Emissions control is a hot topic in the cement industry. Cement plants are driven by throughput, but if they fail to comply with the new NESHAP (National Emission Standards for Hazardous Air Pollutants) regulations, production could be stopped immediately, introducing a slew of cost factors that affect plants’ bottom line.
What’s more challenging for cement plants is how compliance is calculated: with the MACT (Maximum Achievable Control Technology) approach, which sets compliance limits in line with the top 12% of plants. Plant compliance is calculated not at a given moment, but on a 30-day rolling average.
Prior to NESHAP, plants had to prove their compliance based on annual tests. The MACT approach to setting the new limit at the average of the best 12% is a significant change. What makes the change even more challenging are plants having to now prove their compliance on a continuous 30-day rolling average.
This is why cement producers around the globe trust GORE® Filter Bags. Once installed, our bags remain reliable, providing unconstrained operations while keeping plants comfortably and continuously compliant. In addition, Gore’s system approach to filtration process optimization includes our technical support for the lifetime of the filter bags.
As industry and baghouse needs have evolved, Gore has introduced new developments in filtration technology that deliver industry-leading performance and reliability. New products include our GORE® Low Emission Filter Bags, which are seam-taped to block emissions, ensuring cement plants meet NESHAP and other regulations. GORE® DeNOx Catalytic Filter Bags are designed to destroy NOx and NH3 at levels similar to an SRC tower, but at a much lower investment cost. GORE® LOW DRAG™ Filter Bags are proven to increase throughput by promoting greater airflow. The GORE® Mercury Control System (GMCS) is a unique fixed sorbent system for capturing elemental and oxidized gas phase mercury from flue gas streams and reduces SO2 concentrations.
Regardless of the Gore solution you choose, our filtration solutions require virtually no process changes and are easy to install.
The three key filtration factors
Baghouse operators purchase filter bags primarily for particulate collection. This is a primary filtration factor. As the particulate is collected, the resistance to flow, differential pressure, increases, causing higher fan energy costs. This is a secondary filtration factor. When the filters have holes so they are no longer as efficient at particulate capture as they need to be or when the differential pressure of the filter bags is too high, the filter bag life is over. Although life is usually one of the major factors considered during a filter selection, it is defined by the primary and secondary factors. Gore provides the optimal balance of
- extremely high filtration efficiency
- very low resistance to flow
- and extremely long filter life.
These qualities make our filter bags highly durable and reliable through each cleaning cycle, resulting in a long product life overall. Typically, our filter bags will provide five-year effective filter bag life in a pulse jet cement kiln baghouse. Because our bags operate consistently for longer, they don’t need to be replaced as often — equaling lowered maintenance costs, increased yield and greater productivity. Additionally, they are proven to operate with less pressure drop, requiring less energy from the main kiln baghouse fan.
What this amounts to is a lowered overall cost of ownership.
As the leading developer of high quality, reliable filtration products for baghouses in the cement industry, we have listened to our customers and considered industry needs when developing solutions that truly address what cement producers face each day.
Gore was the first to develop PTFE-based membrane filters, which are proven to increase airflow and capture up to 99.99% of harmful particulates that pass through a baghouse. With their PTFE membrane and robust construction, our filter bags deliver high performance — and value — while ensuring your plant meets all environmental regulations.
When analyzing Gore’s filtration products for use in your filtration system, we encourage you to consider 3 important factors:
- our truly innovative products which offer filtration performance that you will not find elsewhere
- our proven product reliability
- our unique system approach to filtration process optimization, which includes our technical support for the lifetime of the filter bags
These three attributes enable Gore’s solutions to deliver the lowest total cost of ownership available in a filtration system.
Controlling particulate emissions
Though each of our standard filter bags is proven to capture up to 99.99% of emissions, we have a new product especially effective at helping cement plants comply with NESHAP.
GORE Low Emission Filter Bags have a PTFE-based seam tape that makes it virtually impossible for dust to leak through the stitch holes. Studies show that emissions spike with each pulse of your cleaning system. Our Low Emission Filter Bags don’t let dust through despite the constant pulsing — eliminating those emissions spikes, reducing your baseline emission level, and even extending bag life.
As the industry has evolved, other filter bags have adopted membrane-based seam tape on their filters and technologies — but the Gore membrane remains ahead of the curve. Other seam tapes tend to crack and split during pulsing, eventually exposing stitch hole leak paths after 12–18 months. Our proprietary membrane remains mechanically robust, keeping emissions under control for the life of your filter bags while increasing your total amount of dust collection.
To find out if GORE Low Emission Filter Bags are right for your application, please contact us.
In some areas of the world, such as Europe, cement producers must also follow regulations for the control of NOx. To meet these regulations, we recommend GORE DeNOx Catalytic Filter Bags, which are specifically designed to destroy NOx and NH3.
These bags allow plants to achieve NOx and NH3 levels similar to an SCR tower, but at a much lower investment cost. They combine an outer-layer filter bag for particulate removal with a catalyst insert for NOx and NH3 reduction. And there’s very little installation or maintenance involved — in most cases, you just need to replace your current filter bags with GORE DeNOx Filter Bags.
To find out if DeNOx is right for your application, please contact us.
Increase production rate
Cement plants can benefit from Gore's latest innovation — GORE LOW DRAG Filter Bags — in multiple ways. Check out these scenarios:
Production is limited by airflow constraints through the kiln?
Increase airflow and use this additional airflow for higher clinker production rates.
Burning alternative fuels and limited by the amount of fuel burnt due to a shortage of available O2?
Increase airflow and utilize this airflow to increase alternative fuel utilization.
Can’t utilize additional airflow for production increases or alternative fuel increases?
Reap the benefit of significant fan energy savings.
Problem spots in the baghouse due to localized failures or abrasion?
Permanently remove filter bags from these areas of the baghouse, while increasing performance.
Based on a novel Sorbent Polymer Composite (SPC) material, the GORE Mercury Control System provides both high efficiency and a high capacity for removing elemental and oxidized mercury from flue gas streams, and reduces SO2 concentrations.
There is no impact on the final product – the finished cement remains essentially mercury-free and carbon-free. By continually removing mercury from the process, it does not continually concentrate in the CKD. This eliminates the need for Dust Shuttling or Dust Wasting and their associated process changes. The kiln dust can be completely recycled back into the process to maximize clinker yield as is standard for the industry. There is also no need to worry about the logistics and safety of transporting and storing large amounts of powdered sorbents.
Our reputation for reliability is based on many years of experience in the field, but starts with the materials, which we use. All our membranes are made from ePTFE (expanded polytetrafluoroethylene), which is
- chemically inert
- resistant to extreme temperatures
- mechanically tough
Gore was the first to develop membrane-based filters for cement baghouses; today, the membranes in our filters simultaneously capture the most miniscule particulates while allowing a high rate of airflow. Regardless of the materials used to fuel your kilns, we deliver consistently high airflow over the lifetime of the filter bags.
As the industry has evolved, we have worked to understand and continuously improve our filtration product designs, to meet and/or exceed our customers’ expectations. Over the years, we have perfected the form, fit and function of our designs. These qualities make our filter bags highly durable. Time and again, GORE Filter Bags are proven to last longer than our competitors’, which means lower maintenance costs, less unexpected downtime and lower overall cost of ownership for our customers.
Finally, we have a dedicated manufacture system. Our worldwide manufacturers complete production of our filter bags by following our strict production and testing measures, ensuring they perform just as they’re designed to.
Bottom line: Once your GORE Filter Bags are installed, you can rely on them to work as intended — from the initial installation to 5 or more years into operation.
When you buy filter bags from Gore, you’re buying a partnership with a highly trusted, time-honored manufacturer and a system approach tailored to your specific needs.
As part of our system approach, we:
- determine, design and manufacture the filter bags that fit your specific application and process
- analyze and optimize your total system performance
- provide technical support and troubleshooting for the lifetime of the filter bags
This means you’ll receive expert support not just on bag design and installation, but also on how to optimize the flow parameters of your system to get the absolute best productivity without sacrificing compliance reliability. This process-specific product design and applications engineering approach has proven to be the lowest risk way to optimize your system's performance.
We understand that you don’t always have filter bag experts on staff. As your partner, we’ll be on call to get you back up and running if you experience any problems related to your filter bags.
What Do Filter Bags Cost?
Many customers make buying decisions based on perceived reliability of filters and the initial purchase price believing the purchase price is one of the highest contributors to total cost of ownership. However, several factors impact the total cost of ownership for a baghouse, including:
- purchase price of filter bags
- labor cost to install filter bags
- duration of product life
- energy cost of fans that move air through a baghouse
- stack testing and CEM monitoring costs
- costs of maintenance and cleaning
GORE Filter Bags help you achieve the lowest cost of ownership for your filtration system by combining:
- superior membrane laminate
- robust filter bag design and construction
- unique system approach optimized for your baghouse
- technical support for the life of your filter bags
- and the reliability our customers come to expect from Gore.
We’d like to help you get a sense of what your filter bags will initially cost and the overall cost of ownership you can expect. To begin our conversation, please contact us.
Cement producers have found success using GORE Filter Bags to maximize their productivity while keeping emissions under control. Learn a few of the stories behind their success.
Global Cement Producer
A global cement producer operates two inefficient wet process cement kilns with an approximate production combination of 1.7 million tons per year. Recently, the plant embarked on a major modification project, replacing the two kilns with a single state-of-the-art preheater/precalciner kiln capable of producing approximately 2.8 million tons per year.
In addition to boosting efficiency with this modification, the plant aims to increase its emissions control through a Fives TGT® baghouse and GORE Filter Bags. To date, we have successfully partnered with Fives Solios on over 20 kiln baghouses within the North American cement industry.
This particular plant needs to meet NESHAP and New Source Performance Standards (NSPS) regulations with a federal limit of 0.02 pounds per ton of clinker emission level via the Continuous Parametric Monitoring System (CPMS). To meet these standards, the plant will install a brand-new Fives TGT baghouse with significant portions of the clean air plenum manufactured from stainless steel construction to prevent corrosion. The baghouse will be equipped with GORE Low Emission Filter Bags, whose ePTFE seam-tape construction positions the plant to remain confidently compliant with its strict operating limits.
The new, high-efficiency baghouse is slated to begin operation in 2017. Once in place, the plant will be prepared to meet the strict NESHAP and New Source Performance Standards (NSPS) regulations.
Eco-Friendly Cement Plant
Our customer runs progressive and environmentally friendly cement plants. To accomplish this, they rely on GORE Filter Bags, the lowest risk way to optimize system performance, meet emissions targets, and see immediate and long-term cost savings.
With our filter bags in place, our customer has exceeded emissions goals and reduced costs. Says a process engineer, “GORE Filter Bags allow us to meet aggressive environmental standards without sacrificing productivity.”
North American Supplier of Construction Materials
We provide GORE Filter Bags to one of North America’s largest suppliers of diversified construction materials. Our bags have optimized system performance at a low risk. GORE Filters ensure maximum productivity now, plus total cost reductions over the life of their kiln exhaust system.
Our customer has been very pleased with its production increases resulting from the installation of GORE Filter Bags. The director of engineering: “GORE Filter Bags allow us to keep up with production demands without having to add additional capital equipment.”
Gore produces a wide range of filter bags that vary by material and resistance to temperatures, acid and alkali.
In your cement plant, GORE Low Emission Filter Bag provide extra assurance that you’ll meet NESHAP regulations. The bags are seam-taped to prevent any leaks, allowing them to meet the strictest emissions regulations while providing the same level of quality and reliability as our standard filter bags.
In Europe, cement plants are also regulated for NOx output. GORE DeNOx Catalytic Filter Bags are designed to destroy NOx and NH3. These easy-to-install bags enable plants to achieve NOx and NH3 levels similar to an SCR tower, but at a much lower investment cost.
Compare our range of filtering solutions, and contact us to discuss which solution is right for your industrial application.
The following basic information will help us to choose the right material for you:
- filterbag size, current material and quantity
- baghouse operating parameters (e.g.: airflow rate, temperature, differential pressure)
- particulate description (ideally including concentration, particle size, bulk density)
- cleaning cycle parameters (e.g.: pulse jet pressure, cycle time)
570 g/m2 (16.8 oz/yd2)
FOR INDUSTRIAL USE ONLY
Not for use in food, drug, cosmetic or medical device manufacturing, processing, or packaging operations