Bag Filters

Cyclone cum Bag Filters

For

Flue Gas Particulate Pollution Control De dusting systems

Product recovery in Dryers/Coolers

ECOKLEEN POLLUTION CONTROL PVT. LTD. Pushpa Heights, 1st Floor, Bibwewadi Corner, Pune – 411 037.India

Tel: +91-20-64005334, 65240946 ,24212390 Fax: +91-20-24210128 E-mail: mktg@ecokleen.com Web: www.ecokleen.com

About Transparent Group of Companies: The Group has been promoted in 1986 and has been active in the area of engineering and technology, the head offices being in Pune, India. The group has grown by leaps and bounds with several innovative and path breaking technological solutions in India as well as countries like Germany, Saudi Arabia, Indonesia, Malaysia, China, Egypt etc. The Group focuses on several key engineering sectors, undertaking contracts from concept to commissioning of various equipment for Waste Heat Recovery, AARP, Boilers and Heaters, Flash Dryers, Spray Dryers, Multi Stage Evaporation Plants, Heat Exchangers, Hot Air Generators, Emission and Pollution Control and Flue Gas Desulphurization Plants. Sound Abatement and Noise Pollution control systems. The Transparent Group of Companies has the following companies with in the GROUP. 1. Transparent Energy Systems Pvt Ltd www.tespl.com 2. Transparent Technologies Pvt Ltd www.ttplpune.com 3. Ecokleen Pollution Control Pvt Ltd www.ecokleen.com 4. Decimin Control Systems Pvt Ltd www.decimin.com The group employs skilled and experienced engineering staff and has more than 200 Engineers in various disciplines. The group has three manufacturing locations, well equipped with plant and machinery to supply equipment of high sophistication and performance. Group Companies have technology tie ups for some of the products with the best names in the relevant products such as Mattes Engineering GmbH of Germany for Ammonia Absorption Refrigeration Plants and IAC BOET STOPSON of France for Acoustic Canopies for DG Sets, Compressors, Machinery, Noise Silencers for Engines, Blowers, Compressors, Valve exhaust, Acoustic Louvers & Baffles and with Lamont – Kassel GmbH and Co KG of Germany for High pressure Steam Boilers , Hot Water Boilers and Thermic Fluid Heaters in India and globally.

Conventional (Counter current) Vs Ecokleen (Co current) Bag Filters Recovery of particulate matter from exhaust gas is vital for any industry and in many instances a bag filter is deployed to separate fine particles from air/gas .to recover, finished product and /or to limit the particulate pollution of flue gases emitting from the plant.

A conventional bag filter in most of the cases employ the Counter Current principle for filtration. In a Counter current principle of filtration, as conventionally carried out, due to the bottom entry of the dirty flue gas, the already filtered particles which are dropping down due to the pulsing action, again partly get entrained in the incoming flue gas, there by increasing the dust loads for filtration and limit the efficiency of filtration due to the limiting ‘ Can velocity’ As a result of this several problems are encountered leading to unstable operation and Unplanned shutdowns as a result of the following causes. F Frequent bag chocking - hence high plant shut down time. F Higher pressure drops across bag filter – hence higher

blower electrical power. F Bag chocking, resulting in reduced flow & therefore

reduction in plant capacity.

Counter Current (Conventional) Vs Co current (Ecokleen) Filtration

Conventional - Counter current Ecokleen – Co current

The above illustration furnishes the comparison between the two principles of filtration and It can be well imagined that, for any given filtration area provided, the Counter current filter is bound to suffer for more dust loads due to the entrainment of the already filtered particles, hence leading to the re entrainment and chocking problems.

Ecokleen have overcome these short falls by unique design of gas/powder co current flow pattern and using advanced modelling procedure for design of bag filter » Ecokleen bag filters are co-current gas flow (Indian patent

awarded). Here in the air/gas and dust to be separated flows in downward direction in bag house chamber as depicted in the illustration above

» The co-current flow avoids entrainment of dust in air/gas

avoiding bag chocking, higher-pressure drops leading to reduced plant capacity, unstable operation and shutdowns.

It has been thus proved that due to this COCURRENT filtration principle Ecokleen Bag filters works with lower pressure drops leading to a stable operation. It has been observed from several field operations that the pressure drop never exceeds 100 mm WC.

Ecokleen Cyclone cum Bag Filter » Conventionally cyclone is installed as primary separating device

followed by bag filter as the final separation devise. » Such an arrangement i.e. a cyclone followed by bag filter has

following disadvantages F Pressure drop is more (cyclone plus bag filter) thus fan

power required is more thus, energy bills are more. F Space required is more – increasing civil and structural cost. F Two point collection system – needs two separate packaging

areas (more man power), or additional equipments (screw conveyor) to make it single point collection (more energy bill).

Realising the above, Ecokleen has developed cyclone cum bag filter, which uses the patented Co current filtration technology clubbed with the cyclone design.

Such an arrangement as compared to the two stage particulate separation, has lower pressure drop, requires less space, and has single point collection.

Working Principle of Ecokleen Bag Filter and Cyclone cum Bag Filter

Working principle of Ecokleen co current design Bag filters And Cyclone cum bag filter.

The dust-laden air enters in to the cyclone chamber,

1. The powder separates due to cyclonic action and then enters into the bag filter chamber.

2. Air is uniformly distributed avoiding channelling while the powder separated by cyclone slides down from sides.

3. Initially a coat of material forms on the bags. Subsequently, the coat acts as the filtering medium.

4. The dust accumulated on filter elements while the air passes through the filter bags from outside to inside.

5. The accumulated powder dislodged from the bags by reverse pulsejet air intermittently.

6. The dislodged powder falls on bottom cone and it discharges through powder discharge valves.

7. The dust free air is suck by induced draft fan and is exhausted to atmosphere.

8. Knockers provided on conical portion especially for sticky/hygroscopic materials.

Main components of Ecokleen Bag Filter and Cyclone cum Bag Filter 1. Air entry Cyclone chamber and Bag filter housing:

» All the components of the Bag filter-housing casing are designed individually considering the application. Ample safety factors are provided for bursting strength of the casing. Adequate stiffening is provided for mechanical strength.

» Materials of construction are chosen according to the nature of the flue gas, temperature and corrosive behaviour.

» The design of the hoppers is carried out with adequate valley angles depending on the material characteristics.

» Air entry Bustle type construction ensures uniform distribution of air at the entry there by ensuring no chocking.

» A most important feature for maintenance is the ease for bag replacement. Bag removal is carried from f top, hence facilitating maintenance, in dust free atmosphere.

2. Filter bags: • We carefully select filter bag fabric considering temperature,

particulate size, air-to- cloth ratio, and properties of material to be separated and the particulate emission guarantees.

• The Felt media bag minimizes pressure fluctuations giving uniform and high collection efficiency.

• Specially selected Anti-stick coating on bags minimizes bag chocking.

3. Bag cages: • The cage forms the most important support member for

ensuring long life of the Bags. Ecokleen Bag filters invariably have Cages made out of larger diameter bars to make the assembly rigid an often-overlooked aspect by many other manufacturers.

• The pitch between bars kept providing adequate support by cages. This avoids flex line failure between the vertical wires.

• Careful selection of fit between cage and bag avoid premature bag failure.

• If bag is oversized then bags may have internal abrasion along vertical lines causing bag failure.

• Sharp edges on Pan are avoided as they cut / damage the bag where it comes in contact, with the edge of Pan.

4. Cage, Ventury assembly: • Higher thickness ventury mounting plate – uniform pressure is

applied - seals better.

• Ventury are cast –rigidity in clamping reducing leakages.

• Special Silicone gasket ensures Leak-proof joint between ventury and ventury mounting plate.

• Clamps provided to hold the bags on cages and seal for

leakages. Clamps are always made from Stainless Steel to prevent bag damage.

Robust Positive Clamping Assembly of Venturys ensures no slippage of the Assembly and no loosening leading to a stable performance

Assembly of Cage Ventury Die cast and machined ventury And Clamp

4. Pulse Jet system, with Isolation Valves: • Under normal running condition, the process air enters the filter

bags and is exhausted above ventury mounting plate. • The bag filter cleaned on-line by compressed air pulses given

periodically by a timer circuit. The duration of pulse time and its frequency can adjust.

• While on-line cleaning of bags, compressed air pulse injected into the ventury by solenoid valve.

• The bag inflates and dust accumulated on its outer surface gets dislodged and removed. One row of bags cleaned at a time.

Pulse Jet system

5 Shop testing and Assembly:

F Airflow rate, F Pressure drop at no dusting, F Workmanship

Bag Filter casing under Shop Test

Bag Filter with Bleed air arrangement at site

How Ecokleen Bag Filter and Cyclone cum Bag Filter pays for itself? Ecokleen Bag Filter: » The pressure drop across Ecokleen Bag Filter is 100 mm WC while

that of conventional Bag Filter is 150 mm WC. » Thus, Ecokleen reduces the load on fan by 50 mm WC. » Table below gives the power savings for different airflow rates.

Sr. Gas flow rate (m3/hr)

Power saved per hour (kWh)

Power saved per annum (kWh)

Savings per annum (Rs)

1. 1,000 0.21 1,680 6,972/-

2. 5,000 1.05 8,400 34,860/-

3. 10,000 2.10 16,800 69,720/-

4. 15,000 3.15 25,200 1,04,580/-

5. 20,000 4.20 33,600 1,39,440/- Note: » Working hours per year considered is 8000 » Electricity tariff rate considered is 4.15 Rs/kWh Ecokleen Cyclone cum Bag Filter: » The total pressure drop across Ecokleen cyclone cum bag filter

is typically 125 mm WC. » The total pressure drop across conventional cyclone is 100 mm

WC and across bag filter is 150 mm WC – totalling to 250 mm WC. » Thus, Ecokleen reduces the load on fan by 125 mm WC. » Table below gives the power savings for different airflow rates.

Sr. Gas flow rate (m3/hr)

Power saved per hour (kWh)

Power saved per annum (kWh)

Savings per annum (Rs)

6. 1,000 0.52 4,192 17,398/-

7. 5,000 2.60 20,800 86,320/-

8. 10,000 5.20 41,920 1,73,980/-

9. 15,000 7.80 62,400 2,58,960/-

10. 20,000 10.40 83,840 3,47,936/- Note: » Working hours per year considered is 8000 » Electricity tariff rate considered is 4.15 Rs/kWh

Optional Extras: Air bleeding arrangement • A temperature monitored automatic “Air bleeding’’ arrangement

avoids exposure of bags to higher temperatures and ensures longer bag life.

• The temperature of air entering bag house sensed. If the temperature of air increases above set limit, pneumatically actuated damper opens and fresh air sucked in and mixes with process air lowering its temperature. A Manual damper is also provided when automatic damper is under maintenance

Applications of Bag Filters Installed :

Iron Ore Pellet Plant : dedusting systems , Product collection from Rotary Dryer Boiler Flue Gas cleaning Spray Drier and Flash Dryers for Paints and Pigments Flash Dryers for Agrochemicals Metal (Lead) Melting Plants and Pollution control there of.

For Further information contact:

Ecokleen Pollution Control Pvt. Ltd. ’Pushpa Heights’ Ground Floor, Bibvewadi corner, Pune – 411037 , INDIA Tel : +91 20 64005334, 65240946 Fax : 020 24210128 E Mail : mktg@ecokleen.com Web: www.ecokleen.com