Redecam offers highly engineered air pollution control solutions for the Cement & Lime, Metals & Mining, Coal & Oil Power, Waste-to-Energy & Biomass Power and Biomass & Pulp and Paper industries, helping customers meet or exceed their air emission reduction targets in a rapid and cost-effective manner. Our track record is strong with over 2,000 projects in nearly 90 countries and on every continent.
Here are a few of our projects in North America:
Stockertown & Maryneal Cement Plants
Our Client: Buzzi Unicem USA, one of the leading cement manufacturers in the US, with a production capacity of approximately 8 million metric tons.
Country: U.S.A. (Pennsylvania)
The addition of our Gas-to-Air Heat Exchanger and the replacement of an old ESP by a Redecam Bag Filter ensured adherence to the most stringent NESHAP PM rules.
Our Contract: Since 2008, we have provided turnkey solutions to update the existing air filtration systems at the two plants.
Our Solution: At Maryneal Cement Plant, we were hired to design, manufacture and install one of our high efficiency DPM-Model Bag Filters (baghouses) on the mill and separator which, with Redecam’s Bi-Jet Bag Cleaning System, could reduce the system’s consumption of compressed air by up to 40%. A few years later, we updated the air filtration system on the clinker cooler at the Stockertown Plant by adding an RF-Model Gas-to-Air Heat Exchanger to control the temperature at the clinker cooler outlet upstream of a new DPD-Model Bag Filter which replaced an existing electrostatic precipitator (ESP). The solutions at both plants optimized performance, ensuring adherence to the most stringent National Emission Standards for Hazardous Air Pollutants’ (NESHAP) PM rules.
US Navy Hospital Thermal Reduction System
Our Client: Pennram Diversified Manufacturing Corporation
Country: client in U.S.A., product destined for Guantanamo Bay, Cuba
Our supplied high performance Bag Filter, as well as our Mercury Adsorption and DI-Desulfurization systems with reactor and recirculation, exceed all emissions requirements.
Our Contract: This contract is currently underway. We are providing a turnkey air pollution control solution for this 55 kg/hr thermal reduction system.
Our Solution: We are designing one of our special Bag Filters (baghouses) and are fully pre-assembling it to reduce on-site installation time and costs. This Bag Filter offers the highest particulate removal efficiency on the market, exceeding the most stringent emissions requirements. Our APC system is high performance with a reactor and a recirculating system. It includes our Mercury Adsorption System with activated carbon and our Dry Injection Desulfurization system with hydrated lime. All together, they will effectively remove particulates, acid gases, metals and any potential dioxins that may have reformed post-oxidation. This will be an auto feed system with manual ash removal via a vacuum.
Apazapan Cement Plant
Our Client: Cementos Moctezuma, Mexico’s fourth largest cement manufacturer and a company jointly controlled by Buzzi Unicem, Italy’s second largest cement manufacturer and Cimentos Molins.
Country: Mexico
We designed highly environmentally friendly solutions for this plant including our special Dual-Input Integrated System, reducing costs and saving space.
Our Contract: Provide a highly environmentally friendly turnkey air filtration solution for this new plant’s two lines with a production capacity of 1.3 million tons of cement a year.
Our Solution: We designed, built and installed two DPD-Model Bag Filters (baghouses), one for each of their two mill and separators, as well as a DPD-Model Bag Filter for their petcoke mill dedusting. Redecam engineers designed each of these Bag Filters to offer the highest particulate removal efficiency on the market. We also provided one of our special integrated systems, a Redecam Dual-Input Integrated System, using one Bag Filter to dedust both kiln ends (kiln/raw mill and kiln/clinker cooler), reducing costs and the space required for equipment. This system also included an RF-Model Gas-to-Air Heat Exchanger for optimal performance.
St Mary’s Cement
Our Client: St Mary’s Cement, one of the oldest cement companies in North America and a leading manufacturer of cement and related construction products in the United States and Canada. It is a wholly-owned subsidiary of Votorantim Cimentos, the largest cement company in Brazil and the eighth largest in the world.
Country: Canada (Ontario)
Our Gas-to-Air Heat Exchanger enhanced plant operations and reduced operating costs, while our Bag Filter was designed to avoid unscheduled production stoppages and facilitate maintenance.
Our Contract: Provide a complete upgrade to the air filtration system on the clinker cooler at the company’s original plant in St Mary’s, Ontario, built in 1912, and manage its installation.
Our Solution: We replaced the obsolete heat exchanger with one of our Gas-to-Air Heat Exchanger models in order to cool the gas flow from the clinker cooler, enhancing plant operations and reducing operating costs. We designed, built and installed one of our top-quality DPD-Model Bag Filters which we divided into four compartments, each of which can be separately closed with dampers in order to allow continued production even when one compartment requires maintenance. A new system of screw conveyors and flap valves was installed to discharge the dust collected in the Heat Exchanger and the Bag Filter into the existing dust transport system. A new I.D. Fan with an electric drive motor completed the installation. Finally, Redecam ensured the entire system was included into the main automation of the plant.
Black River Lime Production Facility
Our Client: Carmeuse, a worldwide leading producer of high calcium and dolomitic lime, limestone and derived products.
Country: U.S.A. (Kentucky)
We replaced the entire air filtration system while using the existing support structure to minimize costs. Our solution also decreased water condensation to avoid corrosion and mud clogging.
Our Contract: After completing a contract for Carmeuse at their Grand River plant, we were contracted to replace the entire air filtration system at this facility, in operation since 1964 and producing 2.5 million tons of lime annually.
Our Challenge: It was advantageous to our customer’s budget and timeline to use the existing support structure. We therefore re-designed our equipment to fit their structure.
Our Solution: We installed a new Redecam Bag Filter using the existing support structure and replaced an old inefficient U-tube heat exchanger with a Redecam Double-Passage Heat Exchanger, specially designed for lime applications. Our innovative design avoids local water condensation on the tubes, in order to avoid corrosion and mud clogging.
