ปัญหาฝุ่นละอองในโรงงานซีเมนต์… แก้ได้แล้ว!
โรงงานซีเมนต์เจอปัญหาฝุ่นละอองหนักหัวใช่ไหม? ต้องควบคุมมลพิษให้ได้มาตรฐาน EPA แต่ก็ไม่อยากให้การผลิตสะดุด แถมยังต้องแข่งขันราคาอีก! ปัญหาใหญ่เลยนะเนี่ย
เครื่องมือวัดฝุ่นแบบเก่าๆ น่ะ ไม่ช่วยเท่าไหร่หรอก มันแค่บอกว่าตอนนี้เป็นยังไง ไม่ได้ช่วยคาดการณ์ปัญหาล่วงหน้าเลย ต้องคอยตรวจเช็คถุงกรองบ่อยๆ เสียเวลา แถมยังต้องหยุดเครื่องบ่อยอีกต่างหาก
แต่เดี๋ยวนี้มีเทคโนโลยีใหม่ช่วยได้แล้ว! Auburn FilterSense B-PAC™ เป็นตัวช่วยเทพเลยนะ
ระบบนี้เก่งมาก! มันไม่ใช่แค่บอกว่าตอนนี้เป็นไง แต่ยังคาดการณ์ปัญหาล่วงหน้าได้ด้วย! ช่วยให้โรงงานผลิตซีเมนต์ทำงานได้ลื่นไหล ปล่อยฝุ่นน้อยลง และประหยัดพลังงานไปเยอะเลย
Challenge
Cement producers are challenged to meet EPA regulations without interrupting production, while striving to improve profitability in a competitive cement market. Typical sensors and controls for baghouses are often basic and do not provide intelligent control or preventive insight into the process. Time-consuming manual inspection of filters and baghouse components become necessary. This can require a shut down or extend an outage. The historical EPA requirement for an opacity monitor in the stack provides little value toward preventive and proactive emissions control.
At just 10% of the total project cost, the system provides complet
While striving to improve operations and meet US-EPA NESHAP requirements for particulate emissions, Buzzi Unicem USA researched solutions to implement during a rebuild/conversion of three kiln baghouses. “We want a control system that can identify and inform operations of any filtration issues.” The Plant Manager wanted an experienced leader in the field capable of engineering and supporting large projects. They trusted Auburn FilterSense based on technology and application experience. To fully monitor and optimize the kiln filtration systems and overall plant production, Buzzi purchased three Auburn FilterSense B-PACs™ (Baghouse Performance Analyzer & Controller) with a full array of process sensors, integrated particulate monitors, and ancillary control electronics. Auburn FilterSense’s FilterWARE™ software was purchased for local HMI while the B-PACs also provided Ethernet IP to an IFix SCADA system. Auburn FilterSense also provided full support, including electrical engineering design and documentation, on-site installation review, product commissioning, and training. B-PACs feature tightly integrated sensing and control providing intelligent differential pressure control, optimized filtration and pulse cleaning, actionable diagnostics, and advanced DynaCHARGE™ particulate monitoring, which utilizes charge induction sensing. Using the local FilterWARE HMI, operators can easily view process variables,diagnostics, total particulate emissions, filter leaks by row, pulse rates, and energy use. Pressure and cleaning settings and damper controls are readily available for easy adjustment. The solution provides total insight and control to minimize emissions and maximize production.
Benefits
The wide range of benefits available to Buzzi Unicem USA
include:
B-PAC – Baghouse Performance Analyzer & Controller Optimize production and minimize downtime
Detect and locate failed solenoids and pulse valves Tight pressure control from IntelliPULSE Technology
Stable airflow regardless of inlet loading Multi-compartment online pulsing Minimize compressed air consumption Less pulsing extends filter life and reduces emissions DynaCHARGE Filter Leak Detectors in each compartment Detect pre-visible particulate emissions Leak detection and locating by individual row
Trend/compare total emissions from each compartment for maintenance planning DynaCHARGE Particulate Monitors for the stacks 1/4 to 1/10 the maintenance of optical sensors
Preventive sensitivity (< 1 mg/m³) FilterWARE HMI Improved process control and insight Better operator awareness and maintenance Auburn FilterSense On-Site Services Quick return to production and trained
Process
Filtration systems are a critical part of productivity and emissions control in cement manufacturing. In addition to the kiln, other baghouses include the raw mill, clinker cooler, and coal mill. There are also material handling and nuisance dust collectors. Larger baghouses are required under federal NESHAP, MACT, or state regulations for continuous monitoring, while nuisance filters often have no visible emission requirement. In addition to EPA regulations, there are process and maintenance benefits from Auburn FilterSense solutions. For example, B-PACs can help address concerns with coal mill fires
by avoiding coal dust buildup in the clean air plenum or coal buildup between filters. Basic DynaCHARGE leak detectorscan replace manual inspections of small dust collectors and individual compartments. All Auburn FilterSense products can be networke
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