Course 7 Environmental Protection

7.2 Dedusting Equipment

Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 781
Fax: +49 211 45 78296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Gravity Separators and Centrifugal Separators............................................ 1
2.1 Gravity-Counterflow Separators ......................................................................... 2
2.2 Gravity-Crossflow Separators............................................................................. 3
2.3 Inertial Separators............................................................................................... 3
2.4 Centrifugal Separators ........................................................................................ 4

3 Filtering and Electrostatic Dedusters ............................................................. 6

3.1 Bag Filters........................................................................................................... 7
3.2 Panel Filters or Pocket Filters............................................................................. 9
3.3 Electrostatic Precipitators ................................................................................... 9
3.3.1 Conditioning Towers........................................................................................... 13

4 Health and Safety Practices ............................................................................. 14

5 Factors Affecting Plant Production and Product Quality............................. 16 i

6 Maintenance and Inspection............................................................................ 16

7 Energy and Environment ................................................................................. 17

8 Questions on Course LB 7.2 Dedusting Equipment ................................... 18

Solutions............................................................................................................................... 20
Glossary ............................................................................................................................... 23

Index..................................................................................................................................... 24

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1 Introduction
Dust is the collective term for extremely fine solid particulate material (particles) that is
produced by mechanical processes or by entrainment and may be suspended in gases, in
particular in the air, for a long period of time. The particles may contain heavy metals
and/or inorganic pollutants.

The pollutant content of the dust and the size of the dust particles are of particular impor-
tance from an environmental and health perspective.

Particles with a diameter greater than 10 m that become trapped in nasal hair and
mucous membranes in the nose and throat area when inhaled are referred to as coarse
dust. In contrast fine dust, which refers to particles having a diameter less than 10 m,
may penetrate deep into the lungs and so cause a number of lung diseases, including
cancer.
Dust may be produced by various natural and anthropogenic processes. Large amounts
of dust are produced in nature, for example by soil erosion, sandstorms, forest fires or 1
volcanic eruptions. Anthropogenic sources of dust are mainly industrial processes and
traffic.
Cement production is an industrial process that creates a particularly large amount of dust.
This starts with the blasting in quarries, including during the numerous operations involved
in transporting and handling the blasted material, and continues during the processing of
the raw materials and fuels, and in particular during the clinker burning process in rotary
kiln plants and during cement grinding.
Typical dust concentrations in the raw gas stream of rotary kilns with cyclone preheater Typical dust
are within a range of 500 100 g/m3. Concentrations in the exit gas of grate coolers are concentrations

between 1-10 g/m3; and in the exit gas of grinding systems dust concentrations of up to
1000 g/m3 are possible.
In the 1950s there were dust emissions of up to 3000 mg/m3 from the chimneys of rotary
kiln plants in the cement industry, but thanks to modern equipment for reducing dust emis-
sions this can now be limited to a maximum of 20 mg/m3 .

In this course you will learn about the methods and systems used to reduce dust in cement
works, with separate sections on product separators used to collect the production dust
in the gas flows from grinding plants, preheater systems or pneumatic conveyors (mostly
Course Summary
gravity separators and centrifugal separators in grinding plants also cloth filters), and on
separators for dedusting exhaust gases that are released into the atmosphere (electrostatic
and filtering separators).

2 Gravity Separators and Centrifugal Separators

The following systems for separating production dust in the gas flow of grinding plants,
preheater systems or pneumatic conveyors will be described:
 Gravity-Counterflow Separators, p.2
Course Summary
 Gravity-Crossflow Separators, p.3
 Inertial Separators, p.3
 Centrifugal Separators, p.4

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 2 Gravity Separators and Centrifugal Separators

2.1 Gravity-Counterflow Separators

Gravity-counterflow separators are dust chambers through which the exhaust gas flows
vertically. The particles fall downwards against the flow due to the force of gravity (Fig.
2.1-1).
Use This design is used with flow velocities of 1 to 3 m/s.

Calculation
Gravity-counterflow separators collect all particles with a settling velocity (w)
greater than the flow velocity (v).

The following condition therefore applies to the design of a gravity-counterflow sepa-

rator:
w>v
Explanation:
 w: settling velocity of the particles [m/s]
2  v: flow velocity of the gas [m/s]

At this point in the online course you would see an animation of a gravity-counterflow
separator instead of Fig. 2.1-1.

clean gas

collected
raw gas dust
a) coarse particles
b) fine particles
c) lines of flow of the
carrier medium

Figure 2.1-1: Gravity-Counterflow Separator .

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 2.2 Gravity-Crossflow Separators

2.2 Gravity-Crossflow Separators

Gravity-crossflow separators are dust chambers through which gas flows horizontally.
The particles fall into the outlet by the force of gravity, perpendicular to the direction of
flow.
This design is used with low flow velocities of 0.5 to 1.5 m/s. Use

Calculation
The size of a gravity-crossflow separator is determined by:
H v
L = w

Explanation:
 H: height of the separator [m]
 L: length of the separator [m]
 v: flow velocity [m/s]
 w: settling velocity [m/s]

At this point in the online course you would see an animation of a gravity-crossflow sepa- 3
rator instead of Fig. 2.2-1.
raw gas clean gas

b
c
a

collected dust

a) coarse particles
b) fine particles
c) lines of flow of the carrier medium

Figure 2.2-1: Gravity-Crossflow Separator .

2.3 Inertial Separators

Inertial separators are gravity separators that divert the gas flow, for example with obstacles
such as deflector plates. Due to their mass inertia the dust particles do not follow the flow
or only follow it to a certain extent.
At this point in the online course you would see a number of animations on inertial sepa-
rators instead of Fig. 2.3-1.

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 2 Gravity Separators and Centrifugal Separators

a) settling chamber b) settling chamber c) vertical elbow

with no internal with internal
fittings (dust bag) fittings

c
b
b
b
a
c a c

a a collected material

a coarse particles
b fine particles
raw gas
collected c lines of clean gas
material flow of the
4
carrier medium

Figure 2.3-1: Animations 3a, b and c: Inertial Separators .

2.4 Centrifugal Separators

For high levels of dust centrifugal separators in the form of cyclones are used as product
separators and as preliminary collectors.
Structure and Function Centrifugal separators consist of four main parts:
 inlet cylinder (top)
 cone (centre)
 particle collection container (hopper, bottom)
 top outlet duct (installed centrally from above in the inlet cylinder)
The gas flow enters the separator tangentially and, after being diverted, exits vertically
in an upward direction via a top outlet duct. A centrifugal force that acts on the dust
particles is produced by the rotational movement. As the cone tapers the speed of rotation
increases to such an extent that the particles are flung against the wall of the cone by the
centrifugal force. The gas leaves the cone upwardly through the central top outlet duct
whilst the separated particles fall downwards into the hopper.
Types Cyclones are grouped into different categories, depending on the design:
 single cyclone, normally with large diameters (up to 1,500 mm) and large overall
height.
 multiple cyclones, each with a diameter of about 500 to 1,500 mm, in which the gas
flow is divided equally between the individual cyclones connected in parallel.
 multicyclones (multi-stage separators) that have diameters of 500 mm, are installed
in compartments and have a common dust outlet.
Multicyclones normally require less ground area than multiple cyclones connected
in parallel. In addition the smaller diameter provides the individual cyclones with a
greater centrifugal effect and therefore a better collecting efficiency.
At this point in the online course you would see an animation of a single cyclone instead

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 2.4 Centrifugal Separators

of Fig. 2.4-1.

clean gas outlet

raw gas inlet

top outlet duct

dust-drop chamber 5

Figure 2.4-1: Single Cyclone .

At this point in the online course you would see an animation of multicyclones instead of
Fig. 2.4-2.

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 3 Filtering and Electrostatic Dedusters

A raw air inlet

B clean air outlet
C housing doors
D coarse dust discharge
E fine dust discharge

Figure 2.4-2: Multiple Cyclones .

3 Filtering and Electrostatic Dedusters

The following separator systems for dedusting exhaust gases that are released into the
atmosphere will be described:
 Filtering Dedusters
Course Summary
 Bag Filters, p.7
 Panel Filters or Pocket Filters, p.9
 Electrostatic Dedusters
 Electrostatic Precipitators, p.9

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 3.1 Bag Filters

3.1 Bag Filters

Bag filters belong to the group of filtering dedusters. Woven fabric is used as the filtering
medium and the air is drawn through it (similar to the filtering principle in a vacuum
cleaner).
Compared to electrostatic precipitators, bag filters are less sensitive to carbon monoxide Advantages and
and have a better collecting efficiency. However, it should be noted that bag filters are Disadvantages

sensitive to moisture and excessive temperatures. The gas to be cleaned may therefore
only contain a low level of moisture and must have a temperature of approx. 160-180C,
as filters containing the filter fabrics currently used are destroyed if they are exposed to
higher temperatures. When using bag filters particular attention should be paid to ensure
the bag filter is free of condensation, as otherwise the filter fabric sticks together and may
have to be replaced.
Bag filters consist of a very finely woven fabric and are tubular. Bag filters come in the Structure
form of single-chamber or multi-chamber filters and are positioned either in rows or in a
circle (Fig. 3.1-1). In most cases the raw gas is drawn through the filter, with a vacuum on
7
the clean gas side. The dust particles remain adhering to the inlet side of the filter media,
forming a filter cake. These filter cakes achieve a high level of dust collection from the
flue gas. The filter cake must be removed after a certain length of time and, depending on
the application, is then either reintroduced as material, recycled or dumped .

clean gas valve

clean gas valve rapping device

clean gas duct

bag suspension
scavenging air inlet

filter bags

raw gas inlet

bag base

dust collecting chamber

dust discharge dust discharge

Figure 3.1-1: Structure of a Bag Filter .

Two options are available for cleaning the bags: mechanical and pneumatic cleaning. With Cleaning
mechanical cleaning the bag is cleaned by rapping, shaking and vibrating, normally with
a simultaneous flow of scavenging air in the reverse direction.
There are three possible types of pneumatic cleaning:
 low-pressure cleaning with scavenging air by brief reversal of the gas flow
 medium-pressure cleaning with a pulsating air flow
 compressed-air cleaning ( pulse-jet cleaning)

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 3 Filtering and Electrostatic Dedusters

In recent years the compressed-air cleaning method has been increasingly used to clean
filters. Fig. 3.1-2 shows the filtration and cleaning processes in a bag filter.

cleanin


cleanin filtering

ting frame filter medium

Figure 3.1-2: Cleaning Process in a Bag Filter .

The bags are drawn over supporting frames and are exposed to a flow of gas from the
outside to the inside. During the cleaning process (cleaning controlled on the basis of
time or differential pressure) a propulsive jet of high-pressure compressed air (min. 5 bar
overpressure) lasting for approx. 0.1 to 0.2 seconds is discharged from a nozzle ( venturi
tube ) and in this way draws secondary air that has already been cleaned back into the
filter bag from the clean gas chamber (from the inside towards the outside).
This initiates the following cleaning steps:
 The normal filtering flow is briefly interrupted by the blocking effect of the opposing
flow of scavenging air.
 The bag is suddenly inflated from its star-like shape when it lies against the supporting
frames to its original circular cross-section (Fig. 3.1-3); the dust is detached from the
filter fabric and falls into the collection chamber.
 The scavenging air flows through the filter medium in the opposite direction to the raw
gas flow.
Factors Both the efficiency of filter cleaning and the associated costs may be substantially affected
AffectingCleaning by pulse duration, pulse interval, valve size and pressure. The benefits of compressed-
air cleaning include the fact that it can take place during routine operation and the clean-
ing process is very brief so the entire filter area is almost always available for filtering.
Acoustic cleaning using acoustic horns (sonic horns) may also be a useful addition to
the existing cleaning system. These horns generate shock waves of approximately 120 to
150 dB that clean the filter media.
Filter Media Various factors such as temperature, moisture, raw gas composition and abrasive proper-
ties need to be considered when selecting the filter media. Abrasion is a well-known
problem, particularly at the raw gas inlet. This can be counteracted by, for example, using
filter cartridges (folded filter elements).

At this point in the online course you would see a video on the replacement of an electro-

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 3.2 Panel Filters or Pocket Filters

filtration cleaning

clean gas scavenging air

filter bag

filter
housing,
gastight
raw gas exhaust air

dust

Figure 3.1-3: Principle of the Cleaning Process .

static precipitator with a bag filter.

3.2 Panel Filters or Pocket Filters

Panel filters or pocket filters belong to the group of filtering dedusters.
They have frames that are covered with filter fabric. In this case, the dusty air also filters Function
through from the outside towards the inside and the dust is retained on the outer side of
the filter surface.
Cleaning may be carried out using compressed-air jets, as in bag filters, or else using a Cleaning
travelling scavenging air duct with fans.
Panel filters require less space than bag filters although it is more difficult to obtain a
uniform distribution of gas over the surfaces. Bag filters are also easier to maintain. Fig.
3.2-1 shows the structure of a pocket filter.

3.3 Electrostatic Precipitators

Electrostatic dedusters are mainly used when dedusting kiln exhaust gas and cooler ex- Use
haust air, but are also used for dryers and combined drying and grinding plants, cement
grinding plants and raw meal grinding plants with water injection.
The collecting efficiency of electrostatic precipitators is lower than that of bag filters. In Advantages and
addition, attention must be paid during operation to the concentration of carbon monoxide Disadvantages

in the gas since otherwise the gas could explode in the electrostatic precipitator (sparking

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 3 Filtering and Electrostatic Dedusters

9 2

8
8

5 3

10

7
1. raw gas inlet
2. raw gas distribution chamber
3. dust collection chamber
4. filter elements (pockets with spacing mats)
5. partition between raw gas chamber and clean gas chamber
6. clean gas collection chamber
7. clean gas outlet
8. travelling cleaning device
9. scavenging air inlet

Figure 3.2-1: Structure and Operating Principle of a Pocket Filter .

caused by electrical discharge). However, electrostatic precipitators are less susceptible

than bag filters to moisture and higher exhaust gas temperatures.
Structure In electrostatic precipitators, which are mostly in the form of horizontal chambers, the
gas flow containing dust is guided as uniformly as possible through one or more consec-
utive electrostatic high-voltage bays. The high-voltage bays are made up of alternating
discharge electrodes and collecting electrodes. The collecting electrodes are earthed. A
direct-current voltage of 50 to 110 kV is applied to the discharge electrodes. The dust
particles contained in the gas flow become electrically charged in the electric field formed
between the discharge electrodes and the collecting electrodes.
Process The collection process may be divided into five separate phases, which are explained in
greater detail below:
 generation of electric charge
 charging of the dust particles in the electric field
 transport of the charged dust particles to the collecting electrode

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 3.3 Electrostatic Precipitators

 adhesion of the dust particles to the collecting electrode

 cleaning of the layer of dust from the collecting electrode
At this point in the online course you would see an animation of the collection process
instead of this picture.

11

Figure 3.3-1: Simplified Illustration of the Collection Process .

The discharge electrode is normally connected as a cathode (-). It is in the form of a Operating Principle
wire and is either smooth or has barbs (barbed wire). A negative corona is generated at
this electrode and this releases electrons. Gas molecules are ionized around the discharge
electrode as they take on or release electrons. Due to the applied voltage the electrons and
gas ions move towards the collecting electrode (anode) in the form of an earthed plate.
In order to keep the electron flow as high as possible the applied voltage is controlled
so as to avoid continuous sparking ( arcing ). On their way to the collecting electrode
the ionized gas molecules eventually come in contact with dust particles, which become

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 3 Filtering and Electrostatic Dedusters

charged by taking on electrons. The flow of electrons, charged gas molecules and dust
particles is called an electric wind, which may have a migration velocity of several
m/s. The migration velocity, also known as the m-value, is a key empirical value for
the dimensioning and can be used to help calculate the dedusting efficiency. Fig. 3.3-2
illustrates the collection process.
A loose deposit consisting of up to 90 % gas inclusions and up to 10 % solids is formed on
the collecting electrode. As the dust load increases the dust layer becomes compacted. It
is important that the dust layer and the particle build-up exhibit sufficiently high resistance,
as this prevents the charge from dissipating too quickly towards the collecting electrode
and prevents the dust from falling back too soon into the gas chamber. The dust layer
should accumulate until it is so thick that it falls down, either by the force of gravity
alone or with the aid of mechanical vibration of the collecting electrode (rapping), and is
collected in the dust hopper. If the dust layer becomes too highly charged a reverse corona
discharge may take place and the dust collection is reduced.
It is therefore necessary to regulate the electrical resistance of the dust and control it so
12 that the collection conditions are optimal. The electrical resistance of the dust particles
is regulated by conditioning the gas. The gas temperature is lowered and the dew-point
temperature is increased by spraying and vaporizing water in a conditioning tower .
Fig. 3.3-2 shows that optimal dust resistance is also close to the critical dust resistance at
approx. 180 C.

dew-point of the gas [C]

critical dust
resistance
specific dust resistance [ cm]

exhaust gas temperature [C]

Figure 3.3-2: Dust Resistance as a Function of Exhaust Gas Temperature .

Designs Electrostatic precipitators differ in the shape and size of filtering channels (pipes, plates),
the shape of the discharge electrodes (helix, wire, barbed electrode), the operating voltage
(direct- or alternating-current voltage, pulsed or pulse-superposed direct-current voltage)
and the type of cleaning (rapping, scavenging). The filter housings are made of sheet steel
or reinforced concrete and generally have insulation between 50 and 150 mm thick. The
gas is distributed uniformly at the filter inlet over the entire cross-section of the chamber
opening by appropriate internal flow fittings (e.g. perforated plates). The dust collection
hoppers are equipped with internal fittings to prevent by-pass flow through the hopper (Fig.
3.3-3).
The discharge electrodes are fixed to supporting profiled parts inside pipe frames or may
also be weighted and freely suspended. The collecting electrodes, on the other hand, are
normally formed as plates with differing profiles. A high level of rigidity and good collect-
ing efficiency for the dust are required here. The distances between discharge electrodes

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 3.3 Electrostatic Precipitators

flow baffles to
avoid by-pass
gas flow

pointed hopper

troughed hopper
13

flat hopper

Figure 3.3-3: Examples of Internal Hopper Fittings .

and collecting electrodes, which are usually made of normal steel (or corrosion-resistant
special steels in exceptional cases) are between 125 and 150 mm in older precipitators
and are 200 mm in new precipitators. The duration and intensity of electrode rapping is
adapted to suit the mass of accumulating dust and the dust properties. Iindividual rapping
of the individual voltage bays is advisable. The first voltage bay is normally rapped more
frequently than the subsequent voltage bays.
The high-voltage system consists of a transformer, rectifier and switch cabinet. It is nor-
mally supplied with alternating-current voltage and is operated just below the arcing limit
using an automatic voltage control. This is necessary because the collecting efficiency is
heavily dependent on the voltage applied.

3.3.1 Conditioning Towers

Where necessary conditioning towers provide the physical conditions required for the
electrostatic precipitator to operate smoothly. The hot transport gas, and therefore also the
dust, is cooled to the optimal operating temperature by water injection in a conditioning
tower. The increase in gas moisture also reduces the dust resistance.
The main components of a conditioning tower are: Components
 the gas inlet cone with internal fittings for gas distribution,
 the cylindrical conditioning tower shell in which the exhaust gases are cooled and
conditioned by the injection and subsequent evaporation of water,

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 4 Health and Safety Practices

 the dust collection hopper in which the dust that has dropped out of the gas is collected,
and
 the spray system with recycling or dual-material nozzles.
Requirements Requirements for optimal gas conditioning in the conditioning tower include:
 a sufficiently high inlet temperature (above approx. 280 C),
 a uniform distribution of the gases over the entire cross-section of the conditioning
tower, for example via gas distribution baffles,
 a sufficient residence time in the spray tower so the injected water is completely evap-
orated, and
 uniform, extremely fine injection of water.
Water is normally injected through the annular recycling nozzles in the upper part of the
cooler, co-current with the gas (Fig. 3.3-4). These nozzles are controlled by the tempera-
ture at the gas outlet and in some cases also by the volume flow.

14
cross-section along A-A

electrostatic
precipitator

conditioning
tower

Figure 3.3-4: Electrostatic Precipitator with an Upstream Conditioning Tower .

System When the conditioning tower is in operation the amount of water injected must be adjusted
quickly and accurately to suit changing operating conditions. The usual positions for the
conditioning tower within the overall system consisting of the kiln, combined drying and
grinding plant and electrostatic precipitator are as follows:
 conditioning tower after the cyclone preheater, before the kiln exhaust gas fan
 conditioning tower after the kiln exhaust gas fan, before the combined drying and
grinding plant
 conditioning tower in parallel with the combined drying and grinding plant
 conditioning tower after the combined drying and grinding plant for hot kiln exhaust
gas and cooler exhaust air (inlet from above) and exhaust gas from the combined dry-
ing and grinding plant (inlet in the middle or below)

4 Health and Safety Practices

ProtectiveEquipment Personal protective equipment must be worn when working on or in any type of separa-
tor, i.e. it is compulsory to wear:
 protective clothing

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 a hard hat
 safety shoes
 gloves
 protective goggles
 protective breathing mask
The following measures must be taken before and during any work performed: Measures
 inform production supervisors and managers of any work taking place.
 disconnect fans before and after the separators at all poles and secure against recon-
nection.
 disconnect all feed and discharge conveying equipment (for example rotary feeders,
screws, aerated trough conveyors, etc.) at all poles and secure against reconnection.
 ensure that no gas can penetrate into the separator; if necessary install manual slide
gates, blanking plates or the like in the pipelines.
 depressurize any installed cleaning devices (air cannons, air nozzles, etc.) and secure
against reconnection.
 ensure that there are no inert gases in the separator, if necessary flush with outside air. 15
 never work in separators without safety lookouts.
 radio equipment or intercoms should be used if visual contact with the safety lookout
cannot be ensured.
The following additional measures must be taken when working on filtering separators: Filtering Separators
 turn off the supply of compressed cleaning air and secure against reconnection.
 depressurize the compressed cleaning air reservoir.
 disconnect scavenging air carriages or similar devices at all poles and secure against
reconnection.
The following additional measures must be taken when working on electrostatic separa-
tors:
 all inspection and entry covers must be closed with a safety lock during operation. Electrostatic Separators
The keys must be kept safe by the person responsible for the safety of the electrostatic
precipitator (for example the electrical foreman).
 inform the electricians before work is carried out in the electrostatic precipitator. This
ensures that:
 the system is shut down from the control room,
 the earthing isolators are connected and the internal fittings in the precipitator are
earthed, and
 the supply to the electrostatic precipitator is disconnected at all poles and secured
against reconnection.
When the system has been made safe the electricians can give clearance for work to be
carried out in the electrostatic precipitator. The rappers should be operated manually for a
few minutes to detach dust from the electrodes in order to prevent unnecessary generation
of dust in the electrostatic precipitator.
The following measures should be taken when working in separators positioned after
coal grinding plants:
 take fire protection measures CoalGrinding Plants
 ensure that there is no gas in the separator and that no gas can form by taking appro-
priate measurements; separate aeration is essential
 work with oxygen breathing apparatus if the formation of gas cannot be excluded

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 6 Maintenance and Inspection

5 Factors Affecting Plant Production and Product

Quality
There are two factors that affect production operation and product quality:
 Mechanical defects, which have a direct effect on product quality, such as a faulty
product separator in the gas flow of a system for drying granulated blastfurnace slag.
This causes the end product to contain an increased amount of unwanted dust from the
gas flow. A faulty product separator in the bypass gas off-take can also, for example,
lead to an increase in undesirable recirculation in the hot meal.
 Process irregularities, which have an indirect effect on product quality, for example
an increase above a specific limit in the dust emissions from separators for exhaust
gases that are released into the atmosphere. This may lead to plant shutdown and
therefore have a negative effect on product quality.

16 6 Maintenance and Inspection

Wear and Corrosion
The material of the separator is matched to the operating conditions of the plants, i.e. it
must be ensured:
 that the operating temperature does not fall below a certain value, resulting in the
separator operating below the dew-point. This can lead to corrosion and if necessary
the system will have to be heated.
 that certain measures are taken in areas that experience particularly excessive wear,
for example the application of wear-resistant materials, such as certain high-grade
ceramics, at elbows.

Maintenance

Maintenance and inspection should always be carried out at set intervals and should be
recorded in a maintenance and inspection book as part of the QM system. This gives an
overview of forthcoming repair and maintenance work.
Maintenance of all separators includes:
 regular visual checks of the system for leaks
 lubrication of discharge units (such as rotary feeders)
 checking the areas that are subject to most wear (such as elbows)
 checking the clean gas duct
 checking the dust discharge
Maintenance of filtering separators also includes:
 checking the cleaning system
 checking the air distribution through deflector plates in the filter housing
 checking dust measurements, if available
 checking the filter media and supporting frames, since experience has shown that dam-
aged or corroded supporting frames are a major cause of bag damage.
Maintenance of electrostatic separators also includes:
 checking the rapping devices
 checking the water injection
 checking the power consumption of the individual chambers

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 checking the dust emissions

Inspection (in electrostatic dedusting units)

 checking the tightness of filter chambers, filter covers, dust hoppers, discharge feeders,
doors, insulation with rain protection, explosion flaps
 checking the condition, attachment and spacing of the electrodes in the electrostatic
precipitator
 checking the gas distribution in the electrostatic precipitator and the gas distribution
partitions
 checking the rapping device (drives, rapping systems, rapping times)
 examining cables and cable connections as well as insulators
 checking the high-voltage units and their control devices
 cleaning the high-voltage switch rooms
 checking the water nozzles, water filters, water pumps, gas distribution, insulation and
dust discharge at the conditioning tower
17

7 Energy and Environment

Energy Consumption
There is no direct influencing factor on energy consumption that applies to all separators
since the structure and shape of separators are designed to be appropriate for the particular
plant. However, an unnecessarily high consumption of compressed air in filtering separa-
tors should be avoided by optimal timing of the cleaning intervals and by eliminating leaks
in the cleaning system.

Environmental Protection and Emissions

Gravity separators and centrifugal separators are used to relieve the load on down- Gravity Separators
stream filter plants, so the following points should be observed in order to avoid disruption andCentrifugal
Separators
to the operation of these separators:
 In areas that are subject to high wear this wear must be counteracted by measures, for
example the application of wear-resistant materials at elbows, etc.
 Fine dusts can easily cause coating and clogging. The following measures can be
taken to avoid this:
 prevent the temperature falling below the dew-point by installing insulation
 at places where the temperature does not fall below the dew-point, coating must be
avoided by installing appropriate materials.
 regular cleaning of problem areas
 The separators are designed for a gas volume flow appropriate to the plant. It is there-
fore necessary to avoid
 underloading the separators as this reduces collecting efficiency, or
 overloading the separators as this leads to an increase in pressure drop and wear.
 Ingress of false air should be avoided by monitoring:
 the fan speed and
 the adjustable damper settings
The following factors may have a detrimental effect on emissions from filtering separa- Filtering Dedusting
tors and should therefore be avoided: Units

 false air ingress

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 8 Questions on Course LB 7.2 Dedusting Equipment

 temperatures falling below the dew-point

 damage to the bags caused by high cleaning pressure or a crooked cleaning jet
 poor filter cake formation caused by excessive cleaning pressure or by cleaning the
bags too often
 poor gas flow distribution over the filter cross-section caused by worn or soiled gas
distribution plates
 incorrect installation of the filter bags, for example
 crooked bag seating
 poor seating of the tensioning rings
 supporting frames that are too short
Electrostatic Dedusting The following factors may have a detrimental effect on emissions from electrostatic pre-
Units cipitators and should therefore be avoided:
 CO shutdown or significant process irregularities
 incorrect conditioning in the conditioning tower or faulty conditioning tower nozzles
 reduced voltage owing to faulty rectifiers or an incorrectly adjusted control system
18  mechanically defective rapping systems
 incorrect rapping intervals
 short circuits caused by deformed plates/wires or the formation of drifts in the elec-
trostatic precipitator caused, for example, by faults in the dust removal system
 soiled or defective gas distribution plates in the electrostatic precipitator inlet
 false air ingress
 temperatures falling below the dew-point
 incorrect gas temperatures (causing changes to the dust resistance)

8 Questions on Course LB 7.2 Dedusting Equipment

You can test your knowledge by answering the following questions.

Question 8.0 A:
1. What is dust and which fraction of dust are distinguished?
2. Why is fine dust so dangerous?
3. Specify 5 different sources for dust in a cement plant!
4. Which types of dedusting technologies do you know?
5. Where and why are gravity separators and centrifugal separators used in a cement
works?
6. What are the main types of gravity separators and centrifugal separators?
7. What are the separation conditions for collecting particles in gravity separators?
8. What are the main parts of a cyclone?
9. You have to do some maintenance work at an electrostatic precipitator. What mea-
sures are necessary to prevent from disruptions and accidents?
10. How can energy consumption be optimized with bag filters?
11. What are the main aspects related with maintenance of a filtering separator?
12. Name a few aspects that can have a negative impact on emissions when operating
an electrostatic precipitator!
13. How does the dust filtration operate in a bag filter?
14. What cleaning method is now used most frequently for bag filters? Briefly describe
its operating principle.
15. Briefly describe the principle of dust collection in an electrostatic precipitator.

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16. How is raw gas conditioned in a cement works?
17. Why is it important to condition the raw gas correctly?
Solutions see p. 20

19

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Research Institute of the Cement Industry
 8 Questions on Course LB 7.2 Dedusting Equipment

Solutions
Solution for 8.0 A:
1. Dust is the collective term for extremely fine sold particulate material (particles)
that is produced by mechanical processes or by environment and may be suspended
in the air for a long period of time. According to the size of dust particles a distinc-
tion is made between coarse dust (diameter gt; 10 m) and fine dust (diameter < 10
m)
2. The particles are so small, that they may penetrate deep into the lungs when inhaling
and so cause a number of lung diseases, including cancer.
3.  blasting in the quarry
 transportation of raw material by truck
 raw mill
 clinker burning process
 cement mill
20  conveyor belts
 clinker silo
4.  gravity and centrifugal separators
 filtering dedusters
 electro static dedusters
5. For high levels of dust they are used as product separators and as preliminary col-
lectors, for example in the gas flows from grinding plants, preheater systems or
pneumatic conveyors.
6. -gravity-counterflow separators
-gravity-crossflow separators
-inertial separators
-centrifugal separators
7. The separation conditions are w > v, where w = settling velocity of the particles and
v = flow velocity of the gas.
8. Inlet cylinder, cone, particle collection container (hopper) and top outlet duct.
9.  inform production supervisors and managers of any work taking place
 inform electricians and wait for clearance to work
 disconnect fans before and after the separators at all poles and secure against
reconnection; disconnect also all feed and discharge conveying equipment.
 depressurize any installed cleaning devices
 never work in separators without safety lookouts (use of radio equipment or
intercoms)
 manual operation of rappers for a few minutes to detach dust from the elec-
trodes
 all inspection and entry covers must be closed with a safety lock after the fin-
ishing of maintenance works
10. Minimizing of pressurized air consumption by
 by optimal timing of cleaning intervals
 by eliminating leaks in the cleaning system
11.  regular visual checks of the system for leaks
 checking the areas that are subject to most wear
 lubrication of discharge units
 checking of the clean gas duct and the dust discharge
 checking of the air distribution through deflector plates in the filter housing
 checking dust measurements, if available

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Research Institute of the Cement Industry
  checking the filter media and supporting frames
12.  CO shut-down or significant process irregularities
 incorrect conditioning in the conditioning tower or fault conditioning tower
nozzles
 reduced voltage owing to faulty rectifiers or an incorrectly adjusted control sys-
tem
 mechanically defective rapping systems
 incorrect rapping intervals
 short circuits caused by deformated plates/wires of the formation of drifts in
the electrostatic precipitator caused, for example by faults in the dust removal
system
 soiled or defective gas distribution plates in the electrostatic precipitator inlet
13. The raw gas is drawn through the filter, with a vacuum on the clean gas side. The
dust particles remain adhering to the inlet side and form a filter cake, which also
achieves a high level of dust collection from the raw gas.
14. Pneumatic cleaning, also known as pulse-jet cleaning.
21
During the cleaning process a jet of high-pressure compressed air (min. 5 bar over-
pressure) is discharged from a nozzle against the gas flow and draws secondary air
that has already been cleaned back into the filter bag from the clean gas chamber
(from the inside towards the outside). This suddenly inflates the bag to its original
circular cross-section. The dust is detached from the filter fabric and falls into the
collection chamber.
15. The gas flow containing dust is guided through one or more consecutive elec-
trostatic high-voltage bays. The high-voltage bays are made up of alternating
discharge electrodes and collecting electrodes. The discharge electrodes release
electrons, ionizing the gas molecules. The high voltage applied causes the gas
molecules to move toward the collecting electrodes. As they move, the gas molecules
come in contact with dust particles, which become charged by taking on electrons
and thus also move toward the collecting electrodes, where the dust is finally col-
lected. When the dust layer becomes thick it falls down, either by the force of
gravity or by mechanical vibration, into a dust hopper.
16. The dew-point temperature is increased and the gas temperature is lowered by
spraying and vaporizing water in a conditioning tower in order to obtain optimal
dust resistance.
17. The electrical resistance of the dust must be controlled and regulated so that the
collection conditions are optimal. This is achieved by conditioning the gas. A
sufficiently high dust resistance prevents the charge from dissipating too quickly
towards the collecting electrode and prevents the dust from falling back too soon
into the gas chamber. If the dust resistance is too high then this may lead to reduced
dust collection.
Questions see p. 18

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Research Institute of the Cement Industry
Glossary
anthropogenic
The term anthropogenic (from the Greek anthropos meaning man and from genesis meaning generation/creation)
refers to anything that is influenced, caused or produced by humans
arcing
Term used to describe a self-sustaining gas discharge between two electrodes
centrifugal force
Physical force that acts upon a body moving along a curvilineal path
Conditioning Tower
Unit for physical conditioning of the kiln exhaust gas before it enters the electrostatic precipitator
corona
Halo of light
formation of drifts
mass of dust formed by drifting particles that overhangs a slope and may easily slide downward (drift = a mass
formed by drifting particles)
mass inertia
Property of a body that causes it to remain in a state of motion, provided no external forces are acting on it 23
pulse-jet
Common term used to describe the process of cleaning bag filters using compressed air
venturi tube
A common throttle device that works on the venturi principle and consists of a tapering inlet section with a
rounded profile, a cylindrical neck section and a discharge cone. In the venturi tube the pressure is at its lowest
where the cross-section of the tube is at its narrowest and the flow velocity is at its highest. Liquids or gases can
be sucked in by the resulting pressure differential. Venturi tubes are used, inter alia, to mix gases or to measure
the flow velocities of liquids and gases.

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 Index

A
anthropogenic 1
arcing 11

C
centrifugal force 4
Conditioning Tower 12
corona 11

F
formation of drifts 18

M
mass inertia 3

24
P
pulse-jet 7

V
venturi tube 8

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