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The next generation in advanced technologies for emission reduction, EMC+, SCR and DeCONOx: Andreas Renetzeder, Scheuch GmbH (Austria)

Filmed at Cemtech Asia 2015, 21-24 June, Grand Hyatt, Bangkok, Thailand

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Good afternoon Ladies and Gentlemen! I'd like to present our newest technology for pollution cleaning and dust control. It's also a big issue already in Asia to reduce all the emissions what occurred in the big cities and even the cement industry. We are a family-owned company owned by the family Scheuch and based in Austria, Upper Austria close to the border to Germany.

Our managing directors are Mr. Scheuch and Jeliniewski. We're about 665 people in our headquarter and in total 785. Our turnover is about 140 million Euro and we're investing in research and development about 300 million per anum. Our export share is 75%, and now following a short video clip to show production and and in what kind of fields we are working.

The environmental performance of industry forms an important basis for prosperity and business development. This involves harmonizing industrial production with the environment. At Scheuch, we contribute to this in two ways, with our ventilation and environmental technology products, we guarantee that our customers are always able to manufacture at safety in the highest quality, and we ensure that hazardous materials arriving from production processes, do not impact on the environment.

Our technology is complex. Each of the the sectors that we serve has it's own special requirements. We know this well for decade we've been working in sustainable partnership with our customers, our suppliers and our own personnel. We've specialist from all divisions from our product range in house together with the customers they are able to develop optimum tailored economical solutions compliance with all environmental regulation today and in the future is inherit in our work and part of our philosophy.

We've had great success with this we are active globally and our ventilation and environmental technology products are in operation in systems of every shape and size, and have been for more than half a century, our quality requirements are high. This is one reason why we produce a large portion of our production in-house, in the most modern production systems, precisely tailored to the requirements, guaranteeing the secure function of the technology supplied by Scheuch.

Our employees are an important factor in the success of our product, taking off the challenges with skill and commitment and developing innovating solutions. As a family business, we're firmly rooted in the region, but at the same time looking far beyond the borders of our own comfort. In doing so, we can look to the future with great optimism and open minded curiosity. With our extensive experience, we stand ready to fulfill future demands on environmental technology, and indeed to exceed them by far. A trustworthy and flexible partner for industry, specialist who enable our customers to manufacture their products safely, thus, preserving our environment for all to enjoy. We're mainly based in the mineral industry and producing big houses for the Kiln filters, Clinker Cooler dusting and coal grinding, as well cement business and all other kind of mineral businesses.

We're starting with our focus from small filters as well big scale gas cooling, gas conditioning, power, heat air to air heat exchanger, screw conveyors, fans, and rotary feeder, everything from a single source. Also the planning, observation, consultant, in-house manufacturing, assembling, commissioning, emission testing, maintenance, and spare parts is produced by ourselves and served to the customers.

Even our biggest success for the last year was the EMC minimizing concept. We've already installed more than 200 plants and filters of this kind of filter technology worldwide with the big length up to 12 Meter. The most advantage is that we combinate two systems, normally standard was in the past the online cleaning system, several disadvantages, a constant differential pressure, but the disadvantage was constant increasing of the dirrerential pressure, the early aging of the bags through the often cleaning with compressed air and even the high amount of compressed air and energy consumption.

And the other past system was the offline cleaning. It had a good small differential pressure, longer bag life time, and small cleaning pressure, cleaning without counter pressure, but the high variation was the greatest disadvantage of this cleaning system, and have a big negative effect on the primary process. And our EMC system combines false advantages in one cleaning system with our own developed control system. Now a short film, how it works and to understand the functions. This is, sorry, once again.

Our systems have modules, and these modules are doing cleaning till it isolate it from the root cause pipe, so no counter pressure. The [incomprehensible] cleaning jet pipe insure an combination with the [incomprehensible] and very high efficient cleaning with very low pressure. And with this we also ensure a cleaning of big lengths up to 14 meters now. As the variation of the [incomprehensible], we're contaminated open and close in the same time, so the difference in variation keeps stable during the operation. To insure on each bag and their nozzle have different dimensions for exactly on the every bag are all bag the same amount of compress air to reach. And the primary air with a high speed ensure a lot of secondary air what comes into the bag, and this is the biggest advantage of the cleaning, and with our buffer plate construction with brief separation of the dust of 85% on the inlet of the crude gas. And these are the main topics of the EMC system.

And through this low pressure, its noise is a very big issue already in Europe. Now, I want to show you the big difference of the cleaning system of the EMC compared to the online cleaning, where you can see how the dust gets removed from the bag. Please stay online from the online cleaning, thank you.

Here, it's very easy to see that the fine dust particles get immediately off the cleaning sacked bag to the bag, maybe you can play it once again. And during this cleaning of the bag, the fine particles go into the fiber and block the fiber and this is the reason why the edging of the bag is very quick and increasing of the [incomprehensible] during operation.

Now as a comparison, the EMC cleaning system and the previous one was the cleaning pressure five bar. Now, here you can see it's about one bar cleaning. Without counter pressure, no fine particles can sack bag, very low emission, below one milligram, and the dust flow down on the bag into the hopper. And very smooth cleaning both extend very long bag lifetime.

We've reached now with these cleaning systems up to 12 years at the longest bag lifetime, but we get on the cleaning vehicles. This once again, very important for this system is this the optimist on their operation in the right manner between 8-11 millibars because this have a big influence on the cost of operation. This a typical Kiln because with a volume of 1 million actual cubic meters with a task load of 50 gram, filter inlet temperature is 240 degrees, and bag was glass fiber with PTfe membrane.

Here on the graphs, you can see the compress, their consumption. The black one is the filter, bag lifetime, the blue one is the fan energy, and the red one is the total operating cost. If the differential pressure is too low, the bag lifetime gets reduced and it's increase also the cost for operation.

If it's too high, the differential pressure is the same. So, it's very important that you operate it in a certain value between 8-11 millibars with our control system, should be this or is this possible optimization even on the aging of the bag if taken full consideration. And also, what kind of operation process you operate.

It makes no difference between compound, and direct operation, and task load. Same is for a cement mill. It's similar with the task load of 500 grams per cubic meter, half a million actual cubic meter filter load. You can also see, if you operate too low the cost increase and also the differential pressure is too high, also the cost increase, and operation cost.

Longer filter bags enable less size of filtration unit. The footprint getting smaller, 20% of saving on investment and for 10 meter vice OMC cleaning. This is a typical six meter installation, this was originally done together with on a rotary cooler mil and then we modify after 10 years of operation to a 10 meter bag house. So it was, could save a lot of investment and production increasing of about 30% of the mill the capacity through higher volume of filter and fan.

This is the footprint that you can see 6 meter pig house compared to 10 meter pig house. So especially, for ESP conversions, we can install a lot of filter area in ESP casing and can also ensure the capacity increasement of the kiln. The benefits are, operation costs will decrease 30% of less fan power, doubling of the bag lifetime, 80% less compressed air consumption, and reduction of investment costs, and less secondary investment costs.

Now, a case study of ESP conversion at Holcim, Germany, what we did in 2011. With the first installation of 10 meter fill the bags worldwide in a kiln operation process. Start please.

You'll see the days,
how long does that take place for the modification. The total clean shutdown for this conversion for both filters was 33 days including commissioning, and everything was executed by Scheuch together with Holcim.

The future starts now, 10 meter is already state of the art for kiln and cement mills, 12 meters can be installed and 14 meters, we already offered. Also, we're working on other technology, because in Europe, most of the dust pollution is already solved. Now it's going on the gas cleaning systems of particles what you cannot see, but also have a health infect of the population. This is SCR. With the first installation in Mannersdorf am Leithagebirge, full scale and maybe in the next same this conference, in September in Vienna, you can visit this installation with the catalizer. Here's some overview of how this is installed, and the ESP was just choosen through this the dust content over the catalizer, it can free adjust it, and also what is the best operation point for the catalizer in conclusion with the cleaning system for the SCR. Also, big advantage where we have under commissioning in this state first, DeCONOx in Austria. The performance is NOx with action of 90% below 200 mg per normal cubic meter with a 10% ammonia slip. CO and VOC reduction by 99%, catalyst deactivation range of a Low Dust cut, CSR and the autothermic operation, you just need the gas for initially starting up this process. If you have a CO content in the base gas of about 3,500 mg CO, pressure drop of such plants is about 30 millibars.

Then working like this that you have this three-column tower, here it's coming to crude gas, going in, going over the two columns, and one is in flushing, and after certain period, it's switched to the other which was flushed and cleaning the other one in reverse air. In-let temperature is about 120-250 and outlet is 150-280, so it can be installed after the filter and the clean gas side. So no cleaning is necessary for the catalizer. This is a typical plant arrangement what is now under commissioning in Austria. Also, we've installed and commissioned six months ago the first ExMercury in Austria and [incomprehensible] of a plant and the target of this is together incorporation with the company A TEC from Austria, to have all the little amount of mercury dust what have to be disposed on the [incomprehensible].

The biggest benefit is 80% initial reduction on mercury, no additional thermal losses for treatment, low additive consumption, low gas quantities, be treated only 3-10%, have to be treated to get out all the melt to mercury, a high efficiency cyclone, low life cycle cost and no raw meal separation necessary, and very low disposal, and this will be operated with the high temperature filter up to 450 degrees with ceramic. Some references what we've installed worldwide, South Africa, Ulco South Africa, [incomprehensible], Holcim Guayaquil, Clinker Cooler dedusting, Cement Mill Incl Guayaquil together with Russia, [incomprehensible] mill, ESP conversion with 10 meter bags in Cemex Colombia, Untervaz, Clinker cooler filter, Air HEX, Lagerdorf, this is Suddeutschland Holcim as well, catalyzer the blend in Lafarge Mannersdorf, Austria. This is Amreyah cement in Egypt for group basic recovering in Austria for Salzburg , Leube. Loesche is a cement grinding station in Bilbao, Spain. Bypass, maybe this is a Bypass we've worked with A TEC as well and we'll solve lot of problem with Alkali problems what you occurred in the kiln operation as my colleague mentioned before. As well Cementos Argos, Latin Americas, and the first Bypass, Alkali with EMC cleaning in Saudi Arabia for Yamama cement. Thank you very much for your attention. I hope it was interesting for you and if you have additional questions, you can visit me on my booth, thank you.

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