Emissions reduced by 50%

Lodge Cottrell Limited, has introduced a new electrostatic precipitator upgrade concept known as ‘Skewed Baffles’.
One such upgrade was carried out at the Cauldon Works of Lafarge Cement UK, one of the main integrated plants operated by Britain’s leading cement producer.

Cauldon was one of the first UK cement works to introduce the use of chipped scrap tyres as a fuel in place of the traditional fuels – coal and petroleum coke. Burning ‘waste’ fuels means that, in addition to emission limits set by the Environment Agency, the Works will be required to comply with the Waste Incineration Directive (WID).

Lodge Cottrell, was called in to discuss the options available for improving the plants electrostatic precipitator performance. At this time, Lodge Cottrell had successfully completed model flow tests on skewed baffles and indications were, that significant reductions in particulate emissions could be achieved with minimal investment.

Lodge Cottrell proposed a phased minor upgrade scheme. The first phase involved new gas distribution screens and the installation of skewed baffles. Such was its success that Lafarge decided there was no immediate need to proceed with further modifications.

Commenting on the installation, Martin Stocks, Process Manager at Cauldon says: “The skewed baffles have proved a great success contributing towards reducing the kiln precipitator emissions by over 50%. It’s a relatively simple technique that avoided the need for us to consider other costly alternatives such as extending the ESP or replacing it with a bag filter. We also benefited greatly from Lodge Cottrell’s ability to carry out the on-site work within our normal two week stop period.’’

John Wyatt, Lodge Cottrell’s Gas Flow Distribution Specialist, with over 25 years experience in the field of precipitator gas flow distribution explains: “Correct application and strategic location of the skewed baffles within the precipitator is key to their successful implementation and performance. During initial tests, the interbank skewed baffles proved to be much more effective than conventional outlet flare baffles’’.

Lodge Cottrell report similar skewed baffle successes on various different precipitator designs and applications.