Compact yet powerful: Thermax’s advanced baghouse solution for cement plant expansion

Project overview

A leading cement manufacturer planned to expand production capacity within its existing plant.

As part of this expansion, the customer required a high-performance air pollution control solution that could be seamlessly integrated into a highly space-constrained layout without disrupting ongoing operations.

Challenges

Severe space constraints within the existing plant layout
Requirement to install a bag house larger than the available footprint
Need for a customised design that could be integrated without affecting plant operations
Expectation of high emission control performance despite layout limitations

Solution

Conducted a detailed as-is study of the site and operating conditions
Engineered a custom-designed pulse jet bag house (PJBF) optimised for compact installation
Integrated the Thermax Ad-APT® system, a header-mounted pulse valve cleaning solution
Used CFD analysis to optimise flue gas flow distribution through ducting and baffle modifications
Designed a compartmentalised bag house with provisions for online maintenance

Result

Achieved outlet emissions of 7 mg/Nm³, well within regulatory limits
Reduced compressed air consumption by 20–30% due to the Ad-APT® system
Improved filter media life through efficient and controlled cleaning
Delivered reliable, cost-effective performance
Bag house has been operating successfully for over four years, meeting customer expectations

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