Investor: Lias Vintířov, lehký stavební materiál k.s. (producer of light building materials)
Location of implementation: Vintířov, Czech Republic
“Oxygen moved to ... Vintířov” — This was the motto of the ceremonial launch of the technology for the cleaning of flue gases from rotary kilns for lightweight aggregates in 2010. Lias Vintířov is one of the largest Czech manufacturers of light building materials and the launch of technology, worth about 100 million CZK, has significantly reduced the amount of pollutant discharged into the air from production lines. The ecological investment in Lias has been partially enforced due to complaints about the stench in the surroundings and a pressure from the state authorities and legislation. The people at Vintířov and Chodov often complained about the smell from the production.
Oxygen moved to ... Vintířov
ILD cz s.r.o., as a general contractor and simultaneously a supplier of filtration equipment, has chosen the following main subcontractors to collaborate on the creation of a unique technology: Hellmich GmbH Germany (desulphurization technology), ENETEX TECHNOLOGY, s.r.o. (post-combustion unit) and our company ENETEX-TEP s.r.o.
Our collaboration with ILD company dates back to the mid-1990s and it is one of our important customers. As with the previous larger orders that we jointly implemented, we were also responsible, besides supplying the design documentation of the electrical components, for supplying both power and control distribution boards, frequency inverters, and control systems, as well as PC with monitors to operate and monitor the technology.
However, before the preparations for the projects and the actual implementation had begun, it was necessary to undertake long series of difficult negotiations involving not only the main contractors but also the suppliers of the subparts and, of course, the representatives of the investor. In the above-mentioned contract, it was not only the delivery of the technology itself, it was necessary to design a whole new building, chimney, silos for pure and reacted sorbent, the power supply including the transformer, etc.
After this stage, it was possible to begin work on the project documentation. The electrical part prepared by us included virtually all the low-voltage parts. From the grounding system, through the design of the main distribution board with electricity consumption measurement, building wiring, motor installation, to the design of the control system, including interconnection with the existing parts of the technology. Furthermore, we designed elements for measuring the non-electrical quantities (pressure, temperature, flow, level, etc.) and, last but not least, the PC dispatching station including the graphic part of technology visualization. To make the commissioning as short as possible, but also to shorten the response times for possible service actions, the technology was connected to the Internet and equipped with remote access software. We have been offering this service as a standard to technologies delivered by us since 2007.
To control the technological processes, the control system from the ControlLogix family from Allen-Bradley was used on the request of the customer; the frequency inverters of up to 132 kW were also supplied by the same company. The MX eco 4V630 frequency inverter from Schneider Electric Power Drives was installed to power the 630kW main exhaust fan.
The flue gases from the rotary kilns are led through the existing three-chamber electrofilter and then through the pipes to the desulfurization circuit from Hellmich GmbH, into which a sorbent (hydrated lime) is introduced. The flue gases with sorbent are then fed into the textile hoses of the filter ALFA JET Plus 2880 and react with undesirable substances (HF, HCl and SOx). Only flue gas with an excessive amount of CO and VOC (volatile organic compounds) exits from the filter and these components are disposed of by burning in the ENETEX RTNV 60/2 post-combustion unit.
The solid pollutants (SP) trapped in the electrofilter are returned through the pipeline and added to the raw material. The finest parts of the SP trapped on the textile filter are carried by conveyors to big bags and are not further processed.
Preparations for this unique project (the only one of its kind in the Czech Republic) started in 2008 and the trial operation was successfully completed in July 2010. Over this period, more than 20 companies of different professions participated at different stages, which made it very difficult to harmonize terms and deliver shared data. However, all parts were successfully completed, allowing us to complete the test run to full customer satisfaction and even a few days before the scheduled deadline.
Below are links to the above-mentioned companies: