Cement Industries

Cement dust often poses application-specific challenges related to abrasion, moisture content and high dust loading Rajdeep Engineering understands that cement production requires extensive levels of dust control – from nuisance venting to process-specific applications – we have experience with them all! For over 40 years, high-efficiency fabric filters have been used in the cement industry and most major production facilities have 40 to 80 fabric filter control systems ranging in size from 1,000 ACFM to over 1,000,000 ACFM.

The cement industry stands as a pivotal and dynamic force globally, serving as the cornerstone of countless construction projects. Analogous to the binding force of friendship, cement is indispensable in virtually all forms of development, from commercial and residential buildings to essential infrastructure like airports, railways, and ports. With a staggering annual production of 4180 million metric tons in 2014, predominantly originating from expansive manufacturing facilities, its significance cannot be overstated.

However, despite its indispensable role in the economy, cement manufacturing poses substantial risks to both human health and the environment. These risks stem from the production of cement kiln dust (CKD), a byproduct of clinker manufacturing. Comprising ash, particulates, calcium carbonates, halides, volatile chemicals, alkalis, sulfates, and other constituents, CKD poses significant health and environmental hazards.

Cement production facilities commonly face challenges with their dust collectors, experiencing issues like short bag life and low-pressure problems, particularly in areas distant from the central air system. Many operate on timers, but attempts to switch to demand control often result in short-cycling, exacerbating bag problems. 

Rajdeep Engineering has numerous installations on Cement Industries processes including:

  • Dust Extraction System
  • Material handling systems
  • Bag Loading/unloading stations

We are also experienced with handling the following material types related to cement production:

  • Limestone
  • Cement kiln dust
  • Clinker Dust
  • Gypsum Powder
  • Fly ash

Impacts on health and environment:

The tiny toxins from these mills are major threats to human health since they cause respiratory issues like bronchitis, asthma, and coughing which could be persistent. Exposure to prolonged periods also raises the high potentiality of the cancer. Nevertheless, this dust makes great contributions to environmental damage through the pollution of air and water bodies.

Issues with current collection methods:

Presently, industries encounter numerous challenges in managing the emission of fine particulates released from the clinker. Primarily, existing systems struggle to fully capture and eliminate all particulates, leaving free particulates in the air.

Moreover, the chemical composition of these emissions corrodes collectors, impacting their functionality. Sulfur emissions elevate acidity levels, accelerating the corrosion of metallic components, while alkalis further degrade collectors, diminishing their lifespan and effectiveness.

Inadequately sized equipment exacerbates issues as dirt and moisture accumulation impairs operational efficiency. Additionally, uncontrolled airflow further compromises performance.

Solutions to collection issues in cement industry:

To address these challenges effectively, it’s crucial to implement a robust particulate capture and recycling system within the production process. The selection of an optimal dust collection system is paramount to enhance the efficiency of particulate gathering.

Before installation, a thorough assessment of the plant’s specifications is essential. Sizing the waste removal equipment should consider factors such as particulate size, waste properties, temperature, particle flow rate, and moisture content.

In employing inertial separators, ensuring adequate force application is imperative for comprehensive waste collection. These separators leverage centrifugal, inertial, and gravitational forces. Settling chamber types necessitate sufficient space for particulates to settle and separate, while cyclone separators require centrifugal force to effectively remove waste.

For wet scrubber systems, ample area provision is necessary to facilitate the effective mixing of water and dust for optimal particulate removal. Additionally, modern collectors like electrostatic precipitators, fabric filters, or hybrid systems can be integrated to ensure a safe and dust-free environment in these industries.