BART Sp. z o.o. | Dust Extraction Technologies and Organized Dust Emission Technologies in the Ceramics Industry
In industries that use bulk materials as raw materials, we encounter the process of dust emission at many stages of production. The daily operation of the infrastructure of a large gres tile production plant, with an installation capacity of 400 Mg/day – which translates to an annual production of 5.5 million m² of tiles – requires the implementation of systems for organized dust emission into the atmosphere. These include process filtration and ventilation installations using transport systems and dust extraction devices.
SOURCES OF DUST EMISSIONS IN THE TECHNOLOGICAL PROCESS OF GRES PRODUCTION
The disintegration of raw materials and the movement of fragmented products, resulting in dust suspension, is a natural characteristic of aggregates and their processing technologies. Here, we deal with unorganized dust emissions directly from technological processes, e.g., from open storage areas and conveyors, secondary emissions from industrial surfaces, and organized emissions in the presence of functioning dust extraction devices. Organized emission installations allow for the control of pollutant emissions in terms of the place or method of introduction into the air via emitters (such as chimneys, general or local mechanical exhaust ventilation), the time of introduction, and its level. “Tailor-made” dust extraction installations using extraction, transport, and dust extraction systems are designed to capture and collect dust from each technological installation node that is a source of its formation. In the multi-stage production process of ceramic products, in the form of large-format gres tiles, there are indeed many such points. The technological line includes, among others, a raw material warehouse (raw material boxes, feeder scales); a mass processing plant, which includes: a continuous mill, a spray dryer, a slip tank, and a conveyor belt system; granulate storage silos; a pressing conveyor belt system; a horizontal dryer; a glazing line; a tunnel kiln; a polishing line; a sorting plant; and a packaging line.
BART’s Experience in the Bulk and Mass Materials Industry
BART Sp. z o.o. has been comprehensively implementing investments related to air treatment and purification in industrial plants in the bulk and mass materials industry for years. It has carried out many dust extraction and industrial ventilation installations for the production of ceramic products. Its experienced engineers select solutions and devices that meet legal requirements, are optimal in terms of cost, ergonomics, and safety.
Another Dust Extraction Project by BART for a Ceramic Products Manufacturer
Recently, BART participated in an investment project for its long-term client, aimed at expanding the ceramic tile production plant and adapting the installations to environmental requirements and market expectations. The investment allowed for an increase in the efficiency of the raw material processing line and doubling the annual production level of large-format gres tiles. It included equipping the production hall with, among others, a glazing line installation with a dryer, a roller kiln, a pre-kiln dryer, as well as a polishing and rectification installation, an additional sorting line, and a technological water treatment plant with a closed circuit. It also required adapting the technological line to new assumptions and the expectations of the end customer. A new format of gres tiles was proposed: 120×280 cm, which necessitated, among other things, the modification of the sorting line and equipping it with devices for attaching fiberglass mesh to the tiles using special UV-cured resin.
BART Dust Extraction Technologies and INSTALFILTER Filtration Devices Used at Several Stages of Decorative Gres Tile Production
BART implemented dust extraction installations with a total capacity of 161,900 m³/h, connected to 257 aspiration points located on technological lines. The company executed three dust extraction systems, based on modern FPS-type filtration devices manufactured by INSTAL-FILTER. The dust extraction system for the silo technological line had the highest air output: 72,000 m³/h, while the one developed for the pressing line had 62,700 m³/h. The glazing line had a system with a capacity of 27,200 m³/h. A feature allowing effective air purification from solid particles was the use of bag filters guaranteeing dust levels behind the filter at 5 mg/m³. Each system was equipped with a radial exhaust fan, and the devices were located inside the hall. Importantly, the dust separated on the filter cartridges was not returned to production but was transported via a screw conveyor and then a rotary valve to a sealed container. Both the screw conveyor and the rotary valve are integral parts of the proposed FPS filters. Additionally, based on BART’s CDC-O cartridge filter, a fourth dust extraction installation with an output of 6,400 m³/h was implemented, aimed at removing dust pollutants from gres tiles on the conveyor belt before firing in the kiln. As in the previously described installations, the system operates based on a radial exhaust fan, and the dust collected on the filter cartridges is transported to a container. The regeneration of cartridge inserts is carried out by the compressed air system. The entire implementation entrusted to BART was complemented by a central vacuum system. The plant installed 30 sockets enabling the connection of cleaning sets, allowing the elimination of dust already settled on the floor. For the system, a high-efficiency BFC bag cyclofilter adapted to work in a high vacuum atmosphere and a Roots pump were used.
BART – Investment Implementation in the “Design and Build” Formula
BART offers a wide range of services for the comprehensive handling of new investments and modernization of industrial plants from various industries. The scope of services includes engineering and design, technology selection, and comprehensive investment execution in the “design and build” formula. The company specializes particularly in clean air solutions, including process dust extraction systems and workplace filtration systems, industrial ventilation systems, central vacuum systems, exhaust extraction, pneumatic transport installations, gas and volatile organic compound combustion.
BART has its own design and commercial offices in Sosnowiec, Warsaw, Wrocław, and Gdańsk, as well as a specialized unit responsible for the assembly, commissioning, and service of the installations performed. Examples of implementations and details of solutions for the plastics and rubber industry can be found on the website www.bart-vent.pl.
BART’s dust extraction installations have been operating for many years across a wide range of applications. They are characterized by the proper selection of devices and correctly executed design in terms of extraction solutions and pipeline velocities, as well as efficiently and properly executed installation assembly.
BART offers servicing of its installations during the warranty and post-warranty periods, which can also be extended to other installations and devices of the client.
Ceramic Dust Extraction Installations
BART has completed several projects related to the implementation of ceramic and mineral dust extraction installations. These projects were carried out for leading manufacturers in the sanitary, architectural, and technological ceramics industries.
One example is the mineral-composite dust extraction installation executed for a renowned manufacturer of washbasins, shower trays, and bathtubs. The dust extraction installation, with a capacity of 15,000 m³/h, was integrated into the exhaust system.
Dust-laden air is extracted through an exhaust wall and transported via pipeline to the filtration unit. After passing through the filter, where it is purified, the air is pumped to the ventilation unit and then, through EU-type filters, it reaches the heat exchanger and further to the exhaust outlet located on the roof of the hall.
Another example of implementation is the ceramic dust extraction installations intended for a set of rooms in a newly built plant.
For dust extraction purposes, installations using bag filters (7 units for this stage) with capacities ranging from approximately 3,000 m³/h to nearly 70,000 m³/h (both ATEX and standard versions) were implemented.
BART SP. Z O.O. – SOLUTIONS FOR CLEAN AIR
Other aspects of dust emission reduction and details of the technologies used in the wood industry plants can be discussed at a meeting with specialists from BART Sp. z o.o. BART offers a wide range of services for the comprehensive handling of new investments and modernization of industrial plants from various industries. The scope of services includes engineering and design, technology selection, and comprehensive investment execution in the “design and build” formula. The company specializes particularly in clean air solutions, including process dust extraction systems and workplace filtration systems, industrial ventilation systems, central vacuum systems, exhaust extraction, pneumatic transport installations, gas and volatile organic compound combustion.
BART has its own design and commercial offices in Sosnowiec, Warsaw, Wrocław, and Gdańsk, as well as a specialized unit responsible for the assembly, commissioning, and service of the installations performed. Examples of implementations and details of air treatment solutions can be found on the website www.bart-vent.pl.
