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Reflectingon a Successful Project

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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

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Projects

Adani Group to invest Rs 55,000 cr in Gujarat projects, including cement plant

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Billionaire Gautam Adani announced over Rs 55,000 crore investment in next five years in a clutch of projects in Gujarat including the world’s largest solar park, a copper plant, a cement unit, and a lithium battery manufacturing complex, envisaging direct employment to 50,000 people.

Adani Group, which operates Mundra port in the state, announced plans to foray into petrochemical business with a Rs 16,000 crore project with German chemical major BASF.

Speaking at the 9th Vibrant Gujarat Summit here, Adani said his group’s investments in Gujarat in the past five years exceed Rs 50,000 crores and “we are further accelerating our investments.”

“Over the next 5 years, our investments will include the world’s largest solar hybrid park in Khavda. The anticipated investment in this park is Rs 30,000 crore. We also plan to establish a 1 GW Data Center Park in Mundra, a one million ton copper smelting and refining project, a cement and clinker manufacturing unit in Lakhpat, an integrated Lithium battery manufacturing complex and expand our Photovoltaic manufacturing capabilities. Overall, we anticipate a total of Rs 55,000 crore of investment in all these projects,” he said.

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Bangladesh’s Chhatak Cement announces modernisation project

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Bangladesh’s Chhatak Cement Co Ltd has announced plans to modernise its facility and convert it from wet process to dry process. The company has begun to prepare a development project proposal, with a schedule to implement the upgrades by 2021.

According to company officials, Chhatak Cement has incurred an accumulated loss of over BDT3.63bn (US$43.25m) between FY13-14 and FY17-18, mainly due to its outdated machinery resulting in loss of production capacity. The plant is currently operating at 70,000 tonnes per annum (tpa).

However, the new project is anticipated to boost production capacity and increase annual company profit to around BDT1bn. The modernisation is expected to be financed by a BDT8.9bn investment from the government, with BDT5.34bn as a loan with a payback period of seven years and the rest as equity, according to The Financial Express.

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Forced shutdown of Viet-Dung Quat cement plant in Vietnam

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The Dai Viet-Dung Quat cement plant has been forced to temporarily shut down in the central province of Quang Ngai due to environmental pollution. Since 26 May, the locals had gathered in front of the plant to call for a shutdown.

Director of Central Region Cement JSC Trinh Van Dien, investor in the Dai Viet-Dung Quat cement plant, said, “We invited an environmental monitoring team to check the dust concentration and the results are safe. The local Department of Natural Resources and Environment hasn?t reached a conclusion on the noise level yet.”

He added, “We?ve had to temporarily close the plant, meaning we”re losing VND300m (US$13,437) and the 100 workers are kicking their heels at home. I don”t know what to do.”

The ground clearance work should have been done this year but the coal-powered plant project was delayed until 2020. As a result, the ground clearance work has also been delayed.

According to the locals, they want to be compensated for the relocation if the plant stays. “We don?t want to stay. We have to move,” local Nguyen Ne said.

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