Intensiv-Filter India won the contract to design, realise and commission the bag filter for kiln/raw mill application at the Rauri plant for Ambuja Cements (ACL). This plant is located 2,000 m above sea level at the foot of the Himalayan Rohtang Mountains. ACL decided to consider bag filter technology instead of an ESP for the new plant.Technical solution provided by Intensiv-Filter India : The aim was to de-dust the rotary kiln and raw mill with a bag filter complying with the maximum dust emission limit of 10 mg/m?. Due to large volumes and space limitations, Intensiv-Filter India proposed and implemented two filters of the type IFJCN 80/48-8000 D ECO. The filters are designed for a gas volume of 2.1 million m?/h and a gas temperature of 200 ?C. They were arranged in two rows with 12 compartments each. In total, the filter has 7680 bags with a length of 8 m, providing a total filter area of 31 795 m?. The filter material used is the P84 so that during raw mill shut down, the gases will be cooled down to 190 -195 ?C and will be filtered for gas temperature at less than 195 ?C. For easy maintenance, a penthouse is installed on top of the bag filter and chain conveyors are installed below the bag filter for dust collection. The filter bags are cleaned by a periodic compressed air pulse at pressures of 1.0 to 3.5 bar, depending on the filter differential pressure. The operation of the filter installation is automatically adjusted to the prevailing conditions by the JetBus Controller?, which regulates cleaning pre-pressure and controls the shutoff dampers when necessary. The JetBus Controller? is used as an intelligent cleaning control unit within the Intensiv-Filter system. The modular structure of the system ensures that the controller can be flexibly configured and can be easily changed or extended at a later date. The filter can be operated either in online or offline mode. The controller regulates the cleaning pre-pressure and controls the pneumatically-activated clean gas dampers. The controller is linked to higher level systems via standard coupling modules, which switch between the controller and the existing process control system. In addition, its uses the JetBus Controller?. The benefits of the system are adjustment of cleaning to meet the operating conditions in the dust removal installation, more precise monitoring and direct assessment of the cleaning system, more precise error analysis and identification of error sources, optimising and reducing compressed air consumption, optimising and homogenising of dust discharge, etc. SummaryIncreased productivity, optimised flexibility, improved efficiency and, above all, the newest technological achievements in dust removal were essential on account of the sustainability promise of Ambuja Cements at its Rauri cement plant. On the basis of the specific customer conditions, Intensiv-Filter India designed the dust removal and gas cleaning systems for the plant. The filtering installation represents a complex waste gas treatment plant that required process engineering solutions to be implemented. This is proven by the constant performance of the bag filter, which has now been operating for a year. In order to design the gas cleaning installations and to implement this optimum solution within the remit specified by Ambuja Cements, it was essential to know each procedure in detail and to specify the framework parameters in consultation with the operator. It is only possible to plan the gas cleaning installation for a specific requirement if all the circumstances that are relevant to measuring, operating methods and selecting materials are known. This is particularly true when providing a technical warranty. Plant concepts from Intensiv-Filter India are far more than simply dust collectors. This is proven at Rauri."The dust removal of the rotary kiln contributes to Ambuja’s scope of environmental engagement. This is possible due to Intensiv-Filter India’s co-operation and support. The entire Rauri team enjoyed working with the company and setting high standards throughout the duration of the project," Sunil Duggal, Joint President of Ambuja Cements Ltd