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Basics of bag filter based de-dusting system.
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Air pollution is the introduction into the atmosphere of chemicals, particulates, or biological matters that cause discomfort, disease, or death to humans, damage other living organisms such as food crops, or damage the natural environment or built environment.
Basic Concept
Dust laden air enters through the hopper by suction or positive pressure
The heavier dust particles fall immediately into the hopper, while the lighter ones deposit on the outer surface of filter bags
Dust deposited on bag surface is dislodged & bag is cleaned by pulse of high pressure compressed air.
Top-Down flowin filter housing
Insulation to avoidundershootingof dew point(hot gas version
Dust particles areretained on thesurface of the filtermedium and thecleaned air passesthrough the filtermedium and flowsinto the clean gaschamber or duct.
Penthousewith hoist
Dust collection hopper or tray with materialdischarge screw or scraper chain conveyor
Bagfilters : Classification based on how the fabric is cleaned
1. Shaking 2. Compressed Air 3. Reverse Air
Reverse Air
Types of Cleaning
In an industrial system of gas cleaning, the fabric is media made into either an envelope or a tube. These envelopes or tubes are called the bags and a housing of these is called Bag Filter or Bag House.
Bag Filter - Basics
Inlet dust load in gm/Nm3
Gas volume in Nm3/hr
Gas temperature
Nature of pollutant : Gaseous /
Particulate Properties of dust : Physical
(density / size fraction /temperature / ‘wettability’)
Properties of gas : Physical / Chemical (nature: acidic /alkaline, moisture content critical)
FACTORS GOVERNING SELECTION OF TYPE OF APC EQUIPMENT - 1
Nuisance value / Recovery value of both dust and gas
Outlet emission requirements / Efficiency required
Space availability Economics / Budget / Fund availability
/ Return on Investment
FACTORS GOVERNING SELECTION OF TYPE OF APC EQUIPMENT - 2
Air-to Cloth Ratio =
Total volume of gas (or air) handled by the Bag filter [m3/min] /Total filtration area provided in the Bag Filter [m2]
= [ m3/min-m2 = m/min, => velocity unit; hence also called filtration velocity, and is actually the velocity at which the dust
laden gases travel across the filter element ]
The more critical the dust { fine, light, sticky, non-agglomerating, abrasive, etc} or higher the dust loading, the larger is the filtration area provided, i.e. lower is the air-to-cloth ratio maintained.
Can Velocity =
Velocity at which the gas travels upwards across the cross section of the Bag filter =
Total volume of gas (or air) handled by the Bag filter [m3/min] /Cross sectional area of Bag Filter casing [m2]
This is an important aspect and has to be restricted especially for fine, light, and non-agglomerating dust (lime, carbon black are typical examples) as otherwise the dust may remain in a fluidised state in the bag filter and not get discharged from the unit at all.
Filter Fabric selection
Online type :-Cleaning is done on line ( chamber in
operation)
Off Line type :-Cleaning is done in the off line mode. i.e
cleaning of the chamber after isolating the flue gas entry .
This avoids re entrainment of dislodged dust
Used in case of fine dust
Bag Filter – Type-Online
Single module-hopper Entry
How it works – Normal Gas Flow
Bag Filter – Type-Offline
How it works – Reverse Gas Flow
Bag Filter – Type-Offline
In offline Pulse Jet Bag Filter which is a compartmentalized Bag Filter, one compartment is sequentially taken out for cleaning purpose. Rest all the compartments are under filtration process. Typically offline cleaning is employed for finer dust particle sizes which does not settle easily.
In Modular construction Pulse Jet Bag Filter which is Online in cleaning operation, one compartment can be taken out doe maintenance purpose if required.
• The cleaning in this type of filter is online i.e. filtration and cleaning simultaneously occurs in a compartment. These type of filters are usually designed for Process application which handle large gas volumes.
• In both the above types of Bag Filters outlet type poppet dampers pneumatically operated are required for isolation of compartments.
PJBF-Offline
Bag Filter – Type-Offline
Constant emission air pollution control (APC) equipment. Suspended particulate emission control using positive filtration. Possible to achieve lower outlet emission. Suitable upto gas temp. of 260 deg C. Can handle various types dust viz. explosive/non-explosive, abrasive,
hygroscopic, sticky, coarse/fine. Low initial set-up cost.
Pulse Jet: Pulse Valve
Pulse Jet Components - Diaphragm Valve
Pulse Jet Component – Air Manifold Tank
Pulse Jet Components – Tubesheet (Cell Plate)
Pulse Jet Components - Venturis
Pulse Jet Components - Bags
Pulse Jet Components – Bags
Pulse Jet Components - Cages
Pulse Jet Components – Cleaning system
Pulse Jet Components – Cleaning system
Pulse Jet Components – Timer or DP Based Control
Pulse Jet Cleaning Operation through Timer
6 Ways Dust Gets to Clean Air Plenum
Hole in Bag Snapband/Flange Top Welding Cracks Clean too soon (Over Cleaning) Not Cleaning (Under Cleaning) Air Leaks at Door Seal
Pulse Jet Component – Blowpipe
Enlarged Holes
Normal Holes
Pulse Jet– Blowpipe Misalignment Problemof Cage
of Blowpipe
Less than 1/4 inch(6.35 mm)
PROBLEM POSSIBLE CAUSE
SOLUTION
High DP Bad Gauge Check gauge by blowing into it. If needle does not move replace gauge
Leaking gauge pipe
Repair leaking gauge pipe
Choked gauge pipe
Clean / replace gauge pipe
Low header pressure
Minimum required pressure is 6.3kg/cm2g (90psi). Check supply pipe, drain valve for leaks. Check Diaphragm & solenoid operation
PROBLEM POSSIBLE CAUSE
SOLUTION
High DP Static Charge on Filter
Static Electricity will interfere with the cleaning operation. Ground the filter
Water in Air Line
Remove water & clean the system. Check regularly the manual/Auto drain valve of Air Filter. Replace the defective one.
Bag Blinding or chocking
High moisture & condensation will cause dust cakes, which are difficult to remove & it blinds/chokes bags.
1)Preheat Bag Filter on start-up & use space heater ON for long shutdown. 2)Wash bags & use after drying.
3) Membrane bags – Permanent soln.
PROBLEM POSSIBLE CAUSE
SOLUTION
High DP Wet Compressed Air
Humid compressed Air allows dust cake to stick to the bags. Ensure, clean & dry compressed air
Too high System Air Flow
Check for airflow figure. If it is very high the A/C Ratio will also be very high causing high DP as well as Re-entrainment
Dust Particles – Too fine
Ask customer for actual particle size analysis & compare with figures given in the order – Excessive fines will simply choke the pores on bag surface
Pulse pipe mis alignment
The pulse pipe nozzle should be concentric with the bag centre
PROBLEM POSSIBLE CAUSE
SOLUTION
High DP Bag-Cage Pinch – not Okay
For normal felt bags the bag –cage pinch should be within 6mm ~ 12mm. Replace ‘Too tight’ bags, as well as ‘Too loose’ bags
Long Pulse Frequency
Adjust OFF Time by observing Bag Filter DP and set. Reduce OFF Time by 5seconds interval and watch till DP stabilize
Pulse ON Time
Pulse ON time should Typically in the range of 80~100ms. Some Fine dust application, it may require higher ON time, but that should be verified first
PROBLEM
POSSIBLE CAUSE
SOLUTION
High DP Sequential Controller Problem
Any malfunction can cause irregular pulsing, causing raise in DP across BF. Repair/replace card(s)
RAV Leakage
High Dust Load
If actual value is higher than design, check everything and then increase pulse frequency till 10sec interval time.
Else, advice customer to go for pre-filter
Failure of solenoid valve diaphragm
PROBLEM POSSIBLE CAUSE
SOLUTION
Low DP Bad Gauge Check gauge by blowing into it. If needle does not move replace gauge
Leaking / choked gauge pipe
Repair leaking gauge pipe
Holes in Bags Replace worn bags
Low System air volume
Check duct systems for deposits & closed dampers – It causes work area problem for dedusting system
Wrong Bag installation
Look for dust on clean air plenum & blank /dummy the defective bags
PROBLEM POSSIBLE CAUSE
SOLUTION
Emission Holes in bags, cut in snapbands
Replace damaged bags
Precoating / seeding not done for new bags
Carryout proper precoat/ seeding. If not possible, wait for sometime till the process stabilizes after start-up
Wrongly installed dummies
Check all dummies and ensure tight fit, else replace them
Chemical attack
Check whether bags are being torn just by hand pressure. If so, chemical attack is confirmed
PROBLEM POSSIBLE CAUSE
SOLUTION
Poor Bag Life
Overcleaning Increase pulse frequency or OFF time duration
Abrasion Poor inlet design causing high inlet velocity and elbows at inlet can cause accelerated abrasion of bags –
Bent / corroded Cages
Replace bent / corroded cages
High Air Volumes
High A/C ratio shortens bag life.
PROBLEM POSSIBLE CAUSE
SOLUTION
Poor Bag Life
Moisture in Comp air
Moisture in compressed air might cause acid mist in some application and weaken bags. Moisture also shrink some fabric materials. Take corrective action to control moisture
Thermal Shrinkage
Some Fabrics like PPS (Ryton) is having thermal shrinkage. Over exposure of high temperature might cause such shrinkage. Setting of temperature alarm is important
PROBLEM POSSIBLE CAUSE
SOLUTION
Hopper Plugging
Cleaning malfunction
Check pulsing system as a whole and take corrective action
Dust disposal system – malfunction
Inform customer about mal functioning about RAV/Screw Conveyors/ chain conveyors
Wrong design of Dust disposal system
Establish thru’ data collection