New Technology Beats Dust in the Cement Industry

Donaldson has released a new cartridge based range of dust collectors that are proving to be highly successful in the control of the pollution caused by cement dust.

Cement dust is known to create ill health by skin contact, eye contact or inhalation. Hazardous materials in the dust can include alkaline compounds such as lime (calcium oxide) that are corrosive to human tissue; crystalline silica, which is abrasive to the skin and can damage lungs; and chromium that can cause allergic reactions. In addition, excess dust can clog machinery, affecting operation and impacting on equipment maintenance costs.

To combat the impact of cement dust and other similar pollutants, Donaldson has launched a new range of cartridge dust collectors that utilise a filtration technology known as PowerCore.

PowerCore filter cartridges feature a patented nanofibre media technology that delivers performance efficiency greater than that of traditional cellulose-based cartridge filters and bags.
In addition to improved efficiency, the performance characteristics of the PowerCore media technology allows for the creation of CPV collector units which are up to 70% smaller than conventional collector units.

This smaller footprint and unit size delivers the benefit of PowerCore units being easier and cheaper to install than conventional bag collectors, making them attractive to operations where space is at premium. Maintenance is also easier as the PowerCore filter cartridges are engineered so that they may be removed by hand and replaced without the need for messy service machinery.

Local customers are already experiencing the benefits that Donaldson’s range of PowerCore CPV series collectors are offering.

Morgan Cement required a dust filter to vent a finished product bin being fed by two screw conveyors and aerated by air pads for product discharge. The site, located at Port Kembla, south of Sydney, has many dust collectors, all of which are traditional baghouses.

Morgan Cement were attracted to the relatively smaller size and higher efficiency of PowerCore and were happy to install a PowerCore CPV-3 unit as the first trial unit in Australia. After updating the unit with revised pulse-valve targeting and cradle design in the tubesheet, the unit continues to perform well with a stable delta-p. The customer is also impressed with PowerCore’s ability to recover from high delta-p situations.

Donaldson has had a similar positive experience at another leading cement plant in south-west Sydney with their PowerCore CPV-6 collector unit. In this instance, Donaldson were required to replace an existing dust collector that was proving to be inefficient in the existing operating conditions onsite where cement mixes were being loaded from silo storage units into haul trucks.

Concerns about the filtration efficiency and size of the dust collector required were founded on there being only a limited amount of space to house the unit at the customer’s site and the units ability to handle a mix of different types of dust in an area where other machinery, including haulage vehicles, needed to be protected from dust pollutant which could damage equipment.
Donaldson’s PowerCore CPV-6 unit matched both requirements.

The unit has been operating for twelve months on intermittent duty with a stable and low pressure drop below 50 mm wg. The customer commented that the performance has been more than adequate for the application and have loaded a number of different cement blends from storage silos into trucks with no complaints from truck drivers about dust problems during the filling operation.

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