Reducing emissions with zero downtime

CASE: ACC Limited, Gagal Plant, IndiaFLSmidth’s unique 10-metre bag technology significantly reduced dust emissions

from the environmentally-conscious ACC Gagal Plant, close to the Himalayas.

FabriClean® filter with 10m-long filter bags

View over the Himalayas from the Gagal Plant

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In just 10 months, emissions from the Gagal Plant in India have been successfully reduced. Utilising FLSmidth’s unique long-bag technology ensures compliance with environmental regulations now and in the future

Fast, future-proof emission solution

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The background ACC Limited is part of the Swiss-based Holcim Group and is India’s foremost manufacturer of cement and concrete. It takes a lead in environmental protection at all its plants; situated close to the Himalayas, the ACC Gagal Plant is com-mitted to responsible, sustainable development that respects the environment.

The plant has two lines producing 4300 tpd and 5000 tpd respectively. FLSmidth has had a close relationship with ACC for many years and is its preferred supplier.

The objectiveThe Gagal Plant wanted to comply with current environmen-tal regulations and also reduce emissions as much as possible. The plant wanted to capture the maximum amount of fly ash and minimise the amount of dust going into the stack.

Defining the projectBeing a brownfield project, there was a space constraint that needed to be considered. There was no space for placing the bag filter near to the stack except on the road, which is in use. Therefore, FLSmidth designed the bag filter to be placed at an elevation to allow continued use of the existing road. Civil works were also designed to allow access below the filter for heavy vehicles and other transportation. To accommodate the space constraint, the filter was designed with 10-metre long filter bags.

The solutionFor this EPC (Engineering Procurement Construction) project, FLSmidth supplied:

- FabriClean® filter with online maintenance facility- 1,728 10-metre long bags (woven glass with PTFE mem-

brane)- User-friendly Smart Pulse Controller®: SPC 1691- Bucket elevator- Conveyors - ID Fan and HT motors- Compressor

The scope included a duct and duct support from the cyclone outlet to the inlet of the stack, and dust transport equipment, such as a drag chain, bucket elevator, compres-sor and ID fan.

ChallengesThe site is located in an extremely hilly area so one of the challenges was to transport equipment to the site, and extreme rain and cold added to these transport difficulties. It was also important to motivate labourers to stay on the site in the extremely cold conditions.

Excavating close to the existing plant foundation was a very tough task and some unexpected pipe lines were discovered that had to be re-routed. The civil works was still successfully completed in spite of rain during most of the project.

Erecting heavy equipment was a big challenge as existing conveyors are located on both sides of the filter. The teams worked well together and careful planning contributed to a quick and smooth installation.

Results The project was completed with a very short delivery time: just 10 months from start to finish. All construction took place while the plant was in operation and the installa-tion was connected during a regular planned maintenance shutdown.

All the equipment was stabilised within one day of operation and a very satisfactory performance test was completed. The emissions achieved are 1.75 mg/Nm3, which is well below the guaranteed figure (10 mg/Nm3) and the local environ-mental regulations (30 mg/Nm3).

The pressure drop over the entire filter is as low as 9.7 mbar, which indicates a very efficient cleaning system as well as an advanced filter media. The power consumption of the ID fan is also lower than the guaranteed figure at 600 kW.

The Gagal Plant now has:- Reduced power consumption due to reduced pressure

drop across the filter (and the whole system) and reduced compressed air consumption

- Reduced environmental impact due to low emissions in the stack

- User-friendly Smart Pulse Controller® for bag house op-eration

Heavy rain during erection challenged civil work

“FLSMIDTH WAS OUR RELIABLE PARTNER FOR THIS IMPORTANT

TURNKEY EPC PROJECT, WHICH WAS SUCCESSFULLY COMPLETED WITH

EXCELLENT SAFETY PERFORMANCE. EQUIPMENT IS PERFORMING BETTER

THAN THE GUARANTEED PARAMETERS – WELL BELOW THE

STATUTORY EMISSION REGULATIONS. THE BAG HOUSE IS SUPPLIED WITH

10-METRE LONG BAGS AND PULSEJET TECHNOLOGY, WHICH IS THE FIRST TIME IT HAS BEEN USED IN INDIA.

OPERATION HAS BEEN VERY SMOOTH AND PROBLEM-FREE.”

K.N.RAODirector Energy & Environment

ACC Gagal Plant, India

www.flsmidth.com/apc

Project Centre Denmark FLSmidth A/SRamsingsvej 30DK-2500 ValbyCopenhagenTel: +45 3618 2000Fax: +45 3618 2030 E-mail: info@flsairtech.com

Project Centre USAFLSmidth Inc. 2040 Avenue CBethlehem, PA 18017-2188Tel: +1 610-264-6011Fax: +1 610-264-6170E-mail: info-us@flsmidth.com

Project Centre IndiaFLSmidth Private LimitedFLSmidth House34, Egatoor, Kelambakkam(Rajiv Gandhi Salai, Chennai)Tamil Nadu – 603 103Tel: +91-44-4748 1000Fax: +91-44-2747 0301E-mail: salesairtech-in@flsmidth.com

Copyright © 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. C

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FabriClean® with 10m-long filter bags