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Bag filter optimization in Cement Industry
1.
© Confederation of
Indian Industry Bag Filter Optimization
2.
© Confederation of
Indian Industry Concept of Dedusting Dedusting plants may be divided into the following components:- Equipment's to be dedusted Dedusting pipes and valves Filter Fan and motor Insulation
3.
© Confederation of
Indian Industry How to design? Identify the equipment to be dedusted Maximum 6 dedusting points should be connected to one common filter. Calculate the dedusting airflow for each dedusting point and duct Calculate the air flow for the complete dedusting pipe system. Determine the pipe sizes from the air flows
4.
© Confederation of
Indian Industry How to design? Choose the auxiliary equipment- throttle valves, ventilation flaps , filter, fan and insulation-,based on the dedusting air volumes Also check the physical site process parameters such as temperature, RH and barometric pressure.
5.
© Confederation of
Indian Industry Design Guidelines Amount of dust source to vent:-Not more than 8 venting points to be connected to bag filter. Venting Air Volume:-The true required venting air volume that the ventilation system has to handle must be determined first. Venting velocity norms are dependent upon following parameters:- Characteristic of material (Explosive or not explosive dust) Equipment Type(Open or Closed)
6.
© Confederation of
Indian Industry Venting Velocity Norms-Not explosive dust
7.
© Confederation of
Indian Industry Venting Velocity Norms- explosive dust(coal meal)
8.
© Confederation of
Indian Industry Open Equipment's-Bag Filter design Apron conveyor or feeder bucket conveyor Crushers Weigh feeders Belt conveyors
9.
© Confederation of
Indian Industry Closed Equipment's-Bag Filter design Drag Chain Pneumatic transport system silos screw conveyor Air lift Bucket conveyor
10.
© Confederation of
Indian Industry Insulation:-Bag Filter design Criteria In cases where the relative humidity of the dedusting air is so high that condensation may arise as a result of heat emitted by the dedusting pipe The filter bottom hopper should in rare situations be equipped with heating elements.
11.
© Confederation of
Indian Industry Dust Concentration The type dust concentration in the dedusting air from the transport equipment, silos, stores etc. is between 20 and 50 g/ cubic meter of the dedusting air.
12.
© Confederation of
Indian Industry Hood Design Intake Velocity at Hoods is almost equals to1.4 m/s
13.
© Confederation of
Indian Industry Venting hood velocity norms
14.
© Confederation of
Indian Industry Venting Hood designs Venting hood V=1.4 m/s Duct velocity=16-18 m/s
15.
© Confederation of
Indian Industry Pipe design Norms The pipe design after filter, as well as, the exhaust from the fan should be one size larger than the pipe just before filter Clean air velocity range in the pipe 16-18 m/s Velocity with dust laden air: 9-12 m/s(non explosive) 20 m/s(explosive)
16.
© Confederation of
Indian Industry Discharge Chute Height-Design
17.
© Confederation of
Indian Industry Discharge Chute Height-design
18.
© Confederation of
Indian Industry Venting Flow Requirement-Conveyors
19.
© Confederation of
Indian Industry Venting Flow Requirement:-Bucket elevator
20.
© Confederation of
Indian Industry Venting Flow Requirement:-Elevators & Conveyors
21.
© Confederation of
Indian Industry Venting Flow Requirement-Crushers
22.
© Confederation of
Indian Industry Venting Flow Requirement:-Packers
23.
© Confederation of
Indian Industry How to calculate dedusting air requirement in CF silo? CF Silo BF2 Silo extraction BF1 Aeration Blowers-Q3 Q Silo Top Q Silo bottom
24.
© Confederation of
Indian Industry Dedusting Calculations Q silo Top-Dedusting air requirement for top part of CF silo q2 = Displacement Air Displacement air = F / 60 m3/min; F is the feed to silo/tank(m3/hr) q3 = Air For aeration for CF silo q1 = Temperature adjusted amount of air from transport equipment eg:-Pneumatic conveying
25.
© Confederation of
Indian Industry Dedusting Calculations Q silo bottom-Dedusting air requirement for bottom part of CF silo
26.
© Confederation of
Indian Industry Air for Aeration of CF silo
27.
© Confederation of
Indian Industry Clinker Storage Silo The required dedusting air requirement for air tight clinker silo:- Q=DXDX0.055 D= Diameter of Silo in meter The value of Q should satisfy the minimum venting velocity norms as per discussed earlier(9-12 m/s)
28.
© Confederation of
Indian Industry Air Requirement-Crusher section 1 2 3 4 5 H Belt Conveyors-3,4,5 1-Point for Apron 2-Main dedusting
29.
© Confederation of
Indian Industry Air Requirement-Crusher section Point 1:-Air requirement- Connected to Apron Conveyor = 47 m3/min per m apron belt width (As per design guidelines) Point 2 :- Main Branch Point 3,4,5 :- Sub branches Point 2 :- Air requirement as per main branch rule by using the below formulae Q crusher = 11 X cube root of (P X HXH)
30.
© Confederation of
Indian Industry Air Requirement-Crusher section Q crusher = 11 X cube root of (P X HXH) P = capacity of crusher(t/h) H = Distance between crusher shaft & belt conveyor(m) H approx. = 3.6 -4.0 m Point 3,4,5 - Air requirement as per rubber belt conveyor designs Total = Q1+Q2+Q3+Q4+Q5
31.
© Confederation of
Indian Industry Calculation of dust concentration before filter:- S = Crusher Output(t/hr) X 10^6 X0.3 g/m3 Total dedusting air(m3/min) X 60X100 Depending upon dust load concentration the filter load is to be decided. Dust Concentration
32.
© Confederation of
Indian Industry Bag Filter Material selection Criteria Filter Type Moisture level Gas Temperature Composition & Chemical properties(gas dust load) Physical characteristic(Abrasiveness) Allow dust load Emission level
33.
© Confederation of
Indian Industry Air to Cloth ratio The air-to-cloth ratio (A/C ratio) is simply a mathematical expression used to measure the amount of filtering cloth area available to filter a given volume of air at a given flow rate. Significance:-Determine the operating limits of the baghouse.
34.
© Confederation of
Indian Industry Characteristic of filter material High air permeability ( low pressure loss) Good mechanical strength Good thermal stability at operational temperature Good dimensional stability at operational temperature
35.
© Confederation of
Indian Industry Selection Criteria
36.
© Confederation of
Indian Industry Bag Filter purging sequence
37.
© Confederation of
Indian Industry Troubleshooting points Operation Problems Possible Reason Countermeasures High pressure drop across filter Ineffective Cleaning cycle & malfunction Modify cleaning cycle(check overall cycle time),check compressed air pressure, solenoid valves working. Wetting of bags Due to gas dew point; moisture in compressed air High air cloth ratio High volume of ventilated gas.
38.
© Confederation of
Indian Industry Operation Problems Possible Reason Countermeasures Low pressure drop across filter Venting lines are plugged or jammed Avoid the venting line jamming problem by maintaining sufficient venting velocity & gas temp above dew for avoiding moisture. Ineffective Utilization of capacity Add more venting lines to increase the dust load on filter Bag permeability increase Bag inspection Over cleaning of bags Modify cycle time. Troubleshooting points
39.
© Confederation of
Indian Industry Latest developments: Star Bag Filter Technology
40.
© Confederation of
Indian Industry What is an extended surface filter? Round Extended Surface filter bag with more than 2.0 x the surface area of a standard bag, using standard non-woven filter media Star bag Tm
41.
© Confederation of
Indian Industry Working Principle Extended surface filter technology (Star Bags) was originally developed to provide an alternative to capital equipment upgrades in dust collectors whose design was insufficient to meet increasing capacity requirements. It is designed to offer twice the filter surface area of traditional cylindrical filter bags. Filter cake porosity increases and cake specific resistance decreases with decreasing superficial face velocity.
42.
© Confederation of
Indian Industry Working Principle A broader distribution of dust cake over a greater filtration area provides dramatically reduced air and dust velocity at the face of the filter, yielding lower particulate emissions and a significant reduction in pulse frequency. The lower face velocity also alters the morphology of the filter cake, resulting in less resistance to air flow and greatly improved dust cake release
43.
© Confederation of
Indian Industry Filtration Principles Initial filtration relies solely on filter media, however most filtration is done by both the media and the filter cake. Pulse cleaning is triggered by a timer or differential pressure Particulate emissions spike with each cleaning pulse Blinding occurs when particles penetrate the filter surface Media strength loss occurs by flex fatigue around cage wires
44.
© Confederation of
Indian Industry Filtration Principles
45.
© Confederation of
Indian Industry Comparison between extended surface filter technologies Pleated Cartridges •Low Dust Loads •Temperature Limitations •Limited Length •Difficult to clean •Up to 600% filter area increase. •Integral Core Star Bags •High Dust Loads •No Limitations of Temperature •No Length Limitation •Uniform Cake, easy to clean •Up to 100% filter area increase •Re-usable cage
46.
© Confederation of
Indian Industry Concept of Baghouse Design Velocity of dust/gas greatly affects filtration efficiency High velocity compacts filter cake, drives dust into filter mA well designed baghouse balances capital cost with adequate operation For best operation… −ATC ≤ 1.0 m3/m2/min (dust/fabric dependent) −Differential Pressure 1.0 - 1.5 kPa −Moisture should be minimized −Then use “On-demand” pulse cleaning
47.
© Confederation of
Indian Industry Concept of Baghouse Design
48.
© Confederation of
Indian Industry Star bag filter -History The Star Bag, first developed by SOLAFT, has delivered significant operational improvements for our customers in cement worldwide with greater surface area within the same footprint
49.
© Confederation of
Indian Industry Star bag Filter –Benefits & features Benefits Lower emissions Reduced fan energy consumption Reduced Compressed Air usage Reduced mechanical failure Longer bag life Features Pleated bag construction Upto 2 times filtration area Lowers differential pressure Reduce pulse frequency
50.
© Confederation of
Indian Industry CASE STUDIES-Star Bag Filter Location USA Application Cement mill Fabric type Polyester Star length 2.13 Standard bag length 3.05 outcomes Reduced DP & Bag filter life increased from 2 to 4 years
51.
© Confederation of
Indian Industry CASE STUDIES-Star Bag Filter Location Mexico Application Raw mill Fabric type Polyester Star length 1.83 Standard bag length 3.05 outcomes Reduced DP from 9-14” to 4” Flow increased from 33,00cfm to 40,970cfm Bag life increased from 12 months to 4 yrs.
52.
© Confederation of
Indian Industry Case Studies
53.
© Confederation of
Indian Industry Clinker Bag filter-DBC -41mmwg V1-18 m/s Power-22 kW B/F DB1 DB2 Yard -51mmwg -48mmwg -3mmwg -61mmwg -94mmwg Damper-40% -540mmwg -3mmwg V1-22 m/s V2-22 m/s Belt Conveyor Belt Conveyor
54.
© Confederation of
Indian Industry Clinker Bag filter -DBC Observations No of main branches - 3 No of sub branches - 2 Header Pressure = 4.8 kg/cm2 Static Pressure Below RAL = -3 mmwg Pressure Drop Across Bag filter = 10 mmwg Fan Flow = 13702 m3/hr Velocity at main branches = 22m/sec Fan efficiency = 97% Pressure Drop Across Damper = 431 mmwg Fan Power = 22 kW
55.
© Confederation of
Indian Industry Present Challenges Dust emissions from belt conveyor High power consumption of Fan Uneven venting velocity Low DP across Bag filter(10mmwg) Un-utilization bag Filter Capacity Clinker Bag filter -DBC
56.
© Confederation of
Indian Industry Clinker Bag filter -DBC Recommendation Dust emissions from belt conveyor Install additional venting line in tail ends of belt conveyor . Recommended Ventilation Volume in tail end 3000m3/hr in tail end Velocity in venting line-10m/sec High power consumption of Fan Remove damper & replace with VFD. Saving Potential :-18 kW
57.
© Confederation of
Indian Industry Benefits:-After implementation After adding additional venting lines the differential pressure across bag filter has been increased from 10 mmwg to 80 mmwg. No dust emission because bag filter is effectively utilized with full capacity. Beauty of the project-Nil investment(in house) Annual Saving - Rs 6.02 Lakhs Investment - Rs 1.50 Lakhs Simple Pay back - 3 months
58.
© Confederation of
Indian Industry Bag filter :-Additive Feeding B/F -16mmwg V2-12 m/s Belt Conveyor1 -34mmwg -1mmwg -68mmwg -72mmwg Damper-50% -371mmwg +4mmwg V’-15 m/s Power-8.2 kW -33mmwg BeltConveyor2 V1-13 m/s
59.
© Confederation of
Indian Industry Bag filter:-Additive Feeding Observations No Of Sub branches-2 No of Main branches-1 Velocity at Sub branch1-13m/s Velocity at Sub branch2-12m/s Fan flow -6501m3/hr Fan Efficiency-90% Pressure drop across damper-299 mmwg Fan Power-8.2 kW
60.
© Confederation of
Indian Industry Bag filter:-Additive Feeding Present Challenges High power consumption of Fan Uneven venting velocity
61.
© Confederation of
Indian Industry Bag filter :-Additive Feeding Recommendation Optimize fan flow as per standard velocity Velocity in venting line-10m/sec High power consumption of Fan-Remove damper and replace with VFD. Saving potential-6.54 kW Annual Saving - Rs 2.1 Lakhs Investment - Rs 0.55 Lakhs Simple Pay back - 3 months
62.
© Confederation of
Indian Industry Bag filter :-Fly Ash Silo Bin B/F B/E discharge -145mmwg -31mmwg -36 mmwg -166mmwg -161mmwg Damper-NW -460mmwg +2mmwg V’-4m/s Power-7.6 kw -145mmwg weigh bin Air Slide Bin Airslide -136mmwg -136mmwg
63.
© Confederation of
Indian Industry Bag filter /Fly Ash Silo Bin Observations No of main branches-1 No of sub branches-4 Header Pressure-3.8 kg/cm2 Static Pressure Below RAL = -36 mmwg Pressure Drop Across Bag filter = 22 mmwg Fan Flow = 1716 m3/hr Velocity at Fan duct = 4m/s Fan efficiency = 31% Pressure Drop Across Damper = 299 mmwg Fan Power = 7.6 kW
64.
© Confederation of
Indian Industry Bag filter:-Fly Ash Silo Bin Present Challenges Clean air velocity in duct is very low (4 m/s) which should be around 16-18 m/s. Fan flow is not adequate for de-dusting air requirement. Pressure drop across damper is 299 mmwg that led energy losses of 4.9 kW
65.
© Confederation of
Indian Industry Present Challenges Compressed air pressure is maintained 3.8 kg/cm2, which is less than recommended. Physically damper is not working at site. Pressure below rotary air lock is -36 mmwg, which is greater than -6 mmwg that indicates RAL is not working properly and possibility of ingress air has been increased
66.
© Confederation of
Indian Industry Bag filter :-Fly Ash Silo Bin Recommendation Maintain the fan flow(8000m3/hr) As per recommended velocity(9-12m/s) in main branch Remove damper and replace with VFD if pressure drop is still high by increasing flow. Saving potential : 4.9 kW Replace existing RAL with new one to reduce false air tendency across filter
67.
© Confederation of
Indian Industry Benefits Annual Saving - Rs 1.59 Lakhs Investment - Rs 0.55 Lakhs Simple Pay back - 4 months
68.
© Confederation of
Indian Industry Bag Filter :-Cement mill B/F Belt Conveyor1 -1mmwg -90mmwg -100mmwg Damper-50% -220mmwg +3mmwg Power-25.2 kW V2- 10.4m/s V- 10.5m/s -32mmwg V- 20 m/s V- 5.4m/s -47mmwg Belt Conveyor2 Belt Conveyor3 Belt Conveyor4 V2- 7.5m/s
69.
© Confederation of
Indian Industry Bag Filter – Cement Mill Observations No of main branches - 4 No of sub branches - 3 Header Pressure - 5.0 kg/cm2 Static Pressure Below RAL = -1 mmwg Pressure Drop Across Bag filter = 53 mmwg Fan Flow = 28821 m3/hr Velocity at main branches = 8.50m/sec Fan efficiency = 73.30% Pressure Drop Across Damper = 120 mmwg Fan Power = 25.2 kW
70.
© Confederation of
Indian Industry Bag Filter:-Cement mill Present Challenges It found that venting velocity was uneven in main branch it should be in the range of 9-12m/s in all branches. Velocity in sub-branches are also uneven that may affect the bag filter efficiency. Pressure drop across damper is 120 mmwg that led the energy loss of 14.4 kW
71.
© Confederation of
Indian Industry Bag Filter :-Cement mill Recommendation Fan flow should be maintained by optimizing the velocity at main branches . Maintain uniform velocity by checking all the ventilation lines whether it is working or jammed. Remove damper and replace with VFD. Saving potential is 14.4 kW
72.
© Confederation of
Indian Industry Benefits Annual Saving - Rs 4.7 Lakhs Investment - Rs 1.50 Lakhs Simple Pay back - 4 months
73.
© Confederation of
Indian Industry Crusher Bag Filter B/F -23mmwg -184mmwg -188mmwg Damper-100% -191mmwg -26mmwg Power-15 kW V2- 7.3m/s V1- 9.6m/s -10mmwg V- 10.5m/s -109mmwg V3- 12.3m/s -12mmwg Crusher discharge Belt conveyor Belt conveyor
74.
© Confederation of
Indian Industry Crusher Bag filter Observations No of main branches - 3 No of sub branches - 2 Header Pressure - 6.4 kg/cm2 Static Pressure Below RAL = -1 mmwg Pressure Drop Across Bag filter = 79 mmwg Fan Flow = 27915 m3/hr Velocity at main branches = 8.50 m/sec Fan efficiency = 93.30% Fan Power = 15 kW
75.
© Confederation of
Indian Industry Crusher Bag Filter Present Challenges It found that crusher bag-filter was running almost 100 % flow to maintain the venting velocity at main branch. Pressure drop across filter is 79 mmwg that shows additional venting lines could be add in main branches to improve nuisance condition there. Compressed air pressure is slightly higher side
76.
© Confederation of
Indian Industry Crusher Bag Filter Recommendation Add the additional venting lines to utilize the capacity of bag-filter upto 100%. Slightly reduce the compressed air pressure and maintain in the range of 5-5.5 kg/cm2 to avoid the energy losses.
77.
© Confederation of
Indian Industry Roto Packer1-Bag filter B/F -57 mmwg -171mmwg -381 mmwg Damper-50% +2 mmwg Power- 30 kW Packer1 V-12 m/s
78.
© Confederation of
Indian Industry Roto Packer1:-Bag filter Observations No of branches - 1 Header Pressure - 6.2 kg/cm2 Pressure Drop Across Bag filter = 114 mmwg Fan Flow = 13104 m3/hr Velocity at main branch = 12 m/sec Pressure drop across damper = 210 mmwg at 50% damper. Fanfficiency = 50 % Fan Power = 30 kW
79.
© Confederation of
Indian Industry Roto Packer1 Present Challenges Pressure drop across damper is higher side 210 mmwg. Compressed air pressure is maintained 6.2 kg/cm2 that may result energy losses.
80.
© Confederation of
Indian Industry Roto Packer1:-Bag filter Recommendation Header pressure should be maintained in the range of 5-5.5 kg/cm2 to avoid energy losses. Remove damper and replace with VFD. Saving Potential- 16.45 kW
81.
© Confederation of
Indian Industry Roto Packer1:-Bag filter Annual Saving - Rs 5.33 Lakhs Investment - Rs 1.80 Lakhs Simple Pay back - 4 months
82.
© Confederation of
Indian Industry Cement Silo –Bag filter -40 mmwg B/F -181 mmwg -560 mmwg -19 mmwg Power-28.7 kW Cement Silo4 Cement Silo3 Screw Conveyor Damper-60% 18 m/s
83.
© Confederation of
Indian Industry Cement Silo –Bag filter Observations No of branches - 3 Header Pressure - 6.2 kg/cm2 Pressure Drop Across Bag filter = 131 mmwg Fan Flow = 14234 m3/hr Velocity at fan inlet = 18 m/sec Pressure drop across damper = 379 mmwg at 60% damper. Fan efficiency = 79 % Fan Power = 28.7 kW
84.
© Confederation of
Indian Industry Cement Silo –Bag filter Present Challenges Pressure drop across damper is higher side:- 379 mmwg. Compressed air pressure is maintained 6.2 kg/cm2 that may result energy losses.
85.
© Confederation of
Indian Industry Cement Silo –Bag Filter Recommendation Header pressure should be maintained in the range of 5-5.5 kg/cm2 to avoid energy losses. Remove damper and replace with VFD. Saving Potential- 20 kW
86.
© Confederation of
Indian Industry Cement Silo –Bag Filter Annual Saving - Rs 5.33 Lakhs Investment - Rs 1.80 Lakhs Simple Pay back - 4 months
87.
© Confederation of
Indian Industry Key Encon points Installation of additional venting lines to the bag filters. Optimization of branch velocity in the range of 9-12 m/s. Replacement of inefficient RAL with new one to reduce false air across bag filter. Removal of damper and then replace with VFD.
88.
© Confederation of
Indian Industry Key Encon points Maintain the compressed air pressure in the range of 5-5.5 kg/cm2 Install baffle plate at inside discharge chute to increase the collection efficiency Install DP transmitter for bag filter and interlock air-purging operation with the bag filter DP. Maintain bag filter DP in the range of 90 to 120 mmwg
89.
© Confederation of
Indian Industry http://energy.greenbusinesscentre.com/ THANK YOU ! For any queries related to energy efficiency log in @ For latest updates on energy efficiency please visit http://energy.greenbusinesscentre.com/sup/ @CII_GBC cii--godrej-gbc For further details Contact:- Nitin Asnani Associate Counsellor nitin.asnani@cii.in/8963965157
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