SUCCESSFUL OPERATION OF BAG HOUSES WITH NEEDLE FELTS

Georg Rathwallner
Evonik Fibres GmbH

Table of content
Bag house operating and maintenance costs Bag material selection Bag condition monitoring Typical failure patterns Operating experience

Bag house operation and maintenance costs

Table of content
Bag house operating and maintenance costs

Bag material selection

Bag condition monitoring Typical failure patterns Operating experience

Peak temperature resistance of bres

300 250 200 150 100 50 0 PAN PES PPS
PROCON
* Actual application temperature is below the shown maximum depending on the flue gas composition and bag life expectation! expectation!

260 200 140 150 220

260

m-Ar.

PI

PTFE

Properties of lter bag materials

PET PAN PROCON PPS M-Aramid Polyamidimid Polyimid PTFE Glass oxidation humid acids ltration cont. op. heat efciency temperature 4 4 3-4 3 < 130 4+ 2 2 3 110-130 3 1 1-2 2-3 140-170 2 4 3-4 2-3 160-180 2+ 3-4 3-4 2-3 160-180 1-2 1-2 2-4 1 160-200 1 1 1 4 < 240 1 1 2-4 4 < 240

Resistance on a scale from 1-4; 1 indicating the best value and 4 weak performance

Specic surface of different bres

P84 (polyimide)
600
P84 Fibre Surface (m/kg)
2,2 dtex

400
PROCON trilobal

m-ARAMIDE PPS

Procon (PPS)
2,2 dtex round (206 m/kg)

200

0 4

2
Fiber Titre (dtex)

Procon (PPS)
1,7 dtex trilobal (317 m/kg)

Filter bag materials by application

Application
Coal mill Cement mill Clinker cooler

Fibre material
PAN, (+P84) PES (+P84) at low humidity PAN (+P84), PAN/PES P84, m-aramide, poly-amid-imid PAN <140C PPS (+P84) <150(200)C P84 <180(260)C PTFE(+P84), glass/membrane PTFE, P84, glass

Kiln, Kiln/mill

Alkali Bypass

.temperatures in brackets indicate the max. peak temperature

Table of content
Bag house operating and maintenance costs Bag material selection

Bag condition monitoring

Typical failure patterns Operating experience

Bag condition monitoring

tenacity (chemical and mechanical ageing) air permeability (dust penetration/clogging) cross section analysis (dust penetration into the felt)

infrared analysis, differential scanning calorimetry, .. (chemical ageing of polymers)

material specic analysis to determine chemical ageing

Table of content
Bag house operating and maintenance costs Bag material selection Bag condition monitoring

Typical failure patterns

Operating experience

Typical failure patterns

contamination from the clean gas side - no penetration through the felt penetration through leakages or holes

penetration through the felt (insufficient filtration efficiency or too frequent cleaning/too low cleaning set point)

Typical failure patterns

Abrasion
typically related to high local gas velocity and dust load bag materials show different abrasion resistance, but problems of inhomogenious gas distribution have to be solved to get satisfactory operating behaviour

Typical failure patterns

Cracks as a result of chemical ageing (loss of tenacity below critical limits) as a result of mechanical burden
e.g. as a result of dust penetration (high dp, frequent cleaning, internal abrasion)

As a result of damaged cages or contact between bags or bags and wall

Typical failure patterns

Membrane damage along a supporting cage wire

- Penetration of dust into the glass fabric results in internal abrasion

Table of content
Bag house operating and maintenance costs Bag material selection Bag condition monitoring Typical failure patterns

Operating experience

Operating experience Comparative test in a nish mill operating conditions

2 similar grinding lines with ball mills Bag lter : size: 720 m A/C ratio: 1,2-1,3 m/min dust load: 500 g/m Temperature: 85 C As a result of an increase of the a/c-ratio the bag life of the polyester felts dropped from 18 to 7 months. Problems with increasing differential pressure and dust emissions were experienced.

Comparative test in a nish mill - felt construction

Polyester Fine Fibre Bag scrim construction
Felt weight Air permeability 200 Pa Performance @ Filtration side Clean gas side

P84/Polyester 40% P84 / 60% PET PET PET

600 g/m2 40-50 l/dm2min
differential pressure ange-ange:

PET with scrim PET PET

600 g/m2 40-50 l/dm2min Bag change after 7 months

1500 Pa, stable for >48 months

Comparative test in a nish mill

More information

Polyester (PET) ne bre after 7 months Air permeability1): 7 l/m2min as received 10 l/m2min cleaned Dust incorporation: 730 g/m2
1)

P84-PET bre blend after 48 months Air permeability1): 10 l/m2min as received 18 l/m2min cleaned Dust incorporation: 260 g/m2

at 200 Pa, cleaning by pressure pulse

Another comparative test in a nish mill: bag material after 29 months operation

Air permeability [l/(dm.min) @ 200 Pa] as received after simulated pulse cleaning washed (in a conventional laundry machine)

Glass/ membrane 13-14 15-22 39-42

P84 28-29 39-48 88-89

PAN/PET +P84 15-19 29-34 65 69

CLINKER COOLER JAPAN

P84/P84, 4450 m Pulse Jet - On Line Temp: 150 C ACR: 1,04 m/min H2O: 0-3 vol% O2: 20,5 vol% Emission: < 10 mg/Nm
lifetime of filterbags: >5 years

KILN/MILL FILTER NORWAY

P84/Hybrid scrim, 17.200 m Pulse Jet On Line Flow: 2 x 230.000 Nm/h Temp: 170-180C (max 250C) ACR: 1,37 m/min H2O: 14 - 20 vol% O2 : 8 - 12 vol% SOx: 115 - 1.000 mg/Nm NOx: 780 - 900 mg/Nm Dust: 1 65 g/Nm Emission: < 5 mg/Nm

# Compound & Kiln Op. # Incin. of Haz. Waste # 2 x 3.584 Filterbags # Start Up: October 1998 Lifetime: 8years

KILN/MILL FILTER NORWAY

P84 bag after 8 years in operation

Kiln/raw mill lter UAE

100% P84, 16896 bags (160mm x 6000mm) app. 50.000 m Pulse Jet On Line Flow: Nm/h Temp: 150-200C (max 260C) ACR: 1 m/min H2O: 9 - 18 vol% O2 : 4 - 13 vol% SOx: 150 - 320 mg/Nm NOx: 190 - 310 mg/Nm Dust: 40 170 g/Nm Emission: < 5 mg/Nm

SUCCESSFUL OPERATION OF BAG HOUSES WITH NEEDLE FELTS

Georg Rathwallner
Evonik Fibres GmbH