ANRAK Aluminium Limited

PULSE JET FABRIC FILTER FOR

ALUMINA CALCINER
(BAG HOUSE)
Types of Air pollution control equipments:

 1.ESP (Electrostatic precipitator)

 2. RABH (Reverse air bag house)

 3. Pulse jet fabric filter

 Comparison between Bag house , ESP & RABH

S.NO Description Bag house ESP RABH

1 Installation cost Low High Moderate

2 Emission control High low High

3 Online maintenance Can be possible Not possible Can be possible

4 Variable efficiency Yes No Yes

5 Space occupancy Less space req More space req More space req

6 Running maintenance cost Moderate Low Low

7 Compressed air consumption High Low Low

8 Power consumption Low High Moderate

9 Efficiency 99.5 % 99 % 99.5 %

1. ESP (Electrostatic precipitator)
 Working principle of ESP:

An electro static precipitator is

device that removes dust
particles from flowing gas using
the force of an induced electro
static attraction
2. RABH (Reverse air bag house)
  Working principle of RABH:
RABH working is similar to that
of Pulse jet filter but the bag
cleaning phase will be carried
out after isolation of chamber .

Cleaning phase
Operating phase
 PURPOSE OF pulse jet filter ……..?

1. TO COLLECT ALUMINA DUST FROM FLUE

GASES

&

2. TO FEED COLLECTED DUST INTO THE SYSTEM

 WHERE IT IS USED ……..?

CALCINER CEMENT KILN

RAW MILL POWER PLANT BOILER

WHERE EVER THERE IS A REQUIREMENT OF

DE-DUSTING THE SYSTEM
 Working principle of Pulse jet Fabric filter
 The pulse jet fabric filter is operated automatically for cleaning
of Raw gas for Particulate .

 It is designed for long period of operation with a minimum

maintenance.

 It is designed for both online & offline cleaning and

maintenance.
 Working
Fresh air intake
P01 2 to 3% of O2
&
Water spray system
0.2 to 0.4 % of CO

 As ID fan createsP02
a negative draft in calciner system the over flow
(Raw gas) of cyclones will moved in to bag house through pre-
heating cyclone 1.
P04
HV03

ID FAN
 Working :

 The Raw gas enters the inlet manifold of the filter through the
inlet connection and from there it is distributed to various
compartments of the filter.

 At the inlet of the compartments the gas path is expanded

through distribution screens then the gas velocity decreases &
a part of dust drops into the bottom hopper
 CHAMBERS

HOPPERS
 INLET DUCT

BAGS BAGS
 Working :

 The gas path is directed to the top part, passes through gas
distribution screen & distribute in a horizontal and downward
pattern.

 Because of the low gas velocity in the compartments another

portion of dust drops out before it reaches the surface of the bags.

 Then the gas is sucked into the filtration compartments and is

cleaned on passage through the filter bags from the outer side and
into the bags, while the dust is deposited on the outer side of the
bags.
 Working :

 The collected dust outside the bags are cleaned by injection of

compressed-air (pulse jet cleaning or purging) down through
the bags in the direction opposite to that of filtration.

 The bags are inflated so that the dust layer releases the bags
and drops into the bottom hopper and is removed by the Dense
phase conveying system.
Venture

Purging
 Working :

 This clean-up operation is carried out sequentially with several

rows of bags being handled simultaneously and is automatically
controlled.

 Depending on number of chambers in operation the type of

purging sequence is selected by DCS

 The cleaned gas passes through the bags/ventures that are

supported by the tube sheet into the top section (the top box)
of the compartment and then to the clean gas manifold from
where it leaves the filter.
 Air manifold

Solenoid valves
 Working :

 Each compartment is provided with inlet and outlet dampers

which are operated pneumatically & dampers make it possible
to isolate the individual compartment for off-line cleaning and
for on-line maintenance.

e.g: For changing of bags can be possible during operation.

 If the temperature of gas is higher than the maximum allowable

temperature for the bags the dampers may also be used to
close the compartments to protect the bags. In emergency
situations, the dampers for one or more compartments can be
open allowing the gas pass through. In this case the bags in
those compartments will be sacrificed.
 What to be checked while operation:

 Inlet temperature of Bag house

 If inlet temperature of bag house exceeds the normal operating

temperature i.e 170 to 180 Co there is a chance of bag catching
fire. So it has to be controlled by water spraying or fresh air intake
in calciner system.
 Port for
leak test

Mono axial
bearings

Bi-axial
bearings

Hopper
heaters
 Arrangement of mono axial & Bi-Axial bearings

MOMO AXIAL BEARING

BI-AXIAL BEARING
Hopper heaters:

They are used for preventing the blockage of material

in hopper because of moisture.

Mono-axial &Bi-axial bearings:

These bearings separate hot & cold zones of

equipment. Thermal expansions of equipment are
taken by these bearings without developing stresses in
structures.

Inlet duct port:

This ports are used for inducing the fluorescent powder

in to the chamber for performing the leak test .
 Conveying the collected dust to the system :

 After achieving the desired quantity of dust in bottom hoppers the

dust will be conveyed back to the system through pneumatic
conveying(Dense phase conveying system).

 The dense phase contains collecting vessels with dome valves which
will operate in sequence & controlled by DCS
 Differential pressure
transmittal

Outlet

Inlet

To the system

TO THE SYSTEM

Air receiver
 Bag filter technical data
S.No Description Unit Data
Designed / Operating
1 Inlet Flow rate m3/min 7733 6724
2 Pressure mm WG -826 -663
3 Temperature °C 187 170
4 Max Short Duration °C 230
temperature
5 Mechanical design °C 300
Temperature
6 Mechanical design Pressure mm WG -1530
7 Gas dust loading (Wet) g/Nm3 73.7 36.6

8 Gas dust loading (dry) g/Nm3 194.6 84.1

9 Total Filtration area M2 7833
10 No of Bags Nos 2448
11 No of bags per purge valve Nos 17
 Bag filter technical data
S.No Description Unit Data
Designed / Operating
1 Cleaning Type Semi Off / On Line cleaning
2 Filter bag fabric material P84
3 Scrim Material PTFE membrane
4 Air to cloth ratio (gross) m/min 0.99 0.86
5 Air to cloth ratio (Net) m/min 1.19 1.03
6 Emitted Dust Kg/h 2.4 2.5
7 Dust Emission mg/Nm3 25 25
8 Collected Dust t/h 18.6 8.5
9 Pressure Drop over fabric mm WG 150 150
filter
10 Hopper Volume M3 209
11 Length of Bags M 8

12 Diameter mm 127

13 Filter Bags m2 3.2

Filtration Area per bag
 Dense phase technical data
S.No Description Unit Data

1 Conveying technology Pipe in pipe Technology

2 Plant air quantity required for conveying M3/min 75

3 Inst air quantity required M3/min 1.5

4 Cooling water quantity required M3/min 0.16
5 Cap of Air receiver M3 10
6 Dome valve operation pneumatically operated

ID Fan technical data

S. Description Unit Data
No Designed / Operated

1 Fan capacity M3/min 7920 6887

2 Static pressure mm WG 887 805

3 Total pressure mm WG 907 825

4 Fan speed RPM 980 904
5 Efficiency % 85.6 84.6
6 Coupling type Spring coupling
 What does the system require:

 1. Plant air (For Dense phase system – 6Kg/Cm2)

 2. Instrument air supply to (6 Bar)

 A. Purging unit

 B. Dense phase conveying system

 C. Pneumatic damper actuators

 3. Non alkaline cooling water (NCW)

 Dense phase conveying system for dome valve
 What is to be done before commissioning:

 Leak test for bags

 By performing leak test for bags we can find whether any bag has got
puncture or damaged.

 Pre-coating for bags

 The objective of pre-coating is to cover the outer surface of the bags with
a basic layer of dry inert dust in order to protect them against moisture,
acid, oils, hydrocarbons, etc. that are often present during start-up and
shut-down periods.
Leak test:

 By performing the leak test we will identify which bag has leak in
the chamber.

 Run the ID fan in around 600 rpm & Induce the florescent
powders from ports in the inlet duct (4 Kg per chamber).
 Shut off the ID fan and wait till its rpm come to zero.

 Open the top box lid and inspect the bag ventures with UV torch.

 The punctured bag can be identified under the UV light .

 Replace the bag.

Preventive maintenance

 Whilst the fabric filter is virtually maintenance free, preventive

maintenance is recommended at regular intervals.

 The only moving parts in the fabric filter are the inlet and outlet dampers,
and depending on the filter type the dust discharge system.

 The correct fitting of the bags to the tube sheet and to the cages is crucial
to keep a low dust emission level, therefore check the fitting of the
bags regularly.
Weekly schedule

 Check access doors/covers for air leaks, visually and by listening at each location.

 Observe the stack for visible signs of excessive emissions or observe readings from dust monitor.

 Check the compressed air supply and pipe work for signs of leaks.

 Observe the operation of the cleaning cycle to ensure that the diaphragm valves are operational and
the compartments are being cleaned effectively.

 Observe the operation of the dust removal system.

 Read and record all meters, pressure gauges, etc.

Monthly schedule

 Check for damper leakage, and inspect bearings and actuators. Pay particular attention to the
pneumatic connections.

 Inspect all valve packing.

 Grease bolt whenever possible or necessary for top box lids, access doors to the inlet and outlet
ducts and the bottom hoppers access doors.
 Planned shutdown (12 months)
 Inspect and thoroughly clean the fabric filter

 Check for presence of visible dust in the air-flow discharge from the filter
Visible dust is a sign that a filter bag is defective or incorrectly fitted.

 Check damper sealing ledges for signs of damage. Check and adjust their gland packing.
Observe the operation of the damper.

 Inspect all the valves for signs of damage.

 Check the connections on all pneumatic pipe work.

 Inspect and renew, if necessary, all access door seals.

 Check the calibration of all instruments.

 Ensure that the control panel is operating correctly.

 If the installation is equipped with heating elements, check that they are intact by measuring the
power consumption.
Replacement of filter bags
The fabric filter is designed for on-line maintenance, the bags can be changed in one
compartment while the other compartments are still in operation.

 Make sure that the compartment is out of operation, that the inlet and outlet dampers
are safely closed, that the supply of compressed air to the compartment is shut off, and
that the compressed air manifold is empty of compressed-air.

 Make sure the safety instructions and shutdown procedures are followed.

 Access the tube sheet in the clean gas compartment by removing the top cover.

 Locate the bags to be removed. This can often be seen as visible dust accumulations on
the tube sheet or on the internal surface of the cover.

 Release and remove the purge tube over the defective bag.

 Remove the bag and cage by lifting it up vertically. The procedure may vary depending
on the bag fit used.

 Collect some dust from the dust transport system. Prior to installing the bag,
pre-coat it by dipping the exterior of the bag in the collected dust.
 Verify that the hole in the tube sheet is clean and smooth; otherwise clean the hole in
the tube sheet with a steel brush.

 Replace the bag

 Check the cage for straightness, sharp edges, broken wires, etc. Damaged cages should
not be refitted if they are bent or without venturi. Mount the cage, compressed air
manifold and purge tube.

 Remove any tools, auxiliary equipment from the top section and clean the clean-air
chamber before closing.

 Open the compressed air supply to the compartment .

 Trouble shooting
S.No Trouble Cause Remedy

1 Visible dust from 1. Bags incorrectly installed. Check bag installation:

outlet. Adjust the bags and remove all dust
deposits in the clean-air chamber.
2. Damaged bags. Replace damaged bags and remove all
debris and dust deposits in the clean air
chamber.
3. Leakage at tube sheet. Check tube sheet joints for dust
leakage by lifting top doors. Repair as
necessary and remove all dust
deposits in the clean-air chamber.
4. Bypass damper (optional) allowing Check the damper seals.
dust-laden gas to pass. Repair as required.
2 Inadequate 1. Faulty or undersized Check compressor
compressed air compressor.
volume for cleaning
2. Leakage in main air-line. Locate and repair leak.
the bags.

3. Solenoid valve sticking open. Check solenoid valve:

Clean or repair as necessary.
4. Diaphragm valve broken. Replace diaphragm valve.
 Trouble shooting
S.No Trouble Cause
3 High differential 1. Improper cleaning action, due to
Pressure drop. Insufficient compressed air supply.
2. Improper solenoid valve operation
3. Improper pulse valve operation
4. Incorrect timing sequence.
5. Blinding of filter bags due to
moisture.
4 Filter bags 1. High temperature.
deteriorate rapidly.
2. Shrinkage of filter bags.
3. Incorrect bag installation.
Remedy
Check cleaning-air supply:
Correct if necessary.
Check solenoid valves:
Repair as necessary.
Check pulse valves:
Repair as necessary
Check cleaning intervals.
Correct to specification requirements.
Check the function of the water separator at the
compressed-air supply. Check the process
parameters. Correct cause of excess moisture
and replace the bags.
Check reason for high temperature:
Correct if possible.
Replace shrunken bags.
Check that bag is correctly fitted in the tube
sheet. Correct as necessary.
 Do’s & Do not’s :

 1. Always operate bag house in recommended temp 170 to 180 deg C.

 2. Before opening the hopper inspection door ensure weather the particular
chamber is isolated.
 3. Never open any of the pressurized lines (Air & Water) before ensuring
there is no pressure inside.
 4. While working with dense phase conveying system Isolate all the 3
conveying vessels in the row.
 5. Ensure bags alignment after any kind of maintenance activity in side the
chamber so that the proper alignment will increase the bag life.
 6. Don’t run ID fan when bag house chamber inlet dampers are in closed
condition.
Queries…?
Thank you