The plant currently has a four-stage suspension preheater kiln with an in-line raw mill. The system has an alkali bypass system designed for 10% bypass. From the kiln, exhaust gases are collected by two baghouses, A-side and B-side. A-side has 16 compartments, each with 290 filter bags (5" diameter by 16.5' long)---> total bags = 4,640 with a design airflow of 154,000 acfm. B-side has 16 compartments, each with 140 filter bags (8" diameter by 26’ long)---> total bags= 2,240 with a design airflow of 183,000 acfm. High emission levels resulted in fines from the Texas Air Control Board. High differential pressure of 14 to 16" H2O across the baghouse and bag blinding problems resulted in an average bag life of 18 months for conventional bags.
Collector Designation: Kiln Baghouse 317A
Collector Manufacturer: Fuller Dracco
Process Description: Cement Kiln Exhaust
Model Number: R/A-4640
Particulate Collected: Kiln Dust
Design Airflow Rate: 154,000 acfm
Design Temperature: 300º F
No. Bags/Compartment: 290
Inlet Grain Loading: 10-300 gr/acf
No. Bags/Collector: 4640
Particulate Size: 99% less than 4.02 microns
Bag Dimensions: 5" dia. x 16.5' long
Distribution: 78% less than 1.12 microns 50% less than 0.78 microns
Cleaning System: Reverse airflow
Bag Material: GORE-TEX® membrane/acid resistant fiberglass fabric (10 oz/yd2)
Air-to-Cloth Ratio Design: Gross 1.53:1 Net 1.63:1
Actual Airflow with GORE-TEX® Membrane Filter Bags: 226,000 acfm
Actual Air-to-Cloth Ratio: Gross 2.25:1 Net 2.41:1
Sealing Mechanism: Grooved snap band
Date Installed: A side–April 1991 April 1997
The first set of GORE® membrane filter bags lasted six years. Emission levels decreased by 75% after installing GORE® membrane filter bags. The differential pressure decreased by 50% across the baghouse. Airflow increased from the design flow rate of 154,000 acfm to 226,000 acfm with an air-to-cloth ratio of 2.25:1.