Installation modernization
Filtration system retrofits
Modernization of existing installations to improve performance, reliability, and emission control, assessing opportunities to reuse available equipment and structures.
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Modernization to restore performance and optimize investment
Production process changes, component wear, and new performance requirements can compromise existing filtration and extraction systems. Retrofitting modernizes and adapts this equipment while reusing structures and components that remain suitable for the new operating conditions.
Kleema modernizes filters and extraction systems, including conversion of electrostatic precipitators to baghouses. Work may include adjusting flow rate to increase extraction capacity, expanding filter area to handle higher dust loads, and upgrading cleaning systems for greater efficiency, along with improvements to gas distribution, ductwork, and particulate discharge.
The scope also covers fan modernization and operational adjustments, matching flow rate and pressure to process requirements and improving operating conditions, efficiency, and system reliability.
Reusing existing equipment can offer significant savings compared with installing a new assembly, reducing procurement, material, and installation costs depending on its condition and the extent of modifications required.
Every project starts with an assessment of existing conditions and operating objectives. The solution considers required performance, plant interfaces, and implementation planning to reduce downtime and optimize investment.
Retrofit — Cimento Nassau, Itautinga
Diagnostics and engineering for a sound modernization
- Existing installation assessmentSurvey of equipment, structures, and components, considering condition, wear, operating limitations, and reuse opportunities.
- Extraction and filtration adjustmentsAssessment of the flow rate required for particulate capture and conveying, filter area, and gas distribution, adapting the assembly to new process conditions and expected dust loads.
- Cleaning system upgradeReview of filter element cleaning configuration and operation to improve efficiency, control pressure drop, and use compressed air appropriately.
- Fan modernizationAssessment of operating point, impeller, casing, and drive, with attention to flow rate and pressure suitability, wear, vibration, and operational reliability.
- Implementation planningDefinition of interfaces and work sequence, considering activities that can be completed in advance and the shutdown window available for installation and integration.
The integration of engineering and in-house manufacturing allows adaptation components to be developed for the existing installation. Assessment considers interfaces, materials, and the checks required for assembly and operation of the modernized system.
Adapting installations to new operating requirements
Retrofitting is suited to installations that need to restore performance, increase extraction capacity, or adapt equipment to production process changes.
Main applications
- Conversion of electrostatic precipitators to baghouses.
- Expansion of extraction capacity and adjustment of ducts and capture points.
- Expansion of filter area for new flow rates and dust loads.
- Upgrade of particulate cleaning and discharge systems.
- Fan modernization to adapt flow rate and pressure, improve operation, and increase reliability.
- Replacement of worn components, assessing opportunities to reuse existing structures.
Industries
Technical information
Retrofit design starts with a survey of the existing installation and the desired operating conditions.
| Equipment condition | Condition, wear, integrity, and reuse opportunities for components and structures. |
|---|---|
| Flow rate and pressure | Current and required conditions, capture points, pressure losses, and extraction capacity. |
| Filtration | Filter area, dust characteristics, gas temperature, and flow distribution. |
| Cleaning system | Configuration, cleaning efficiency, pressure drop control, and compressed air availability. |
| Fans | Operating point, impeller, casing, drive, wear, and vibration. |
| Particulate discharge | Discharge device capacity and integration with collected material handling. |
| Interfaces and installation | Dimensions, connections, access, and compatibility with retained equipment. |
| Implementation | Scope of work, activities that can be completed in advance, and available shutdown window. |
Retrofit
Modernize your installation and make better use of your existing investment
Share the system's current conditions, operating difficulties, and desired results. Kleema engineers can assess opportunities to modernize, expand, and adapt equipment, considering reuse of existing structures and implementation planning.