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Author:
Anna Frank, Equipment Selection Expert
Anna Frank, Equipment Selection Expert
Sources
Every day, millions of tons of cement are delivered by trucks, trains, and other means of transportation to various regions of the world. It is used to produce concrete and mortar, which are essential for the construction of different structures, as well as at concrete plants and facilities manufacturing reinforced concrete products.
Production facilities are often located close to residential areas and public or recreational zones. Emissions from such industrial sites are extremely high. Cement dust enters the air in residential areas as a result of mechanical processing, drying, firing of ore materials (clay, lime), and additives (slag, ash), as well as during the transportation and storage of the product and its components.
Investments in modern technology improve the dust collecting system and efficiency in cement industry, ensuring safer and cleaner operations.
Production facilities are often located close to residential areas and public or recreational zones. Emissions from such industrial sites are extremely high. Cement dust enters the air in residential areas as a result of mechanical processing, drying, firing of ore materials (clay, lime), and additives (slag, ash), as well as during the transportation and storage of the product and its components.
Investments in modern technology improve the dust collecting system and efficiency in cement industry, ensuring safer and cleaner operations.
Cement Manufacturing
Description and Composition
Since the size of cement particles does not exceed 200 μm, the material itself is considered dust. With a settling velocity of 0.2 to 6.0 cm/s, the proportion of long-suspended particles in a polluted environment can reach 25%. For this reason, the handling and transfer of cement contribute to the formation of dust clouds.
These characteristics make this powder a significant problem for cities where cement is produced or consumed. Along with the particles, heavy metals enter the atmosphere. Cement production accounts for up to 15% of mercury emissions into the air. This dust also contains cadmium, lead, zinc, nickel, copper, and chromium. The presence of these components is due to the use of various inorganic additives in the production process.
These characteristics make this powder a significant problem for cities where cement is produced or consumed. Along with the particles, heavy metals enter the atmosphere. Cement production accounts for up to 15% of mercury emissions into the air. This dust also contains cadmium, lead, zinc, nickel, copper, and chromium. The presence of these components is due to the use of various inorganic additives in the production process.
Hazards and Harm
Recent studies show that cement is classified as a toxic hazardous substance. It contains 0.8–7.3% free silicon dioxide, which is why it is considered a toxic component.
Cement is characterized by inertness; its particles do not oxidize when in contact with air. For this reason, it is not explosive. The harm manifests in other ways.
Cleaning up cement particles is currently considered one of the most pressing issues due to the toxic components it contains. These substances can cause diseases of the central nervous system, liver, kidneys, gastrointestinal organs, as well as impair hearing and vision.
In the absence of personal protective equipment, the tear glands are the first to be affected. If treatment is not started promptly, various eye diseases may develop, potentially leading to blindness.
The pollutant dries out the skin and, with daily exposure, causes cracking and bleeding.
The danger to the lungs and mucous membranes lies in the fact that contamination can lead to diseases such as asthma, pneumonia, throat cancer, and chronic bronchitis. If necessary measures are not taken in time, the victim’s condition will only worsen.
Cement is characterized by inertness; its particles do not oxidize when in contact with air. For this reason, it is not explosive. The harm manifests in other ways.
Cleaning up cement particles is currently considered one of the most pressing issues due to the toxic components it contains. These substances can cause diseases of the central nervous system, liver, kidneys, gastrointestinal organs, as well as impair hearing and vision.
In the absence of personal protective equipment, the tear glands are the first to be affected. If treatment is not started promptly, various eye diseases may develop, potentially leading to blindness.
The pollutant dries out the skin and, with daily exposure, causes cracking and bleeding.
The danger to the lungs and mucous membranes lies in the fact that contamination can lead to diseases such as asthma, pneumonia, throat cancer, and chronic bronchitis. If necessary measures are not taken in time, the victim’s condition will only worsen.
Cement Dust Collection
We offer services for the calculation, production, and installation of cement dust collection systems, which ensure efficient aspiration. This is carried out by installing cement dust collector filters in close proximity to dust-generating points. These systems not only remove contaminants but also return a significant portion of the finished powder or semi-finished product back into the production process. The most effective cement dust collectors are cyclones, bag and cartridge filters, and silo filters. For dust control in the cement industry, we recommend air purification units that demonstrate a high degree of filtration efficiency.
View the cheat sheet for engineers
Selecting the Best Dust Collector for Cement Dust Management
We’ve created a useful cheat sheet and a comprehensive brochure to guide you through the various filter types, their key features, and applications for cement dust.
Download the resources and learn how to enhance the efficiency of your cement dust collection system!
Download the resources and learn how to enhance the efficiency of your cement dust collection system!
Silo Filters
At points where cement and other bulk materials are unloaded mechanically or pneumatically, a large volume of dust-laden air is generated. Cement dust control in such cases is achieved using silo filters. A silo is a container used for storing bulk materials. The filter is necessary not only to clean the air from the dust generated during unloading but also to minimize the loss of the construction mixture.
The main component is the housing, where the air purification takes place. Inside the housing are filter elements, which can be bags or pleated cartridges that increase the filtration area and allow even fine particles to be captured.
Flanges and gaskets are used to ensure a tight connection between the housing and the silo, preventing air leaks. The system is equipped with safety valves. An important part is the clean gas chamber, where the purified air flows before being released into the atmosphere, as well as the duct connections. The regeneration system automatically removes accumulated dust from the filter elements and returns it to the silo. All cement silo dust collector parts are secured with mounting components, ensuring the structural stability and proper operation of the unit.
The air purification unit is connected to the silo via a flange supplied with the equipment. To ensure a tight connection, the elements are welded. Then the body of the gas-cleaning unit is sealed to the flange with a gasket. Before installation, it is essential to ensure that there are no foreign objects inside the unit, as these could damage the filter elements.
The main component is the housing, where the air purification takes place. Inside the housing are filter elements, which can be bags or pleated cartridges that increase the filtration area and allow even fine particles to be captured.
Flanges and gaskets are used to ensure a tight connection between the housing and the silo, preventing air leaks. The system is equipped with safety valves. An important part is the clean gas chamber, where the purified air flows before being released into the atmosphere, as well as the duct connections. The regeneration system automatically removes accumulated dust from the filter elements and returns it to the silo. All cement silo dust collector parts are secured with mounting components, ensuring the structural stability and proper operation of the unit.
The air purification unit is connected to the silo via a flange supplied with the equipment. To ensure a tight connection, the elements are welded. Then the body of the gas-cleaning unit is sealed to the flange with a gasket. Before installation, it is essential to ensure that there are no foreign objects inside the unit, as these could damage the filter elements.
Animated Operation of a Torch-Air Silo Filter
Principle of Operation of Cement Silo Dust Collectors:
The standard configuration of a silo filter includes:
We have extensive experience in supplying dust collectors for silo aspiration.
- Excess pressure generated during cement unloading in the silo is first released.
- The contaminated air-gas mixture is then directed into the unit.
- As the air evenly distributes through the unit, it passes through the filter elements.
- Secondary particles are retained on the surface of the filter elements, while the cleaned air continues through their internal cavities into the clean gas chamber.
- The purified air is finally discharged into the atmosphere.
The standard configuration of a silo filter includes:
- Painted steel housing
- Hopper with supports
- Compressed air receivers
- Cleaning membrane valves
- Cartridge or bag filter elements
- Emergency level inducer in the hopper
- Control panel
- Regeneration system with a vibration or pneumatic cleaning mechanism
We have extensive experience in supplying dust collectors for silo aspiration.
Cement Silo Aspiration
Baghouses and Cartridge Filters
According to our research, for solids with a fine particle size (ranging from 1 to 10 μm), it is advisable to use a fibrous cartridge or bag filter with pulse-jet cleaning as part of the cement dust collector design. Depending on production conditions and client requirements, the configuration may include:
- High-strength plastic or steel housing.
- Baffle for separating coarse particles.
- Pyramid-shaped collection hopper for capturing contaminants.
- Valves through which contaminated air enters the unit and cleaned air is discharged.
- Regeneration system that removes pollutants from the surface of the bags or cartridges.
Comparison of Baghouse and Cartridge Filters
Baghouse and cartridge-type units effectively remove dry dust from production areas and around technological lines. Contaminants are drawn in along with air through a branched duct network. These units can operate as part of local or central systems.
In central systems, pollutants are collected from all pollution sources. Operation can be automatic or semi-automatic, with dust accumulated in the hopper. The unit can be installed indoors or outdoors, depending on the facility.
Cement dust filter bags can be made from polyester, PTFE-coated polyester, aramid, polypropylene, or PAN, depending on the operating temperature, chemical exposure, and moisture conditions.
The bag filter dust load in the cement industry typically ranges from 1–5 g/m²·h under normal operating conditions and can reach 10–15 g/m²·h during high particulate load.
Portable cement dust collector is used in small workshops and production shops and is installed close to the emission source. They are especially practical when long duct runs are economically or technically impractical.
In central systems, pollutants are collected from all pollution sources. Operation can be automatic or semi-automatic, with dust accumulated in the hopper. The unit can be installed indoors or outdoors, depending on the facility.
Cement dust filter bags can be made from polyester, PTFE-coated polyester, aramid, polypropylene, or PAN, depending on the operating temperature, chemical exposure, and moisture conditions.
The bag filter dust load in the cement industry typically ranges from 1–5 g/m²·h under normal operating conditions and can reach 10–15 g/m²·h during high particulate load.
Portable cement dust collector is used in small workshops and production shops and is installed close to the emission source. They are especially practical when long duct runs are economically or technically impractical.
The operation of baghouse and cartridge units is very similar:
Contaminated air is directed into the unit through an inlet valve. The movement of the polluted stream is achieved using a compressor, pneumatic pump, or forced-draft fan.
Once inside the dirty gas chamber, the airflow passes through the filter elements. Fine particles accumulate on the surface, while the cleaned air passes through the bags or cartridges and is directed into the clean gas chamber.
When an automatic sensor is triggered, the filter regeneration process begins. During regeneration, particulate matter deposited on the filter surface falls into the hopper for subsequent removal.
To protect the cartridges and cement dust socks from abrasive wear, it is sometimes advisable to use a two-stage filtration system. The first stage is a cyclone, and the second stage is a bag or cartridge filter.
Contaminated air is directed into the unit through an inlet valve. The movement of the polluted stream is achieved using a compressor, pneumatic pump, or forced-draft fan.
Once inside the dirty gas chamber, the airflow passes through the filter elements. Fine particles accumulate on the surface, while the cleaned air passes through the bags or cartridges and is directed into the clean gas chamber.
When an automatic sensor is triggered, the filter regeneration process begins. During regeneration, particulate matter deposited on the filter surface falls into the hopper for subsequent removal.
To protect the cartridges and cement dust socks from abrasive wear, it is sometimes advisable to use a two-stage filtration system. The first stage is a cyclone, and the second stage is a bag or cartridge filter.
Cyclones
Cyclones demonstrate high efficiency because the particle fraction does not exceed 30 μm and is characterized by low moisture content.
The operation of counterflow cyclones is based on the inertial-vortex principle, which works as follows:
- The contaminated airflow enters the unit through an inlet duct, located at the top of filter, either by suction or forced injection.
- The design of the inlet duct creates a vortex in the incoming flow, which intensifies as the air enters the main body of the gas-cleaning unit.
- Under the influence of inertia forces, particles are thrown toward the walls of the housing, losing speed upon impact. Then, due to gravity, they fall into the hopper. At the client’s request, the system can be equipped with automatic waste discharge.
- The cleaned airflow is then turned 180°, a phenomenon known as counterflow, which is achieved through the conical or cylindrical-conical shape of the housing and the principles of gas movement within the unit. As a result, the purified air reaches the upper part of the device and is then discharged into the atmosphere through the outlet duct or directed to the next stage of purification.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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