Improvement of cement plant dust emission by bag filter system

The limestone quarry in PT Indocement Tunggal Prakarsa (ITP) in Cirebon is considered as a complex quarry in terms of chemical composition and material hardness. From the beginning of the plant operation up to the end of 2015, the dust removal was rely on electrostatic precipitator (EP) system. Whenever limestone from specific quarry zones were incorporated into Raw Mill (RM) feed or there was an upset condition, the dust emission increased significantly. Beside higher demand of electricity, an EP system requires lower gas inlet temperature in order to remove the dust effectively which requires larger cooling water in the previous gas conditioning tower to cool down gas from 400 degrees C to about 100 degrees C. By considering the drawbacks, the EP system was replaced by a bag filter (BF) system. The BF allows higher temperature of gas inlet and it has higher dust removal efficiency. In this study, the efficiency of the two different dust removal systems is compared. The effect of process variables i.e. RM feed, kiln feed, inlet temperature and pressure, and small size particle fraction to the dust emission are studied by multivariate linier regression analysis. It is observed that the BF system can reduce significantly the dust emission from 30 to 6 mg/m(3) and in the same time reducing CO2 emission by 0.24 ton/year from the electricity consumption saving.