DIS/CREADIS

JPG BUDOWNICTWO SP Z O. O.

JPG BUDOWNICTWO SP Z O. O. – ADVANCED SOLUTION FOR ENHANCED EMISSIONS COMPLIANCE

Effective filtration systems are essential for the cement industry, especially when it comes to filtering chemicals, process byproducts, and cement dust. Some filtration systems are designed and implemented in newly built facilities, while others are added to existing plants. JPG is a general contractor who was tasked with developing a comprehensive cement dust filtration system for their client, complete with schematics, scripts, and everything else needed to take the design from the drawing board to the plant.

Challenges

To stay ahead of continuously evolving standards, JPG’s client was looking to decrease the PPM (parts per million) dust emissions of five cement production stages to levels significantly below the allowable limits. Implementing a cutting-edge solution would not only help them stay in compliance but also provide greater protection for their people and equipment, and for the environment surrounding the plant. In addition, it would demonstrate their commitment to more environmentally friendly operations. JPG required an engineering service provider to assist in designing the new equipment and processes.

Solution

JPG chose DIS/CREADIS to assist in designing a solution that involved a comprehensive cement dust filtration system that they could implement for their client. The filtering solution is tightly integrated with all the plant’s existing technology, including its power supply and automated processes. From advanced filters, conveying systems, and sensors to new control and electrical systems, DIS/CREADIS' solution covered every aspect of the cement production process.

 

The implemented solution included:

  • A new set of filters and conveying system to be installed by JPG.
  • A new control and electric system developed and implemented to allow smooth operation and interlocks between existing and new plant machines.
Benefits

Today, the system designed by DIS/CREADIS and implemented by JPG is delivering emissions compliance that does not only meets current requirements but exceeds them. The goal was a 70% reduction in emissions, but the result was close to an 80% reduction. As a result, the plant is positioned to be within the guidelines for cement dust filtration and chemical emissions for years to come. The company will be able to avoid noncompliance fees and several system upgrades and the associated costs. With this solution, the plant has significantly mitigated pollution and dust.

Why DIS/CREADIS

DIS/CREADIS has extensive experience in a wide range of disciplines related to manufacturing emissions filtering, bulk material management, and alternative fuels. This expertise includes:

  • Filtering solution concept design
  • Conveying systems concept design
  • Filtering solution control and electrical system concept design
  • Production, separation, drying and enrichment of RDF-based fuel blends
  • Waste-2-Energy plants
  • Alternative raw materials plants for clinker production (process decarbonization)
  • Analysis of heat exchanger towers including pre-calciner burners—safety optimization and static-dynamic model analysis
  • Thermal analysis of heat exchanger tower process piping
  • Pulverized coal production plants
  • Process steam production plants with dual gas boiler systems
  • Replacement of filter systems in all departments: milling, clinker production and additive–contaminants reduction
  • Alternative fuel drying systems for rotary kilns—collection, separation and storage systems
  • Clinker silo reclaimer system efficiency enhancements, along with relocation and improvement of slag storage
  • Implementation of sampling systems for cement plants and trucks
  • Mobile systems for dust-free unloading of clinker from trucks and transport to storage
  • Custom equipment–sampling station, magnetic separator, etc.

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