Dedusting Equipment

2
Dedusting Equipment
Bag filter

Electrostatic precipitator
Electrostatic Precipitators
4
The electrode system
Gasflow
Gap width
250400 mm
Max. field
height
12,5 m
Discharge electrodes
5
3 steps for particle collection

Charging precipitation rapping
mA
kV
Migration
velocity
(~6-14 cm/s and
thus ~60% of dust
collected within first 3 m

~84% in 6 m,
~94% in 9 m,
~98% in 12 m)
6
Charging Precipitation - Rapping
Charging you need mA

7
More power input improves the dust emission
Dust
Emission
kW
Potential for improvement
kW ~ kV
avg

x
mA
avg
Curve from test
8
Charging Precipitation - Rapping
Precipitation
you need kV

9
Conditioning with water improves EP efficiency
0
20
40
60
80
100
120
140
160
180
45 47 49 51 53 55 57 59 61
Dew point

[C]
C
l
e
a
n

g
a
s

d
u
s
t

c
o
n
t
e
n
t

r

[
m
g
/
N
m
3
d
r
y
]

design point
Potential for improvement
Example
e.g.: 38 g/Nm
3
more water
(5.4 m
3
/h for a 2000 tpd kiln)
or 63C lower CT exit temp.
10
How to increase Moisture?
Improve conditioning tower efficiency with better water
evaporation and lower the EP inlet temperature
Flow distribution optimization (new CT inlet?)
If Spillback nozzles:
Higher water pressure (new pumps?)
Optimize control loops (new control valve?)
Change to Dual fluid nozzles (only if flow distribution is OK)
If Dual fluid nozzles:
Higher atomizing air throughput (add compressor?)

11
Exponential impact of flow on dust emission
0
10
20
30
40
50
60
70
80
90
100
80 85 90 95 100 105 110 115 120
Relative gas flow Q [%]
C
l
e
a
n

g
a
s

d
u
s
t

c
o
n
t
e
n
t

r

[
m
g
/
N
m
3
d
r
y
]

design point
12% more gas can double dust emissions
Example
12
Local condensation when false air enters
13
Charging Precipitation - Rapping
Rapping

14
The rapping system
15
Without grounding still 3000 Volt in a shut off filter
Remove fuses from controller
Local grounding of T/R-set and EP roof isolator
Local grounding of each electrical field directly at
inspection door
T/R-set



Almost good

Discharge electrodes
16
CO Trip
17
Zero Dust Clouds
If above 6% O
2
, then
explosion risk already at low
CO concentrations
In presence of H
2
or CH
4

from incomplete combustion
the critical CO limit is very
low
H
2
/CO ratio up to 2
[normal: 0.1 1.0]

Explosion limit in any case
around 2.0 vol-% CO
Explosive
Range (200C)
O
2
[vol-%]
C
O

[
v
o
l
-
%
]

0 vol-% H
2

1 vol-% H
2

2 vol-% H
2

3 vol-% H
2

18
An EP is a selective dust collector
Dust that is easy to collect is mainly in the first zones,
while difficult dust is concentrated in the last zones
Difficult dust:
Very fine dust <1mm (having a high specific surface an thus
enriched in absorbed substances e.g. Hg)
Salts (KCl, NaCl, K
2
SO
4
, Na
2
SO
4
)

Dust extraction from last fields to open the outer cycles
is state of the art and highly recommended
Effect can be used for CKD minimization

19
Changed conditions due to AFR can have
an impact on EP performance
More CO peaks due to instable combustion (fuel feed,
net calorific value)
Higher gas flow rate (due to higher heat consumption or
additional water)
More Cl, SO
3
, NH
3
can lower the EP performance:
sublimates bypassing the electrical zones
space charge suppressing the filter current
sticky material builds-up and lowers the field strength
Organic matter can lower the conductivity of dust and
cause effects that look like back corona

Dedusting: Bag Filters
21
Bag Filter Technologies
Reverse Gas Bag Filter
Pulse Jet Bag Filter
High or Low pressure online cleaning
Offline cleaning
Quasi offline cleaning

Hybrid Filters
Serial EP/BF-part
Parallel EP/BF-part
(advanced hybrid from Elex, discontinued)
22
Velocities have main impact on function
1. Filtration
(Formation of dust cake)
2. Cleaning
(Moving cake into hopper)
Critical parameters
air-to-cloth ratio (~1 m/min) can(yon)-velocity (~1 m/s)
= gas flow rate / fabric area = gas flow rate / tubesheet area w/o bag area
Critical for pressure difference Critical for dust accumulation
23
Cleaning Principles of Bag Filters
a, b: manual or mechanical, by rapping or shaking
c: mechanical, by vibrating
d: pneumatic, by reverse air flow (often combined with shaking or vibrating)
e: pneumatic, by compressed air (pulse jet)
Vibrator
24
Reverse Gas Bag Filter: The Vacuum Cleaner
Dust emission <10-30
mg/Nm
3
Typically 12-15 mbar at
air-to-cloth ratio 0.6
m
3
/m
2
min
Large footprint
(n-1) chamber operation
requires many chambers
Dp
Filtration Cleaning
25
Cleaning Cycles Reverse Gas Bag Filter
Purge Air
Valve
Deflation Valve Outlet Valve
Clean Gas
Outlet
Purge Air
Shaking
Mechanism
Tubesheet
Dust Extraction
Purging
Maintenance
Bypass
Valve
Dirty
Flue
Gas Inlet
Filtering
Inlet
Valve
Null Deflation Cleaning
(Shake)
Thimble
Deflation Gas
26
Pulse Jet
Holcim State of the art
Dust emission <10-20 mg/Nm
3
Typically: 10-12 mbar at air-to-
cloth ratio 1.0 m
3
/m
2
min
Small footprint and ideal for
EP conversion
n-chambers nice to have
Clean gas side
compartmentalized is
recommended
Dp
Filtration Cleaning
27
Pulse Jet Cleaning
Compressed Air
Inlet Valve
Tube
sheet
Clean Gas
outlet
Cage
Compressor
or Blower
Outlet Valve
Dust Disposal
Bypass
Valve
Gas Inlet
Filtering Maintenance Pulse-Jet
Cleaning
Filtering
28
Pulse Jet Cleaning Mode: Online
Standard mode (the most
common filter and cleaning type)
No compartmentalization
required
No division walls required and
thus dust transport from
converted EPs can be reused
Can velocity is limiting the filter
geometry

29
Pulse Jet Cleaning Mode: Offline
Unusual mode, but good when
intensive cleaning required (helps only
for a short time, if root cause not
solved)
Can velocity has no impact on cleaning
operation
On-line maintenance possible (seldom
used in kiln filters; safety issue)
Requires new dust transport when
converting EPs
Requires additional inlet dampers
Allows to shut-off compartment with
broken bag
30
Pulse Jet Cleaning Mode: Quasi Offline
No can velocity impact
Low air consumption and low
cleaning pressure
Allows to shut-off compartment
with broken bag
No division walls required and
thus dust transport from
converted EPs can be reused
31
Hybrid Filter
Up to 90% pre-collection of
dust in EP part, thus lower
bag load
Electrically charged residual
dust forms permeable dust
layer resulting in low diff.
pressure
Possibly better for PM2.5
High investment, low
operating costs
Attractive if system fan and
EP parts can be reused
Short CO shut-down of EP
part has no big impact on
operation
Both filter parts need
maintenance (two systems)

33
Needle Felt
Penetration of fine dust
particles into fabric and thus
continuously increasing diff.
pressure during bag life
Cleaning pulse dust peaks
Average: <20 mg/Nm
3
dust
emission
Enhancement with PTFE-
coating possible
Life guarantee between 2 y
and 4 y
34
Woven glass fiber with PTFE Membrane
Slightly higher fabric
resistance during first few
month
Negligible dust penetration
and negligible dust peaks from
cleaning pulses
Average: < 10 mg/Nm
3
Careful installation required
High gas velocities can cause
bag damage more easily
Life guarantee from 4 y to
4 y + 2 y pro rata
35
Bag Life
Differential Pressure over Filter fabric
0
2
4
6
8
10
12
14
16
18
1 10 100 1000 10000 100000
Operating time [hr]
F
a
b
r
i
c

d
i
f
f
e
r
e
n
t
i
a
l

p
r
e
s
s
u
r
e

[
m
b
a
r
]

Early clogging phase Bag midlife phase End
Logarithmic time scale
36
Differential Pressure Reaction
Bag filter reaction to gas flow increase
0
5
10
15
20
25
0 20 40 60 80 100 120 140 160 180 200
Gas flow [% from design]
F
i
l
t
e
r

d
i
f
f
e
r
e
n
t
i
a
l

p
r
e
s
s
u
r
e

[
m
b
a
r
]
0
2
4
6
8
10
C
l
e
a
n
i
n
g

c
y
c
l
e
s

p
e
r

h
o
u
r

[
1
/
h
]
Sufficient dust cake for bag protection
(Distance arrow proportional to cake thickness)
Continuous cleaning,
no bag protection
High can-velocity
hinders dust settling,
filter out of control
Cleaning cycle
Diff. pressure
Design
37
Filter Protection
Chemical attack
Acid or water condensation (bag blinding)
respect dew points (water & acid) and do pre-coating
Mechanical attack
Erosion (holes, rips, high emissions)
respect velocity guidelines
Penetration of finest dust (high Dp, high emissions))
do pre-coating
Thermal attack
respect fabric temperature range
and use emergency cooling
38
Pre-coating
First Filter Start-up:
Do Pre-coating with approx. 200 g/m
2
inert material
(e.g. CaCO
3
, Ca(OH)
2
)
e.g. bag filter with 5000 m
2
bag surface 1 ton raw meal being
injected upstream of the bag filter into the gas duct by a rented
silo truck equipped with an on-board compressor

Short Stop (hours up to max. a few days):
deactivate cleaning cycle before stopping the filter
Long Stop (several days to weeks):
clean down the filter as much as possible and do pre-coating before
restarting the filter

39
Guide Values for Bag Filters (Pulse Jet)
Inlet velocities (central duct): < 10 m/s
Can velocities: < 1.2 m/s
A/C ratios: < 1.0 m/min

Experience with bag length up to 7m
State of art cleaning: <3.5 bar compressed air
Fabric:
PE (140C) or Nomex (250C) for cooler filter
Glass fiber/membrane (260C), P84 (220C) or Ryton (180C) for
kiln/mill filter
PAN (120C) or PEAC siliconized (140C, lower moisture) for coal mill
filters
PAN (120C) or P84 (250C) for cement mill filters

Safety on system fan: +10% flow, +10 mbar pressure
40
Impact of not meeting the guidelines
41
Corrosion Protection
Filter for combustion gas dedusting
Minimum 30C above acid dew point
Gas temperature <150C:
Epoxy resins
Gas temperature >150C:
Flue Guard 225
Avoid using stainless steel in
presence of Cl and not required if
gas temperature always >180C

Filter for air dedusting
Minimum 20C above water dew
point
FlueGuard 225
Prerequisite
Good insulation (100 mm, rain water
tight) when combustion gas
Avoid cold spots/bridges