Grate Cooler ESP Inlet Wall Replacement, Co. Louth

Tusker was commissioned by Irish Cement to replace an ageing Electrostatic Precipitator (ESP) Inlet Wall filter system, essential for emissions control and environmental compliance. The project required a complete end-to-end solution, which Tusker delivered entirely in-house — covering design, fabrication, transport, and installation.

The existing ESP system had become inefficient and difficult to maintain. Tusker’s objective was to deliver a high-performance replacement that would improve particulate capture, integrate with existing infrastructure, reduce maintenance, and provide long-term durability. A bespoke modular system was developed to suit the site’s spatial constraints.

Key innovations included optimised airflow, improved electrode configuration, and a modular design for off-site fabrication and easier on-site assembly. Fabrication took place at Tusker’s facility, incorporating 150mm-thick specialist insulation rated to 650°C, and custom-rolled aluminium cladding for durability and thermal performance. Precision welding ensured all internal joints were airtight.

The structure was transported as abnormal loads, assembled on-site, and lifted into position using in-house designed and tested lifting beams — minimising crane time and installation risk. During the same shutdown window, Tusker also replaced drag chains, bearings, and serviced mechanical systems.

The completed system significantly improved efficiency, reliability, and compliance, and was delivered safely, on time, and within budget.