Replacement of two Electrostatic Filters at Hanson Cement's Ketton Works

Dust Collection

Replacement of two Electrostatic Filters at Hanson Cement's Ketton Works

Hanson Cement, a subsidiary of HeidelbergCement, has recently replaced two Electrostatic (ESP) filters at its Ketton Works will improve the recovery of dust particles, as well as reducing particulate emissions.
(ed. WoMaMarcel - 21/2/2017)
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Working at height with the use of cranes with fly jibs led to an extra level of complexity during replacement of two Electrostatic filters at Hanson Cement’s Ketton Works.

Adlington, United Kingdom – Hanson Cement at Ketton approached Fairport Engineering in early 2016 to discuss a plan for the replacement of their ESP’s on Mills 9 and 10. Hanson identified their preferred bag filter manufacturer but wanted an organisation to act as a main contractor, taking overall responsibility for the project, including control of the site under the CDM 2015 regulations and to manage the design, supply and installation of the balance of plant. After reviewing the construction phase options with Hanson, Fairport developed a proposal that would minimise disruption to cement production, but meant that work would have to be undertaken within two, pre-planned, four week shut down periods, one for each filter.

Mill 9 was the first unit to be replaced and once pre-works and site establishment had been completed Fairport took control of the site under CDM 2015 regulations. Installation teams worked in back to back shifts to disconnect and remove Mill 9 ESP. Support structures, the existing fan and ducting were also removed to prepare the location for the installation of a new bag filter. The new system also required the installation of new screw conveyors, rotary airlocks and the reconfiguration of existing control panels, plus the installation of new 160KW central exhaust fans and associated clean gas ducting.

All works were completed within the agreed shut down period for Mill 9. A short break then followed prior to the Mill 10 shut down, this enabled pre-assembly works to begin. Upon commencement of the Mill 10 shutdown Fairport began to remove the second ESP, its supporting equipment and associated processes. Installation of this second bag filter, with its attendant equipment and processes to recover the captured dust, could then begin and was, again, successfully completed and handed over within the agreed period.

The construction phases of this project could only begin after detailed planning and the preparation and agreement of risk assessments and method statements (RAMS) to ensure all equipment could be safely removed and replaced. Working at height with the use of cranes with fly jibs led to an extra level of complexity. Despite this complexity, Fairport delivered the construction phase on time and to budget with all works completed safely with no lost time incidents after the expenditure of over 15,000 construction hours. It is reported that to date the daily averages on both filters are well below the target emission level.

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