137CementMaterials.jpg Cement & Minerals

Cement production and mineral processing are complex processes with challenges related to dust collection. Many steps of the process require dust control, and each step presents its own set of challenges related to material properties, moisture, and temperature. Following are a few examples of dust control opportunities:

  • Limestone Quarrying
  • Primary & Secondary Crushing
  • Additive Blending & Store
  • Material Transfer & Storage
  • Raw Feed Grinding & Storage
  • Cement Kiln Dust Capture & Handling
  • Clinker Handling & Storage
  • Gypsum Handling & Storage
  • Lime Storage & Injection
  • Fly Ash & Activated Carbon Handling & Storage
  • Finished Cement Handling, Storage, & Distribution


Donaldson® has dust collectors designed for each step of the process. We understand environmental challenges facing the cement industry today and our products provide the robust, yet easy to service designs required, to help you meet or exceed current and future emissions regulations. Donaldson dust collectors in hundreds of cement plants worldwide are operating as both “source capture” and “remote mounted” dust collection solutions.

Where practical, Donaldson advocates “source collection” designs in plant applications. This design has the dust collector operate right near the point of dust creation. An example would be at a belt transfer point (instead of using a hood and ductwork to a central or remote collector) where the captured dust is returned directly to the process.

Advantages OF source Dust Collection

  • Less ductwork
  • Fewer discharge systems
  • Lower purchase costs
  • Lower energy consumption


Both the PowerCore® CPV-Series and Dalamatic® Series collectors are well suited for source collection strategies.

PowerCore (CP-V) dust collectors offer many advantages over traditional “baghouse” designs. Utilising Ultra-Web® media, PowerCore filter packs provide higher efficiency and better dust release properties. Their compact size allows for installation in places never considered before and perhaps most interesting, they offer easy filter change-outs that can save maintenance costs.

The Dalamatic Insertable (DLMV) is also a popular choice in the cement industry. Easily integrated in the majority of material handling processes, it uses “envelope style” filter bags with a shorter length than conventional round bags. This design offers superior dust release versus many other “bag style” products on the market and design modifications are available for high temperature and high moisture environments.

Where “source collection” is not a viable option, we offer several styles of dust collectors to mount remotely from the actual dust generation point. Each series of Donaldson dust collector offers a unique set of features and physical characteristics, thus allowing a customised solution for virtually any cement or minerals processing application. Donaldson dust collector options would include the following products:

PowerCore CPC Series Dust Collector

Dalamatic Cased Dust Collector

MB Baghouse Dust Collector

Processes In a Cement Plant

Processes involving cement production are often material handling applications at various stages:

  • Crushers,
  • Milling,
  • Conveyors,
  • Elevators,
  • Classifiers,
  • Separators,
  • Bins & Silo Venting,
  • Packing,
  • Rail, Road, & Ship Loading & Unloading


The cement production diagram below identifies where dust control may often be required.

CementProduction1_Key.jpg

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Special Considerations for Cement Dust*

Abrasion
Abrasion is a big challenge in cement dust collection. It is imperative to size dust collectors to limit velocities of abrasive particles thus keeping wear to a minimum.

Moisture
Moisture is inherent in some of the processes in cement production. It is important to consider moisture content of each application prior to selecting a filtration technology.

Dust Loading
Dust loading is a challenge in many processes in a cement plant. Proper design of dust collection hooding is essential to keeping capture velocities high enough to eliminate emissions but low enough not to pull valuable product out of the production stream and into the dust collector.

*Please contact your Donaldson Representative for more details regarding design considerations of these and other cement plant dust challenges.