Two significant FabriClean™ orders for FLSmidth Airtech demonstrate long-term performance and Airtech’s ability to support the entire life-span of APC equipment.

FLSmidth Airtech is continuously developing innovative solutions to improve Air Pollution Control (APC) Technology. FLSmidth Airtech’s FabriClean™ filter utilizes low pressure pulse-jet cleaning; and a unique gas distribution design which creates a downward or Negative Can Velocity at the inlet of each filter compartment. The proprietary inlet design of the FabriClean™ provides lower pressure drop across the entire system, minimizing total energy consumption. A Computational Fluid Dynamics (CFD) study is conducted to optimize the gas flow pattern of each FabriClean™. This proven technology enables FLSmidth Airtech to use 8 meter long filter bags. Combining the inlet design and long filter bag technology reduces the overall footprint of the FabriClean™, and results in a fewer number of original filter bags, cages, diaphragm valves, and other wear parts that require replacement. The FabriClean™ design allows for semi-compartment and full compartment isolation in order to perform online maintenance, preventing unscheduled production outages. In the long run, operation and maintenance cost are reduced significantly.

In 2001, FLSmidth Airtech designed and supplied three (3) FabriClean™ pulse-jet systems for Queensland Alumina Limited (QAL) Australia Calciners on all three (3) production lines. Each FabriClean™ was designed for a gas flow of 654,000 Am3/hour at 155 deg C under normal operating conditions, with a peak temp of 240 deg C, and inlet dust concentration of 75g/Nm.

FLSmidth Airtech provides parts and service solutions for the entire life-span of APC equipment. In 2008, Airtech was awarded the order to replace 9,500 filter bags at QAL with an advanced scrim construction. This technology is expected to significantly increase filter bag life.

Another FabriClean™ installation in 2008 was at Tarmac Buxton, UK. The FabriClean™ filter was designed for a combined kiln and raw mill gas flow capacity of 758,600 Am3/ hr.

In 2008, FLSmidth Airtech’s pledge to deliver solutions for the entire life-span of our APC equipment was put to the test. Tarmac contacted Airtech to supply 3,166 replacement filter bags. However, Tarmac required these bags be on-site within three weeks due to an unexpected event that required a kiln outage that consisted of only seven days. FLSmidth Airtech moved quickly in order to meet the short turnaround time to produce, ship, and install all new filter bags and cages. In order to meet stringent emissions requirements, Airtech recommended the use of fiberglass filter media with PTFE laminate. FLSmidth Field Engineers worked around the clock supervising the installation ensuring it was executed properly and efficiently. The entire process, from receiving the request to supply bags, the manufacturing and shipment of the complete set of replacement bags and cages, and the installation of the new parts was completed within a period of 4 weeks.

Benefits:

– Short lead time and on time delivery.

– P84® Felt bags and cages replaced with woven fiberglass with PTFE laminate.

– Upgrading to more efficient filter media lead to a 40% cost savings for the entire set of replacement of bags and cages.

– Reduced operational costs due to less cleaning.

– Increase in production capability & energy savings due to consistent pressure drop.

– Particulate Emissions < 10mg/Nm3

Ultimately, FLSmidth Airtech’s reputation for providing parts and service solutions was reaffirmed; and emissions were reduced below the required limits.

FLSmidth Airtech applies over 70 years of application knowledge and experience when delivering APC solutions to the Cement and Minerals industries. FLSmidth Airtech’s objective is to provide innovative APC solutions for the entire life-span of our equipment. We believe our collaboration with our industrial partners in the development and application of these solutions demonstrates a real commitment towards environmental sustainability.

Photo below shows FLSmidth Airtech FabriClean™ filters at QAL, Australia