fraction before the gas enters the filter proper.
Figure 16.15 shows the precipitator, type P, for a cement grinding plant. It is smaller
and slightly different in design. In figure 16.16 is shown a vertical precipitator, type
R, for smaller coal grinding installation.
Figure 16-13
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Figure 16-14
Figure 16-15 Figure 16-16
16.9 Migration velocity and resistivity
The velocity at which a dust particle approaches the collecting electrode under the
influence of the electrical forces is called the migration velocity. It is directly
proportional to the intensity of the electric field and to the particle size. The latter
explains why the gradually decreasing dust consists of ever finer particles as the gas
passes through the filter.
Another deciding factor for the migration velocity is the resistivity of the dust, i.e. its
ohmic resistance. High-resistivity dust has a low migration velocity and is therefore
difficult to precipitate. The resistivity depends both on the dust itself (chemical
composition and particle size distribution) and on the surrounding gas (temperature
and moisture), and the aim of precipitator operation is to reduce the resistivity as
much as possible.
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From the graph, figure 16.7, it will be seen that the dust from the 4-stage cyclone
pre-heater kiln has a much higher resistivity than for example the dust from the wet
kiln, and it therefore requires a larger precipitator. By treating the kiln gas in a
cooling tower it obtains a temperature and a moisture content which reduces the
resistivity. However, if the gas is utilised for drying purposes in a raw mill or a drum
drier it will be sufficiently cool and moist without having to pass the cooling tower.
Alkali compounds in the dust has the effect of lowering the resistivity, a
phenomenon which mirrors the high resistivity of dust from the 4-stage cyclone pre-
heater kiln. This type of kiln is a distinctly closed air circulating system, retaining the
alkali vapours in the kiln and cyclones with the result that the kiln gases are alkali-
poor and consequently difficult to precipitate. Research regarding conditioning of
alkali-poor dust with alkali compounds before introducing it into the precipitator has
led to improvement in precipitator operation, as shown in figures 16.18 and 16.19.
Figure 16-17 Figure 16-18 Figure 16-19
16.10 Pulse-energised precipitators
In the FLS pulse energisation system precipitator performance is improved by
superimposing short-duration, high-voltage pulses on the DC-voltage, figure 16.20.
The surplus energy not emitted as corona discharge is recovered and stored in a
generator for subsequent application.
Pulse energisation is especially suited for high-resistivity dust and will reduce the
size of new precipitator. Also, the system is easy to install on existing precipitators
where it will improve performance, figure 16.21.
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Figure 16-20
Figure 16-21
16.11 Resistivity-reduction with SO3
Restrictions in sulphur pollution has led to the use of low-sulphur coals with high
resistivities and subsequently requiring large precipitator installations. The resistivity
of ash from such coals can be reduced by injecting sulphur trioxide, developed from
sulphur dioxide, into the gas flow to the precipitator. The SO 3 acts as a conditioning
agent, and this procedure is particularly useful for improving the performance of
existing precipitators. The below figure shows an installations for SO3-injection.
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Figure 16-22
16.12 Precipitator installations
Electrostatic precipitators may function either as pressure filters with the fan placed
before the precipitator, or as suction filters with the fan placed after the precipitator.
The pressure filter is used to collect the dust from two or more sources, as for
example the kiln and raw mill in the dry process plant. The gases are better blended
by placing the fan before the precipitator. The pressure filter installation is shown in
figure 16.23.
Figure 16-23
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Slurry grinding mills do not require dedusting in the wet process plant the
precipitator served only the kiln. In the precipitator works here as a suction filter.
The precipitator for the cement mill, shown in figure 16.24, likewise dedusts one
source only and operates as a suction filter.
Figure 16-24
From the point of view of the fan the suction filter is the preferred installation, since
the fan is in this case transporting clean air and thus less exposed to wear.
The below figure illustrate typical precipitator installation at a cement factory.
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Figure 16-25
Figure 16-26
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Figure 16-27
Figure 16-28
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Figure 16-29
Figure 16-30
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Figure 16-31
Figure 16-32
Page 16.22
