engineering for a better world

Flexible and reliable solution with low pressure bagfilter technology

Efficient reduction of emissions with GEA ECOpuls filter

2

• GEAlowpressurecleaningconcept• Lowenergyconsumption• Lowcleangasdustcontent(<1mg/m³)• Extendedbaglifetime• Optimizedsystemforbaglengthupto10m• Fordustloadsupto>1.000g/m³evenatlargergasflows• Multicompartment,customizedandmodularsolution• Nocompressor&drying-systemrequired• Maintenancefriendly• Smallfootprint

GEA ECOpuls filter key characteristics

Bag filters are the preferred solution to separate and collect fine dust. Installations in the field of industrial processes like cement, iron & steel and non-ferrous stand for the success of this technology. Demanding conditions caused by high dust loads and sorption processes of gaseous pollutants (e.g. SO2, dioxins/furans and heavy metals) are the different kinds of challenges for a modern gas cleaning solution to master. Being capable of extremely low emissions, bag filters are considered as best available technology (BAT).

GEA is in the business of emission control with a long supply record for more than 120 year. We apply the GEA Elliptical COncentrical puls filter with the intention of combining the de-dusting performance of conventional bag filters with the reliability, extended lifetime and energy saving capabilities of low pressure cleaning technology.

Having less moving and wear parts, the GEA ECOpuls filter also excels in requiring less maintenance when compared to a conventional system.

Nearly zero emission atlowest cost of ownership

3

Total Cost of Ownership

Rotating pulse

cleaning manifold

Gear box

Compartmentization

by division walls

Concentrically arranged

elliptical shaped fi lter bags

Baffl e plate for

gas distribution

Dust collection hopper

Diaphraghm pulse valve

Air reservoir

Walk-in plenum

Raw gas inlect duct

Clean gas outlet duct

Outlet damper

Inlet damper

GEA ECOpuls fi lter

Thereducedamountofindividualparts,thehighgascleaningefficiencyandthesmallplantfootprintallowforminimuminvestcostoftheGEAECO-pulsfiltersolution.However,alsotheoperationalcostsneedtobeconsideredwhencomparingdifferentsolutions.DuetotheGEAlowpressuretechnol-ogy,theairusedforbagcleaningneedstobecompressedtoonly0,8bar(g).Thiscompression isachievedbyuseofreliableandenergyefficientrootsblowers.Noadditionalcompressorstationorairdryersarerequired.Incontrast,thecompressorstationofaconventionalhigh/mediumpressuresystemwillhaveasubstantiallyhigherenergyconsumption.ThelowoverallpressuredropoftheGEAECOpulsfilterandtheextendedfilterbaglifetimehelptoreducefurtheroperationalcost.Asaresult,theGEAECOpulsfilternotonlyistechnologicallysuperior,italsoofferslowestcostofownership.

4

WALK-IN PLENUM

The walk-in plenum is gas tight welded andaffords an easy access to the filter bags dur-ing maintenance, the GEA ECOpuls filter isequipped with a walk-in plenum. Individualfilterbagscanbepulledorexchangedonthespot.Alternatively,asanintermediatesolutionbrokenbagscanalsobesealedbyeasily.Nodis-mantlingoradditionalcranesarerequiredforbagexchangework.

SEGMENTED CAGES

GEAECOpulsfilterbags areheld inpositionbyspecialsegmentedcages.Thecagesfeatureasmartdesignedandconvenientsnapincon-nectionforquickmounting.Thewearandhightemperatureresistantcoat-ingof the cagewires contributed to the longlastingqualityofGEAECOpulsfilterbagcages.

ROTATING CLEANING MANIFOLDS

Eachcleangaschamberisequippedwithalowspeedrotatingmanifoldwithcleaningairnoz-zlesatitsbottomside.Therotatingmovementensures that allfilterbags areprovidedwithcleaningairatreducedpressurelosses.Itisnotrequiredtohaveindividualvalvesornozzlesforeachfilterbagtohavingasfewmov-ingandwearpartsaspossible.Hotcleaningairpreventscondensationeffectsduringpulsing.

BAFFLE PLATE FOR OPTIMIZED GAS FLOW

Topreventthedirectimpactofdustladenrawgasonthefilterbagsimmediatelyafterenter-ing,eachGEAECOpulsfilterchamberisequippedwithabaffleplate.Thisresultsnotonly in anoptimizedgasdistributionwithinthefilterchamberbutalsohelpstoreducebagwear,which isan importantpreconditionforlonglifetime.

GEA ECO puls fi lter technical features

5

During normal filtration the filter bagsare held in place by thewires of the bagcages,preventingcollapsingbydifferentialpressure.Duringbagcleaningphases, lowpressurepulsesofcleaningairareinjectedintothefilterbags.Theresultingoverpressureinsidethefilterbagsleadtotheaccelerationofthebagfabrictowardstheoutside.Thelateralmovementofbagmaterialcomestoanendwhenthefullextentofbagcircumferenceisreached.In consequence, precipitated dust on theoutersurfaceofthebagsisseparatedfromthefilterfabricbymassinertia.Asthedustalreadyhasbeenagglomeratedintoasolidfiltercake–fallingdownintothehopper-reentrainmentofdustisminimized.

UNIQUE ELLIPTICAL SHAPED FILTER BAGS

KeyfeatureofeachGEAECOpulsfilteristheellipticalshapeofthefilterbags.Thebagsarearranged in concentric circles– thus formingcircular shapedbundles.Thecirculargeometryallowsfortheuseofonlyonesinglerotatingcleaningmanifoldperfilterchamber.

ONLINE CLEANING

TheGEAECOpulsfilterconceptallowsforonlinepulsecleaning.Itisnotrequiredtoisolatetheindividualfilterchambersfromgasflowforbagcleaning.Asaresult,theGEAECOpulsfilterisalwaysworkingwiththefullefficiency,withouttheneedtooperateatn-1conditionandthereforeallowingforaminimizedplantfootprint.Still, individualchamberscanbeseparatedbydampersincaserequired.TheGEAECOpulsfilterusessufficientlysized,longlasting12”diaphragmvalves,excellinginreliability.Thesystemisoptimizedforupto10mbaglength.Thedesignisreadyforevenlongerbags.

GEA ECO puls fi lter technical features

Filtration

Cleaning

LOW PRESSURE - HIGH EFFICIENCY

ToperformbagcleaningtheGEAECOpulsfilterutilizesairwith0.8barg(atreservoir)suppliedbystandardrootsblowers.

Bagcleaningrequiresthreephases:

(1) Inflationwithfastacceleration(2) Buildupofsufficientcleaningpressure(3) Purgingofthefilterbag

Whilepressureislow,theactualcleaningefficiencyishigherthanwithconventionalsystems.Jetpulseswithupto3timeshighervolumeofcleaningairexpanddirectlyintothebagrows,withouttheneedofaventurisystem.TestshaveshownthatGEAlowpressuretechnologyresultsinhighestutilizationofcleaningenergyalongthecompletelengthofthefilterbag.ThistechnologyallowsforON-LINEcleaningevenoflongerbagsandresultsinlesswearandextendetfilterbaglifetimeatreducedenergyconsumption.

(2) Buildupofsufficientcleaningpressure

Comparison of jet pulse at end of 10m bag

6

For decades GEA has been serving the cement industrywith reliable and highlyefficientgascleaningsolutions.TheGEAECOpulsfilterissuitableforawidefieldofgascleaningapplicationsrelatedtocementproduction.

GEAECOpulsfilter-applicationsforcementinclude:• Kiln• Clinkercooler• Raw,millandcoal• Bypassextractionanddedusting

Ourbagfiltersarecompliantwith latestU.S.NESHAPrequirements,allowing forcleangasdustemissionslessthan1mg/m³.

Cement

Productionfacilitiesofnon-ferrousindustry,e.g.copperandzincsmelter,requiresecureandreliablededustingequipment.GEAECOpulsfilterismainlyusedfor:

• Secondarydedusting

LikeinotherindustriestheGEAECOpulsfilterallowstherecyclingtheseparateddusttotheproduction.

Non-Ferrous

Latestregulationsaffectingiron&steelmakingplantsinmostpartsoftheworldaredemandingforextremelylowdustoutletconcentrations.Thisespeciallyappliesforsinterplants,whereinadditiontodedustingthereductionofSOxanddioxins/furansisanimportantissue.ProvidingtheGEAECOpulsfiltertechnologyasaprovensolution,GEAistheidealpartnerforcustomersrequiringasignificantreductioninemissionlevels.

GEAECOpulsfilter-applicationsforiron&steelinclude:• Blastfurnacecast-andstockhouse• Sinterprocessgas• Sinterwastegas• Secondarydedusting

Iron & Steel

GEA ECOpuls filter - a reliable solution for our customers

7

While environmental regulations getting more strict, older existing electrostaticprecipitatorsoftenarepushedtowardsandevenbeyondtheirdesignlimitations.TheadvancedandflexibleGEAECOpulsfilterdesignmakesitpossibletoconvertexistingelectrostaticprecipitatorsintobagfilters,whileallowingforre-useofexistingcasing,hopper,supportanddischargesystem.

Withtherelativelysmallamountofadditionalpressuredropinducedbythefilterbags,formanyapplicationstheexistingID-fanscanbekeptalsointhefuturewithoutfurtherupgrade.Whilecleangasoutletconcentrationof50mg/m³–100mg/m³aretypicalforolderexistingelectrostaticprecipitators,theseeasilycanbereducedto5mg/m³orevenlesswhenchangingtofilterbags.Asshownonthepicture,thecleangaschamberscanbeinstalledasapre-assembledmodule,shorteninginstallationandsavingvaluabledowntime.

Conversion from existing ESPs to GEA ECOpuls filter

GEA R&D Efforts Behind Success

GEA Emission Control Service

R&Dwork is the onlyway to preserve technological leadership,wewill continueimplementinglatestscientificfindingsinourgascleaningsolutions.

Therefore,wehaveourownR&DcenterlocatedinFrankfurt,Germany.Amongmanyotherimprovementscurrentlyunderdevelopment,theoptimizationofflowdesignandapprovedbagcleaningefficiencyisanimportanttaskofGEAR&D.

Inaddition,GEAR&Disabletoofferarangeofservicestocustomerswhoseekourexpertiseforgascleaningprocessesandequipment,including:• Technicalstudiesforoptimizationofplantperformance• CFDstudiesforoptimizedgasflowanddistribution• Operationofpilotplantsincustomerproductionsite• Measurementservices

AtGEA,wetakegreatprideinofferingdedicatedandhighlypersonalizedservice.Ourprojectmanagersnotonlykeeptrackofeachsinglestepofthedifferentprojectphases,theyalsoserveasyourdirectcontactperson.Havingin-depthknowledgeofyourindustryandinternationalregulations,ourprojectmanagerwillworkcloselywithyoutoensurethatyourbusinessrequirementsoverthelifecyclearemet.

GEAwillalsobeavailableforallyourquestionsandneedsaftertheplanthasbeenputinoperation.GEAAfterSalesServiceoffersinspectionsandpreventivemaintenanceaswellaspartsreplacementandupgrades.

Withthesafetyandprotectionofourcustomersandtheirenvironmentasaprimaryconcern,GEAiscertifiedaccordingtoDINENISO9001:2008andSafetyCertificateContractors(SCC**:2011).

© G

EA B

isch

off

Gm

bH

. All

rig

hts

res

erve

d.

GEA Process Engineering China Ltd

Room 1405, CITIC Building, No. 19Jian Guo Men Wai StreetChao Yang District Beijing, 100004, ChinaPhone: +86 10 8526 2025

GEA Process Engineering (Pty) Ltd.

286 16th Road 1685 Midrand, South AfricaPhone: +27 11 805 6910Mobile: +27 72 479 9019

GEA Process Engineering SAS

23 Quai de Paludate33 000 Bordeaux, FrancePhone: +33 5 5795 9566

GEA Process Engineering S.p.A.

Centro Direzionale Milano 220090 Segrate (Mi), ItalyPhone: +39 02 2101 0611

GEA Bischoff GmbH

Ruhrallee 31145136 Essen, GermanyPhone: +49 201 8948 0E-Mail: gea-bischoff@gea.comwww.geabischoff.com

GEA Process Engineering A/S

Gladsaxevej 3052860 Søborg, DenmarkPhone: +45 3954 5454E-Mail: niro@niro.dk

GEA Finland Oy

Hiomotie 1900560 Helsinki, FinlandMobile: +358 (0)10 322 11 00

GEA Process Engineering Inc.

9165 Rumsey RoadColumbia, MD 21045, USAPhone: +1 410 997 8700

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA Process Engineering (India) pvt LTD

Coral Square, 3rd floorVijay Garden NakaGhodbunder RoadThane (W) 400 607, IndiaPhone: +91 98 3006 9550

GEA Process Engineering, ООО

ГЕА Процессный инжинирингSemenovsky Val st. 6, bldg. 1105094 Moscow, RussiaPhone: +7 495 787 2020

GEA Engenharia de Processos e Sis. Ind. Ltda.

Prédio 4 D2, 1 Floor, Office 213051-750 Campiñas, SP, BrazilPhone: +55 19 3725 3001

www.gea.com

GEA Emission Control