what we do
Cement
Waste to energy
Metals and non-metals dedusting solutions
Glass
Power plants
Waste heat recovery
Bulk handling materials
Eco hoppers
Our Specialties
ApZolution is your Consulting company. Our founder has more than 40 years of experience in industrial treatment and gas filtration technology.
ApZolution is the most reliable international partner for new plants or upgrading existing facilities with gas cleaning solutions, engineered with the Best Available Technology that complies with the new regulations for clean air emissions into the atmosphere. We also know the best way to comply with our client’s Capex and Opex targets.
BAG CLEANING WITH LOW-PULSE-JET COMPRESSED-AIR INJECTION
EKO E(3) CLEANING SYSTEM gets high-efficiency results and does not require injectors, Venturi and other accessories on the top of the bags to increase the secondary air during bag cleaning.
The main variables affecting the separation force between the dust layer and the fabric are acceleration force generated by internal pressure and acceleration distance. The design criterion for the cleaning system is to produce high pressure inside the filter element by injecting a large sonic wave of pressurizing gas against the resistance offered by the filter fabric.
With this technology, to get sufficient energy to separate the dust from the bag’s surface it is necessary to have a cleaning system capable of strong accelerations to the “dust-bag” system, leading to the separation with high forces in a very short time.
This feature is achieved through the following basic principles:
- Special valves that perform with an opening speed of about 20-40 milli-seconds.
- Maximum use of the law of aerodynamics (impulse force).
This effect is related to physical parameters connected to:
- Pressure cleaning (from 2.5 to 3.0 bar)
- Optimized ratio between diameter of holes in the blower tube and the diameter of the bag.
The parameter optimization mentioned above allows the bags to be cleaned with sonic waves, which progressively pass through the bags at a speed of Mach 1, avoiding cleaning by swelling the bags like other traditional systems normally do.
For this reason, EKO E3 CLEANING SYSTEM can clean bags up to 12 meters in length, with a maximum number of 30 bags per row cleaned in one valve shot.
Cement
Cement and lime are one of the main sectors in which we have extensive experience. That means hundreds of cement plants visited around the world, hundreds of installations and successes. Conferences with the most reliable partners to explain innovative solutions and equipment for gas treatment, which are designed for the heaviest process applications such as kiln/raw mill, clinker coolers, cement and coal grinding and kiln bypass. Electrostatic precipitators, Hybrid filters, Bag Filters, Gas Conditioning Towers, Heat Exchangers and EP conversion or upgrade of existing units have been proposed and installed, all in compliance with international regulations for dust emission.
Any application in a corrosive environment, inlet dust with high loads, high humidity, abrasive, explosive or sticky dust are all part of this industry’s challenges and ApZolution can offer its own extensive experience in in equipment design and process control.
Waste to energy
The combustion of Urban, Industrial, Hospital, biomass and Bagasse waste has a cocktail of pollutants in the raw gas: SO2 – HCl – HF – HBr, Nox, Heavy metals, PCDD, PCDF, PCB and PAH, and Dust. Dealing with this mix of pollutants is where the experience of ApZolution comes in; guaranteeing a safe application and high performance, keeping Capex and Opex under control and offering long-lasting efficiency. Injection of reagents like Hydrate lime Ca(OH)2, Bicarbonate NaHCo3, Milk of Lime, Activated Carbon, Minsorb®, a solution of Ammonia NH3, a solution of Urea CH₄N₂O are all part of our experience in achieving compliance with the increasingly stringent regulations for the emission of clean air into the atmosphere. Over the past years, many installations have been researched and installed, incorporating innovative bag filters, typical medium and small scale equipment specifically designed for this industry such as reactors, SCR systems, Deacidification solution, centrifugal separators and with or without waste heat recovery units to combine air pollution control with energy production as a full green-and-clean installation.Metals and non-metals dedusting solutions
For the metals and non-metals production sector, increasingly restrictive limits will be applied for atmospheric emissions, this aims to get closer and closer to green technological production.
To align metal manufacturing processes with this new trend of environmental requirements, our customers and industrial manufacturers require reliable partners with knowledge, experience and commitment to ensure operational health, sustainability and competitiveness.
Sustainability, through the most advanced fume treatment technologies, are among the basic technologies offered to metal producers. We have exceptional experience in the area of abatement of EAF dust with quenchers, natural draft coolers, forced coolers, heat accumulators, spark arrestors, Cyclones and bag house heat recovery as well as the secondary and primary gas treatment from BOF. Sinter plants, Pelletizing plants, Cast house and Stock house purification systems are also part of our extensive experience with winning technological solutions.
Glass
Factories with Melting furnaces for flat and container glass production are our clients. The gas combustion that comes from the furnace gas combines dust, Nox, Sox, and HF pollutants.
Dust removal with electrostatic precipitators and the desulphurization the denitrification systems are sized to comply with the most stringent regulations. Plants are specifically designed to operate in combination with desulfurizing towers, SCR reactors reagents, dosing systems and the ammonia injection packages. Ceramic candles can be sized for removing 3 pollutants like dust, sulphur, and nitrogen oxide in the same casing.
The high temperature emitted by the furnaces is also suitable for the installation of Waste Heat Recovery systems in series with the flue gas treatment plant. Organic Rankine Cycles or Steam Rankine Cycles can be applied including in-house boiler design, economizer, turbo-generator and ancillary equipment for energy production.
Power plants
EKO E3 bag cleaning technology uses a sonic wave acceleration pulse — offering the highest efficiency with minimum energy consumption for longer filter-bag life when compared to a conventional cleaning system — and finds its best application in large sized bag houses typical of those installed in power plants. Thousands of filtering elements are installed in a bag house casing, and energy saving is dramatically increased when the EKO E3 cleaning system’s low-pressure technology, with fast piston type pulse-valves, is applied.
Waste heat recovery
Waste heat recovery systems green technology consists in a heat exchanger that conveys diathermic oil or steam with medium or low pressure which is subsequently expanded through a turbo generator producing power.
The ORC turbogenerator converts thermal energy into electrical energy with high efficiency. The thermal energy that enters the system at a high temperature is provided with a thermal oil circuit. The thermal energy that leaves the system at low temperature is discharged via air.
ORC turbogenerator operation is based on the principles of the closed thermodynamic Organic Rankine Cycle (Rankine cycle with organic fluid). A simplified functional diagram is attached to this document.
When compared to a conventional solution like SRC, ORC plants demonstrate the following advantages:
- Very high turbine efficiency (up to 85 %)
- Low mechanical stress on the turbine, due to the low peripheral speed
- Low RPM of the turbine allowing the direct drive of the electric generator without reduction gear
- No erosion of blades, due to the absence of moisture in the vapour nozzles
- High cycle efficiency
- Long life
Bulk handling materials
In cooperation with international companies, we can propose solutions for handling systems — such as Rubber Belt Conveyors, Rubber Belt and Chain Bucket elevators, Pipe Conveyors, Air Slide Systems, Apron Feeders, Vibrating Feeders etc. — which optimize them in terms of operation, maintenance and energy use. Because ApZolution is also specialized in all types of storage systems for bulk materials, the company with which we cooperate has added two systems, Stacker – up to 2500 t/h capacity – and Reclaimer – up to 600 t/h capacity – to its product range. They ensure these systems are planned, supplied, installed and commissioned 100% locally, and have gained references in this regard.
Eco hoppers
Eco dust proof hopper is an economical, environmentally friendly dust discharge hopper, suitable for handling a variety of dry bulk materials, including: gypsum, cement clinker, slag, sulphur, nickel ore, iron ore, fine copper mine, coal, bentonite, soda ash, limestone and many other dry materials.