Intensiv-Filter GmbH & Co. KG

15TH ARAB-INTERNATIONAL CEMENT15 ARAB INTERNATIONAL CEMENT CONFERENCE AND EXHIBITION 18-20 NOVEMBER 2008 - CAIRO EGYPT18-20 NOVEMBER 2008 - CAIRO, EGYPT

Conversion of electrostatic precipitatorsConversion of electrostatic precipitators into bag filters presented by Jens Lange & Ralf Esser

85 Years - Innovation is our Tradition

Agenda 15TH ARAB-INTERNATIONAL CEMENT CONFERENCE AND EXHIBITION 2008 in CairoCONFERENCE AND EXHIBITION 2008 in Cairo

1. Company Profile of Intensiv-Filter GmbH & Co. KG2. Advantages of Intensiv-Filter bag filters g g

(versus Electrostatic Precipitators)3. Benefits for ESP conversions & retrofits made by Intensiv-Filter 4. Different concepts of ESP conversions executed by Intensiv-Filter5. Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant 6. Summary7. Contact @ Intensiv - Filter

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Company Profile of Intensiv-Filter GmbH & Co KGCompany Profile of Intensiv-Filter GmbH & Co. KG

Intensiv-Filter at Velbert – Langenberg GermanyIntensiv Filter at Velbert Langenberg, Germany

Managing BoardDipl.-Kfm Thomas BlüggelDipl. Kfm Thomas BlüggelDipl.-Ing. Konrad Meyr

FoundationFoundation1922 by Theodor Hansen

Dedusting Solutions forDedusting Solutions for− Cement Lime Gypsum Industries− Food Industries− Power Plants & IncineratorsPower Plants & Incinerators− Steel -/ Iron- & Non Ferrous

Industries− Glass - & Chemical Industries

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Company Profile of Intensiv-Filter GmbH & Co KG

Intensiv - Filter Group www.intensiv-filter.deI t i Filt G bH & C KG V lb t G

Company Profile of Intensiv-Filter GmbH & Co. KG

Intensiv-Filter GmbH & Co. KG Velbert, GermanyIntensiv-Filter Austria GmbH Grieskirchen, AustriaFiltres Intensiv S.a.r.l. Bouzonville, FranceIntensiv-Filter (UK) Ltd. West Midlands, EnglandIntensiv-Filter do Brasil Ltda. Sao Paulo, BrasilIntensiv-Filter Korea Ltd Seoul KoreaIntensiv-Filter Korea Ltd. Seoul, KoreaIntensiv-Filter India Pvt. Ltd. Pune, India

Subsidiary CompaniesInfastaub Bad Homburg, Germany Nuisance Filters < 30.000 m³/hSolidux Billerbeck , Germany Noise Abatement Equipment, y q p

400 employees world wide G T 70 illi E

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Group Turn over appr. 70 million Euros

Reasons for ESP conversions & retrofitsReasons for ESP conversions & retrofits

Stricter emission regulation by the authorities

Use of secondary fuelsUse of secondary fuels

Reduction of operation costs

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Advantages of Intensiv-Filter bag filters (versus ESP’s)Advantages of Intensiv-Filter bag filters (versus ESP s)

Lower and constant clean gas dust emissions for the use of secondary fuels as kiln fuel to meet strict authority regulations

Performance is independent on changing parameters and operating modes (e.g. compound & direct mode)

Precipitation is not pending on moisture and chemistry of the gas & dust

No CO – trips for kiln dedusting applications

Online Maintenance possibilities and easy maintenance access (from the clean gas side)

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Benefits for ESP conversions & retrofits made by Intensiv-FilterBenefits for ESP conversions & retrofits made by Intensiv-Filter

Lower clean gas dust emissions (constantly) compared to the ESP operationE i l b filt d i i l ff li l i iEconomical bag filter design using low pressure off-line cleaning incombination with bag length up to 8m can be foreseen for ESPconversions, to decrease the pressure drop across the bag filter and to increase the bag life timeto increase the bag life time. Re-use of existing casing, duct work, steel support, dust transportand auxiliary equipment y q pFlexible and pre-assembled filter head module design reduces downtime to a minimum and enables the plant to execute ESP conversionsduring regular plant shutdown timesduring regular plant shutdown timesLow cost solution (compared to a new installation)

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Different Concepts of ESP conversions executed by Intensiv-Filter

Pre- assembled filter head modules (incl. new penthouse)

Different Concepts of ESP conversions executed by Intensiv-Filter

on top of ESP casing

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Different Concepts of ESP conversions executed by Intensiv-Filter

Pre-assembled casing on top of existing ESP hoppers

Different Concepts of ESP conversions executed by Intensiv-Filter

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Different Concepts of ESP conversions executed by Intensiv-Filter

Pre- assembled filter head modules inside ESP casing

Different Concepts of ESP conversions executed by Intensiv-Filter

upper casing used as penthouse

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plantKiln bag filter conversion at Dyckerhoff Zement s Deuna plant

Design Data

Process Kiln- / Raw Mill - bag-filter

Original ESP Supplier ELEX / Switzerland

Gas Volume Design up to 550.000 Am³/h

Gas Temperature Range up to 240°CGas Temperature Range up to 240 C

Intensiv-Filter Type IF PJM 136/6 + 119/12 - 8000

Installed Filtration Area 9.274 m² gross

Filter Media Glass fibre with PTFE Membrane

Shut down time for Retrofit < 6 weeks

Clean gas dust load 2 mg/Nm³

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g g

Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plantKiln bag filter conversion at Dyckerhoff Zement s Deuna plant

Process atProcess at Deuna

1. Rotary kiln 5. Raw meal grinding plant 1 + 22. Cyclone preheater 6. Pro-Jet mega bag filter 3. ESP for alkali bypass 7. Exhaust fan4 Gas conditioning tower 8 Stack

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4. Gas conditioning tower 8. Stack

Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant

ESP before conversion in 2007

Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant

Start of work by the end of January 2008

Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant

Removing of ESP internals and gas outlet hood – February 2008

Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant

Frame installation for new bag filter head modules – February 2008

Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plantKiln bag filter conversion at Dyckerhoff Zement s Deuna plant

Closed backside back wall / new clean gas duct installation

19 02 2008 26 02 2008

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19.02.2008 26.02.2008

Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plantKiln bag filter conversion at Dyckerhoff Zement s Deuna plant

New filter head modules incl. sleeve bottom plate and 8m bags

03.03.2008

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plantKiln bag filter conversion at Dyckerhoff Zement s Deuna plant

Re-connected clean gas duct / installed compressed air vessels

False air dilution system y

2010.03.2008

Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant

View inside penthouse

Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant

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Kiln bag filter conversion at Dyckerhoff Zement’s Deuna plant

Complete installation today

Kiln bag filter conversion at Dyckerhoff Zement s Deuna plant

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Operation Data & Results at Dyckerhoff Zement’s Deuna plant

Filter Description

Operation Data & Results at Dyckerhoff Zement s Deuna plant

Intensiv-Filter Type IF PJM 136/6 + 119/12 – 8000

Filter Media 8 m Glass fibre with PTFE MembraneFilter Media 8 m Glass fibre with PTFE Membrane

Operation Data

G V l D i 0 000 A ³/hGas Volume Design up to 550.000 Am³/h

Gas Temperature up to 240°C

Clean gas load less than 2 mg/Nm³

Differential pressure 12hPa

Cleaning Mode Semi Off-line

Cleaning pressure appr 1 3 up to 3 4bar

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Cleaning pressure appr. 1,3 up to 3,4bar

SummarySummary

Low clean gas dust emissions (constantly) independent from gas & dust properties

Economical bag filter design can be foreseen for ESP conversions, to decrease the pressure drop across the bag filter and to increase the bag life time

Re-use of existing equipment

Reduced down time, enables the execution of the conversion during regular plant shutdown times

Short amortisation time due to low invest cost solution

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New Filter Generation ProJet mega Volumes up to 2 Mio M³/hNew Filter Generation – ProJet mega Volumes up to 2 Mio. M³/h

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www.intensiv-filter.de