Cement Kiln / Raw Mill

Cement Kiln

Plant operates with two wet kilns. They have a combined capacity of 675,000 metric tons per year or 744,188 English tons per year. The kiln exhaust from the two kilns was originally designed to be treated with five and six field electrostatic precipitators (ESPs) respectively. The plant currently utilizes waste oil as approximately 15% of their total fuel. The system has an alkali bypass system in place. During early 1992, the plant received many complaints regarding kiln ESP emissions. The system implemented was an ESP/baghouse hybrid. It was first applied to kiln #2 and due to the success, was applied to kiln #1 a short time later. The first two fields of the ESP were kept intact while the last four fields were gutted and a baghouse cell plate was installed. The particulate getting to the proposed filter bags would be very sticky and have approximately 25-27% moisture in the stream.

GORE® Membrane Filter Bag Experience

Collector Designation: Kiln #1 exhaust ESP/baghouse
Collector Manufacturer: Wheelabrator
Particulate Collected: Kiln dust
Design Airflow Rate: 200,000 acfm
Design Temperature: 374º F
No. Bags/Compartment: 2 Comp. - 260 ea.
Inlet Grain Loading: 10-30 gr/acf 2 Comp. - 340 ea.
Particulate Bulk Density: 60-80 lbs/cf 2 Comp. - 240 ea..
Cleaning System: Pulse jet 2 Comp. - 200 ea.
Bag Dimensions: 6.06" dia. x 167.375" long
No. Bags/Collector: 2,080
Air-to-Cloth Ratio Design: Gross 4.37:1 Net 4.83:1 to 5.22:1 (Depending)
Bag Material: GORE-TEX® membrane/ TEFLON® B fiberglass (16.8 oz/yd2)
Cage Construction: 2-piece cage, 20 vertical wires, galvanized, 6" horizontal ring spacing and no taper
Installed: Kiln #1 retrofit – April 1993

Due to the success of this ESP/ baghouse hybrid on both kilns, a technical paper was written on the application, co-authored by Gore and the Director of Engineering from the customer. A write-up of this application has also been published in international cement trade journals, as well as having been presented at several conferences.

Due to expansion/modernization of other sister plants in the region, this plant was shut down during 1997.