Ashaka PulseJet Presentation

Pulse Jet Dust Collector
Bag Filters
Why dust collectors?
Bag Filter Training Ashaka / 16/01/16 - 2
Process Dust Collectors

Air Slide Dust Collectors
Bucket Elevator Dust Collectors
FK Pump feed hopper Dust Collectors
Silo Dust Collectors
Clinker Cooler Dust Collectors
To separate solid particulate matter from a gas

stream in order to maintain environmental
compliance
In most cement manufacturing applications, the
Dust Collector returns solid particulate matter back
to the operation for further processing
......and because DUST is also Money
(, $ or )
Dust Collectors
Expansion chambers
Cyclones
Multi-cyclones
Sand filters
Scrubers
Fabric filters
Cartridge
ESP
Fabric filters
Bag filters: three types according the

cleaning system
1. Shaker
2. Air reverse
3. Pulso jet
Bag filter: shaker cleaning system
Particulate is collected on the inside surface of
the bag. The dust-laden gas enters through the

dirty side (inlet) of the collector and flows up
through the bag.
Tensioning assembly
Clamps
Bag filter: reverse air
Additional
fan create
reverse air flow to
blow the bags and the
cake
is
dislodged.
Compartments need to
be isolated.
Bag filter: pulso jet cleaning system

Blowpipe
Induced
Secondary
Pulse
Tube Sheet
Snap Band
Venturi
Cage
Shockwave
Normal flow
Dust
Bag filter: pulso jet cleaning system
PJBF Components
Dust Collector Intake

Deflector, Diffuser, or
Baffle Assembly
Dirty Air Chamber
Airlock
Filter Bag
Cage
Venturi
Tubesheet
PJBF Components (contd)
Pulse Control System

Compressed Air Supply
Manifold
Solenoid Valve
Diaphragm Valve
Blow Down
Clean Air Chamber
Dust Collector Exhaust
Differential Pressure Indicator
PJBF Components: Cleaning system

The essential parts:
C.A. manifold (14)
Pneumatic valves (13)
Solenoid valves box (8)
Air tube (7 / 19)
The airtight system between
ramps and body filter (detail B)
Air tube (compressed air
distributors) plus nozzles (5 / 6)
PJBF Components: Manifold
C.A. Manifold
PJBF Components
Manifold
+
Pulse valves
+
Expansion joint
Clean air chamber
+
Air pipes
PJBF Components
PJBF Components
Solenoide valve box
PJBF Components: Tube sheet
PJBF Components: Tube sheet
Up
Down
PJBF Components
Bag
Venturi
Cage
PJBF Components
Pulse valves
Solenoide valves
Principle of Operation
System fan creates airflow thru Pulse Jet DC

Dust-laden gas enters thru inlet duct @ velocity x
Initial separation occurs as gas velocity slows due
to increase in volume as it enters dirty air chamber
(gas velocity decrease allows coarse material to fall
out of suspension)
Coarse material separation further enhanced by
inlet baffle/deflection plate that forces gas to make
abrupt change in direction in dirty air chamber
Change in direction forces more coarse material to

fall out of suspension
Inlet baffle also serves to diffuse airflow evenly
throughout DC (ensures even wear on filter media)
Fine material left in suspension carried upward &
deposited on filter bag surface forms a cake on
bag surface
Bags cleaned regularly to maintain airflow done
by blast of compressed air injected thru venturi @
top opening of filter bag
Roles of the venturi:

Increases velocity to enhance shock
wave created by compressed air pulse
Reduces filter bag abrasion by
directing compressed air blast to
center of filter bag
Create secondary induced draft from
clean air chamber helps fill bags with
air & enhances effect of shock wave
dramatically
improves
cleaning
efficiency
Blast of compressed air stops normal flow of gases

in the bag & creates shock wave that travels down
inside of cage & back up
Shock wave removes agglomerated cake from
surface of the bag
Agglomerated material falls as a mass into bottom
of dirty air chamber by gravity
Superfine particles are re-entrained
After passing thru filter media, clean gas stream

exits clean air chamber thru exhaust duct
Material collected in hopper is metered out by
some form of airlock or screw conveyors
Airlock @ material discharge acts as barrier
between flow of solids (material existing DC) &
false air (air trying to enter from hopper discharge
[in leakage])
Bag caking or P
The level of bag caking

is measured by the
filters
differential
pressure P between
the clean air chamber
and
the
dirty
air
chamber.
100 < P <150 mm WC
Bag caking or P
100 < P <150 mm WC
Optimum Cleaning Cycle

What is the importance of an optimum cleaning
cycle configuration?
Maintains rated airflow through the Dust Collector

at all times
Maintains stable dust return to the process
Optimizes the use of expensive compressed air
Ensures longest possible service life of the filter
media
Shortest possible time to recover pressure in manifold

Pulsing system frequency, duration, and sequencing
The
pulsing system is used to control the firing

frequency and duration of the individual diaphragm
solenoid valves
Frequency is configured to maintain a stable DP
ensures a stable airflow through the Collector
The duration is adjusted to ensure optimum use of the
supplied compressed air
Pulsing system frequency, duration, and sequencing
The
pulsing system is used to control the firing

frequency and duration of the individual diaphragm
solenoid valves
Frequency is configured to maintain a stable DP
ensures a stable airflow through the Collector
The duration is adjusted to ensure optimum use of the
supplied compressed air

Frequency
Too
often Premature bag failure & high

energy
consumption
Too infrequent Large drops of material & unstable dust
returned to the process. Also creates instability in airflow
Duration
Too long Waste of compressed air & increases header

pressures regain timing
Too short Shock wave not strong enough to remove filter
cake

Sequencing
Never pulse two adjacent rows of bags one after the

other
Clean bags are the path of least resistance to airflow
through the Dust Collector
Pulsing an adjacent row -material released from one set
of bags, some of which will be deposited directly on the
surface of the adjacent clean row of bags
Pulse every other row as a minimum
Pulse length: 50 ms
10s - 30s between pulses

Shortest possible time to
recover
manifold
pressure
in
Sequence 1,2,3 = Bad
Sequence 1,3,5 = Good
Never 2 adjacent rows

Types of Pulsing Control
Timer Board Systems
Pulsing system runs continuously during operation

Defined frequency & duration
Local Pulse on Demand

System
Timer board cycle starts &

stops based on target
differential pressure
Programmable Logic Controllers (PLCs)
Computer controlled pulsing system capable of ondemand pulsing & greater sequencing flexibility
Compressed air
Dry air
5 < P < 7 bars
Engineering
Ducting system:
Gas speed from 16 m/s to 25 m/s
Filtering velocity:
From 1 m/min to 2 m/min
Also called air/cloth ratio
Velocity can:
V<300 fpm (1,5 m/s)
Filter Media & Fabric Finishes
Conventional Depth Filtration
Relies on primary dust cake forming in cross-section of
filtration media
Secondary dust cake accumulates on outside of filtration
surface
Secondary dust cake removed during cleaning cycle
Over time, primary dust cake gets denser, reducing
permeability
Differential pressure increases steadily over life of filter
media
Membrane Surface Filtration
Surface laminate applied directly to conventional filtration

fibre
Effective pore size much smaller than conventional depth
filtration media
Primary filter cake not required
Smooth surface released filter cake during cleaning cycle
Permeability recovers to almost original levels & no gradual
decrease in permeability over time
Consistently lower differential pressure across filter media,
less abrasion, increased airflow & filter life
Filter Fabrics
Coarse Polyester
Felt:
deep penetration
Typical - polyester or glass

(high temp) felt
Allows particles to migrate
through over time & blind bag

Needs thick precoat, layer
Higher $$$ membranes like

Gore-Tex or teflon (PTFE)
Shallow penetration, lasts

Fine Membrane:
shallow penetration
longer before blinding

precoat not as critical
less pressure drop
Filter Fabrics
Fabric Comparison
Material
Max Op
Temp
Filtration
Abrasion
Cost
Polypropylene
76 C
Good
Excellent
Polyester
134 C
Excellent
Excellent
Acrylic
140 C
Good
Good
$$
Nomex
205 C
Good
Good
$$
Fibreglass
260 C
Fair
Fair
$$$
Fabric Finishes Non-Fibreglass
Singe improves cake release

Glaze/Eggshell provides short-term improvement
for cake release, but may impede airflow
Silicone aids in initial dust cake development &
provides limited water repellency
Flame retardant retards combustibility, not flameproof; some water repellency, may impede airflow
Surface membrane improves fine particulate
capture, filtration efficiency, cake release & airflow
Fabric Finishes - Fibreglass
Silicone, graphite, teflon protects glass yarn from

abrasion, adds lubricity
Acid resistant shields glass yarn from acid attack
Positive Pressure Dust Collector
Uses
fan on dirty side of Dust

Collector to push dust-laden gas
through system
No pressure differential on casing &
sidewalls;
only
atmospheric
pressure
Less expensive than negative
pressure Dust Collector
Significantly more expensive to
operate & maintain than negative
Negative Pressure Dust Collector
Uses fan on clean side of Dust Collector
to pull air through system

Filter streams contain high moisture,
corrosive gases & high concentrations of
abrasive dust
Structure must be re-inforced
Leakage contained inside Dust Collector
& emissions dont reach atmosphere
Wear on fan less than with positive
Bag Break In
Bag conditioning agents used to develop optimum

primary dust cake within cross-section of conventional
depth filtration media
Conditioning or breaking in new DC bags can improve
Collector efficiency thru enhanced cake release & fine
particulate capture efficiency
Conditioning agents typically not required on surface
membrane filtration media due to lower porosity of
material enhancing particulate capture
Bag Break In Procedure
Disable pulse control system or isolate compressed air

supply to manifold to isolate cleaning system
Operate fan at 75% of target airflow
Add conditioner
Start main process line
Operate normally, allow DP to reach 4-5 WC
Enable pulse control system or re-establish
compressed air supply to re-establish cleaning system
Monitor differential pressure until process line has
stabilized at normal
Inspections
Running Inspection
Static Inspection
Inspections: the filter
Inspections: the support
Inspections: Bearing supports
Inspections: conveyors
First level inspection

What
How
Noise (From Diaphragms)
Ear
Dust puffing (Walls)
See
Cleaning sequence
Ear
Drive/Bearings T
Touch
P (Between 4-6 w.c.)
See
V-belts
See, Nose
Fan vibrations
Ear, Touch
Guards
See
Inleaks (Doors, joints,housing, ducts)
First level inspection

What
Stacker emissions
How
See
Check for cladding

Sequencial purging
Ear
Check A/C pressure gauges (5-7 bars)
See
Speed monitor
Dampers position
See
Specific inspection
What
Torn bags
Blocked bags
Diaphragm damaged
Chambers
Bearings
Groken screw & flight
V-belts
Pulley status alignments
Air sluice/Double flap valves
Fan dampers
Fan impeller
9. Troubleshooting
Reduced System Airflow
Safety
Run cleaning mechanism 20 mins, fan off to clean filter

bags
Discharge all material from collection hopper
Shut off, blank & tag compressed air supply & relieve
pressure in header
Lock out electrical power on all rotating equipment
being serviced
Follow confined space entry procedures to the letter
If oxygen-deficient, purge with fresh air; secure or
remove doors; ensure safe working atmosphere
Safety..
Cool internal before entering to avoid high internal

surface temps
Wear properly fitting respirator or dust mask when
working inside
Take extreme care when working inside tripping
hazards:
blow downs
perforated tubesheet
ASHAKA
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Pulse Jet Dust Collector

Pulse Jet Dust Collector

Pulse Jet Dust Collector

Why dust collectors?

Bag Filter Training Ashaka / 16/01/16 - 2

Pulse Jet Dust Collector

Why dust collectors?

Process Dust Collectors

Bag Filter Training Ashaka / 16/01/16 - 3

Pulse Jet Dust Collector

Why dust collectors?

To separate solid particulate matter from a gas

Bag Filter Training Ashaka / 16/01/16 - 4

Pulse Jet Dust Collector

Why dust collectors?

......and because DUST is also Money

Bag Filter Training Ashaka / 16/01/16 - 5

Pulse Jet Dust Collector

Pulse Jet Dust Collector

Bag filters: three types according the

Bag Filter Training Ashaka / 16/01/16 - 7

Pulse Jet Dust Collector

Bag filter: shaker cleaning system

Particulate is collected on the inside surface of

the bag. The dust-laden gas enters through the

Bag Filter Training Ashaka / 16/01/16 - 8

Pulse Jet Dust Collector

Bag filter: reverse air

Bag Filter Training Ashaka / 16/01/16 - 9

Pulse Jet Dust Collector

Bag filter: pulso jet cleaning system

Bag Filter Training Ashaka / 16/01/16 - 10

Pulse Jet Dust Collector

Bag filter: pulso jet cleaning system

Bag Filter Training Ashaka / 16/01/16 - 11

Pulse Jet Dust Collector

Dust Collector Intake

Bag Filter Training Ashaka / 16/01/16 - 12

Pulse Jet Dust Collector

PJBF Components (contd)

Pulse Control System

Bag Filter Training Ashaka / 16/01/16 - 13

Pulse Jet Dust Collector

PJBF Components: Cleaning system

Bag Filter Training Ashaka / 16/01/16 - 14

Pulse Jet Dust Collector

PJBF Components: Manifold

Bag Filter Training Ashaka / 16/01/16 - 15

Pulse Jet Dust Collector

Bag Filter Training Ashaka / 16/01/16 - 16

Pulse Jet Dust Collector

Bag Filter Training Ashaka / 16/01/16 - 17

Pulse Jet Dust Collector

Solenoide valve box

Bag Filter Training Ashaka / 16/01/16 - 18

Pulse Jet Dust Collector

PJBF Components: Tube sheet

Bag Filter Training Ashaka / 16/01/16 - 19

Pulse Jet Dust Collector

PJBF Components: Tube sheet

Bag Filter Training Ashaka / 16/01/16 - 20

Pulse Jet Dust Collector

Bag Filter Training Ashaka / 16/01/16 - 21