Design recommendations For process filters in Cement Industry

Prepared For

HOLTEC CONSULTING PRIVATE LIMITED

Date : December 18, 2009

This document is considered confidential and proprietary. It is intended only for the use of those who are employed by Holtec Consulting Pvt. Ltd.. and/or "W. L. Gore & Associates, Inc.

Table Of Contents
1. Kiln Baghouse
1(A)
i. ii.

Pulse-Jet Bag filter

Design Recommendations Expected Performance

1(B)
i. ii. iii.

Reverse Air Baghouse

Design Recommendations Specifications for Membrane filter bags Expected Performance

2. Cement Mill Bag Filters

i. ii. Design Recommendations Expected Performance

3. Coal Mill Bag Filter

i. ii. Design Recommendations Expected Performance

In Cement industry,
GORE filter bags have been found particularly useful in the following types of bag filters.
1. Primary process bag filters such as Kiln baghouse, Coal Mill and Cement Mill bag filters. - Due to its longest un-interrupted bag life. - Stable pressure drop over the life period - Ability to recover from process upsets. 2. Bag filters having high moisture such as Clinker Conveyor Ventilation. - Due to its unmatched moisture resistance 3. Silo-top bag filters - Reduces the frequency of maintenance on the bags

1. Kiln Baghouse :
Gore has more than 200 pulse-jet and reverse air installations working successfully at present with Gore bags worldwide. In India, due to lower Fabrication cost and import duty on filter bags, the Bag filter cost for Reverse Air Baghouse is generally lower than pulse Jet for larger flow rates.

A.

For Airflow Less Than 200,000 M3/hr, Pulse Jet may be More Economical

B.

For Airflow More Than 200,000m3/hr, Either Pulse Jet Or Reverse Air Can Be Recommended. Pulse-Jet Bag Filter may be preferred for ease of maintenance.

1. (A) Pulse-Jet Bag Filter

Gore pioneered the use of GORE High Durability Filter Bag (Fiberglass Fabric coated with Polytetrafluoroethylene, 746 g/m2) in Pulse-Jet bag filters. Traditional Fiberglass fabric bags show poor performance in Pulse-Jet bag filters. With Gore's membrane technology, this limitation was removed. The Pulse-Jet bag filter when compared to Reverse Air baghouse, offers following benefits : It eliminates Reverse Air fan, thus eliminating capital and operating cost related with the fan, ducting, dampers, etc. Thus, the cleaning is now carried out by compressed air at 40 - 50 psi (Max. 50 psi). The bag filter is much smaller due to the higher air to cloth ratio employed with Pulse-Jet bag filters. This reduces the civil and other related costs. Since most maintenance people are familiar with the operation of Pulse-Jet bag filters, it is easier to maintain compared to Reverse Air baghouse, which is generally not very common in cement industry. 1(A) i. Design Recommendations : FILTER MEDIA : a) Gore High Durability Filter Bag (fiberglass fabric coated with polytetrafluoroethylene, 746 gm/m2) b) Gore High Durability Filter Bag (Superflex fabric, 630 gm/m2) AIR TO CLOTH RATIO : 1.0 - 1.3 m/min. (Net) (Depends on the dust load, Dust type and Bag filter design) CAGE DESIGN : 1) Tolerance: a) In diameter b) In length 2) No. Of Vertical Wires 3) Wire Diameter +0, - 0.8 mm. +0, - 1.6 mm. Minimum 24 (for 150 mm dia) 4 mm unstiffened wire 3 mm stiffened wire. 4) Maximum Space Between Two Horizontal Rings : 150 mm. 5) The cages should be free of sharp edges or sharp welding spots 1(A)ii. Expected Performance : BAG LIFE EMISSIONS : 3 - 5 years for Filter Media (a) 5 - 8 years for Filter Media (b) : Maximum 25 mg/Nm3 : : : :

1(B) Reverse Air Baghouse

1(B) i. Design Recommendations : FILTER MEDIA : Gore High Durability Filter Bag (Acid resistant fiberglass fabric 10 Oz/Yd2)

AIR TO CLOTH RATIO: 0.6 to 0.7 m/min. (Net) ( Depends on the dust load, moisture level, Dust type and Bag filter design) 1(B) ii. Specifications for Membrane filter bags :
Filter Media : Units
100% PTFE % psi cfm/sq.ft. 99.99 >1 5

a) Membrane properties
Membrane Membrane filtration Efficiency for 1 size particles Ball burst strength Permeability at inch mmwg

b)

Laminate properties
Fabric Finish Mullens Burst Strength Weight Continuous Operating Temperature: Maximum Surge Temperature: Acid Flex Cycles Warp Fill Breaking Strength: Machine Direction: Cross-Machine Direction: kg/5 cm kg/5 cm 148 91 > 10,000 >1500 psi gm/m2 Deg. C Deg. C Acid Resistant 500 Minimum 330 260 288

c) Sewing Thread :
Type % shrinkage at 232 C after 2 hrs. Tenacity % strain % gr/denier % 100% microporous PTFE <1 Minimum 1 Min. 100

1(B) iii. Expected Performance : BAG LIFE : 8 - 12 years EMISSIONS : Maximum 25 mg/Nm3

2. Cement Mill Bag Filters

2 i. Design Recommendations :
TYPE OF BAG FILTER

: On-Line Pulse Jet With Off-Line Capability

FILTER MEDIA : a) GORE High Durability Filter Bag (polyester felt, 16 oz/yd2) b) GORE Filter Bag (acrylic felt 14 oz/yd2) (for more than 10% moisture) AIR TO CLOTH RATIO: 1.3 to 1.6 m/min.(Net) ( Depends on the dust load, Dust type and Bag filter design) CAGE DESIGN : 1) Tolerance: a) In diameter : +0, - 0.8 mm. b) In length : +0, - 1.6 mm. 2) No. Of Vertical Wires 3) Wire Diameter : Minimum 12 (for 150 mm dia). : 4 mm unstiffened wire 3 mm stiffened wire

4) The cages should be free of sharp edges or sharp welding spots

2 ii. Expected Performance :

BAG LIFE EMISSIONS : 5 - 7 years. : Maximum 25 mg/Nm3

3. Coal Mill Bag Filter

3 i. Design Recommendations :
TYPE OF BAG FILTER

: ON-LINE PULSE JET WITH OFF-LINE CAPABILITY

FILTER MEDIA

: GORE Filter Bag (anti-static acrylic felt, 14 oz/yd2) (for more than 10% moisture)

AIR TO CLOTH RATIO : 1.3 1.7 m/min. (Net) ( Depends on the dust load, Dust type and Bag filter design) CAGE DESIGN : 1) Tolerance: a) In diameter : +0, - 0.8 mm. b) In length : +0, - 1.6 mm. : Minimum 12 (for 150 mm dia). : 4 mm unstiffened wire 3 mm stiffened wire

2) No. Of Vertical Wires 3) Wire Diameter

4) The cages should be free of sharp edges or sharp welding spots

3 ii. Expected Performance :

BAG LIFE EMISSIONS : 5 - 7 years : Maximum 25 mg/Nm3