A tightened national emission limit gave an operating kiln eleven months to reach a standard its existing electrostatic precipitator could not meet.
- Measured stack emission
- 3.8 mg/Nm³
- Conversion completed in outage
- 17 days
- Compressed air saving vs. timer cleaning
- 48%
- Capital saved by reusing casing
- 62%
The challenge
A revised emission standard cut the permitted limit from 50 to 30 mg/Nm³, with a further reduction announced for the following cycle. The existing ESP averaged 34 mg/Nm³ and could not be economically uprated. The kiln could not stop outside its planned annual outage of nineteen days.
How we approached it
- 01Gas composition, temperature profile and acid dew point were measured across a full production cycle including kiln upsets.
- 02The conversion was designed to reuse the existing ESP casing, cutting both cost and installation time substantially.
- 03PTFE membrane media was selected to deliver headroom against the announced future limit rather than only the current one.
- 04Erection sequencing was planned hour by hour against the nineteen-day outage, with pre-assembled modules staged on site beforehand.
What we delivered
Conversion of the existing precipitator casing to a CYCLA-BH pulse-jet baghouse with PTFE membrane bags, on-demand differential-pressure cleaning, and full explosion protection designed to the measured Kst of the kiln dust. Completed within the outage with two days to spare.
They planned the outage in hours, not days. The modules arrived pre-assembled and we restarted two days early — that had never happened on this site.
Project facts
- Client
- Integrated cement producer
- Industry
- Cement & Building Materials
- Location
- Rajasthan, India
- Year
- 2024
Measured results
- 3.8 mg/Nm³
- Measured stack emission
- 17 days
- Conversion completed in outage
- 48%
- Compressed air saving vs. timer cleaning
- 62%
- Capital saved by reusing casing
Other programmes
Next step
Tell us what is in the stream.
Flow rate, contaminant, target rating, chemistry and available pressure. Six inputs, and our engineers return a staged design with the sizing basis attached — typically inside 48 hours.
Or call +91 79 4890 2200 · sales@worldasatech.com