Our global contribution to a greener future.
Portfolio selection.
Every industrial environment presents unique technical and operational challenges.
This section highlights selected projects delivered by REDECAM across different sectors and geographies. Each case study outlines the client context, the specific air filtration or dust control challenge, the engineered solution, and the measurable results achieved.
ENEA Research Station
Antarctica
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In 2002, Redecam supported ENEA and the National Antarctic Research Program (PNRA) at Italy’s Mario Zucchelli Station in Terra Nova Bay, providing critical wastemanagement infrastructure to enable safe, reliable base operations during the 38th Italian Antarctic expedition.
The project was scope was the engineering and the supply of the complete line for solid waste incineration, from boiler to the flue gas treatment: Bag Filter, Dry Injection Desulfurization & Mercury Adsorption with Sorbalite, mechanized ash unloading system, chimneys for emergencies & process with exhaust fan. The design and installation have been done using containers to reduce the erection and the commissioning time on the coldest place on earth.
Operating in Antarctica is not just a technical mission, it’s a test of resilience, innovation, and precision. Year after year, scientific and logistical activities generate municipal solid waste that must be managed on site, with solutions capable of ensuring maximum efficiency without compromising the pristine environment or interrupting PNRA field campaigns coordinated by ENEA.In one of the most remote and demanding research environments on Earth, every operation is a race against time. The narrow weather windows, extreme distances, and complex transport conditions made the rapid erection and commissioning of the system one of the project’s greatest challenges.
Delivering a fully functional plant under such constraints demonstrates not only technological excellence, but also the ability to operate where few others can—turning an extreme environment into a showcase of reliability, sustainability, and highperformance engineering.
The project safeguards continuity of PNRA field campaigns and supports ENEA’s responsibility for technicallogistics management of Antarctic stations, maintaining high safety and environmental standards. Operational scale is consistent with the station’s real demand: approximately 15 tons incinerated per summer season across around five cycles, serving a seasonal population of about 80–90 people—evidence of reliable, continuous service in extreme conditions.
In short, Redecam and ENEA turned an extreme challenge into a showcase of reliability, sustainability, and execution precision—with a solution purposebuilt for Antarctica that protects the environment, supports the scientific mission, and delivers where few can operate.
Orcan & Buzzi Unicem.
Vernasca Plant. Italy
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The main objective of this project was the reduction of water consumption in the gas conditioning tower within the process. The adopted solution was the installation of a boiler associated with a steam turbine capable of producing energy thanks to the superheated water generated by the above-mentioned equipment.
As this is a brownfield plant, the positioning of the equipment was carefully studied in order to minimize the impact and footprint on the existing facility. The current solution allows the plant to avoid the use of the gas conditioning tower under all operating conditions by routing the gases through the boiler.
The Redecam solution consists of a boiler installed in series with the kiln process, with the possibility of being bypassed for maintenance operations. Connected to the heat exchanger is a steam turbine system that produces energy.
The Redecam boiler is designed to deliver up to 11 MW of thermal power at peak and approximately 9 MW of thermal power on average.
Holcim Italia SpA, Holcim Group
Ternate Cement Plant. Italy
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Redecam was awarded the EPC contract to modernize the main process kiln filter at Holcim’s Ternate Cement Plant. The obsolete electrostatic precipitator (ESP) was dismantled and replaced with a stateoftheart bag filter, ensuring full compliance with dustemission limits. The key challenge was to execute a largescale upgrade—about 470 tons of equipment and structures—within a highly constrained footprint and a kiln shutdown window of no more than 24 days.
Our Solution:
At the heart of the project lies modularization. The new process filter—sized for up to 815,000 Am³/h—was split into 8 independent modules, each specifically engineered, fully preassembled, and delivered installationready. Standardized interfaces, preequipped steelwork, and plugandplay connections drastically reduced onsite assembly time, compressing critical activities into the short outage. Offsite prefabrication shifted most works to the workshop, minimizing work at height and onsite welding, with clear benefits in schedule, safety, and build quality. The lift-and-set sequence was planned to limit interference with existing assets. The system handles gases from the kiln, raw mill, and clinker cooler, delivering a fully Integrated Bag House Filter across both sides of the plant.
The final configuration
A completely new bag filter and fan were installed within the original footprint, complemented by optimized and enlarged ductwork. The upgrade delivers significant emission improvements, greater system reliability, and enhanced operational flexibility under all operating conditions—while ensuring a shorter, safer, and more predictable site execution thanks to the modular approach.
Duferco Group. Travi e Profilati (TPP)
Pallanzeno. Italy
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This specific EAF dedusting plant has several secondary or auxiliary suctions (LF, MHS, Ladle Treatment) including a dog-house installed around the furnace; moreover, it has been modified during its long history with additional suctions but has experienced a significantly reduced efficiency of canopy hood suction.
Our Solution: Using our internal know-how, we conducted a complete simulation of the scrap charging process, thanks to a new CFD approach with 4 variable parameters (T, V, P and time).
We improved the EAF dedusting system effectiveness and efficiency by studying a modification to the secondary suction from EAF Canopy Hood, that started from a complete CFD simulation of the scrap basket charging process and ended into a new simplified ducts system to reach the existing bag house filters.
The final configuration includes now a modified canopy hood, a simplified ductworks system with fewer but larger ducts, with effective improvement in terms of their better connection to the suction hood in order to suck immediately the dust before some cold air streamline could bring it to lower part of the EAF building. A new damper system and the new mixing chamber located upstream the bag filters complete the Redecam supply, executed on turn-key basis.
Orion Engineered Carbons
Borger Plant (TX, USA)
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Redecam engineered and supplied a high-performance flue gas treatment solution at Orion Engineered Carbons’ Borger, Texas carbon black plant specifically to reduce sulfur oxides (SOₓ) emissions. The system — a recirculating dry scrubber with optimized reagent injection and gas handling — was tailored for the plant’s high-volume of process gas. Operating reliably since installation, it has achieved very high SOₓ removal efficiency (up to ~98 % on treated streams) and significantly lowered sulfur dioxide emissions in support of Orion’s broader emissions control and air quality goals.
Project execution (Engineering, Supply, Delivery DDP): ~18 months
On-site installation phase: ~15 months (by Client)
Operational milestone: system running from January 2023 up today achieving the guaranteed performances
Redecam delivered a highly reliable and easy-to-operate SOₓ control system, achieving up to ~98% SOₓ reduction while meeting guaranteed emission limits with low consumption of standard hydrated lime, thereby minimizing reagent usage and overall operating costs.
The system has been operating reliably for multiple years, demonstrating proven reagent efficiency, predictable OPEX, and long-term performance in a demanding heavy-industrial environment.
Our approach combines process analysis, tailored system design, and long-term operational reliability.
The projects presented here demonstrate how REDECAM solutions improve air quality, support regulatory compliance, and enhance performance in demanding industrial environments.