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Cement Dust Solutions for Africa

Company News Thursday, March 2, 2017: Donaldson Filtration Systems (Pty) Ltd

Despite the slow economic growth of recent months, infrastructure development continues to fuel the demand for cement in many African countries. However, the cement industry is also responsible for an estimated 5% of the world’s greenhouse gases released into the atmosphere. With sustainability ranking high on the list of many of the continent’s emerging economies, finding the right designs and products to meet or exceed current and future emissions regulations is key to industry success.

Since the early 1970’s, Donaldson Filtration Systems has been a trusted service provider to Africa’s cement industry, installing over 300 filter units across the continent. PPC Ltd, AfriSam, Lafarge, Sephaku Cement (subsidiary of Dangote Cement) and NPC are amongst the long list of cement manufacturers who benefit from Donaldson’s extensive and growing range of products.

More than 20 years later, Donaldson remains committed to the design of high- quality materials that capture velocities high   enough to   eliminate emissions but low enough not to pull valuable product out of the production stream.

Leading the field

Designing, manufacturing and installation of filtration systems are Donaldson’s core competencies. The sustainable objective of the project engineers is to deliver products of high quality with increased efficiency in line with the protection of the environment and resources. We are offering, from one source, the construction of new dust collection systems, the modernisation and upgrading of existing systems in plants as well as maintenance, engineering and service. “At   Donaldson we all remain focused on our core mission namely; to offer our valued customers cost effective filtration systems that will enhance equipment   performance and protect the environment. Donaldson is a technology and solutions driven company committed to leading Africa and the world in the design and manufacture of filtration systems,” says Jacques Cato, General Manager of Industrial Air Filtration at Donaldson.

Dalamatic Bag Filters – proven solutions

The versatile Donaldson® Torit® Dalamatic series of dust collectors deliver a powerful solution for nearly any dust filtration application.  These collectors are available in different sizes and come in two models: the Dalamatic Cased (DLMC) which is a standalone collector that can be ducted to many different applications and the Dalamatic Insertable (DLMV), a versatile collector that can be inserted into various applications such as bins, silos, bunkers, storage vessels or transfer points. Both models are continuous-duty dust collectors designed to handle the most difficult product recovery applications. Envelope-shaped bags maximise the amount of media in a given space and provide continuous filtration of high dust concentrations even with small filter surfaces.

Modular Baghouse – flexible design

Due to their modular design, the Modular Baghouse dust collectors are not only suitable as new systems, but are also ideal for retrofitting or converting existing dust collectors. The sectional design allows for a variable filter bag assembly with tiered filter lengths for each section. High level dust inlets guarantee an effective separation even with difficult dust and high raw gas concentrations as well as with a low differential pressure.

Donaldson Downflo® Evolution (DFE) cartridge collector

In addition to the extensive Donaldson range of bag filter units such as flat bag and tubular bag technology, Donaldson also offers a complete range of cartridge filter units. With innovative technologies like the new Donaldson Downflo® Evolution (DFE)  cartridge dust collector, PowerCore® dust collectors and highly efficient filter  media like Ultra-Web®, Dura-Life® and Textratex®, Donaldson sets the benchmark in air pollution control. With these new technologies, Donaldson can guarantee lower emissions, a cleaner environment and higher effi- ciency when compared to current filter media in the market.

Donaldson, the originator of the cartridge collector, launched the DFE   cartridge dust collector in South Africa in June 2016, 30 years after the first cartridge collector was supplied in Africa. The breakthrough performance of the DFE family of cartridge dust collectors is the result of Donaldson’s relentless drive to improve its products and exceed customer expectations.

Donaldson put decades of indus- try experience to work to produce a new, best-in-class dust collector capable of reducing equipment size and the number of required filters by up to 40% compared to a typical cartridge collector. A smaller collector helps lower the initial purchase price, reduces filter replacement costs, and opens up valuable manufacturing floor space. This state of the art collector, coupled with Donaldson’s industry-leading Ultra-Web® nanofibre filtration technology, is truly an intelligent design.

The DFE’s game-changing dust collection performance is achieved through a combination of design features that result in significant customer benefits. One of the main features is the Intelligent Drop Out Zone, where pre-separation of heavy dust particles takes place, resulting in reduction of dust load onto the filter media, lower pressure loss, and minimal filter element abrasion.

The DFE provides breakthrough cleaning performance, with the new MaxPulse Cleaning System, resulting in improved filtration capacity without sacrificing filter life or taxing compressed air consumption. Typical pulse-jet cleaned dust collectors deliver only a fraction of the compressed air energy to clean the filtration media. The MaxPulse Cleaning System minimises energy loss by focusing on the cleaning air’s exact path and delivers uniform cleaning energy to all effective filtration media.

PowerCore® – smaller, smarter collectors

PowerCore® dust collection technology from Donaldson outperforms traditional baghouse collectors and does so in less space:  one 7” x 22” (178 x 559 millimetres). In one extremely small and powerful package, the PowerCore® dust collector handles high airflow, high grain loading, challenging   particulate and fits into the smallest places. The filter change out is remarkably quick, easy and clean compared to the process for traditional bag filters. PowerCore® dust collectors combine award-winning PowerCore® filter packs with a new proprietary compact pulse cleaning system. This proprietary combination delivers high filtration efficiencies not usually found in baghouse filtration.

PowerCore® space-saving dust  collectors are  available as stand-alone models that can be ducted to many different applications, as well as bin vent models used on applications like silos, conveyor transfer points, conveyor discharges, blenders and mixers. Compared to traditional baghouse collectors with similar airflow capacities, PowerCore® CPC dust collectors are up to 50% shorter. The comparison to traditional bag-style bin vents is even more dramatic.  CPV bin vent collectors are almost 70% shorter than other bag-style bin vents and effectively address the frequent challenge of tight space limitations.

 Aftermarket: replacement parts

Donaldson has a dedicated team responsible for aftermarket spares and provides a range of parts and filter media. Get cleaner air with advanced Donaldson replacements cartridges and bags. Our Ultra-Web® nanofiber replacement cartridge filters  and  Dura-Life®  “twice-the-life”  replacement  bag filters are engineered with  proprietary, higher performance industrial air filter media that improves  efficiency,  saves energy and extends cartridge filter and bag filter life. Our cartridge and bag filters are the ‘Cure for the Common Collector’, and they are available for Donaldson and most other brands of dust collectors. Donaldson’s replacement parts are designed to guarantee the highest level of performance of your dust collection.

New technology = ease of maintenance

Due to the unique design of the PowerCore® and DFE cartridge range of filter units, no special tools are required to replace filter elements. Donaldson continually raises the bar in bag filter technology, providing the widest range of bag filters for any baghouse collector, with specific filter media suited for abrasive dusts, high temperature, moist and or oily dusts, as well as explosive and conductive dusts.

The cement industry needs to    embrace   new   technology and innovation to improve productivity whilst containing operating costs.  Real gains require that cement manufacturers work more closely with suppliers to identify shortfalls and encourage accelerated re- search and development programmes to cover the gaps. The cement plants will ultimately benefit directly but will also provide an important catalyst for critical technology advancements across industry.

Donaldson’s focus is on value- added technology, exceptional service and simplified product maintenance to ensure that customers can optimise production through the use of reliable and customised filtration solutions.