Industrial Dedusting System Design and Engineering

Pollutant emissions accompany the metallurgical process into the atmosphere at all hot metal and steel production stages. An increase in efficiency and intensification of metallurgical production processes should run parallel with reducing the environmental impact. Modern dedusting systems for capturing aspiration and processing gases released into the atmosphere make it possible to minimize environmental pollution. We are focused on environmental cleanliness and production safety in our developments.

For many years, experts of M HEAVY TECHNOLOGY have been successfully designing industrial dust collection systems and systems for aspiration and process gases neutralization before their release into the atmosphere at the majority of process stages in the ferrous industry and in solid-fuel thermal power plant units.

When developing projects, the company is guided by the principle of minimizing emissions of harmful substances, with a maximum return of captured dust back into the production process or using it in related industrial sectors.

The selection of equipment type, sequence of installation, and the number of stages for aspiration air and process gases purification are individually determined for each customer, considering all specific technological process features while providing industrial dust collection design.

The installation of dedusting systems in dust-loaded production areas makes it possible to meet workplace sanitary standards and reduce emissions into the atmosphere. Meeting sanitary standard requirements for workplaces of less than 4 mg/m3 positively influences the production environment, reduces risks of injuries, and decreases cases of upper respiratory tract-related illnesses among employees.

The process of separating suspended particles from gases and air as they pass through porous material or media is called filtration (dedusting). The equipment used for dedusting is called filters. Filtration processes can be accomplished by contact, interception, gravitation, inertial forces, diffusion, and electrostatic field.

Depending on the method of removing dust particles from the stream, various filters are used, including fabric filters, electrostatic filters, inertial filters, and hydro-mechanical devices.

Dedusting systems are also categorized into three classes based on their purpose.

1. Fine filters provide for the suspended parts content of no more than 4 mg/m³ at the dedusting system, allowing purified air to be directly released into the production area premises because its quality meets the health and safety standards requirements.
2. Industrial systems typically include two stages of purification – an inertial dust catcher followed by a fabric or electrostatic filter. Such installations provide for the content of suspended particles of no more than 20 mg/m³ in the dedusting system emissions.
3. Hydro-mechanical cleaning systems are used for dust removal from explosive or flammable gases. Due to their compactness, they are also applied when space is limited for traditional filters. Such dedusting systems ensure that emissions at the exit have a content of suspended particles of no more than 50 mg/m³.

Industrial dedusting systems of M HEAVY TECHNOLOGY are applied in:

1. Blast furnace production, in stock- and casthouses. For BFG  cleaning, explosion-proof system versions are installed.
2. Converter shops. By process transfers of iron and steel, converter operations, and dedusting bulk materials (charge materials) handling and preparation systems.
3. Electric steel melting shops. By EAF (electric arc furnace) operation, LF (ladle-furnace), vacuum degasser, heating of steel ladles, ladle lining wrecking stands, as well as bulk materials (charge materials) handling and preparation systems.
4. Lime-burning shops. By lime burning in a lime calcination rotary kiln and dedusting of lime and limestone transportation and preparation systems.
5. Sinter production. Sintering machines, dedusting of bulk material transportation and preparation systems.
6. Coke production. In areas with dust-free coke discharge and bulk material transportation and preparation systems.

The advantages of M HEAVY TECHNOLOGY projects are their commitment to minimizing emissions of pollutants into the workshop environment and surrounding atmosphere, equipment reliability, and competitiveness in the main production cycle, resulting in maximum profitability.

In our projects, we use the most advanced technologies for cleaning contaminated air from dust in inertia-type dedusters, including scrubbers, bag filters, and electrostatic precipitators. By cleaning high-temperature gases, heat recovery is also provided.

One of the distinctive features of M HEAVY TECHNOLOGY is its ability to provide a comprehensive service for the development of project documentation, and selection of state-of-art equipment, followed by its delivery to the construction site, supervision of construction and installation works, maintenance staff training and equipment commissioning with achieving key performance indicators.

Dmytro Semenov

Chief project engineer

Yevhen Yevtushenko

Head of the air protection department

Serhii Nahornyi

Chief process engineer of the air protection department

In 2019 – 2021, design works, designer supervision, and commissioning of casthouse and stockhouse dedusting systems for blast furnaces No. 3, 4, and 5 at “Ilyich Iron and Steel Works” PJSC in Mariupol were carried out. It reduced casthouse and stockhouse emissions into the atmosphere by more than 30% (1772 t/year) if compared with the existing situation. Construction work cost for six dedusting plants made 80 million dollars. As a result of the project implementation, the air pollution levels at the workplaces in the BF cast- and stockhouse were below 6 mg/nm3, which complies with sanitary requirements. During the construction of the new dedusting plants, the existing wet-type plants were dismantled, as they did not provide the required level of air purification, which made it possible to decrease annual process water consumption by 1650 thousand m3.