With 43 years of history, CTP Team Srl (CPT), part of Italy's Bedeschi Group, is an engineering and manufacturing company that is highly specialised and well-referenced in gas filtration technologies. It is mainly involved in cement industry applications. In 2012 CTP commissioned several filtration plants in Turkish cement plants. Some projects were conversions of existing electrostatic precipitators into bag filters, while others involve new equipment in existing plants or installations in new cement production lines. All the bag filters supplied were equipped with Sonic Wave Acceleration Pulse (SWAP) technology for enhanced efficiency, increased bag lifetime and reduced energy consumption, thanks to a new generation of high performance components.
The SWAP technology developed by CTP Team is a unique bag cleaning system working at low air pressure, designed to remove dust from several bags of extended length at the same time. This is done using one single shot of compressed air at the best efficiency and causes minimum stress to the filtering elements.
In comparison with the traditional high pressure bag cleaning method, with SWAP technology the bag is not blown with primary air (from the tank) but with the addition of much more secondary air (from filter plenum) due to the Venturi effect.
The special design of the cleaning valve, operating at high speed and fast response, creates a travelling wave starting from bag top line down to the bottom with the same profile and efficiency, independent of bag length (Figure 1). Depending on the size of blow pipe, bag and pneumatic valve, this system is capable of cleaning more than 30 bags of up to 12m in length at the same time.
With special powerful piston type valves installed directly onto the pulse header tank rather than the more traditional membrane type version, the very fast action of the valve and the elimination of Venturi, normally located at the mouth of the bag, a short and very fast pulse acts as a wave and travels along the entire bag at sonic velocity regardless of its length.
The innovation is related to a much shorter valve opening time and reduced inertia of the valve elements, which leads to significant improvements in terms of cleaning efficiency, energy consumption and long-term reliability. This is thanks to a lower compressed air pressure but enhanced pressure induced inside the bag up to the bottom area.
The final result is that the pulse is shaped such that the required acceleration of the filter fabric are achieved over a much greater length of the filter bag than with any other cleaning system available today on the market. Besides a highly reduced consumption of compressed air, the compressor is capable of cleaning an increased quantity of longer bags at the same time, extending the expected lifetime even further.
References in the Turkish market
Figure 2 shows all the CTP references in Turkey. The blue logo indicates factories where CTP equipment has been installed and put into operation. The red logo refers to new plant installations that are yet to be commissioned. These realisations involve new cooling and dedusting equipment, plant upgrades and modernisation projects as well as full turn-key plants.
The first CTP installation in Turkey was commissioned in June 2011. That means that 12 references have been carried out in the Turkish market in the space of just 18 months.
What follows is a short description of projects commissioned in Turkey in 2012 that confirm the leadership of CTP Team as a reliable partner for major cement producers.
Çimsa Çimento - Eskisehir plant - January 2012
ESP conversion into bag filter for kiln/raw mill exhaust gas dedusting - See Figure 3.
| Maximum gas volume at inlet | 494,000Am3/hr |
| Gas temperature at inlet | 150°C |
| Number of filter bags | 2176 |
| Bag size | ø = 152mm, L = 8000mm |
| Number of bags per row | 16 |
| Air to cloth ratio | 0.99m3/m2/min |
| Bag material | Fibreglass + PTFE membrane |
Çimsa Çimento - Mersin plant - February 2012
ESP conversion into bag filter for kiln/raw mill exhaust gas dedusting - See Figure 4.
| Maximum gas volume at inlet | 353,000Am3/hr |
| Gas temperature at inlet | 125°C (140°C max.) |
| Number of filter bags | 1596 |
| Bag size | ø = 152mm, L = 8000mm |
| Number of bags per row | 19 |
| Air to cloth ratio | 0.99m3/m2/min |
| Bag material | Fibreglass + PTFE membrane |
Çimsa Çimento - Kayseri plant - March 2012
ESP conversion into bag filter for kiln/raw mill exhaust gas dedusting - See Figure 5.
| Maximum gas volume at inlet | 465,000Am3/hr |
| Gas temperature at inlet | 120°C |
| Number of filter bags | 2048 |
| Bag size | ø = 152mm, L = 8000mm |
| Number of bags per row | 16 |
| Air to cloth ratio | 0.99m3/m2/min |
| Bag material | Fibreglass + PTFE membrane |
Aşkale Çimento - Van plant - July 2012
New bag filter for kiln/raw mill exhaust gas dedusting - See Figure 6.
| Maximum gas volume at inlet | 550,000Am3/hr |
| Gas temperature at inlet | 96°C (200°C max.) |
| Number of filter bags | 2592 |
| Bag size | ø = 150mm, L = 7500mm |
| Number of bags per row | 18 |
| Number of compartments | 8 |
| Air to cloth ratio | 1.0m3/m2/min |
| Bag material | Fibreglass + PTFE membrane |
Aşkale Çimento - Van plant - July 2012
Bag filter for clinker cooler dedusting - See Figure 7.
| Maximum gas volume at inlet | 450,000Am3/hr |
| Gas temperature at inlet | 170°C |
| Number of filter bags | 1944 |
| Bag size | ø = 150mm, L = 7500mm |
| Number of bags per row | 18 |
| Number of compartments | 6 |
| Air to cloth ratio | 1.0m3/m2/min |
| Bag material | m-Aramydic |
Aşkale Çimento - Van plant - July 2012
New heat exchanger for clinker cooler - See Figure 8.
| Maximum gas volume at inlet | 650,000Am3/hr |
| Gas temperature at inlet | 153°C (453°C max.) |
| Heat exchanger area | 6200m2 |
Aşkale Çimento - Van plant - July 2012
New bag filter for coal mill dedusting (ATEX design).
| Maximum gas volume at inlet | 111,000Am3/hr |
| Gas temperature at inlet | 90°C |
| Number of filter bags | 704 |
| Bag size | ø = 150mm, L = 5500mm |
| Number of bags per row | 16 |
| Number of compartments | 1 |
| Air to cloth ratio | 1.0m3/m2/min |
| Bag material | Acrylic/Polyester |
OYAK - Aslan plant - October 2012
New bag filter for kiln/raw mill exhaust gas dedusting - See Figure 9.
| Maximum gas volume at inlet | 650,000Am3/hr |
| Gas temperature at inlet | 115°C (200°C max.) |
| Number of filter bags | 3024 |
| Bag size | ø = 150mm, L = 8000mm |
| Number of bags per row | 21 |
| Number of compartments | 6 |
| Air to cloth ratio | 0.84m3/m2/min |
| Bag material | Fibreglass + PTFE membrane |
OYAK - Bolu plant - October 2012
New bag filter for kiln/raw mill exhaust gas dedusting - See Figure 10.
| Maximum gas volume at inlet | 800,000Am3/hr |
| Gas temperature at inlet | 95°C (166°C max.) |
| Number of filter bags | 3600 |
| Bag size | ø = 150mm, L = 8000mm |
| Number of bags per row | 20 |
| Number of compartments | 2 |
| Air to cloth ratio | 0.98m3/m2/min |
| Bag material | Fibreglass + PTFE membrane |
On-going projects
CTP Team is currently carrying out two projects for Turkish clients, detailed below.
Eren Holding - Medcem plant in Silifke: Eren is constructing a new 10,000t/day production line. CTP Team is supplying equipment for two new preheater gas conditioning towers (capacity 2 x 842,400Am³/hr) and two new kiln/raw mill bag filters with fans (capacity 2 x 785,000Am³/hr).
Sönmez Çimento A.Ş. – Adana plant: Sönmez is installing a new 5000t/day production line. CTP Team is supplying a kiln/raw mill bag filter (capacity 900,000 Am³/hr), a clinker cooler bag filter (capacity 600,000Am³/hr) and an air/air heat exchanger for the clinker cooler (capacity 600,000Am³/hr).
