BAGHOUSE.ppt

Australasian Agent for

Total Air Pollution Control -

Company Profile

Total Air Pollution Control -

Company Profile

Australasia’s Leading Supplier of Upgrades, New Units and Replacement Parts/Services for Industrial APC Equipment

EvaporativeGas

Conditioning

EvaporativeGas

Conditioning

Electrostatic PrecipitatorsElectrostatic Precipitators

Fabric FilterCollectors (Baghouses)

Customer BaseMostly Heavy Industrial with some Light industrial.

Our main customers are in the following industries:

• Coal Fired Power Stations• Cement and Lime• Paper Mills• Steel• Metallurgical (Nickel, Zinc, Lead, Gold, Copper, Aluminium)• Alumina

• Filter bags and cages

• Fine filtration products

• Baghouse accessories

• Acoustic horns

• Emissions monitors

• Electrical controls & software

• ESP mechanical parts

• Evaporative gas conditioning systems

BHA-TEX®

PulsePleat®

Powerwave ™

CPM ™

SQ-300 ™

Innovative Products from GESolutions for all OEM styles

Latest innovations

ThermoPleatHigh Temp ElementsThermoPleat

High Temp Elements

STS Tubular FiltersSTS Tubular Filters

Juice Can ESP Power MaximiserJuice Can ESP Power Maximiser

RDE Rigid Discharge Electrodes

• Troubleshooting Expertise

• Responsive to customer problems

• Inspections and Installations

• Engineering / CAD

• New Units, Upgrades, Rebuilds

(Baghouse, ESP, EGC)

• Training Seminars

• After sales service

End user focused services

ESP Rebuilds + New Units

BlueScope Steel, Port Kembla Lurgi ESP

Holcim, Westport NZ

SF ESP rebuild

Experience across all industries

All makes and types of ESP

Proven value adding designs

Visy Paper, NSWFLS precipitatorNickel West ESP rebuild

BHP Billiton Olympic DamAcid Mist ESP

Bagfilter Rebuilds + New Units

Experience across all industries

All makes and types of bagfilter

Technical edge over our opposition due to GE products

BCSC BerrimaCoal Mill Bagfilter

BlueScope SteelNo.5 Blast Furnace Stockhouse Bagfilter

TAPC Headquarters

Head office Wollongong, NSW

Regional office Perth WA

800m2 Warehouse, 200m2 office space

Regional office Singapore

Regional office Philippines

GE Energy Corporate Headquarters

• Kansas City, Missouri USA

TAPC – Australasian Distributor for GE Energy(formerly BHA Group Inc.)

Innovative Filtration TechnologyInnovative Filtration Technology

Total Air Pollution Control Pty Ltdwww.tapc.com.auwww.tapc.com.au

Electrostatic Precipitators

Fabric FilterCollectors (Baghouses)

EvaporativeGas

Conditioning

BHA-TEX®PulsePleat®

Powerwave ™

Acoustic Cleaners

ThermoPleatHigh Temp ElementsThermoPleat

High Temp ElementsSTS Tubular FiltersDCE Vokes replacements

STS Tubular FiltersDCE Vokes replacements

ESP Advanced Automatic Voltage Controls - SQ-300 ™ Juice CanTM

For TRUE DC

Troubleshooting Expertise

Expert sales and technical support

Upgrades and rebuilds

The Air PollutionControl Experts

Toll Free 1800 424 269

Air Pollution Control (APC) Terminology

•TAPC

ACFM (Actual) vs. SCFM (Standard)

Measured at:

•Actual temperature

•Actual elevation

•With moisture

Calculated at :

•70°F

•Sea level

•Dry

• Actual Cubic Feet of gas per Minute

• The volume of the gas flowing per unit of time at the operating temperature, pressure and composition.

• (also measured in cubic meters per hour)

Calculating ACFM from SCFM

ACFM = SCFM x (Actual Temp. + 460° F)

530° F

Temperature Correction

ACM/HR = NCM/HR x(273° C + Temp)

273° C[ ]

Air-to-cloth ratio = acfm÷total filter area

(Filter dia. X length x 3.14) = filter area

Total # filters x filter area = total filter area

Air-to-Cloth calculations

Air-to-Cloth ratio (filter rate)

Type of Filter Maximum RecommendedCleaning System Air-to-Cloth Ratio

Shaker 3.0 0.91

Reverse Air 2.5 0.76

Pulse-Jet:

A. Cylindrical Filter Bags 6.0 1.83

B. Pleated Filters (Non-Paper Media) 3.5 1.07

C. Pleated Filters (Paper Media) 2.0 0.67

Imperial Metric

Can velocity• In a pulse jet dust collector with

the filter elements suspended from the tubesheet, Can Velocity is the upward air stream speed passing between the filters calculated at the horizontal cross-sectional plane of the collector housing at the bottom of the filters.

6:1 AC Ratio

8' bags

6:1 AC Ratio

10' bags

6:1 AC Ratio

12' bags

6:1 AC Ratio

6' bags

Can velocity

6:1 AC Ratio

12' bags

6:1 AC Ratio

8' bags

6:1 AC Ratio

10' bags

6:1 AC Ratio

6' bagsPoint of measuring can velocity (bag bottom)

Can velocity

Grain loading

• The amount of particulate by weight in a given volume of air, usually specified in grains/cubic foot (or grains/cubic meter).

1 lb (0.454 kg) = 7000 grains1 kg = 15,432 grains

Collection efficiency

Efficiency = 15 Grains - 0.01 Grains = 99.93%15 Grains

Example:Inlet Dust Load = 15 GrainsOutlet Emission = 0.01 Grains

Efficiency = Inlet Dust Load - Outlet Emission Inlet Dust Load

@ 5 grain inlet load = 99.80%

Magnehelic® gauge

• An instrument used to measure the differential pressure drop in a baghouse.

Water Gauge (w.g.) or Water Column (w.c.)• A measure of the pressure required to raise

(or lower) a column of water against a vertical scale measured in localized units; e.g., 1 inch w.g. (25.4mm w.g.)

• 1 PSI = 27.7 inches w.g. (703.6 mm w.g.)• 1” Mercury (Hg) = 13.6 inches w.g.

Percentage Tenacity Loss per Week in Water, Saturated Steam

or Moist AirFor Polyester Fabric

Moisture Problem:Temp. Moist Air

ºC 10% RH 20%RH 40%RH 60%RH

0 0.0002 0.0004 0.0011 0.0026

20 0.0009 0.0018 0.0055 0.013

40 0.0045 0.009 0.027 0.063

60 0.022 0.045 0.13 0.3

80 0.1 0.2 0.62 1.4

100 0.5 1 3 7

120 2.5 5 15 34

140 12 24 70 165

Moisture Problem:Temp. Water or saturated steam

ºC 80%RH 100%RH

0 0.0064 0.0075

20 0.031 0.036

40 0.15 0.18

60 0.72 .085

80 3.5 4.1

100 17 20

120 82 97

140 400 465

Psychrometric Chart

Objectives:• To know about APC• To know what APC best suited an application• To know basic operation and maintenance of APC• To comply with government regulations• To eliminate environmental health hazards

Performance Curve of a Filter Bag

Mass of Dust Deposited

Initial dustcake

Effective filtration

Initiation of cleaning cycle

Resistance of clean fabric

Pressure Drop ( P)Function of the pressure drop across both the filter and the deposited dust cake.

P across the clean fabric:

Pf = k1vf

Pf = pressure drop across the clean fabric, in.H2Ok1= fabric resistance, in H2O/(ft/min)

vf = filtration velocity, ft/min

Pressure Drop ( P)P across the dust cake:

Pc = k2civf2t

Pc = pressure drop across the cake, in.H2Ok2= resistance of the cake, in H2O/(lb/ft2-ft/min)ci = dust concentration loading, lb/ft3

vf = filtration velocity, ft/mint = filtration time, min

Pressure Drop ( P)

P across the dust collector:

Pt = Pf + Pc

Cleaning Comparison:Parameter Pulse Jet Reverse Air Shaker type

Frequency Row of bags at a time

Clean one compartment at a time

Motion Shock wave Gentle collapse of bags upon deflation

Simple harmonic or sinusoidal

Peak Acceleration

30-60g 1-2g 4-8g

Amplitude - - 1”-4”

Cleaning Comparison:Parameter Pulse Jet Reverse Air Shaker type

Mode On stream/off stream

Off stream Off stream

Duration 100 msec; 15 seconds off time

Reverse air flow 20-40 seconds

10-100 cycles; 30 seconds to few minutes

Bag dimension

5”-6”; 8-20’L

8”-12”; 22’,30’,40’L

5”,8”,12”; 8’-10’,22’,30’L

Bag tension - 50-120 lbs, optimum varies

Fabric Testing:

• Permeability- is defined in ASTM Standard D-737-69 as the volume of air that can flow through one square foot of cloth area at a pressure drop of no more than 0.5” w.g.

Fabric Testing:

• MIT Flex Test- is used to measure the ability of fabrics to withstand self abrasion from flexing. This method is describe in ASTM Standard D-2176-69

Fabric Testing:

• Mullen Burst Strength- describe in ASTM Standard D-231, is designed to show the relative total strength of fabrics to withstand pulsing or pressure.

Fabric Testing:

• Tensile Strength- provides data on fabric stretch, elongation an tear. This is describe on ASTM Standard D-1682-64 for breaking load and elongation of fabrics.

Baghouse System Design

•TAPC

Ductwork Sizing for Conveying Velocity

3500–4000 fpm

43 mph average

1” + 4” + 1” + 6” = 12”

Cubic Feet per minute (CFM)

Static Pressure

31.1 BHP

Static Pressure

31.1 BHP = 40HP

1” + 4” + 1” + 6” = 12”

Close Damper

Troubleshooting

AMPS on

Tools to Troubleshoot the Baghouse

Troubleshooting

4000 fpm 2800 fpm

Air Growth14°

Troubleshooting

Start Cleaning @4–4.5” P

AMPS on

Open Damper

0.5–1” Of P Change

Static Pressure

31.1 BHP = 40HP

Start Cleaning @4–4.5” P

AMPS on

Open Damper

0.5–1”Of P Change

Temperature100–250F

Fabric/Cage Selectionfor Dust Collection

•TAPC

Fabric Style

Fabric Selection Considerations

– Baghouse operating temperature – Abrasion resistance needed– Resistance to cleaning energy– Gas stream chemistry– Air-to-Cloth ratio– Cleaning method

500°F(259°C)

ExcellentGoodFair

GoodExcellentXXXXXXX

Oper. Vari. Polyester Acrylic Fiberglass* Aramid* PPS P84*

Max. Oper. TemperatureAbrasionFiltration PropertiesMoist HeatAlkalinesMineral AcidsOxygen(15%+)Relative Cost

275°F(134°C)

Excellent

ExcellentPoorFairFair

ExcellentX

264°F(130°C)Good

GoodExcellent

FairGood

ExcellentXX

500°F(259°C)

FairExcellent

FairPoor**

ExcellentXXX

400°F(204°C)

Excellent

ExcellentGoodGoodFair

ExcellentXXXX

375°F(190°C)GoodVeryGood

ExcellentExcellentExcellent

PoorXXXXXX

Fabric Characteristics & Suitability

Finish:

Silicone

AcrylicCoatings

PTFE PenetratingFinished

Expanded PTFE Membrane

Finish Purpose:

Recommended forimproved cake release

Provides short-termimprovements for cake release(may impede airflow)

Aids initial cake development and provides limited water repellancy

Improves filtration efficiency and cake release (may impede flow in certain applications)

Improved water and oil repellancy; limited cake release

For capture of fine particulate, Improved filtration efficiency, cake release

Available For:

Polyester, Polypropylene, Acrylic, Aramid, PPS and P84

Polyester, Polypropylene (felts)

Polyester (felt and woven)

Polyester and Acrylic felts

Aramid, Polyester

Aramid, Polyester, Acrylic,Polypropylene, P84, PPS,Fiberglass

Non-Fiberglass Finishes

Finish Purpose:

Protects glass yarns from abrasion, adds lubricity

Shields glass yarn from acid attack

Provides enhanced abrasion resistance and limited chemical resistance

This unique formulation of polymers and PTFE provides superior resistance to bothacid and alkali attack as well as increasedabrasion resistance.

Finish:

Silicone, Graphite Teflon(SGT)

Acid Resistant

Teflon® B

Blue-Max CRF-70®

Fiberglass Finishes

Filter Bag Failure: Mechanical

• Failure is caused by:– Aggressive cleaning– Abrasion (internal & external)– Faulty construction– High differential pressure– Normal wear– Fabric blinding

Filter Bag Failure: Chemical

• Failure is caused by:

– Acid attack– Poor fiber or finish selection– O2 on PPS– Alkaline attack

Filter Bag Failure: Thermal

• Failure is caused by:

– Fiber limitations• Strength loss• Shrinkage/elongation • Finish loss

– Hopper buildup

Protecting Bags forMaximum Collection Efficiencyand Longer Life

Dustcake options

– Particulate Collecting– Artificial Precoat

New fabric receives more airflow

– New fabric accepts airflows in the range of approximately 20 to 50 cfm.

– Filter bags that have been in service and have a good porous dustcake have airflows at 5 to 10 cfm.

– The new filters will be subjected to three times the airflows as the bags that are currently in service, causing potential damage early in the bag’s life.

Unprotected new fabric interstices work like miniatureventuris to accelerate airflow through the fabric, causing particulate impingement.

Unprotected fabric

How to protect new bags:

– Preheat equipment– Restrict airflows– Lockout cleaning cycle– Build good initial dustcake

Initial dustcake requirements:

1. Porous, ensuring high airflowsA. Range of particle sizesB. Varying particle shape

2. Provide a uniform coat. (1/16” to 1/8”)3. Material should be neutral (pH). 4. Safe to handle.

Protected

Unprotected

ArtificialDustcake

Embedded Particles inInterstices

New fabric protection & porosity

Agglomerated dustcake restricts airflow.

Particulate bleedthrough can cause emissions.

Restricted airflow:

By cleaning the bags thoroughly, and re-establishing a uniform, porous dustcake, we can level-off the damage and recover much of the airflow.

Proper artificial dustcake can help

Bag protection options:

– Fly ash– Lime– Diatomaceous earth– BHA Neutralite®

Fly Ash

10 ft2

15 ft2

20 ft2

1 lb. of Fly Ash covers 4 ft2 of cloth with a 1/16” coating

1 lb. of Lime covers 2-3 ft2 of cloth with a 1/16” coating

1 lb. of Neutralite covers 20 ft2 of cloth with a 1/16” coating

BHA Neutralite®

Precoat volume vs. weight comparison

Neutralite®

Lime: Dolomite Quick Hydrated Crushed Stone

Fly Ash - Treated

503491

.052 lb/sq. ft.

.302 lb/sq. ft.

.177 lb/ sq. ft.

.474 lb/ sq. ft.

.286 lb/ sq. ft.

Amount used per ft2 for

1/16th” Coating

Density ( per ft3 )

Product

Precoat volume vs. weight comparison

Additional reasons to pre-coat:

– Moisture can create agglomerated dustcake that destroys airflows; can create acid reaction, rust components

– Hydrocarbons create sticky dustcake difficult to clean; shorten bag life; high P

– Sparks burn holes in bags, can cause baghouse fires

– Neutralize gas stream chemicals

Agglomeration of filter bags can be caused by gas stream moisture.

Moisture prevention

Bag damage and failure can be caused by spark carryover.

Sparks ruin bags

BHA Neutralite® injectionHigh on hopper wall 3” diameter x 6” long pipe nipple. Neutralite® can be injected here.

3” diameter x 6” long pipe nipple on inlet ductwork/elbow. Neutralite® can be injected here.

Discharge Hose

Vacutrans™

Compressed Air Connects Here

Poke hole port, usually 3” or 4” dia. Location is too low to inject Neutralite, not enough air volume to maintain velocity needed to carry Neutralite to top section of filter bags.

Vacuum Hose

Airlock or slide gate.

To ash removal system.

Hopper door lockout procedures usually won’t allow this access door to be open while dampers are open or fan is running.

Insulation and sheet metal lagging.

Hopper Side Wall

Review

– Selection of material– Cleaning system off– Fan on (continuously)– Correct amount (1/16”-1/8”)– Maintain base cake

Visolite® Leak Detection System

Purpose

– Identify holes in filters– Check for proper installation– Detect structural air leaks

Key information

– Positive/Negative System– Process/Nuisance– Clean Air Plenum Access– Cloth Area– Injection Location

Injecting Visolite®

Keys to successful test

– Shut off cleaning system– Fan in operation– Inject powder (1lb per 1000 sq ft of cloth)– Shut off Fan (45-60 seconds)– Test with light

Australasian Agent forPowder collects around air leaks

Visolite® Leak Detection System

Options:• Visolite® colors:• • Monchromatic lights:

GREEN ORANGE PINK YELLOW

Benefits review:

– Non-formaldehyde– Varying particle size– Labor savings

Fabric SelectionStyle: PE72Fiber: 100% PolyesterWeight: 16 oz/yd2 (544 g/m2)Construction: Scrim supported felt; Duo-DensityCount: (N/A)Air Permeability: 15-35 CFM (.5-1 m3/min)Mullen Burst Strength: 375 psi (26 kg/cm2)Tensile Strength: 2 inch (5 cm) strip Warp: (N/A) Fill: (N/A)Thermal Stability 2% maximum at 275°F (135°C)Maximum Operating Temp: 275°F (135°C)Finish: Heat set, calendered, singed

Improving Dust Collection Performance with Pleated Filter Elements

•TAPC

Common Problems: Pulse-Jet

• Fine Particle Emissions– Particulate bleedthrough of conventional felts– Aggressive design - high filtration velocities

• High Differential Pressure - Loss of Airflow– High air-to-cloth ratios– Poor cleaning mechanism efficiency– Extra drag across filter due to primary dustcake

Common problems:• High differential pressure / loss of airflow - de rate:• High air to cloth ratios• Fine particulate• Poor cleaning mechanism efficiency

• Abrasion failure:• Bottom of filter bags located directly in line with inlet gas stream.• Excessive movement of filter causing bag to bag abrasion.

• Aggressive cleaning cycles:• Accelerated filter bag fatigue and flex failure.

• Difficult installation and removal:• Extra downtime to handle multiple and bulky components.

Multiple piece cages.• Filter bags can become “stuck” to cages and have to be cut off.•

Increase surface filtration area…by as much as 2–3 times

Lower differential pressure... increased airflow

Lower emissions... double filtration efficiency

Solutions with pleated elements

Benefits of pleated filter elements:

– Shorter filtersless abrasion failure

– Easy installationreduces downtime & lowers maintenance cost

– Lower pulse pressurecompressed air savingsreduction in pulse frequency,extending filter life

Spunbond vs. felt

Face view - magnified 100x

Spunbondpolyester

Polyesterfelt

Side view - magnified 50x

Spunbondpolyester

Polyesterfelt

Spunbond vs. felt

*5:1 A/C Ratio (1.5:1), 0.5 micron particulate

inlet loading: 30 grains/acf (69 g/m3)

StandardPolyester

Felt0.006

(13.7 mg/m3)

SpunbondPolyester

0.0025(5.7 mg/m3)

Spunbondw/PTFE

Membrane0.0008

(2.3 mg/m3)

40% Reduction

Outlet emissions (grains/ACF*)

BHA PulsePleat®

Lower differential pressure

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 5050mm

tial P

. ( In

PE806/Membrane

Spun Bonded

Polyester Felt

Differential Pressure

BEFORE

Pulse-Jet with conventional bags>100 bags>6.25 x120.00 bag size

(159mm x 3050mm)>1640 ft2 cloth area (152 m2 )>6.1 air-to-cloth ratio>10,000 ft3/min (283 m3/min)

>6- 8 w.g. average differential pressure (152-203mm w.g.)

Filtration area comparison

Pulse-Jet with BHA PulsePleat®

>100 elements>TA625 x 80.63 (2050mm)

PulsePleat®

>5800 ft2 cloth area (538 m2 ) >2.6 air-to-cloth ratio>15,000 ft3/min (425 m3/min)

>3-4 w.g. average differential pressure (76-101mm w.g.)

253% increase in filter area

50% increase

in airflow

Filtration area comparison

• Increased airflow

• Lower DP

• Increased efficiency

• Extended filter life

• Reduced compressed air usage

134m3/hr167m3/hr

200m3/hr

Increased Surface Filtration Area provides:

Top-load or bottom-load tops

Polypropylene or metal core

Polyurethane or metal bottom pan

Straps strategically placed for strength

Customized pleat depth and spacing

BHA PulsePleat® - for temps up to 265°F (130°C)

Top-Load or Bottom-

Load Tops

Metal Core (Standard)

Metal bottom pan (standard)

ThermoPleat - for temps up to 375°F (190°C)

ISO 9001

Top-load or bottom-load tops

Metal core (standard)

Metal bottom pan (standard)

BHA ThermoPleat® - for temps up to 450°F (232°C)

Pulse-Jet

•TAPC

Diaphragm valve

Manifold

Solenoid valve/bleeder tube

Quick-release blowpipe

Tubesheet (cell plate)

Venturis

1/2”

5-6” Header

Problem #1 - Limited cleaning ability

1 1/2”

5-6” Header

BAGHOUSE.ppt

Documents

Transcript of BAGHOUSE.ppt

Do you admire Leonardo da Vinci?

Basic Buffer Overflows Explained

Chapter-01

European Colinization of Latin America

Venture Capital

Barclays1

How Computer Keyboards Work

Jan Van Eyck and the Man In A Red Turban

Life Is Just A Dream - Or Is It?

Improve the Color Quality Of Your Monitor

Star Wars Trivia!

Cakes Recipes

One Flew Over the Cuckoo's Nest

Personality Development

Keyboard Shortcuts for the Opera Browser for Mac OS X

Oedipus The King: The Ideal Tragic Play

The Dutch Republic In International Trade

Explore The Levels of Creation

Bodybuilding - The Rock Hard Challenge (Month 1 Training)

xCDC14a