JPG BUDOWNICTWO
SP Z O.O.

Effective cement dust filtration, along with filtering of chemicals and other process byproducts, is vital to companies in the cement industry. In some cases, filtration systems are designed and implemented in newly built facilities. In others, it is added to existing plants.

JPG is a general contractor that needed to partner with an engineering company that could produce designs to help its client meet the latest EU (European Union) plant emission standards. They chose CREADIS for that assistance.

CHALLENGE

JPG’s client was looking to decrease the PPM (parts per million) dust emissions of five cement production stages significantly below the allowable limits in order to stay ahead of continually-evolving standards. Not only would implementing a cutting-edge solution help them stay in compliance, but it would also provide greater protection for their people and equipment, and for the environment surrounding the plant.

In addition, it would demonstrate their commitment to “greener” operations—a commitment that is increasingly expected of businesses in their market.

• Decrease level of dust emissions of 5 cement production stages twice below current regulations Remove dust that might be harmful for the personnel
• Protect the equipment and environment

SOLUTION

Our engineers designed a comprehensive cement dust filtration system solution that JPG could implement for its client, complete with schematics, scripts and everything else needed to take the design from the drawing board to the plant.

From advanced filters, conveying systems and sensors to new control and electrical systems, the filtering solution is tightly integrated to all of the plant’s existing technology, including its power supply and automated processes.

• New set of filters and conveying system was installed by customer
• New control and electric system was developed and implemented to allow smooth operation and interlocks between existing and new plant machines

BENEFITS

Today, the system designed by CREADIS and implemented by JPG is delivering emissions compliance that does not simply meet current requirements, but actually exceeds it. Specifically, the goal was a 70% reduction in emissions but the result was close to an 80% reduction.

That means the plant is positioned to be within the guidelines for cement dust filtration and chemical emissions for years to come. And as a result, the company will be able to avoid noncompliance fees and also several system upgrades and the associated costs.

• Expected dust emission level should've been improved by at least 70%. Criteria was met, best results shown reduction up to 80%
• Pollution free and dust-free system was successfully introduced

EXTENSIVE FILTERING, BULK MATERIAL HANDLING AND ALTERNATIVE FUELS EXPERIENCE

CREADIS engineers have unrivalled expertise in a wide range of disciplines related to manufacturing emissions filtering, bulk material management and alternative fuels, including:

• Filtering solution concept design
• Conveying systems concept design
• Filtering solution control and electrical system concept design
• Production, separation, drying and enrichment of RDF-based fuel blends
• Waste-2-Energy plants
• Alternative raw materials plants for clinker production (process decarbonization)
• Analysis of heat exchanger towers including pre-calciner burners—safety optimization and static-dynamic model analysis
• Thermal analysis of heat exchanger tower process piping
• Pulverized coal production plants
• Process steam production plants with dual gas boiler systems
• Replacement of filter systems in all departments: milling, clinker production and additive–contaminants reduction
• Alternative fuel drying systems for rotary kilns—collection, separation and storage systems
• Clinker silo reclaimer system efficiency enhancements, along with relocation and improvement of slag storage
• Implementation of sampling systems for cement plants and trucks
• Mobile systems for dust-free unloading of clinker from trucks and transport to storage
• Custom equipment–sampling station, magnetic separator, etc.