Transcript Bag Selection and How to increase the Lifetime of Kiln raw

‫‪How to increase‬‬
‫‪the Lifetime of Kiln-raw meal Bags‬‬
‫چگونه عمر کیسه های گرانقیمت فیلترهای بگ‬
‫هاوس را افزایش دهیم‬
‫ارائه در‬
‫همایش بزرگداشت هفتاد وهشتمین سالروز صنعت سیمان‬
Introduction
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Present essentiality and approach to barrier filters
(Baghouse, Hybrid filters) for Kiln-Raw meal dedusting
Unique performance of Fiberglass + PTFE Membrane for
Kiln-Raw meal application
Present unacceptable short lifetime of bags in some plants
Cost for a new set of bags
Possible Kiln shut down for bag replacement
Present limitations for Imports
So, it is important to find solutions to increase bags lifetime
Typical Baghouse
Baghouse Design Parameters
Process Type
Gas Volume (Actual; m3/h)
Temperature, Humidity
Inlet Dust Concentration
Gas Analysis
Dust Composition
Cleaning & Maintenance Modes
Bag Cleaning : 1- offline 2- online
Maintenance : 1- offline 2-online
SELECTION CRITERIA OF FILTER MEDIA
Relevant data for a secured selection of the required filter media:
• Process description (including upstream and downstream process steps)
• Bag filter inlet temperature (normal, maximum, minimum)
• Humidity / water dew point
• Raw gas composition (especially corrosive gases)
• Dust concentration [g/Am³]
• Dust composition
• Dust properties (agglomerating, sticky, abrasive, acid etc.)
• Particle size distribution
• Cleaning method (Pulse jet, shaking, reverse air)
• Cleaning pressure
• Cleaning mode (online/offline)
• Air to cloth ratio [Am³/m²/min]
• Operating mode (frequency of shut downs/passing through dew point)
• Previous operational experiences where applicable
Bags for Kiln-Raw meal applications
1- Fiberglass + PTFE Membrane ; Mostly
2- Polyimide (P84) ; Sometimes
3- PPS: Polyphenylsulphide ; Occasionally
PTFE Membrane Producers
DONALDSON MEMBRANE COMPANY
W.L. GORE & ASSOCIATES
GE ENERGY (BHA)
Some European companies Started
Some Chinese companies
ePTFE-Membrane
expanded PolyTetraFluoroEthylene (ePTFE) Membrane
ePTFE-membranes are manufactured from 100% PTFE polymer resin. They
are chemically inert and thermally stable up to 325°C.
The filtration membranes exhibit on average more than 100 million pores per
cm2.
The membranes are thermally bonded onto a range of substrates including
woven, spun bonded and needlefelt materials:
FiberGlass, PPS, Aramid,Polyimide
Polyester, Polypropylene, Homopolymer Acrylic
Tetratex® “Ultra High Efficiency” Benefits
Emission: Near zero emissions with sub micron capture capabilities
Cleanability: Excellent dust cake release, Less compressed air pressure
Energy Saving: Lower constant operating pressure
Durability: Increased bag life; by less frequent cleaning due to the extreme
anti-adhesive properties of the ePTFE membrane.
More Economical: by lower maintenance and operational costs
Tetratex®
Ultra High Efficiency ePTFE-Membrabe
Fractional efficiency
Ultra High Efficiency ePTFE-Membrane
FiberGlass+PTFE membrane
(Product code # 6255) a/c:10ft/min
Depth Filtration Surface Filtration
Tetratex Fiberglass + PTFE Membrane
Specifications
Fibre Composition
Special Treatment
Weight
(g/m²)
Air Permeability
(l/dm²/min @ 200 Pa)
Minimum Mullen Burst
(kg/cm²)
Minimum Break Strength (N/50mm)
Warp
Weft
Continuous Service Temp
(º C)
Finish
100% Fibreglass
PTFE
770
20-40
55
3000
2000
260
Tetratex® Ultra High
Efficiency ePTFE Membrane
Operation condition for
FiberGlass+PTFE Memrane
1- Dew point: The maximum number of shutdowns per year we would recommend for the
filter bags is 10-12 per year. The filter operating 15 deg c above the calculated acid dew
point.
2. Temperature (limits Values)
Continuous Operation Peak
Duration
Temperature
260°C
280°C
15mins/24 hours
3. Oil can be detrimental to the membrane. Conditions where potential problems can be
avoided.
Quality of compressed air is to be clean, dry (i.e. free from moisture) and oil free. The gas is
to be dried and come from a dedicated source. The air mist be dried to –40 deg. C dew point
to prevent reaction with acid gases. Please reference standard, ISO 8573-Class 2, however,
this data should be part of the design by the OEM.
4. Max. accepted pressure drop across the tubesheet
Normal operation < 200 mmWG
Cleaning System Failure:
If the compressed air system fails this will cause the dp to rise across the tubesheet due to the
build up of cake on the filterbags. The emergency bypass is to be activated when the tubesheet
dp reaches 300-350 mmWG.
5. Cleaning Pressure
Energy Source
4.0 - 4.5 bar (g) compressed air
Cleaning Frequency
as per filter design
Duration
100 – 500 ms
Motion
Pulse or air travels down the bag
Order
Staggered order of the rows cleaning to avoid possibility
dust migrating to the clean row. This improves the dust cake for optimum filtration.
Initial Pulse Setting
approx. 4.0 bar. Solenoid valve 0.1 – 0.5 sec
of fine
Suggested Cage Specification for F.G. +PTFE Bags
They do not guarantee good performance, but are intended to reduce the risks of poor
performance or premature bag failure which is often associated with the use or re-use of poor
quality cages.
Substrate
Standard
Woven PTFE
Material
Neeldefelts
Woven Glass
Maximum Stringer Spacing (mm)
40
25
Maximum Ring Spacing (mm)
200
150
Stringer Wire Diameter(mm)
3.0-3.5
3.5-4.0
Ring Wire Diameter (mm)
3.5-4.0
4.0
Notes:
1. No burrs / sharp edges.
2. No bent or twisted cages.
3. End caps should be 2-6mm less than overall cage diameter.
Attachment method should be discussed and agreed.
4. Split cage jointing method must be discussed and approved
5. Cage material, coating and painting must be discussed and agreed.
6. Use of tapered cages must be discussed and approved.
Cage Quality and Handling
2 Parts Cages
The Joints are usually a problem
Tube Sheet & Cage (Redecam design)
Some Bag References
Firouzkuh Cement Co. (the first in operation supplied bags; till now 3 and a half
years in operation)
Kavan Bokan (Sardar ) Cement Company
Esfahan Cement Co.
Shamal Cement Co.
Farz Firouzkuh Cement Co.
Saman Gharb Cement Co.
Esfahan Steel Co.
Golgohar Iron ore
Sarcheshme Copper Industries
Gohar-ravesh Sirjan Co.
…..
Recommended Installation Procedure for FG+PTFE Bags
For optimum performance to be achieved, it is vital that filter bags be installed correctly and that
recommended procedures be followed. Mistakes made during the installation can significantly
impact on the effective life of a set of filter bags.
Fiberglass with PTFE membrane bags are manufactured to exacting standards and it is
recommended that the bags be installed as follows:
1. Remove all bags and support cages from the filter unit. Care should be taken to avoid damaging
the cages as broken wires and bent cages can cause premature bag wear.
2. The clean side of the filter should be thoroughly cleaned down and all remnants of particulate
and other matter removed. The cell plate holes should be checked to ensure they are completely
clear and that an effective seal will be possible.
3. It may be necessary to inspect the “dirty” side of the filter at this point to ensure there are no
excessive build-ups of dust on walls or internal supports and diffusers.
4. The new bags should remain in the protective cases and should only be unpacked once they are
close by the area of the cell plate into which they are to be installed. Avoid throwing the bags or
dragging them across the rough surfaces.
5. Bags should be installed using the protective sleeve. A number of these should be supplied with
the bags. Only the bag (NOT the bag on the cage) should be installed at this moment.
Protect the membrane – by using installation sleeve!
1)Ensure the cell
plate are clean and
free from damage
4) Put in the total
length of filter bag
2) Bring installation
sleeve in position
3) Install filterbag
with care!
to prevent membrane damage
5) Remove installation
sleeve and fix snap ring
6) Repeat procedure
with next filterbag!
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7/17/2015
Pre-coating of Filter Media
Fine, moist, or adhesive dusts will contribute to premature blinding of filter media. Pre-coating
of the filter media with a layer of an inert dust of known particle size distribution, such as
calcium carbonate (CaCO3),can minimize problems associated with these types of dusts.
7/17/2015
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Filter Bag Failure Analysis
• The bag will be visually examined to identify any abnormalities or obvious
areas of abrasion, holing, or degradation.
•Samples will be then cut from the top, middle, and bottom sections of the bag.
•The samples were tested for air permeability in the as received condition and
then again after cleaning.
•The cross section of the cut samples was examined under a microscope to
determine the degree of dust penetration into the media.
•The tensile strength of the filter media will be tested and the results examined
against any evidence of physical degradation.
Special products need special Quality and Special services
Knowledge and experiences in filtration textiles
Very good facilities for making Filter bags
Short and on time delivery (less than7 weeks ready for Shipment)
Very good reputation in making filter bags in Europe
Close Cooperation with Donaldson and best Quality of material
ShayanTarh is exclusive
Fasse Representative in Middle East
Fasse Industrietextilien Bag Quality
Head cuff made from P84-PTFEFelt instead of Glassfabric SEALING
from first to last meter the laps
are in same width which leads
to same diameter of course
Reinforcement covered the seam
that fixes the buttom-LONGER
LIFETIME
Each bag will be signed with
Roll-identy-no from supplier and
month-Year of prodcution
Before & after sales services
• Visit from your plant to analysis the Baghouses and bags performance
• Sending bag to FASSE for failure analysis and making report for any advice
• Refurbishment of bags in kiln overhaul
• Supervision of first installation and replacement of bags
• Training courses in your plant
• Maintenance services in your plant
• Regulating the pulse contorl panel, Compressed air pressure and ..
• Consulting and answer to any of your Question regarding to bag & baghouse
and in case of need getting help from FASSE .
Air pollution Control Equipment
Supplying of :
Baghouses
Electrostatic Precipitators
Hybrid Filters
Gas Conditioning Tower
Rebuild & Retrofits:
Modification of ESP to Hybrid Filter
Modification of ESP to Baghouse
Change of ESP Internals
Change of bag filter cleaning system from
mechanical to jet pulse
Field Services:
Performance Evaluation
Measurement of Process Parameter
and Emission
Inspection, Diagnosis and Troubleshooting
Maintenance and Repair Services
Auxiliary to Air pollution Control Equipment
Material Handling:
Screw Conveyors
Paddle Screw Conveyors
Chain Conveyors
Belt Conveyors
Bucket Elevators
Rotary Air Locks
Electrical Control Cabinets
Other Products:
Duct Works, Steel Stacks
Steel Structures
Dampers, Expansion Joints
Heat Exchangers
Integrated system
Gas Conditioning Towers
Transparent Energy Systems
1- Waste Heat Recovery Systems
2- Waste Heat driven Power Plants
3- Co-generation Systems
4- Ammonia Absorption Refrigeration Plants
5- Power Boilers
6-Combustion Turbine Inlet Air Cooling Systems
7 -Rankine Cycle Power Plants
8 ……..
Fasse IndustrieTextilen;
(Representative in Iran & Middle
East)
NTP (Norwegian Co.)
All Types of ESP Insulators
Supplying of Baghouse Special Parts
• Control cabinet; pulse on demand controllers
• Filtering media:
Fiberglass+PTFE, P84, Polyester, PAN, Nomex,
• Cage
• Venturi
• Airtank
ESP Special Parts
•Collecting Electrodes
•Discharge Electrodes
•Insulators for Collecting
•Insulators for Discharge
•Hammers
• ….
Dampers, Expansion Joints,
Rotary Valves, …. ..
Chain Conveyors, Screw Conveyors,
Belt Conveyors,..
Baghouse and ESP Control Panels
Kangan Cement Co.
Kiln/Raw mill Baghouse
Kangan Cement Co.
Cement mill Baghouse
Esfahan Cement Company
Kiln-Raw meal Baghouse
Mazandaran Cement Co.
Saman Gharb
2 kiln/raw meal Baghouse, 2 Coller ESP
(Redecam Design)
Saman Gharb
6 Cement Mill Baghouses
Torbat Jam, Kiln/Raw meal Baghouse
Torbat Jam, Cooler Baghouse
Any Question?
‫باتشکر از توجه شما‬
Thank you for your
kind attention
M.H. Haghi