dustex turkey - cement industry 11-27-13

7/22/2019 Dustex Turkey - Cement Industry 11-27-13

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Specializing in the

Cement Industry



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Corporate Overview

• In 1947, Dustex was founded in Buffalo, New York

• In 1984, Dustex was incorporated in North Carolina

• Privately-held company

– Ownership active in management & project execution

• Holds over 20 Air Pollution Control (APC) equipment patents

– Split Module Fabrication

– Patent Pending for Floating Pan Top Door Design

Experience the Dustex Advantage



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Dustex Locations

Corporate Headquarters, Kennesaw, GA

– Project Management, Engineering, CFD

Modeling, Drafting, ProcurementDustex Controls, Acworth, GA

– Panel Fabrication

Dustex Fabrication, Rocky Mount, NC

– Module and Duct Work Fabrication

Captive Fabrication Shop, Kingston, OH

– Module, Duct Work, and Misc. Fabrication




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Why Dustex? Experience

With over 280 years of combined experience in the Air Pollution Control

Industry, Dustex personnel design, fabricate, install and commission

• Circulating Dry Scrubbers (CDS)

• Dry Sorbent Injection (DSI) Systems for acid gas control

• Activated Carbon Injection (ACI) systems for high efficiency mercurycapture

• Fabric Filter Baghouse for particulate matter control

Additionally, we have vast experience with nuisance collectors, cyclones and

dust collection for product retrieval. Dustex personnel have experience and

knowledge of applications and technologies gained through presentinvolvement with Dustex plus involvement with many other air pollution control

companies. Dustex’s unique customer relationships and technical advantages

differentiate us from others in the market. Dustex provides efficiency,

innovation, & cost effective solutions to all of it’s customers.




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Why Dustex? Uniqueness

Quality is first and foremost. Dustex prides itself on providing quality, in-house engineered products

that we stand behind through and beyond the sales and installation phases. With over 20 patents in

the APC Industry we provide:

• Modular designs

– Translates to ease of and shorter installation with reduced crane time on-site

– Quality welding in our wholly owned or approved supplier controlled shop environment – Shop insulation and cladding of modules nearly eliminates the requirement for scaffolding on

the baghouse during erection, resulting in large cost savings

– Reduction of overall project costs

• Top door design with integral cleaning manifold and blow pipes

– Elimination of warping and in-leakage due to cyclical thermal expansion

– Quick access to the tube sheet for maintenance and inspection

– No confined space entry requirements as compared to walk-in plenum

• Side entry plenum for flue gas distribution

• Commercial flexibility

– Dustex is a nimble company in an excellent financial position. We are able to arrive at

mutually agreeable terms and resolve any concerns quickly and effectively with a focus on

getting the job done to meet the customer’s needs, even the largest of customers!




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Air Pollution Control Technologies

• Fabric Filters

• Circulating Dry Scrubbers

• Dry Sorbent Injection

• Activated Carbon Injection

• Heat Exchangers

• Cartridge Collectors

• Nuisance Collectors

• CyclonesComplete Installation of 12 Module High

Pressure Pulse-Jet Dust Collector System




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Markets Served

• Steel

• Cement

• Power / Steam Generation

• Iron

• Mining

• Chemical

• Petrochemical

• Glass 8 Module Pulse-Jet Fabric Filter




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In-House Capabilities

• Engineering

– Mechanical, Electrical, Environmental,

Chemical, Civil / Structural

– 3D CFD Modeling

• Fabrication

• Installation & Commissioning

• Design-Build Project Management

• Controls & Automation• Aftermarket Support




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Fabrication Capabilities

• Dustex Fabrication – North Carolina

– 50,000 ft2 shop area

• Captive Fabrication Shop – Ohio

• Approved Fabrication Suppliers – Domestic

– International – Ventor Makina

Dustex Fabrication Shop




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Dustex Fabrication, North Carolina




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Ventor Makina Fabrication, Turkey




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Fabric Filters

• Pulse Jet

– Intermediate Pressure, High Volume

– Particulate Matter Removal

– References up to 2,000,000 ACFM – Process Temperatures up to 550°F

– Bag Lengths up to 30 feet

– Side Inlet for Cross Flow Across Bags

• Reverse Air

– 5”, 8”, and 12” Diameter

– Suction & Pressure Designs




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Fabric Filters – Dustex Advantages

• Design for Constructability

– Split Module Fabrication (Patented Process)

• Mating flange with alignment bolts

• More shop welds, less field welds

– Shop Insulation & Cladding

• Less work at elevation in the field

– Advanced Inlet Designs

• Long Bag Technology

• High Side Entry




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• Developed for use with short bags

(< 18 feet)

• Air flow up through bags inhibits

cleaning and leads to re-entrainment

• Can lead to abrasion problems

and high pressure drop

• Used by some suppliers for longbag designs

• Limited to 4:1 A/C

Hopper Entry – Traditional Design




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Hopper Entry – CFD




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• New technology for long bagdesign >24’

• Flow enters side of module andflows across bags

• Efficient on-line cleaning at high A/C ratios

• Reduces bag abrasion issues

Side Entry – Latest Technology




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Side Entry – Latest Technology




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• Design for Operation

– Side Entry Design

• Gas flow across bags

• Minimization of hopper re-entrainment

– CFD Modeling

• Improved cleaning performance

• Reduced potential for bag abrasion

– Performance

• Meets government compliance requirements

• Reduced in-leakage due to Floating Pan Top Door

and shop welded modules





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• Design for Maintenance

– Top Door Design

• Ease of entry by integrating

cleaning system with top door

• No confined space for ease ofinspection and maintenance

• No warping or leakage due to

floating pan (patented design)





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Circulating Dry Scrubbers

• Multi-Pollutant Control

– SO2, HCL, HF, Hg, Dioxins, Furans

• SO2 Removal Efficiency

– Higher than spray dryer systems – Capable of 99% removal

• Low Maintenance Costs

– Less than Spray Dryer or Wet

Scrubber

– No Moving Parts or Waste Water

• In-House Engineering




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Clean Flue Gas

CDS Design – Process Flow

Water

Process Gas

Fresh

Reagent

Recycled Reagent

Flue Gas with Entrained Reagent

BaghouseReaction

Tower

Air Slide Conveyor

Reagent

Silo

Flue Gas Recirculation (Optional)

Spent Reagent to Waste




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CDS Design – General Arrangement

Reaction Tower

Reagent Storage Silo

Waste Silo

Baghouse

Air Slide Conveyors

Flue Gas Recirculation




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CDS Scrubbers – Dustex Advantages

• High SO2 Removal Efficiency

– Up to 99% removal

• Flexible

– Multi-Pollutant Removal

• SO2, SO3, HCl, Hf, Dioxins, Furans• Hg Removal

– Fuel Switching

• Lower Capital Cost

• Lower Operating Cost

– High Reagent Recycle Rate – Low Water Consumption

– Low Maintenance Costs

• Small Footprint




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Activated Carbon & Sorbent Injection

• Multi-Pollutant Control

– % Reduction

• Multiple Sorbet Injection

– Sodium Bicarbonate – Hydrated Lime

– Activated Carbon

– Trona

• CFD Modeling – Injection Array designed for even

distribution




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Sorbent Injection – Dustex Advantages

• Reliability

– Dual feeder system with 100%

redundancy

– Hopper fluidization system to ensure

material flow through hopper

• Accuracy

– Loss-in-weight feed system accurate

to 1% with 10:1 turndown capability




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Sorbent Injection

Skid Mounted Feeders




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Cement Industry References


Plant Process Flow Conditions Year Scope

Ash Grove

Baker, Oregon

345,000 ACFM, 586,155 Am³/hr Design

280,000 ACFM, 475,720 Am³/hr Operating

2008 ACI, Fabric Filters

Essroc-Italcementi

Picton, Ontario, Canada

229,985 ACFM @ 285°F

390,744 Am³/hr 141C

2009 Clinker Cooler Pulse-Jet Baghouse

Heat Exchanger, Fabricated Steel Stack

Ash Grove

Louisville, Nebraska

185,000 ACFM @ 400°F, 314,315 Am³/hr 204C

285,000 ACFM @ 400°F, 484,215 Am³/hr 204C

2013 HW Kiln Vent Baghouse Assembly, DSI (Hydrated Lime), 8

Fabric Filters

ACL Kiln Vent Baghouse Assembly

Ash GroveMontana City, Montana 166,561 ACFM @ 450°F, 282,987 Am³/hr 232C 2013 Cement Kiln Vent Baghouse Assembly, CDS, 6 Fabric Filters

Trinidad Cement

Trinidad Claxton Bay, West Indies

3,128 ACFM to 13,210 ACFM, 5,314 Am³/hr to 22,444 Am³/hr

141,240 ACFM @ 230°F, 239,967 Am³/hr 110C

2004 14 Nuisance Collectors

2 Module Separator Collectors, Trough Hoppers, Air Slide

Conveyor Discharge, Bin Vents, Walk-In Plenum, Top Door

Access

Illinois Cement

LaSalle, Illinois

141,200 ACFM

239,898 Am³/hr

2005 Fabric Filters

Lafarge Cement

Calera, Alabama

120,300 ACFM Am³/hr 2003 7 Nuisance Collectors, Finish Mill Collector, Trough Hopper,

Air Slide Conveyor

River CementFestus, Missouri

Varies by Collector 2006 14 Nuisance Collectors and Fans

Lehigh Cement

Buda, Texas

16,800 ACFM @ 180F

28,543 Am³/hr @ 82C

2011 Fabric Filters with High Side Inlet

Lehigh, Tehachapi, California n/a 2012 ACI

Holcim Trident, Three Forks, Montana 300,000 2013 Kiln Vent



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PAC Polishing System

• Ashgrove Cement, Durkee, Oregon

• Cement Kiln Vent/Mercury Reduction – 345,000 ACFM at 350°F

586,155 Am³/hr at 177°C

• Scope – PAC Injection System

– 3-Module Polishing Baghouse

– Penthouse and Bridge Crane

– ID Fan – Erection of Equipment




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Cement Kiln Vent System

• Ashgrove Cement, Louisville, Nebraska

• Kiln Vent – 285,000 ACFM at 400°F

484,215 Am³/hr 204

C• Scope

– Hydrated Lime System (HCl control)

– Reagent Storage

– 8-Module Baghouse

– Waste Conveying and Storage System

– ID Fan and Ductwork

– Turnkey Installation

– NESHAP compliant




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Kiln Vent System

• Ashgrove Cement, Montana City, Montana

• Cement Kiln (Wet Kiln) – 166,561 ACFM at 450°F

282,987 Am³/hr 232

C• Scope

– CDS Scrubber (SO2 Control)

– Reagent Storage and Delivery


– ID Fan and Ductwork – Cyclone

– Waste Handling and Storage

– Erection




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Clinker Cooler Vent

• Essroc-Italcementi, Picton, Ontario, Canada

• Clinker Cooler – 229,985 ACFM at 285°F

390,744 Am³/hr 141

C• Scope


– Heat Exchanger

– Fabricated Steel Stack

– ID Fan and Ductwork – Material Handling

– Mechanical Erection




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Dustex Corporation

Thank youVentor Makina Sanayi ve Ticaret Limited Şirketi

Organize Sanayi Bölgesi 1. Bölüm Antalya Bulvarı No:11 Postal Code:07190

ANTALYA / TURKEY

Phone Number (Direct): +90 242 4212527

Phone Number (PBX): +90 242 2581890

Fax Number (INT): +90 212 3817994

Dustex Corpo rat ion

100 Chastain Center Parkway, Suite 195Kennesaw, Georgia, USA

Phone Number: 00-1-770-429-5575

Fax Number: 00-1-770-429-5556

www.Dustex.com


dustex turkey - cement industry 11-27-13

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