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FICEM 2010
Filter Technology:The Optimal Operating Point Has A
Decisive Influence On Life Cycle CostsAlois Hermandinger
Scheuch GmbHAurolzmünster / Austria
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
2
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
FICEM 2010 3
Collection and extraction of dust and pollutants (primary and secondary)
Ventilation and Environmental Technologyfor Industrial Production Processes
Filtration of dust and pollutants
Separation and transportation of bulk materials
Heat recovery and cooling
FICEM 2010 4
The Best Solution -Technically and Economically
Highest Availability Low Life Cycle Costs Guaranteed Fulfillment of Performance
5
Ownership: Family Scheuch
Managing Herbert KendlerDirectors: Stefan Scheuch
Turnover: more than 150 million EURO
Export share: 80 %
Expense R&D: 3 million EURO p.a.
Staff: 640 (Company headquarters)780 (Scheuch Group)
Scheuch GmbHFigures and Facts
FICEM 2010
6
Wood Processing Industry
Wood Based Panel Industry
Metals Industry
Industrial Minerals
Energy Industry
Five Main Business SegmentsSynergies – Multi-sector know-how
FICEM 2010
7
Industrial Minerals
Exhaust and dedusting plants, process filters in the cement, limestone and gypsum industries, the basic material and building material industries, and the recycling of construction waste.
Coal grinding plantKiln / raw mill Clinker cooler
FICEM 2010
Filter Technology
SCHEUCH Products for the Cement Industry
3,000 fans per year
8
SCHEUCH dust loaden fans with wear protection
(up to 600.000Am³/h, up to 20.000Pa)
Filter Technology 9
SCHEUCH Products for the Cement Industry
SCHEUCH dust loaden fans with wear protection
Filter Technology
Screw conveyors
Rotary valves
Double pendulum flaps
10
SCHEUCH Products for the Cement Industry
Filter Technology
Air slides integrated in the filter hopper
11
SCHEUCH Products for the Cement Industry
Scheuch filters for cement industry
Crude material transport and treatmentCrude material transport and treatment
Transport and crude material dumpingTransport and crude material dumping
Kiln and raw mill dedustingKiln and raw mill dedusting
Gas conditioning towerGas conditioning tower
Chlorine bypass dedustingChlorine bypass dedusting
Coal mill dryingCoal mill drying
Heat exchangerHeat exchanger
Clinker cooler dedustingClinker cooler dedusting
Clinker transport – dumpingClinker transport – dumping
Cement mill and separating plantsCement mill and separating plants
Packing plants and loading systemsPacking plants and loading systems
Cement transport and dumpingCement transport and dumping
FICEM 2010 12
13
Our Success FactorsComplete Product and Service Program
FICEM 2010
14
MarketsInstalled Plants Worldwide
FICEM 2010
Scheuch customer reference list (extraction)
FICEM 2010 15
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
16
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
FICEM 2010 17
The advanced bag cleaning system
FICEM 2010
Comparison: Online / Offline
Online OfflineAdvantages • Constant filter differential
pressure• Small filter differential pressure
(cleaning without counter-pressure)• Small cleaning pressure and
compressed air demand• Higher lifetime of the filter bags
Disadvantages • Constant increasing filter differential pressure
• Early ageing of the filter bags
• High energy demand for the cleaning process
• High variation of the filter differential pressure
• Negative effects on primary processes and product quality
18
FICEM 2010
Online OfflineAdvantages • Constant filter differential
pressure• Small filter differential pressure
(cleaning without counter-pressure)• Small cleaning pressure and
compressed air demand• Higher lifetime of the filter bags
Disadvantages • Constant increasing filter differential pressure
• Early ageing of the filter bags
• High energy demand for the cleaning process
• High variation of the filter differential pressure
• Negative effects on auf primary processes and product quality
EMC = Advantages of Online + Offline
19
FICEM 2010
Filtration principle
20
FICEM 2010
EMC – The decisive difference
At the EMC cleaning process, the filter modules are cleaned alternately
The module, which is taken out of the gas flow, is recovered in flowless condition
Due to the patented, diametrically opposed switching, the active filter area stays constantly, and also the filter differential pressure remains roughly constant
21
On 25th April 2003 under no. AT 410403 the Austrian patent, and on 6th Oktober 2004 under no. EP 1404431 the European patent of Scheuch GmbH, Aurolzmünster/Österreich, for EMC cleaning technology was issued.
FICEM 2010 22
EMC: Patented switching sequence
FICEM 2010
Advantage: Patented switching sequence
23
FICEM 2010
Advantage: Cleaning under flowless condition
Efficient and soft cleaning because there appears no counter-pressure
Less cleaning pressure and small compressed air demand
Decrease of the cleaning frequency
Less mechanical load of the filter bags
Noticeably longer bag lifetimes
24
FICEM 2010 25
Advantage: Cleaning under flowless condition
26FICEM 2010
Advantage: Cleaning under flowless condition
27FICEM 2010
Advantage: Cleaning under flowless condition
FICEM 2010
The Benefits of EMC:
28
less investment costs plant availability > 99 % up to 30 % less fan power doubling of the bag lifetime up to 80 % less compressed-air
consumption low outlet dust concentration lower sound emission
FICEM 2010 29
Story of sucess
2001: First EMC filter installed in Lafarge Mannersdorf / AT 2003: Scheuch got patent for EMC technology 2004: Saving effects practically confirmed 2005: EMC makes 8m filter bags possible (standard today) 2007: 100. EMC filter sold 2008: Research project for 10m bags finalized 2009: New controller: EMC-PulseMaster Today: more than 150 EMC filters with 60 Mio. Am³/h sold
FICEM 2010
EMC: Performance data and application
Volumetric flow: up to 3,000,000 Am³/h Dust load: up to 1,000 g/m³ Cleaning pressure: 0.8 – 3 bar Types of application:
Kiln-/Raw millAlkali Bypass Clinker coolerCement millCement separator
30
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
31
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
FICEM 2010 32
Minimum Operating Costs
due to optimum operating point and correct filter design
3 main cost factors: Fan power consumption Filter bag costs and Compressed air costs
cost factors: behave interdependently dependently on filter pressure difference.
FICEM 2010 33
Minimum Operating CostsEMC Filter for kiln dedusting
FICEM 2010 34
Minimum Operating CostsEMC Filter for kiln dedusting
FICEM 2010 35
Minimum Operating CostsEMC Filter for kiln dedusting
FICEM 2010 36
Minimum Operating CostsEMC Filter for kiln dedusting
FICEM 2010 37
Minimum Operating CostsEMC Filter for kiln dedusting
FICEM 2010 38
Minimum Operating CostsEMC Filter for cement mill
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
39
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
FICEM 2010 40
Minimum investment costsdepending on filter area loading
A higher filter area loading enables: Reduction of the
filtration area Less size of the
filter unit Less secondary
investment costs (filter support construction or building, form works)
[m/min]
100%
79%
66%
FICEM 2010 41
Minimum investment costsdepending on filter bag length
Longer filter bags enables: Less size of the
filter unit Less secondary
investment costs (filter support construction or building, form works)
100%
83%
77%
FICEM 2010 42
Customer:HOLCIMThi Vai / Vietnam
Application:Dedusting of a vertical mill for cement grinding with high dust load and 6,000 mm filter bag length
Technical data:V = 622,000 Am3/hm = 322 g/m³m = 200 t/h
Start-up:2004
Benefit: Less investment costsComparison 6 m 8 m
FICEM 2010 43
Benefit: Less investment costsComparison 6 m 8 m
Filter length: 6 m
FICEM 2010 44
Benefit: Less investment costsComparison 6 m 8 m
FICEM 2010 45
Savings
due to 8 m
Technology
Benefit: Less investment costsComparison 6 m 8 m
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
46
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
FICEM 2010 47
Lowest Life Cycle Costs
Minimal operating costs Energy saving Utilization of process heat
The operating costs aremany times higherthan the investmentcosts
FICEM 2010 48
low operating costs high investment costs low investment costs high operating costs
Lowest Life Cycle Costs
Optimum ?
[m/min]
100%
79%
66%
FICEM 2010 49
Lowest Life Cycle CostsComparison kiln dedusting of Online and EMC
FICEM 2010 50
Life Cycle CostsComparison mill dedusting of Online and EMC
FICEM 2010 51
Lowest Life Cycle Costsconclusio
draw attention to the interactive design parameters of filter area loading and pressure drop, which have to be put into an optimum relationship when designing
optimum adaptation to the correct operating point depending on the upstream process
Filter system should able to follow the variable modes of operation and performs continuous adjustment to the optimum mode of operation.
Scheuch therefore developed the EMC-PulseMaster controller specially for controlling the cleaning of process filters.
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
52
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
FICEM 2010
Cementos Apasco S.A. de CVPlant „Macuspana“
53
FICEM 2010
Macuspana dedusting plantFacts
Customer: Cementos Apasco, S.A. de CVMacuspana, Mexico
Application: Clinker grate cooler dedusting
Design data: Kiln performance: 2600 t/d Air ratio at normal operation conditions: 310,000 Am³/h @ 350 °C Air ratio at upset operation conditions: 310,000 Am³/h @ temporary up to 525 °C Raw gas dust load: max. 20 g/Nm³ Clean gas dust content: max. 10 mg/Nm³
Special conditions: Kiln stoppage time: 16 days (for dismantling of existing electrostatic precipitator
including ducts and fan, erection and start-up of the new Bag filter dedusting plant) Tight local installation situation Small area for the pre-assembling works
54
FICEM 2010
Macuspana dedusting plantErection (1)
Pre-assembling of the tube bundle for the air/air-heat exchanger Start of dismantling the electro filter The EMC filter is mounted with pre-assembled construction units
55
FICEM 2010
Macuspana dedusting plantErection (2)
Erection of the filter penthouse Installation of the Scheuch fan
56
Macuspana dedusting plantVideo
FICEM 2010 57
FICEM 2010
Macuspana dedusting plantComparison actual / nominal values
Air/air-Heat exchanger Designnormal operation
Measures aftertwo months operation
Air volume cooler inlet 310,000 368,335 Am³/h*Gas temperature inlet 350 377 °CAir volume cooler outlet 195,000 240,000 Am³/h*Gas temperature outlet 120 145 °CPower consumption of the axial fans 34.0 17.8 kWLoss of pressure 2.5 1.0 mbar
EMC-Filter Designnormal operation
Measures aftertwo months operation
Air volume filter inlet 195,000 217,700 Am³/hGas temperature filter outlet 120 110 °CFilter surface load 0.82 0.916 m³/m²minLoss of pressure over the whole filter 10 3,5 mbarCompressed air consumption 60 7.0 Nm³/hCleaning pressure 0.8 – 3.0 1.9 BarClean gas dust content 10 < 2.0 mg/Nm³
58
FICEM 2010
Content of presentation
Scheuch Company Profile
Case Study Macuspana
Other References in South-America
59
EMC – The Benchmark
EMC – Minimum Operating Costs
EMC – Lowest Life Cycle Costs
EMC – Minimum Investment Costs
Holcim Ecuador S.A.Plant „Cerro Blanco“
Customer:Holcim Group Support, Inc.US-Miamifor Holcim Ecuador S.A.Plant „Cerro Blanco“EC-Guyaquil
Application:Clinker cooler dedustingLine 1 + 2
Air ratio:2 x 310,500 Am3/h
Start-up:2007 + 2010
FICEM 2010 60
Cemex Colombia S.A.Plant „Caracolito“
Customer:Cemex Colombia S.A.Plant „Caracolito“CO-Ibagué
Application:Retrofit electrostatic precipitator to EMC-bag filter
Air ratio:250,000 Am3/h
Start-up:2006
FICEM 2010 61
Cementos Catatumbo C.A.
Customer:Cementos Catatumbo C.A.VEN-Maracaibo
Application:Clinker cooler dedusting
Air ratio:296,311 Am3/h
Start-up:2008
FICEM 2010 62
Cementos Bío Bío S.A.
Customer:Loesche GmbH, Germanyfor Cementos Bío Bío S.A.CHILE-Curico
Application:Cement mill dedusting
Air ratio:360,000 Am3/h
Start-up:2007
FICEM 2010 63
CUSTOMER END USER APPLICATION CAPACITY Am³/h DELIVERYClaudius Peters AG, Germany Acominas, Brasil Hard coal grinding mill 165,000 1999Loesche GmbH, Germany San Antonio, Chile Cement mill dedusting 199,749 2007
Christian Pfeiffer GmbH, Austria San Juan, Chile Cement mill dedusting 1 x 35,0001 x 10,000 2008
Christian Pfeiffer GmbH, Germany Riobamba, Ecuador Cement mill dedustingSeparator and dryer
1 x 73,5001 x 41,5001 x 30,000
2003
Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Kiln dedusting 45,000 2004Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Lime dedusting 45,000 2007Maerz Ofenbau AG, Switzerland Cementos Progreso SA, Guatemala Kiln dedusting 75,500 2009Grenzebach-BSH GmbH, Germany Queretaro, Mexico Gypsum mill calcination 95,000 2002
Grenzebach-BSH GmbH, Germany Tecoman, Mexico Gypsum mill calcination 96,500 2006
Christian Pfeiffer GmbH, Austria Cementos Panama (Cemex) Coal grinding plant 100,000 2008
Polysius AG, Germany Panarol, Panama Cement mill dedusting 275,000 2008
Holcim Miami, USA Cementos de El Salvador Kiln-/Raw mill dedustingClinker cooler dedusting
1 x 150,0001 x 295,000 2008
Polysius AG, Germany Urumincom, Uruguay Petrol coke grinding plant 32,000 2002
Inteco GmbH, Austria Minera Loma, Venezuela Kiln dedusting 110,000 1999Mannesmann Demag, Germany Minera Loma, Venezuela Kiln dedusting 250,000 1999Polysius AG, Germany Lomared, Venezuela Nickel ore processing plant 50,000 1999Holcim Miami, USA Holcim Venezuela C.A. Kiln dedusting, ESP Retrofit 493,000 2007Ehdasse Sanat, Iran Cerro Azul Cement, Venezuela Cement mill dedusting 2 x 470,000 2007
Ehdasse Sanat, Iran Cerro Azul Cement, Venezuela Kiln-/Raw mill dedustingClinker cooler dedusting
1 x 647,0001 x 390,000 2009
Cementos Argos Rioclaro Plant Colombia Coal grinding plant 30.500 2010
Further Scheuch filter plants in Latin America
FICEM 2010 64
FICEM 2010
Thank you for yourattention!