ESP Series Electrostatic Precipitators for the Cement Industry

Kiln Tail ESP (BLESP780/930)

• 📉 Max Gas Volume: 1,800,000 m³/h
• 🌡️ Temperature: 130 – 150°C
• 🌫️ Max Inlet Dust: 1,200 g/Nm³
• 🌪️ Max Suction: -12,000 Pa

Kiln Head Cooler ESP

• 📉 Max Gas Volume: 1,800,000 m³/h
• 🔥 Temperature: Up to 400°C
• 🌫️ Max Inlet Dust: 50 g/Nm³
• 🌪️ Max Suction: -2,500 Pa

Coal Mill ESP

• 📉 Max Gas Volume: 20,000+ m³/h
• 🌡️ Temperature: 60 – 120°C
• 🌫️ Max Inlet Dust: 1,000 g/Nm³
• 🌪️ Max Suction: -2,000 Pa

Working Principle

The Ever-power BLESP Series utilizes electrostatic force (Coulomb force) to separate particulate matter from high-volume gas streams. The process is a masterpiece of applied physics:

1. Gas Distribution: Flue gas passes through highly engineered distribution screens (X-type, square hole, or round hole) to ensure uniform laminar flow.
2. Ionization: High direct current is applied to the Discharge Electrodes (Cathodes). The intense electric field ionizes the gas, creating a corona discharge full of electrons and negative ions.
3. Particle Charging & Migration: Dust particles collide with these ions, acquire a negative charge, and are driven forcefully toward the grounded Collecting Electrodes (Anodes).
4. Rapping & Removal: Precisely timed continuous and revolving-arm hammers strike the electrodes, shearing the dust layer off into the hoppers below for disposal.

Core Internal Structure

The efficiency of an ESP is dictated by its internal geometry. Ever-power has revolutionized these critical components:

• ZT24 Collecting Electrodes (CE): Our proprietary ZT24 plates offer exceptional discharging performance and uniform current density. Crucially, they provide a 10% larger effective dust collecting area compared to standard profiles within the same spatial dimension.
• Advanced Discharge Electrodes (DE): Tailored to the gas condition, we utilize B-type, V-type, and highly efficient Fishbone wires. These guarantee solidity, high-endurance, non-breakability, and aggressive corona generation.
• Robust Rapping Systems: Utilizing Top Cam Lifting Mechanisms for the cathodes and Side Driving Revolving-Arm Hammers for the anodes to eliminate sticky dust buildup.

Extreme Tolerance

Engineered to handle inlet dust concentrations up to an incredible 1,200 g/Nm³ without choking, and gas temperatures peaking at 400°C—environments that would instantly destroy traditional fabric filters.

Ultra-Low Resistance

The aerodynamic design ensures an operating resistance of merely 200-350 Pa. This drastically reduces the workload on your Induced Draft (ID) fans, slashing continuous energy consumption.

Heavy-Duty Housing

Cement plant suction pressures are brutal. Our casings are structurally reinforced to withstand pressures ranging from 2,000 Pa up to an astonishing -20,000 Pa for specialized applications, ensuring zero implosion risks.

Regulatory Strangulation

Environmental policies globally are enforcing strict < 50mg/Nm³ (and increasingly < 30mg/Nm³ or < 10mg/Nm³) emission limits. Failing to meet these standards results in immediate operational suspensions, staggering daily fines, and severe reputational damage. Your dedusting system is no longer an accessory; it is your license to operate.

The “Hidden” Profit Bleed

Aging dust collectors force ID fans to fight through massive pressure drops, burning excess megawatts of electricity daily. Furthermore, poor dust capture leads to the rapid abrasion of downstream equipment. Relying on inefficient filtration is a direct drain on your plant’s profitability.

Cement Kiln Tail

Captures the massive, high-density particulate flow directly from the rotary kiln. Handles up to 1,800,000 m³/h at -12,000 Pa suction, effortlessly dropping 1,200 g/Nm³ inlet loads to compliant levels.

Clinker Cooler (Kiln Head)

Built to withstand intense thermal punishment. The cooler exhaust frequently hits 400°C. Where baghouses melt, our rigid steel internals capture abrasive clinker dust relentlessly.

Coal Mill Dedusting

Coal grinding introduces explosive risks. Our ESPs are structurally adapted with explosion relief valves and precise grounding to safely capture coal dust at 60-120°C without detonation risks.

For over two decades, Ever-power has been the backbone of heavy industrial air purification. The BL Series is not an off-the-shelf product; it is a technically honed benchmark forged through hundreds of complex projects.

• ✔️ Full Value-Chain Capability: We provide end-to-end integration: R&D Design ➔ Lean Manufacturing ➔ Engineering Installation ➔ Intelligent Commissioning.
• ✔️ Trusted by Industry Giants: Our systems successfully protect core operations for conglomerates like Shanshui Group, Huarun Power, and Conch Group.
• ✔️ Complete Qualifications: Fully ISO certified, holding multiple structural patents, and globally recognized environmental manufacturing credentials.

The Cost of Inaction (Current State)

• Energy Penalty: Traditional filters operating at 1500 Pa resistance cost you thousands of dollars monthly in wasted ID fan electricity.
• Consumables Bleed: Replacing 5,000 high-temp filter bags every 2 years demands massive CapEx and labor costs.
• Downtime Loss: Shutting down a 5,000 t/d kiln for baghouse maintenance translates to immense lost revenue.

The Ever-power Upgrade ROI

• Fan Power Slashed: Operating at ~300 Pa saves enough electrical power to often pay back the ESP investment within 3-4 years.
• Zero Consumables: Our rigid steel electrodes and plates are designed for a 20+ year lifespan. No bags to buy.
• Continuous Output: Modular multi-chamber design means maintenance can be done on one section while the kiln keeps producing.

🇨🇳 Tongchuan Shengwei Cement (China)

Application: 5000 TPD Cement Kiln

Challenge: Extremely high inlet concentration and severe negative pressure requirements.

Solution: Installed a customized Hi-Density & Hi-Suction Pressure ESP. Maintained continuous output emissions well below the 30mg/Nm³ mandate without a single structural fault.

🇻🇳 Ha Tien 1 Cement (Vietnam)

Application: Clinker Cooler (Kiln Head)

Challenge: Spikes in exhaust temperature up to 420°C frequently melted their existing baghouse setup.

Solution: Ever-power deployed a high-temperature tolerant 3-field ESP. The plant achieved zero downtime related to dedusting over a 5-year evaluation period.

🇮🇳 Ultratech Cement Grinding Unit (India)

Application: Coal Mill Exhaust

Challenge: Need for a highly safe, explosion-proof dedusting system for volatile coal dust.

Solution: Cylindrical design ESP with integrated relief valves and spark suppression logic. “The Ever-power system completely mitigated our explosion risks while hitting our emission targets,” stated their Chief Engineer.

🇧🇷 Votorantim Cimentos (Brazil)

Application: 3200 TPD Kiln Tail Upgrade

Challenge: High electrical resistance of local raw materials causing back-corona in older precipitators.

Solution: Integrated advanced High-Frequency power supplies with our ZT24 collecting plates, boosting collection efficiency to 99.95% despite the difficult dust physics.