The Cauldon Works of Lafarge Cement UK, located in the Staffordshire moorlands, is one of the main integrated plants operated in England by Lafarge Cement UK, Britain’s leading cement producer.
Cauldon produces 950,000 tonnes of cement a year and was one of the first UK cement works to introduce the use of chipped scrap tyres as a fuel in place of the traditional fuels – coal and petroleum coke. Burning ‘waste’ fuels means that, in addition to emission limits set by the Environment Agency, the Works will be required to comply with the Waste Incineration Directive (WID) which comes into force at the end of next year.
In the summer of 2002, air pollution control equipment specialist, Lodge Sturtevant Limited, was called in by Cauldon to discuss the options available for improving the plants electrostatic precipitator performance to satisfy forthcoming WID requirements. At this time, Lodge Sturtevant had successfully completed model flow tests on a relatively new ESP upgrade concept known as ‘Skewed Baffles’. Indications were, that significant reductions in particulate emissions could be achieved with minimal investment.
Lodge Sturtevant had no hesitation in recommending a phased minor upgrade scheme. The first phase was carried out in January 2003 and involved new gas distribution screens and the installation of skewed baffles. It was planned to follow this work with further performance modifications in 2004 that would include the installation of high emission discharge electrodes. However, emissions reductions achieved, as a result of installing the skewed baffles, were so significant that it was decided there was no immediate need to proceed with the further modifications.
Commenting recently on the installation, Martin Stocks, Process Manager at Cauldon says: “The skewed baffles have proved a great success contributing towards reducing the kiln precipitator emissions by over 50%. It’s a relatively simple technique that avoided the need for us to consider other costly alternatives such as extending the ESP or replacing it with a bag filter. We also benefited greatly from Lodge Sturtevant’s ability to carry out the on-site work within our normal two week stop period.’’
John Wyatt, Lodge Sturtevant’s Gas Flow Distribution Specialist, with over 25 years experience in the field of precipitator gas flow distribution explains: “Correct application and strategic location of the skewed baffles within the precipitator is key to their successful implementation and performance. During initial tests, the interbank skewed baffles proved to be much more effective than conventional outlet flare baffles’’.
Lodge Sturtevant, a part of F.L.Smidth Airtech, have since successfully installed skewed baffles in the upgrading of various different designs of precipitator for other clients, all of which have resulted in similar significant improvements in performance to those achieved at Cauldon Cement Works.
The Cauldon Works of Lafarge Cement UK, located in the Staffordshire moorlands, is one of the main integrated plants operated in England by Lafarge Cement UK, Britain’s leading cement producer.
Cauldon produces 950,000 tonnes of cement a year and was one of the first UK cement works to introduce the use of chipped scrap tyres as a fuel in place of the traditional fuels – coal and petroleum coke. Burning ‘waste’ fuels means that, in addition to emission limits set by the Environment Agency, the Works will be required to comply with the Waste Incineration Directive (WID) which comes into force at the end of next year.
In the summer of 2002, air pollution control equipment specialist, Lodge Sturtevant Limited, was called in by Cauldon to discuss the options available for improving the plants electrostatic precipitator performance to satisfy forthcoming WID requirements. At this time, Lodge Sturtevant had successfully completed model flow tests on a relatively new ESP upgrade concept known as ‘Skewed Baffles’. Indications were, that significant reductions in particulate emissions could be achieved with minimal investment.
Lodge Sturtevant had no hesitation in recommending a phased minor upgrade scheme. The first phase was carried out in January 2003 and involved new gas distribution screens and the installation of skewed baffles. It was planned to follow this work with further performance modifications in 2004 that would include the installation of high emission discharge electrodes. However, emissions reductions achieved, as a result of installing the skewed baffles, were so significant that it was decided there was no immediate need to proceed with the further modifications.
Commenting recently on the installation, Martin Stocks, Process Manager at Cauldon says: “The skewed baffles have proved a great success contributing towards reducing the kiln precipitator emissions by over 50%. It’s a relatively simple technique that avoided the need for us to consider other costly alternatives such as extending the ESP or replacing it with a bag filter. We also benefited greatly from Lodge Sturtevant’s ability to carry out the on-site work within our normal two week stop period.’’
John Wyatt, Lodge Sturtevant’s Gas Flow Distribution Specialist, with over 25 years experience in the field of precipitator gas flow distribution explains: “Correct application and strategic location of the skewed baffles within the precipitator is key to their successful implementation and performance. During initial tests, the interbank skewed baffles proved to be much more effective than conventional outlet flare baffles’’.
Lodge Sturtevant, a part of F.L.Smidth Airtech, have since successfully installed skewed baffles in the upgrading of various different designs of precipitator for other clients, all of which have resulted in similar significant improvements in performance to those achieved at Cauldon Cement Works.