Increased filter lifetime at a cement plant in Switzerland
3 times longer filter lifetime with pleated bags
Customer profile
Effective filtration is crucial in cement production. Not only to maintain energy efficiency, but also to ensure compliance with increasingly stringent environmental standards.
At one of Switzerland's largest cement plants, the outdated filtration technology could no longer keep up with operational requirements. The plant was experiencing performance issues that impacted both energy consumption and air quality, prompting the search for a more reliable and sustainable solution.
Location: Switzerland
Key Results
3 years longer lifetime compared to 1 year with previous setting
60% decrease in differential pressure
Better air quality
High emissions and short filter lifetime
The cement plant was experiencing significant operational inefficiencies due to high differential pressure in the filtration system, which led to increased energy consumption and frequent maintenance.
The existing filter bags, though long (4,500 mm), clogged quickly, requiring replacement every 12 months and contributing to unscheduled downtime. Compounding the issue, poor suction performance and elevated dust levels along the transportation line made it difficult to maintain acceptable air quality, putting compliance with environmental standards at risk.
Challenges
High amount of dust and emissions
Poor filter quality, causing rapid deterioration and shorter lifetime
High differential pressure
High energy consumption
Replacement of filters with high performance pleated bags
The filtration system was upgraded with:
Type of Product: CPB - Top Loader Pleated Bag Filter
Number of filters: 600 pleated bags
Filter media: Polyester melt-blown with ePTFE
Filter media area: 3,2m²
Emission reduction and longer filter lifetime
Together with the customer, we have implemented the new pleated bags and compared the performance of the system over time.
General System Information
| Parameter | Data |
| Air flow in unit | 90.000 m³/h |
| Collector Type | LUESCHER 1991 |
| Collector running hours | 7260 hours/year (more than 300 days/year) |
Technical Data
| Before | After | |
| Filter model | Conventional filter bag | Top Loader CPB pleated bag |
| Filter media | 550g polyester needlefelt | 230g Polyester melt-blown media with ePTFE membrane |
| Length [mm] | 4.420 | 2.000 |
| Number of filter bags / cartridges | 600 | 600 |
| Filration surface in each filter bag / cartridge [m²] | 1,95 | 3,2 |
| Filtration surface in entire system [m²] | 1166 | 1920 |
| Emission mg/Nm³ | 10 to 30 | <20 |
| Differential pressure Pa | 2000 | 800-1200 |
| Lifetime | 1 year | >3 years |
| Compressed air bar | 6 | 4 |
| Air-to-cloth ratio m³/m²/h | 77 | 47 |
Half the Length, Double the Impact
By replacing the filter bags with 600 pleated bags, Hengst boosts air quality, reduces abrasion, and extends system performance. After 3 years of operation, the pleated bags had the following results, while still successfully running:
> 3 years longer lifetime compared to 1 year
The new pleated filter, with its shorter length (4,500 mm compared to 2,000 mm), reduces the risk of abrasion as it is positioned away from the abrasion path. Additionally, its 65% larger filtration surface results in a lower differential pressure, contributing significantly to its extended lifespan.
60% decrease in differential pressure
Pleated bags offer a unique surface filtration capability, allowing for easier cleaning of dust particles with minimal cleaning air requirement. This results in improved pressure drop performance, enhancing overall filtration efficiency.
Better air quality
The air quality has significantly improved as the new installation decreased the emissions under the legal limit, helping the production comply with air quality standards.
Get in touch
Contact our team for any questions and support regarding Filter Cartridges, Pleated Bags & Flat Cells
sales.nakskov[at]hengst.com