ESP conversion projects

in Thailand

Review #177

Reprint of article published

in World Cement, March 2015
By Rasmus Ellefsen, FLSmidth A/S, Denmark
 ESP
CONVERSION
PROJECTS IN
Introduction
For the Siam Cement Company in Thung Song,
Thailand, dust emissions were a growing
problem. Dust emissions from three of its raw mill
departments were putting unnecessary strain on
the plants existing electrostatic precipitators (ESPs).
It turned out that the ESPs had deteriorated to such
a state that they needed replacing.
In Thailand, as in many other countries,
emissions legislation is becoming ever more
stringent and the Thung Song plant was unable to
meet the limits with its existing installations. For
the key reason that some fabric filters can now
deliver extremely low emission levels (less than
2 mg/Nm3), the decision was made to convert from
ESPs to fabric filters. The fabric filters larger, more
efficient process filtration ability would increase the
production capacity of the plants kilns and mills.
Moreover, with the right fabric filter solution, the
costs of conversion could be offset thanks to the
ability to reuse elements of the ESP, such as the
casing, steel support and transport dust system.
Siam Cement Companys management had a
number of objectives for the implementation of
its new air pollution control (APC) solution. Local
legislation in Thailand demands that dust emissions
from stacks are less than 80 mg/Nm3; however,
according to Khun Wichet Chuchaeu, Production
Manager at Siam Cement Thung Song, the plants
goal is to keep emissions under 30 mg/Nm3: We
required a filter system that was effective and easy
to operate and that could give us 100% control
over dust emissions.
An increasing number of ESP filters are
being converted to fabric filters, according to
Henrik Vittrup Pedersen, General Manager of
FLSmidth Airtech Air Pollution Control, and in
response to the demand, FLSmidth has developed
specialist competencies. At our project office in
Denmark, we combine knowledge and utilise global
 Rasmus Ellefsen, General Manager, Southeast Asia & Pacific,
FLSmidth Airtech Air Pollution Control, describes how a combination of
new fabric filter technology and local support has helped Siam Cements
Thung Song plant to dramatically reduce dust emission levels.
 FLSmidth RetroClean filter at Siam Cement Thung Song,Thailand.
engineering resources to provide fast, efficient support to
customers in these types of projects, says Pedersen.
A long-standing relationship
Siam Cement Company is owned by the Siam Cement
Public Company Limited (SCG). In 1913, when FLSmidth
was contracted to build SCGs first cement production
line in Thailand, a good working relationship was already
established between the two companies, and this has
continued with the supply of spare parts and new
equipment to various SCG cement plants. For example,
FLSmidth installed FLS GSA gas suspension absorbers in
three of the plants raw mill systems in 2012.
The installation at the Siam Cement Company
involved removing the entire ESP casing, which had
deteriorated over the years, and replacing it with a
new fabric filter solution the RetroClean fabric filter
type. Behind the plants decision to choose FLSmidth
to provide the new filter equipment was the ability
for online maintenance. Plant operators can perform
maintenance tasks, such as changing filter bags, when the
raw mill is in operation. FLSmidth has provided this ability
with a unique design that divides the filter into several
compartments that can be completely isolated from
the gas stream. Inside the filter, gas-blocking walls are
installed between the fabric filter compartments, and the
inlet and outlet can be blocked as required.
The filters allow the use of long filter bags typically
10 m in length meaning fewer bags, pulse cleaning
valves and other key parts are needed to cope with the
gas flow. In addition to reducing maintenance costs,
the space within the refurbished ESP is utilised to fit the
long bags and top box complete with purging tubes.
\ Reprinted from March 2015
World Cement
Two other features provide important benefits to plant
owners, including increased operational efficiency and
prolonged filter lifetime. These features are the unique
gas distribution system, which ensures that gas is evenly
spread over the entire filtration area, and the Smart Pulse
Controller, FLSmidths advanced control system.
However, technology is not the only prerequisite to an
effective solution. When assisting with filter conversions
or new installations, FLSmidth works closely with plant
staff in seeing the project through to completion and
ensuring that the installation performs to specification.
Fast conversion minimises downtime
FLSmidth has been a leader within air pollution control
technologies for more than 40 years. Products and
technologies are fully tested at Dania, FLSmidths
state-of-the-art global R&D centre in Denmark, before
they are brought to market. The company takes a
responsible, research-based approach to product
development, often in partnership with customers.
For the Siam Cement Company, it was not just a
matter of providing the best solution for the plants
future; it was also a matter of close teamwork, good
service and attending to the customers needs. A short
shutdown time of 35 days was planned for the filter
exchange. During this time, the upper part of the existing
ESP was removed, the longitudinal hopper was rebuilt
into a pyramid hopper, and, finally, the new fabric filter
internals were installed. In addition to engineering a new
layout for the inlet and outlet ducts and supervising the
erection and commissioning, FLSmidth ensured support
for the entire preassembly process and provided project
management assistance to the local contractor. During
and after the process, the plants operators were trained
in how to make the best use of the filters by FLSmidths
specialist engineers.
Michael Thorsfelt, Project Manager at FLSmidth,
was responsible for this RetroClean filter project at
Siam Cement. He explains that to achieve the most
effective solution and to meet performance objectives,
a thorough analysis of the process data was necessary.
Thanks to the analysis of process data upfront, we could
design a perfectly suited solution, and it was actually
different than the solution originally intended. We
also discovered we could reuse the original hoppers by
redesigning them to the benefit of the customer and the
environment.
We use advanced techniques such as 3D onsite
scanning, which enables us to design a solution matching Lifting of filter modules during installation.
the existing plant layout. For example, this helped us
to design an effective and accurate solution for access
facilities and ducts without physical collisions that may
be overlooked if just using drawings as the design basis,
Thorsfelt explains.

Local setup, better support

For FLSmidth, an important goal is quite simply to help
achieve cleaner air. It is a daily reality that cement
and minerals plants around the world need to reduce
emissions and the impact on air quality. The company
works side-by-side with customers, understanding
their business and advising them on what they can do
to minimise emissions. Drawing upon a strong global
network of expert resources, it provides process expertise,
maintenance and service, spare parts, quality assurance,
commissioning and troubleshooting to customers
throughout Southeast Asia.
For this reason, customer service is an important part of
FLSmidths business model. Customers look for up-to-date,
expert advice and the company is committed to delivering
on this promise by recruiting and developing experts and
specialists within air pollution control. Plant operators can
be assured of receiving the assistance they need to achieve
their specific goals, whether technical or business related.
In recent years, Siam Cement Company and a number
of other cement plants in the Southeast Asia and Pacific
region have achieved benefits such as lower equipment
lifecycle costs as a result of FLSmidths local setup. The
company has invested considerably in creating a strong
local network in the region. This has been driven by the
desire to provide effective support to local customers
and to gain an even higher level of understanding of
customers specific challenges. At the Siam Cement
conversion project, FLSmidth deployed Southeast Asian
field engineers and European supervisors to achieve an
appropriate balance between the right knowhow for the
project and a higher level of local involvement. The local
field engineers received specialist training before, during
and after the installation.
Teamwork was very important to meeting the project
deadline, which of course was critical to Siam Cements
ability to resume production. We often need to make
fast decisions during installation and we see that the mix
Weather enclosure.
of highly experienced supervisors and local field engineers
is very effective. The supervisors know the importance of
the fast decisions that need to be made and the local field
engineers can act on the decisions quickly based on their
knowledge and experience of the local environment,
explains Thorsfelt.
We have seen situations where plants have purchased
filters from other suppliers but have been unable to get
support, says Henrik Vittrup Pedersen, commenting on
the importance of a local and global support network.
When repairs were needed, plant managers needed
to source support from abroad, which was expensive, or
alternatively get help from local suppliers who may lack
the necessary experience. The result was a poorly operating
installation, which is simply not acceptable in todays
competitive environment. FLSmidths local setup makes it
affordable to get skilled support.
Conclusion
Thanks to the solution provided by FLSmidth, we have
been able to reduce dust emission levels significantly by
converting our ESPs to much more efficient fabric filters.
The cost of the conversion process was reduced by reusing
existing elements of our ESPs, and the support we have
received throughout the process ensures that we will be
able to maintain efficient operations in the future, says
Khun Wichet Chuchaeu.

Reprinted from March 2015

World Cement /
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