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“How to build Low Cost High
Efficiency Filters- Recent
Industrial Trends”
Ravindra Phadke
Low cost High Efficiency Filters
Project execution Technology
 Planning
 Basic and detail filter design
 Engineering plant
components
 Electrical design
 Steel construction
 Procurement
 Manufacturing
 QA, Supervision
• Technical documentation
• R&D department
• Technical laboratories
with modern
measurement equipment
• Filter pilot plants
• FEM calculations
(inhouse)
• CFD calculations
(inhouse)
• Prototype construction
and workshop
 Erection
 Commissioning
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 Project management
Intensiv-Filter at a glance
Our mission statement is:
Environmentally compatible customer
solutions for more profitability.
Our filtering installations protect the
environment:
•Better and safer conditions in emission
protection
•Economical and energy-efficient filtering
technology for the benefit of our customers
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•Protection of the resources in product
recovery
Business areas
Cement, lime, gypsum – Example dry cement process
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– Beispiel Zementprozess
Business areas
Cement, lime, gypsum – typical design data
PJM
PJM
IF JCC / IF JC
IF TC
PJM
PJM
unit
Kiln - / raw mill
Alkali bypass
Coal mill
Tubular
cooler
Clinker
cooler
Cement mill
Gas volume
m³/h
< 1,200,000
< 800,000
< 450,000
Gas
temperature
°C
85-110
compound
< 250 direct
< 250
80 - 110
250 – 350
120 - 180
80 - 110
CaCO3, CaO
CaCO3, CaO,
Alkali
coal
Clinker
clinker
cement, slag
g/m³
< 550
< 25
< 250
< 250
10 - 30
< 350
mg/m³
(n.c. dry)
< 10
< 10
< 10
< 10
< 10
< 10
online / offline
offline
online
online
online
online
PTFE - PI
/ GL – PTFE
PEA / PAN
n.a.
PE / NX / PI
PE / PEA
Typical design
data
Type of dust
Raw gas dust
content
Clean gas dust
content
Cleaning
Filtermedia
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< 1,600,000 < 800,000
< 300,000
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Filter type
Low cost High Efficiency Filters
Prallblech
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Jet-pulse air cleaner (online operation mode)
Schematic illustration of the Intensiv-Filter basic design
Low cost High Efficiency Filters
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The patented Intensiv-Filter Coanda Injector
Low cost High Efficiency Filters
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The Intensiv-Filter Coanda Injector – Manufacturing precision is a must
Low cost High Efficiency Filters
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Comparison of different injector systems
Low cost High Efficiency Filters
Analysis of the impulse measurement
pressur
ep
pmax
pD
pD
0
pmax [Pa]:
t2
Maximum bag cleaning pressure
t1
dp/dt [Pa/s]:
time
t
Slope of the bag cleaning pressure curve
(between t1 and t (pmax))
pD [Pa·s]:
(Surface integral below the positive part of the bag pressure curve)
t
p
D


t
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p
( t )
 dt
1
10
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Pressure impulse (F. Löffler: Staubabscheiden)
Low cost High Efficiency Filters
The Intensiv-Filter injector technology
Advantages of improved injector systems
Less depositions per unit area of the filter
cake due to more efficient cleaning
→ Reduced average differential pressure of
the deposited filter cake
Reduction of the required air tank pressure
Less mechanical stress of filter bags
→ Reduced emissions
→ Extended service interval
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→ Reduced compressed air consumption
Low cost High Efficiency Filters
Jet pulse filter (offline operation mode) – Intensiv-Filter design
Sectional design with disruption of the raw gas flow during cleaning
(offline operation mode). Available at Intensiv-Filter since 1991.
The modular Intensiv-Filter ProJet mega® filter line (2009)
Semi-offline mode:
Clean gas shut-off
valves
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Offline mode:
Raw and clean gas
shut-off valves
Low cost High Efficiency Filters
Jet pulse filter (offline operation mode) – Intensiv-Filter design
Advantages
Less cake depositions by more efficient cleaning
→ Reduction pFC
Reduction of the necessary tank pressure for cleaning
→ Reduces demand of pressurized air
Less mechanical stress of the filter bags
→ Reduction of the emissions
Reduced pressure loss of the filter housing due to
flow optimization measures of filter components
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→ Extension of the service interval
Low cost High Efficiency Filters
The Intensiv-Filter jet-pulse control technology
JetBus Controller® C41
1 Cleaning system switched on
2 Increase of the cleaning
pressure
(0,05 MPa) and start of the
measuring time
4 Cleaning system switched off
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3 Reduction of the cleaning
pressure (0,05 MPa) and start
of measuring time
Low cost High Efficiency Filters
The Intensiv-Filter jet-pulse control technology
Reduction of the necessary tank:
pressure for cleaning to reach the
demanded operation condition on a
necessary minimum capacity
→ Reduced demand of pressurized
air
→ Extension service period
→ Reduced sound emissions
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→ Reduced emissions
Low cost High Efficiency Filters
The Intensiv-Filter jet-pulse bag filter generation with
enhanced energy efficiency (offline operation mode)
1. Injector technology
2. Design measures
•
Fast switching membrane valves
•
Double-stage Coanda Injector or
ideal nozzle with inlet nozzle
Sectional filter design and offline operation mode
3. Cleaning control system •
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Fully variable and optimized cleaning control
parameters by the Intensiv-Filter JetBus
Controller®
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Flow-optimized filter components
Low cost High Efficiency Filters
Energy flow diagram of a jet-pulse bag filter (online)
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%
Low cost High Efficiency Filters
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Operation costs of a jet-pulse bag filter (online)
Low cost High Efficiency Filters
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Operating costs of the Intensiv-Filter jet-pulse bag filter
with enhanced energy efficiency (offline operation mode)
Long bag technology up to 12 m
Cleaning efficiency of very long bags
Permeability of loaded filter media
Air permeability [l/dm²/min] @
200 Pa according to DIN 53887
1000
2
800
2,5
600
3,3
400
5
200
10
• The differential pressure in the field (over the bag, before cleaning) has
typical values between 200 and 1000 Pa.
• For the tests for long bag technology a filter bag with air permeability of
about 5 l/dm2/min has been selected.
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Pressure drop of filter bags
and cakes [Pa] @ air to cloth
ratio of 1 [m/min]
The modular Intensiv-Filter ProJet mega® filter line
PJM modular design – complete filter + supporting structure
Complete
filter
Supporting
structure
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Creating various
filter sizes based
on a strictly limited
amount of single
parts and basis
modules
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IF-PJM 120/04 - 4500
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The modular Intensiv-Filter ProJet mega® filter line
The modular Intensiv-Filter ProJet mega® filter line
PJM - filter properties and advantages
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 Cleaning system is easily
accessible via large top doors
 High-value components such as
valve blocks and control
systems are protected by metal
cover sheets
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Automatic off-line operation
No re – filtration of already
separated dust particles
Low pressure cleaning
No „down time“ required for
maintenance
The modular Intensiv-Filter ProJet mega® filter line
 Highly reliable and flow optimized clean and raw gas dampers
with pneumatic drives
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PJM - filter properties and advantages – clean and raw
gas flaps
The modular Intensiv-Filter ProJet mega® filter line
 Modular system is
prepared for filterbags up
to 12 m length.
 Minimal space required for
installation
 Optimised modules for
transport
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Completely standardized
Highest precision „Made by
Intensiv-Filter“
FEM and CFD optimized design of
the filter components
Reduction of operating costs
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PJM - filter properties and advantages
Filter design optimization by CFD
Cement process filter (2009), 1.225.000 m3 / h a.c
ProJet mega® 136/36 - 8000 - D
Raw gas flow duct – initial situation
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Raw gas flow duct – optimized
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Example I:
Filter design optimization by CFD
Geometry of the raw gas inlet of a ProJet mega® double-row filter
Baffle plate
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Hopper wall
Filter design optimization by CFD
Filter bags
Example I: ProJet mega® 136/36 - 8000 - D
The references plane
is between the wall
and the filter bags
> 10
[m/s]
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The references plane
is between the baffle
plate and the filter
bags
Baffle pla
Baffle plate
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0
Filter bags
5
The references plane
is in the cross
section of the filter
bags
Filter
bags
Filter design optimization by CFD
Example II: ESP conversion, cement (2009), 750.000 m3 / h a.c.
Raw gas inlet flow distribution – initial situation
> 30
12,5
15
0
0
[m/s]
velocity profile
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[m/s]
velocity profile
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> 25
plane of symmetry
Detail
Filter design optimization by CFD
Filter design optimization by CFD
Example III: ESP conversion, optimization of the raw gas flow distribution
Recirculation zone,
limited dust transport
to the bags.
Very high flow velocity, direction
of the raw gas to the hopper
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Optimized inlet
geometry
Crossflow condition
between the bags,
improved dust transport to
the bags
Achievement of a
crossflow inflow mode
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Initial inlet
geometry
ProJet mega® - References in the cement industry
Existing ESP
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Conversion into a ProJet mega®
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Energy efficient jet-pulse baghouse filters (ProJet mega®)
Dyckerhoff, Deuna Zement: kiln, raw mill and bypass off-gas
ProJet mega® - References in the cement industry
Energy efficient jet-pulse baghouse filters (ProJet mega®)
Dyckerhoff, Deuna Zement: kiln, raw mill
and bypass off-gas
Raw gas dust content
Residual dust content
Filter surface area
Injector / cleaning
mode
Cleaning system
Cleaning pressure
Pressure loss
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550.000 m³/h
80 g /m³
< 8 mg/ m³ i. N. tr.
9.300 m²
Ideal semi-offline
nozzle
C41 JetBus Pre pressure
Controller® control
0,2 – 0,3 MPa
< 1.000 Pa
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Gas volume
ProJet mega® - References in the cement industry
Energy efficient jet-pulse baghouse filters (ProJet mega®)
Cement process filter – ProJet mega® 136/36 - 8000 - D
Gas volume
700.000 m³/h n.c.
Temperature
250 °C
Gas volume
1225000 m³/h a. c.
Raw gas dust c.
900 g/m³
Residual dust c.
< 10 mg/m³
Pressure loss
< 1,500 Pa
Cleaning system
JetBus Controller®
Cleaning method
offline
Filter heads
36
Compartments
12
Filterbags
4896
Filter medium
GL750 - PTFE
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Intensiv-Filter type PJM 136/36 - 8000
ProJet mega® - References in the cement industry
Energy efficient jet-pulse baghouse filters (ProJet mega®)
During erection (July 2009)
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After hot commissioning (Nov. 2009)
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Cement process filter:- ProJet mega® PJM 136/36 -8000 -D
Turnkey project
ProTex filtermedia
ProTex filtermedia & Three E technology for bag filter plants
Three E (Enhanced Energy Efficiency)
Energy saving technology by IntensivFilter. The operating paramters were
adjusted with the criterion of a minimal
energy consumption of the filter plant.
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ProTex
New microfibre based filtermedia
generation, developed by Intensiv-Filter.
The average differential pressure of one
filtration cycle is clearly reduced
compared to other bag filter media. This
is achieved by a low residual pressure
loss and a reduced slope of the
differential pressure curve.
ProTex filtermedia
ProTex PES filtermedia – VDI 3926 results
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Pressure drop of ProTex PES vs. other media within one filtration cycle
VDI 3926, v = 120 m3 / (m2 h), cRG = 10 g / m3, p = 0,5 MPa, test dust: Al2O3
ProTex filtermedia
Surface VDI 3926 8 cycles (x 1000)
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Surface VDI 3926 end of test (x 1000)
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Mechanisms of particle deposition in bag filters – ePTFE media
ProTex filtermedia
Surface VDI 3926 8 cycles (x 1000)
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Surface VDI 3926 end of test (x 1000)
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Mechanisms of particle deposition in bag filters – ProTex PES
ProTex filtermedia
ProTex PES filtermedia – VDI 3926 results
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Pressure drop of ProTex PES vs. other media within one filtration cycle
VDI 3926, v = 120 m3 / (m2 h), cRG = 10 g / m3, p = 0,5 MPa, test dust: Cement, 10.000
Blaine
ProTex filtermedia
ProTex m-Aramid filtermedia – VDI 3926 results
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Pressure drop of ProTex m-Aramid vs. other media within one filtration cycle
VDI 3926, v = 120 m3 / (m2 h), cRG = 10 g / m3, p = 0,5 MPa, test dust: Al2O3
ProTex filtermedia
ProTex PI filtermedia – VDI 3926 results
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Pressure drop of ProTex PI vs. other media within one filtration cycle
VDI 3926, v = 120 m3 / (m2 h), cRG = 10 g / m3, p = 0,5 MPa, test dust: Al2O3
ProTex filtermedia
Three E technology with ProTex filtermedia
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Pilot plant trials (10 bags x 4 m) – ProTex, variation of the cycle time
ProTex filtermedia
Three E technology with ProTex filtermedia
p reduction potential
PES needle felt
300 s cycle time
100 s cycle time
100%
25%
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Time
[s]
Emission: ≥ 10 mg/m3
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Emission: 2,5 mg/m3
ProTex filtermedia
Three E technology with ProTex filtermedia-Energy flow diagrams
(online operation mode)
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Three E / ProTex (online)
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Standard conditions (online)
ProTex filtermedia
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The Intensiv-Filter energy saving technologies-operating costs
Thank you very much
for your attention !!
www.intensiv-filter.com