Engineered systems for capturing fine particulate matter and flue gases from industrial chimneys, optimizing mass balancing in metallurgical smelting plants.
Captures submicron particles with over 99.9% efficiency using densely packed filter bags and automatic pulse-jet cleaning. Designed for copper, zinc, and lead smelters requiring strict emission compliance.
Multi-stage scrubbing that neutralizes acidic gases like SO₂ and HCl while capturing fine aerosols. Recirculating alkaline solution achieves over 98% removal, with mist eliminator preventing droplet carryover.
Primary dust collection using centrifugal force to remove particles larger than 10 microns. Wear-resistant lining and optimized inlet geometry reduce pressure drop, essential for pre-filtration and mass balancing.
Combines bag filters, scrubbers, and cyclones into a unified system that tracks particulate loads across the smelting line. Real-time data on captured mass helps operators adjust process parameters and maintain compliance.
Tailored capture hoods and duct layouts that minimize fugitive emissions at furnace tap holes, converters, and ladle transfer points. Each design accounts for thermal expansion and abrasive dust flow.
Scope and limitations of our emission control systems
The High-Density Bag Filter System is rated for particles down to 0.5 microns at an inlet concentration up to 50 g/Nm³. Performance below this threshold depends on gas temperature and moisture content; we recommend a pilot test for sub-micron aerosols in zinc or lead fume applications.
Our standard wet scrubber targets SO₂, HCl, and particulate aerosols. Mercury vapor removal requires an additional activated carbon polishing stage, which is not included in the base unit. We can integrate this as a custom add-on for smelters processing mercury-bearing ores.
No. The Mechanical Cyclone Separator is a pre-filtration device for particles above 10 microns. It reduces load on downstream bag filters or scrubbers but does not meet emission limits alone. It is designed for mass balancing and coarse dust recovery, not final polishing.
The standard bag material handles continuous operation from 120°C to 200°C. For gas temperatures above 200°C, a gas cooling section or high-temperature filter media must be specified. Exceeding 260°C even briefly will damage the bags and void the warranty.
Yes. The recirculating alkaline solution accumulates dissolved metals and sulfates. A bleed stream must be treated in a wastewater plant or evaporated in a lined pond. We provide a mass balance sheet for each installation to estimate bleed volume and composition.
All three systems are designed to meet CPCB emission standards for non-ferrous metallurgy. We provide performance test reports from third-party labs. Local state board approval remains the client’s responsibility, though we supply all necessary design documentation.
Plant managers and engineers share how our bag filters, scrubbers, and cyclones performed under real smelting conditions.
“We installed the high-density bag filter on our copper converter stack. Outlet dust load dropped from 85 mg/Nm³ to below 5 mg/Nm³. Pulse-jet cleaning kept pressure loss under 1.2 kPa over six months of continuous operation.”
Akanksha Himesh Ray, Process Engineer – Copper Smelter A“The wet scrubber cut our SO₂ emissions from 420 ppm to 12 ppm. The venturi stage handles the heavy aerosol load from the zinc roaster, and the packed tower neutralizes HCl without scaling. We passed the annual compliance audit on the first try.”
Tanay Singh Dugal, Environmental Manager – Zinc Smelter B“We added the mechanical cyclone ahead of our existing baghouse. Coarse lead dust is now separated at the inlet, reducing bag loading by 40%. Mass balance improved, and we extended filter bag life by nearly eight months.”
Mowgli Chia, Maintenance Lead – Lead Smelter COur engineers inspect your smelting stack, measure flue gas volume, particulate load, and acidic gas concentration. We map the existing ductwork and calculate the required capture efficiency for your metallurgical process.
Based on the audit data, we select the right combination of cyclone pre-filter, bag filter density, and wet scrubber stages. Each component is sized to handle peak loads while maintaining pressure drop below 2.5 kPa.
All units are built in our workshop with wear-resistant linings, pulse-jet cleaning manifolds, and alkaline recirculation tanks. We test each module for leak-tightness and flow distribution before dispatch.
Our crew integrates the system into your existing chimney line, connects instrumentation for continuous monitoring, and runs a 72-hour trial to verify particulate removal and gas scrubbing against design specs.
We conduct stack sampling and mass balancing to confirm emission levels meet local standards. A final report documents capture efficiency, pressure drop, and chemical consumption rates for your records.