Cement Dust Collection Systems - for emission and process control

Posted by Justin Dechene on Feb 10, 2015 5:06:00 PM

Are you maximizing your value of your Cement Dust Collection Systems using Bag Leak Detection Systems to monitor both emission and process control applications?

Whether you are working directly with Cement Dust Collection Systems or in other industries where similar monitoring capabilities apply, we would like to outline solutions used by a Major Cement company in the US using triboelectric dust monitors in a few different ways successfully….

Portland Cement rules dictate that manufacturing facilities adhere to strict emission guidelines. In this instance, this particular company wanted to:

  1. both minimize visual inspections while keeping in compliance
  2. measure solids flow in the finish mill circuit to determine reject flow rate.

a cement dust collection system can enhance operations while meeting regulatory requirements

Emission application issues and solutions…….

As most of the material streams in a modern cement plant are dry, emission control is essential to plant operation. Additionally, the plant must monitor the operation of its dust collectors on a regular basis- main dust collectors are also monitored by the Department of Environmental Protection (DEP). While the plant was required to visually inspect(Method 22) dust collector emissions daily per requirements, the plants preference was to automate the process thus making the inspection process more efficient. Therefore, the plant applied to the DEP hoping to use an automatic method as opposed to labor intensive visual observation.

The plant applied for, and received permission to use a Bag Leak Detection System for their regular monitoring requirements. This plant subsequently installed 4 electrostatic triboelectric bag leak detection systems satisfying both DEP requirements and plant goals to eliminate the labor intensive task and automate- thus creating more efficiency.

Plant process application problem and solution…..

As with many Cement plants, there were issues maintaining the proper level of material into the ball mills based on the amount of material going through the reject air slide. There were initial issues determining the best solution as there was not a lot of space for an easily installed traditional approach. However, the plant was determined to know material flow in the reject air slide from the finished mill high efficiency separator in order to continually automate any closed loop adjustment and information to operators.

While closed loop control can be challenging solutions to find, BLDS units were installed on the reject air slide of the finish mill and provided wide dynamic range that was able to capture all different flow levels without manual adjustment for sensitivity. By successfully monitoring the flow rate, the closed loop system was better able to control the feed rate into the finish mill which ultimately provided more efficient operation which created better (more valuable) final product.

To conclude, it's about more than just "check the regulatory box" cement dust collection systems.  When thinking about how to optimize your compliance, production, and operations, a BLDS can offer many application solutions throughout your plant environment ---- think of this technology as more than a simple dust detector, and more of a solution for both environmental and process applications for your plant operations.

Please take a look at the following Cement Case study that in more detail discusses emissionand process control in the cement industry and check out our helpful eBooks as well.

cement plant case study

Topics: MACT Reporting, Dust Collection