Our Client: Titan America, a subsidiary of Titan Cement; a large international cement producer based in Greece.
Country: U.S.A. (Virginia)
We transformed the existing ESP into a Redecam Bag Filter and added a Gas-to-Air Heat Exchanger to adhere to the most stringent NESHAP PM rules and ensuring emissions were under 10 mg/m3 (0.07 lb/st of clinker).
Our Contract: Provide solutions for this cement plant’s clinker cooler and kiln/raw mill using as much of the existing equipment as possible. Our solution had to be the best in the business, as Roanoke Cement Company is an Energy Star® Partner and the recipient of a number of environmental, industry and safety awards.
Our Solution: On the clinker cooler, we transformed the existing ESP into a Redecam Bag Filter, maintaining the exterior casing but changing internal parts. This solution, a Redecam specialty, saves considerable CAPEX yet performs as well as new systems. A Gas-to-Air Heat Exchanger was added. Due to space limitations and to maintain access to a road, Redecam designed a structurally independent steel support that allowed them to install the HE on top of an existing electrical room. Installation and commissioning were completed during a 20-day planned outage. On the kiln/raw mill, the system includes a new Redecam customized Gas Conditioning Tower, a new Bag Filter, a new I.D. fan, dust handling equipment and new ducts and relative dampers. The scheduling was done in order to complete about 95% of the equipment erection before the planned outage, leaving only some tie-in activities during the outage, for which Redecam crews needed a mere six days. Both systems are compliant with all current NESHAP PM regulations and the kiln/raw mill APC system has been designed to be easily modified to adhere to any future, stricter, regulations.