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n Info-FlyerIssue January / February 2012Information for customers and employees

DUST REMOVAL TECHNOLOGY + FILTRATION

ESP retrofit for Bagalkot ce-mentAir pollution is a transnational phenomenon and makes no hold on the land orders. Today in the industrial countries the most evident charges are remo-ved. Now the necessary measu-res concern the industries of the developing countries and newly industrializing countries. This is also valid for India. The subcon-tinent produces about 6 % of the worldwide cement produc-tion (Fig. 1) and consumes after China the worlds second largest amount in cement (consumption in 2010: 212 million t). One of the affected regions is the South-Indian state of Karnataka. The-re lies 22.56 % of the national limestone resources and the ce-ment production amounts to 11 million t/a. This corresponds to a portion of 6.5 % of the Indian cement production. Hence, the Indian cement industry under-takes a lot for the modernisation of the technologies. In doing so, the obtained experiences of in-dustrial countries are taken into account, e.g. the application of secondary fuels in the cement production, effectiveness incre-ases by the energy application and the application of bag filters for the dust removal.

Mostly electrostatic precipitators are used in countries where less extensive environmental condi-tions exist. With regard to the raised environmental specifica-tions in India, electrostatic pre-cipitators that have been in use for many years get a closer look now (Tab. 1). This is with regard to the application of seconda-ry fuels that leads to changing operating conditions. Electro-static precipitators can

not keep up with the demands for environment-friendly utilisa-tion of secondary fuels though. This requires undoubtedly the unavoidable retrofit of electro-static precipitators into fabric filter. They permit compared to electric filters lower residual dust contents and are practical independent of operating condi-tions of the plant.

One of the cement manufactu-rers based in the federal state of Karnataka is Bagalkot Ce-ment. They have produced ce-ment since 1948. Investments in a modern filter technology are evaluated by the cement ma-nufacturer as a right measure for an environment-friendly ce-ment production. In the cement plant the dust removal of the rotary kiln has been carried out for decades by an electrostatic precipitator. It is not able though to keep the low emission stan-dards of 10 mg/m³ n.c. under all conditions. That‘s why and because of too high dust loads during necessary start-up pro-cesses and rundowns, Bagalkot Cement decided to retrofit the electrostatic precipitator into a bag filter. On top of this comes the striking distance of the ce-ment plant to the city limit. The negative environmental influen-ces on the welfare of the neigh-bourhood are put down by Ba-galkot Cement with the retrofit into a bag filter.

(...) One of the priority objec-tives within this project is the extensive use of the existing supporting concrete columns (Fig. 4). This causes special restrictions to some degree. Owing to these, the bag filter will be equipped with filter bags

of 10 m lengths to keep with the small foot print and the demand in an increased capacity (Fig. 5). The emergence of the long bag technology results not only in a high filter surface area, but also generates lower operating costs. This is based on the fact that long filter bags need to be regenerated with a very capable cleaning efficiency. Carrying out the cleaning in an offline mode, it puts the filter modules of the filtering installation into a flow-free state during cleaning. This condition is the essential requi-rement of a successful cleaning of long filter bags. (...)

(...) With regard to the process data, the bag filter is presently handling gas flow of 180 000 m3/h but can be used for gas volume flow of 300 000 m³/h and a gas temperature of 240 °C. This can be achieved by adding filter bags, dampers and dust handling valves in future. A filter bag material of glass fibre with PTFE membrane will be applied for the 672 filter bags. They will be loaded with a dust maximum of 150 g/m³. To ensure an opti-mal installation and commission process, Intensiv-Filter India is responsible for supervising the assembly and commissioning, which is planned for by March 2012.

Newly positionend in the chemical branch

An interview with Jörg Bald-auf, Head of Saltes Intensiv-Filter

Which new accents are put by Intensiv-Filter?In the past the main attention and the strategy of Intensiv- Filter primarily was on dust removal in the pit and quarry industry. The market is fed as well as the production amounts from e.g. building materials like cement sunk. Our export in this business segment will remain on the agenda by long-term du-ties of the threshold countries due to the infrastructure deve-lopment and the resource pro-tection also.

The chemical branch is no stranger for Intensiv-Filter. Al-ready since the foundation of the company in 1922 we are active in this business seg-ment. We have not served this market in the past actively and now have realigned us new in this regard. The development of this business segment will be an essential main issue.

In June Intensiv-Filter will exhi-bit together with the sister com-pany Infastaub on the Achema

in Frankfurt. There we will be present after many years first again.

With which chemical tasks do you expect especially high potentials?The chemical industry has with products like basic chemicals, fertilizers, plastics, varnish, pharmaceuticals or pesticides very varied tasks. We will not serve the area of the phar-maceutical industry. We leave this field to our sister company Infastaub which offers filters for all OEL classes and with high containment equipment. Inten-siv-Filter will concentrate upon processes of the agrarian che-mistry as well as the production of dyes and pigments, fine che-micals and special chemicals, cleaning agents and care pro-ducts as well as polymers.

What is your unique selling proposition?Intensiv-Filter has set up to a leading high-class brand and is known in the industry as a brand name for bag filter tech-nology for now 90 years. The most important criterion what distinguishes us from compe-titors is the technical quality of our filtering installations. This quality is based on the tech-nical availability, long lifetime, achievement and reliability of the filters. With it we react to

the needs of our customers, who not only have in view the investment costs, but rather consider the costs over the en-tire lifetime. A rise and optimum use of the operating life, a re-liable operational safety and a rise of the plant availability are of a high economic use to our customers.

How do you see the next ten years of Intensiv-Filter?The market success proves us right during the past 90 ye-ars. Sustained company‘s suc-cess and growth is based on the continuous enhancements of the product-performance-portfolio. In parallel with the ad-vancement of our products we concentrate upon our services which have a determining size with the shaping of our market success.

ACHEMA 2012From June 18th to June 22nd, 2012 Intensiv-Filter and In-fastaub present on the Achema how efficient and economical de-dusting can be. Infastaub demonstrates on-site the se-cure and free of contamination „safe change“. Intensiv-Filter presents the series ProJet mega as computer simulation.

Vi sit us in Frankfurt and experi-ence the innovative and energy saving technology solutions for your success in filtration. We consult you on the ACHEMA.

Intensiv-Filter GmbH & Co. KGRedaktionsteam Info-Flyer

Voßkuhlstraße 63 42555 Velbert-LangenbergDeutschland Germany

+49 2052 910-0 2 +49 2052 910-248info-flyer@intensiv-filter.com www.intensiv-filter.com