Baghouse Success Stories - Large East Coast Cement Plant

Large East Coast Cement Plant

I am writing to express our satisfaction with the High Efficiency Cleaning you performed on 1280, 10' x 5" dia. Nomex bags in our Kiln 3, Fuller Plenum Pulse clinker cooler dust collector. These bags had reached their normal life expectancy of 4 years as indicated by reaching near maximum capacity on our variable speed fan. As a verification of the bag condition, your LD Mobile equipment, which tests the airflow of bags hanging in place showed them to be nearly plugged, thereby confirming the high fan amps. We were concerned about the potential of going positive at the firing hood with such limited remaining fan capacity baghouse maintenance.

We conducted an HEC on the bags we had just tested for airflow. We then did another LD Mobile flow test and found the HEC had released so much cake that the bags were in virtually new condition relative to air flow acceptance. To verify these results, we removed one of the used/cleaned bags we just tested and replaced it with a new bag. The air flow rate on both bags was nearly identical. The results of these tests and a recent lab test showing nearly original strength of the bag fabric, gave us the assurance to proceed with a full scale HEC.

Another concern was the ability of the cleaned bags to meet our new 18 months major overhaul target, which meant we would need to keep the CCDC operational for 18 more months or suffer a premature shutdown to change bags, which was unacceptable. These concerns would have normally resulted in a new bag and cage purchase. However, the subsequent success of the full collector High Efficiency Cleaning and condition of the cleaned bag convinced us we could meet the required time frame baghouse maintenance.

To address any concern about bag or fabric destruction during cleaning, I sent a bag to an independent testing lab and conducted a black light leak test baghouse maintenance. Both tests confirm there was no destruction to the fabric or bag fabrication (sewing etc.) and we continue to run at the same opacity level.

The results of the HEC were and continue to be, a tremendous success. Our variable speed drive amps have reduced dramatically to a rate we normally see with new bags. Also, the speed of the fan has gone from over 80% to a new bag level of 20 to 40%. In addition to a substantial reduction of power consumption, we also obtained the following advantages from the HEC:

Benefits

Bag replacement eliminated - $30,000 savings -1280 Nomex Bags

Cage replacement eliminated - $15,000 savings -1216 cages based on 5% reusable

Labour for bag/cage removal and replacement - $10,000 savings -6 men 4-5 days.

Labour reduction when bags replaced - $5,000 savings minimum-50% of cost / 6 men 4-5 days.

These CCDC bags became so heavily caked that we are forced to remove bags and cages with a pry bar (which ruins nearly all the cages), and then cut the bags off for separate disposal. We received an unexpected benefit from your HEC which we expect will enable us to save at least 80% of our cages when we finally need to change bags. The high energy blast that removes the cake also pops the bag out from within the cage wires allowing the cage to be removed undamaged baghouse maintenance.
We will also benefit from a hygiene standpoint by keeping the dust in the hopper and reducing our people's exposure to this adverse environment by some 50%. It also makes this undesirable job more maintenance friendly.


Less cages required when bags replaced - saving a min. of 80% fewer cages.

Based upon performance to date, we expect the HEC service will enable these bags to reach our now 18 month major overhaul target/policy and prevent our hood from going positive.

We plan to send bags in for testing on a periodic basis in order to keep the bags in a cleanable mode. Baring some unusual upset, we see the potential to keep these bags operable beyond our current 18 months expectation. We also plan to use this service on other collectors, whereever practical...
Thank you for making us aware of this valuable service and we look forward to utilizing its various capabilities in the future. We are optimistic that this approach to extending bag performance and life will contribute to our goal of reduced operating costs.



AS RECEIVED BY ALBARRIE, FOLLOWING THE INITIAL HEC SUCCESS

Based on the success of the High Efficiency Cleaning (HEC) you did on 1280 Nomex bags in our Kiln 3 Fuller Plenum Pulse clinker cooler dust collector
(CCDC) we decided to have Albarrie conduct an HEC on 1792 Nomex bags in our Kiln 2 Fuller Plenum Pulse CCDC. The cleaning was recently completed
and we saw virtually the same results as the first cleaning by bringing our bags back to near new condition. Once again our fan speed and amps on our
variable speed drive were lowered as a result of better air flow, power consumption reduced, differential pressure reduced, a full set of bags and cage
replacement (usually 80%) was eliminated, and we saved the labor to remove and replace 1792 bags.

In addition, we are now into the 12th month of our major overhaul target time frame of 18 months on the first HEC on Kiln 3. The cleaning has remained effective and we are staying well within an acceptable operating range.

Considering the initial benefits we gained from your High Energy Cleaning and its proven extended performance, we have communicated this success story to all our plants and expect they will also take advantage of your services.

Once again, thank you for providing a cost effective option to buying new bags which will substantially reduce our overall bag expenditures and labor costs.”