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Agenda

Houston Material Handling Society October 2008 Baghouse Cleaning Control Presented by: T.J. Winalski. Agenda. Overview . Baghouse Cleaning Control . Particulate Monitoring . Diagnostics. Baghouse Basics. Baghouses can be very efficient in collecting particulate

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Agenda

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  1. Houston Material Handling Society October 2008Baghouse Cleaning Control Presented by:T.J. Winalski

  2. Agenda Overview Baghouse Cleaning Control Particulate Monitoring Diagnostics

  3. Baghouse Basics • Baghouses can be very efficient in collecting particulate • Media – many media types for different processes • Pressure Loss (Drop) of a baghouse is function of: • Baghouse Design • Media Type • Air Flow • Dust Layer Thickness • Cleaning Media – All media needs to be periodically cleaned to maintain acceptable pressure drop • Cleaning is controlled either by Time OR Differential Pressure

  4. Pulse Jet Baghouse

  5. Baghouse Basics • Ensure cleaning air supply is sufficient (flow/pressure) • Cleaning air supply should be clean and dry • Keep air to cloth ratio at acceptable levels • Avoid condensation in baghouse

  6. Agenda Overview Baghouse Cleaning Control Particulate Monitoring Diagnostics

  7. Cleaning Pulse – The Beat of the Baghouse

  8. Membrane Media In - Depth Filter Material (Felt) Membrane Depth filter media e.g. PPS felt Conventional Media Depth vs. Surface Filtration – Filtering Mode

  9. Solenoid Activation: Current Timer Board • Controls Solenoid ON Time and OFF Time • OFF Time • Adjustable off time 3-600 seconds • Stand Alone of through Other Device

  10. How does your baghouse heart beat? istockphoto.com

  11. Types of Cleaning Modes • Time Only • Pulse On Demand • Single Set Point Hold

  12. Pulse on Demand – 30 days DP 4 DP (“ WC) 2 4 12 20 28 Days

  13. Single Set Point: Hold 4.0” WC DP

  14. Single Set-Point: Hold 4.7” WC DP Pulse Rate

  15. Single Set-Point: Hold 4.0” WC Pulse Rate DP

  16. Single Set Point: Hold 6.5” WC - 12 days DP Particulate

  17. IntelliPulse – Single Set-point Control Pulse Rate DP

  18. Single Set Point Hold Control: 1 day DP Pulse Rate

  19. Single Set Point Hold = Even Filter Cake/Constant Air Flow

  20. Single Set Point Hold - Benefits • Constant Air Flow Through the Baghouse • Minimum Compressed Air Use – for Cleaning • Maximum Filter Life • Reduced Maintenance due to longer component life • Lowest Particulate Emissions

  21. Single Set Point Hold – Total Pulse Count

  22. Single Set Point HoldActual Electricity Savings from Compressed Air

  23. Comprehensive Cleaning ControllerFunctionality • Pulse Control for Each Individual Solenoid Cleaning Modes • Off • Time • Once Through • Cycle Down • Pressure • Single Set Point Hold • POD Full Solenoid Control – Easily Selectable and Adjustable • Multi-Row Pulsing • Pattern Pulsing

  24. Single Set Point Hold Control - Benefits • Steady Differential Pressure by Maintaining Filter Cake • Constant Air Flow through Baghouse • Lowest Particulate Emissions • Optimum Operating Costs • Maximum Media Life • Lowest Compressed Air Usage • Optimum Fan Volume • Minimize Maintenance Costs through longer life of components

  25. Requirements of Today’s Technology: • Comprehensive Cleaning Control • Integrate Particulate Sensing • Integrate Differential Pressure Sensing: Tube DP or Non-Clogging DP Transmitter • Integrate I/O’s • Ethernet/Fieldbus Communication • Performance • Reliability • Flexibility • Information • Communication

  26. Non-Clogging Differential Pressure Transmitter 27

  27. 10 Flange – to Flange P 8 6 Compartment P provides insight: Inches of H2O 4 2 Variation in P amongst compartments 0 Some compartments are taking more flow -2 Time (sec) Cleaning frequency 35 minutes Differential Pressure Monitoring

  28. Agenda Overview Baghouse Cleaning Control Particulate Monitoring Diagnostics

  29. Integration of Particulate Monitoring

  30. Sensor Technology – Protected Probe

  31. Particulate Emissions Pulse Rate

  32. Particulate Emissions Filter Media Change

  33. Particulate Monitoring with Broken Bag

  34. Particulate Monitoring - Cement Kiln

  35. Particulate and DP – over 6 days DP Particulate

  36. Particulate and DP – 1 day DP Particulate

  37. Particulate Emissions: High Resolution DP Particulate

  38. Particulate Monitor - Locations

  39. Particulate Emissions – Maintenance Tool

  40. Proactive Maintenance Tool: MicroFractures DP 4 DP (“ WC) 2 4 12 20 28 Days Particulate

  41. Agenda Overview Baghouse Cleaning Control Particulate Monitoring Diagnostics

  42. Which would you prefer?

  43. Diagnostic Capability Instrumentation is the window into the process • Failed Solenoids • Failed Diaphragm (header pressure) • Failed Filter by Row (particulate) • Process Conditions – high DP, low Header Pressure, air temperatures, moisture, fan vibration, bearing temperatures, etc.

  44. Typical Baghouse

  45. COMPRESSED AIR SENSOR • Checks compressed air (gas) header pressure • Mounted in the compressed gas manifold • DELTA P SENSOR • Non-Clogging Type for reliable maintenance free measurement • Mounted on Dirty Side • Accurate Reliable Measured Differential Pressure • Quick Clamp Connection • PARTICULATE SENSOR • Passive Sensor • Protected Probe Technology • Mounted in clean air duct

  46. Diagnostics • Bag Row Leaks • Particulate • Failed Individual Solenoid • Failed Individual Diaphragm • Header Pressure Compressed Air (Gas) • Differential Pressure • Read Locally Or On HMI

  47. Visualization

  48. Conclusion • Comprehensive Cleaning Control • Operate as a Stand Alone Controller (harsh industrial environments) • Operate out of the box for any baghouse, bin vent to 80 row baghouse • Reliably Monitor Particulate Emissions • Communicate with a HMI

  49. Questions, Discussions, Applications

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