In this blog, we will examine the cement industry and dust collection needs and the benefits of planned maintenance outages. Cement plants rely heavily on dust collection systems for a variety of processes in their plants including kiln baghouses, alkali baghouses, and clinker coolers. Cement producers must comply with strict emissions control standards, NESHAP (National Emission Standards for Hazardous Air Pollutants) Requirements.
Cement: A Vital Part of Essential Infrastructure Sector
Cement is manufactured through a closely controlled chemical combination of calcium, silicon, aluminum, iron and other ingredients. Materials used to manufacture cement include limestone, shells, and chalk combined with shale, clay, slate, silica sand, and iron ore. These ingredients, when heated at high temperatures form a rock-like substance that is ground into the fine powder that we commonly think of as cement. Cement mixed with sand, gravel, and water makes up concrete. Cement – as a binding materials – is a very important building material; it is the cement that serves as the glue that holds the concrete together!
As the principal ingredient in concrete, cement is a vital part of the important infrastructure sector of the economy and cement consumption is typically linked to the demand from the construction industry. Cement consumption is often heavily linked to the demand from the construction industry. According to data from Statista, the consumption of cement in the United States reached approximately 102 million metric tons in 2019, having steadily increased since the 2008 recession.
Challenging Dust Control Environment – Maintenance Outage Planning Is Key
Cement plants can be challenging environments for dust collectors, depending on the process. You may have dust particles that are lightweight and fine, or hard and abrasive, worsened if moisture is introduced into the system.
Combinations of high temperature and high moisture/humidity can significantly shorten filter bag lifetime by creating a dense, hard to clean dust cake on the filter media. In addition, these conditions can cause material build-up in the duct work and dust collector, leading to plugged duct work and bridging in the hoppers.
Besides operating considerations, we don’t need to tell you about the occupational health hazards associated with exposure to cement dust. A variety of studies have suggested associations between cement dust inhalation and acute respiratory symptoms, lung function impairment, and lung diseases.
Proper maintenance of the baghouses in your cement plant can ensure proper emissions control & compliance with NESHAP requirements.
Micronics offers a Full Range of Baghouse Solutions for all areas of the cement plant process flow including:
- Clinker Cooler
- Finish Mill
- Coal Mill
- Storage Silos
- Bulk Loading & Unloading
- Ancillary Belt Transfer Systems
Filter Media Solutions for the Cement Industry
Cement industry filter media solutions that we manufacture in-house in our two high-quality North American filter media facilities include:
High Temperature Media
- Fiberglass with ePTFE
- Blended Felts
Low Temperature Media
All of these filter media options can be laminated with ePTFE or treated with a finish to address the specific challenges you are facing.
Our expert inside and outside technical sales resources will be happy to review your cement plant requirements and assist in finding the right filter media solution for your needs. We will also help you to ensure a proper spare parts inventory for your cement plant process flow. This will help ensure the effectiveness of your next planned maintenance outage.
Baghouse Maintenance Services for the Cement Industry
Micronics has proven experience with cement producers in reducing emissions, controlling associated occupational hazards, and minimizing spikes/emergency excursions. While emergency situations may take place, scheduled plant downtime helps to reduce overall costs including energy, ensure proper inventory of filter bags, spare parts, cages, etc., and ensure trained service crews are properly scheduled.
Having replacement filter bag installations scheduled by our trained and certified crews is a good tool for ensuring proper cement baghouse operation and emissions compliance.
The Micronics Engineered Filtration Group provide expert on-site Baghouse Maintenance & Repair Services including:
- Filter bag change-out services
- Mechanical repairs
- collector rebuilds
- tubesheet floor replacement
- pulse-jet cleaning system rebuilds
- damper repair/replacement
- expansion joint replacement
- hopper repairs/replacements
- and more
- Baghouse inspections
- System audits
Contact us so that we can put our expertise to work for your cement plant’s dust control challenges. If you have not yet scheduled your next planned outage, please reach out to us. Now is the time to be scheduling maintenance for your next planned outage.