A study on the characteristics of improvement in filtration performance by dust precharging

A hybrid dust-collector combining electrostatic charging with fabric filtration was developed and its performance characteristics were evaluated. Charged particles build porous dendritic structure on the filter surface by electrostatic attraction, increasing the collection efficiency of dust particles and reducing the pressure drop through the deposited dust layer and filter media. The cleaning performance of the dust layer is improved because the dendritic structured dust layer may be removed more easily by pulse jet cleaning flow. The results of the experiment showed a reduction of fine particle emission by 37% and 13% energy saving by precharging dust particles before filtration.     

Experimental study of pleated fabric cartridges in a pulse-jet cleaned dust collector

Six pleated filter cartridges with different base media and geometrical dimensions were tested in a full-size dust collector periodically cleaned by a short burst of pulse-jet. The evaluation was performed under two different cleaning modes called clean-on-demand (to clean the filter once the pressure drop reaches a preset value) and clean-on-time (to clean the filter at a fixed time interval). The filter performance was evaluated by the effective residual pressure drop and downstream particle concentration. The results showed that the pleat ratio, defined as the ratio of pleat height to pleat pitch, had a great influence on the preferred operating mode for cleaning the filter. Clean-on-time mode demonstrated better performance for filters with a high pleat ratio (> 4.0), while clean-on-demand mode performed better for filters with a low pleat ratio (< 4.0). The test results also showed the tank pressure was critical for cleaning the pleated filter cartridges, whereas the pulse duration only had a small effect on the cleaning efficiency. With the same base media, cartridges with surface treatment such as fine fiber were superior to those without surface treatment. Pulse-jet cleaning could also promote particle penetration through filter media. The downstream particle concentration during cleaning was at least twice of that during filtration process for all pleated filter cartridges tested. Further, the downstream particle concentration was independent of the applied cleaning mode and the cleaning intensity in this study.     

Influence of cloth structure on dust dislodgement from fabric filters

The residual dust loading and filter drag (flow resistance) of fabric filters after reverse pulse cleaning are strongly dependent on cloth structure. Filament/spun combination fabrics have smaller residual dust loadings but greater residual filter drags than all spun cloths. Calendered needlefelts have smaller residual dust loadings but greater residual filter drags than untreated felts. The dust-cake specific resistance coefficient was found to be independent of cloth structure.     

碳化硅陶瓷膜管高温除尘实验研究

采用自制碳化硅陶瓷膜管对某电厂烟气进行了高温过滤性能和再生效果的实验研究。主要考察了三种陶瓷膜管的处理气量对过滤效率、阻力损失的影响以及反吹再生效果。结果表明,随着含尘烟气量的增加,过滤效率逐渐降低,同时压降损失逐渐增大;复合膜的过滤性能优于单一膜或支撑体,反吹再生效果最佳。     

Performance characteristics of air intake pleated panel filters for internal combustion engines in a two-stage configuration

Previous numerical studies that have used computational fluid dynamics (CFD) and experimental software to address the effects of the geometric parameters of pleats on the pressure drop and air flow rate through a fibrous filter are analyzed. The analysis establishes that using a test dust with gradually smaller particle sizes (10, 5, and 1?μm) results in a more intense increase in the filter pressure drop, thus decreasing the service life of the filter. The benefits of using a multicyclone as the first stage of air filtration are discussed. Selecting the air filter by determining the active surface of the filter medium A_c based on the allowable filtration rate is not sufficient; to select the filter medium of a motor vehicle air filter, the dust mass retained per unit of filtration area (mass loading of dust k_m) must be known for a specific allowable pressure drop Δp_fdop. New methods and conditions for determining the mass loading of dust k_m for filter paper and non-woven fabric in single-stage and two-stage filtration systems are presented. The characteristics of the separation efficiency and filtration performance as well as the pressure drop of a filter set comprising a single cyclone and a filter element with a specific filter medium surface are determined. The effects of the particle size distribution of the dust in the air downstream of the cyclone on the mass loading of dust k_m of the filter paper and non-woven fabric in a two-stage filtration system are presented. The mileage of a truck fitted with a single-stage or two-stage filtration system in a “multicyclone–panel filter” configuration is estimated based on the calculated mass loading of dust k_m of the filter paper and non-woven fabric.

© 2018 American Association for Aerosol Research     

Experimental Study on the Loading Characteristics of Needlefelt Filters with Micrometer-Sized Monodisperse Aerosols

In this work, three types of needlefelt filters, made of Polyester (PE), Ryton Sulfar (RS), and Polyaramid (PA), were tested to in- vestigate the aerosol loading characteristics of fabric filters when challenged with micrometer-sized monodisperse potassium sodium tartrate (PST) particles. A fibrous filter with packing density of 9%, thickness of 0.38 mm, and fiber diameter of 5.1 θ m was included for comparison. A vibrating orifice monodisperse aerosol generator was used to produce three different sizes (5, 10, and 20 θ m) of PST particles for aerosol loading experiment. An ultrasonic atomizing nozzle and a TSI constant output nebulizer were used to generate polydisperse PST particles for the aerosol penetration test. The aerosol penetration of submicrometer-sized particles through the filters was measured by using a Scanning Mobility Particle Sizer. An Aerodynamic Particle Sizer was used to measure the penetration fraction of aerosol particles larger than 0.8 θ m. The pressure drop across the filter was monitored by using pressure transducers, which were calibrated against an inclined manometer. Airflows of 5, 10 , 20, and 30 cm/s were used to study the flow dependency. The aerosol penetration results showed that the particles larger than 3 θ m did not penetrate the clean fabric filters tested in the present study. The loading curves (plots of pressure drop against sampling time) displayed three regions: an initial region of fast increase, a transition region, and a final linear region after the dust formation point. After the formation point of the dust cake, both fabric and fibrous filters shared the same slope (of the loading curves). The slope of different regions of the loading curves was determined by many factors, such as size of challenge aerosol, face found to be critical to the performance of the fabric filters. In order lower porosity, which caused an extra rise in pressure drop across velocity, surface treatment, and the compressibility of the dust cake forming on the filter. The method of final surface treatment was to avoid the unnecessary rise in air resistance, the melting clumps formed during final surface treatment should be as thin and narrow as possible, just enough to support the filter bag cleaning. From the standpoint of filter quality and energy consumption, the low filtration velocity has to be adopted whenever possible, because high filtration velocity not only led to lower filter quality (in particular for submicrometer-sized particles) but also created dust cake of lower porosity, which caused an extra rise in pressure drop across thet dust cake.     

Demonstration of a KIER-Type CYBAGFILTER system at the clinker calcination process

A high performance KIER-type CYBAGFILTER that combines a fabric filtration and centrifugal dust removal technology was developed to enhance the performance of conventional filtration systems. Based on the performance evaluation results obtained from a pilot-scale test and fluid dynamic computer simulation, a test CYBAGFILTER of 18,000 m³/hr capacity was installed in the clinker calcination process of Ssangyong Cement Co. located at Yongwol, Korea. Membrane filters for surface filtration were applied and evaluated. After 12-month operation, the mean pressure drop was maintained at 70–80 mmH₂O, the collection efficiency was more than 99.8%, and the outlet dust concentration was less than 5 mg/Sm³. With an operating pressure drop of 100 mmH₂O, the cleaning interval was much longer than that of conventional ones, promising the prolongation of filter life. This paper was presented at The 5th International Symposium on Separation Technology-Korea and Japan held at Seoul between August 19 and 21, 1999.     

高温陶瓷过滤管性能退化建模及实时寿命预测

高温陶瓷过滤管由内部孔径较大的支撑体和外部孔径较小的过滤膜双层结构构成,在实际应用中,存在大量粒径较小的粉尘颗粒,会穿过过滤膜沉积到支撑体内部,脉冲反吹无法有效清除. 因支撑体内颗粒沉积及管壁外残余粉尘层不断压缩,使陶瓷过滤管渗透率不断下降,残余压降逐渐增加。本工作基于高温陶瓷过滤管壁内颗粒沉积特性及残余粉尘层压缩不可直接观测的特点,结合贝叶斯估计理论,利用过滤管运行期间采集的残余压降数据,提出一种基于状态空间模型的过滤管性能退化建模方法。该方法能融入最新采集到的残余压降数据,实时对模型参数进行更新,可对陶瓷过滤管的剩余寿命进行实时预测,同时对陶瓷过滤管剩余寿命的失效概率密度分布及陶瓷过滤管的退化状态变化率进行预测。对某高温试验装置及壳牌煤气化装置中的陶瓷过滤管残余压降分析表明,预测剩余寿命准确率随残余压降数据增加而逐渐增加,后期预测准确率高于95%,且陶瓷过滤管退化状态变化率逐渐变小,与陶瓷过滤管残余压降前期增加快后期增加慢的现象一致。     

Experimental study of cake formation on heat treated and membrane coated needle felts in a pilot scale pulse jet bag filter using optical in-situ cake height measurement

Pulse-jet bag filters are frequently employed for particle removal from off gases. Separated solids form a layer on the permeable filter media called filter cake. The cake is responsible for increasing pressure drop. Therefore, the cake has to be detached at a predefined upper pressure drop limit or at predefined time intervals. Thus the process is intrinsically semi-continuous. The cake formation and cake detachment are interdependent and may influence the performance of the filter. Therefore, understanding formation and detachment of filter cake is important. In this regard, the filter media is the key component in the system. Needle felts are the most commonly used media in bag filters. Cake formation studies with heat treated and membrane coated needle felts in pilot scale pulse jet bag filter were carried out. The data is processed according to the procedures that were published already [Powder Technology, Volume 173, Issue 2, 19 April 2007, Pages 93-106]. Pressure drop evolution, cake height distribution evolution, cake patches area distribution and their characterization using fractal analysis on different needle felts are presented here. It is observed that concavity of pressure drop curve for membrane coated needle felt is principally caused by presence of inhomogeneous cake area load whereas it is inherent for heat treated media. Presence of residual cake enhances the concavity of pressure drop at the start of filtration cycle. Patchy cleaning is observed only when jet pulse pressure is too low and unable to provide the necessary force to detach the cake. The border line is very sharp. Based on experiments with limestone dust and three types of needle felts, for the jet pulse pressure above 4 bar and filtration velocity below 50 mm/s, cake is detached completely except a thin residual layer (100-200 μm). Uniformity and smoothness of residual cake depends on the surface characteristics of the filter media. Cake height distribution of residual cake and newly formed cake during filtration prevails. The patch size analysis and fractal analysis reveal that residual cake grow in size (latterly) following regeneration initially on the base with edges smearing out, however, the cake heights are not leveled off. Fractal dimension of cake patches boundary falls in the range of 1-1.4 and depends on vertical position as well as time of filtration. Cake height measurements with Polyimide (PI) needle felts were hampered on account of its photosensitive nature.     

Fabric filter bag investigation following field testing of sorbent injection for mercury control at TXU's Big Brown Station

Field testing of mercury control sorbent injection options with a TOXECON™ configuration has been completed at TXU's Big Brown Station. Mercury control results at Big Brown were promising and have been previously reported. However, the high air-to-cloth ratio of operations at this unit results in significant differential pressure, and thus there was little operating margin before differential pressure limits were encountered, especially at high loads. This limited the use of sorbent injection as the added material contributes to the overall differential pressure. After field testing, the residual differential pressure across the test fabric filter module had increased relative to baseline conditions to the point that the plant performed a filter change of the test module several months ahead of schedule. An investigation was conducted on pre- and posttest filter samples from the test module and a parallel nontest module to examine the effect of activated carbon injection. Analysis of the samples indicates an increase in residual dust embedded in the filters which appears to explain the low fabric permeabilities. The long-term increase in differential pressure did not appear to be associated with activated carbon injection, but instead was due to a gradual buildup of embedded material on the filters that was not cleaned away by the pulse cleaning system. The injected activated carbon appeared to behave like additional fly ash in terms of baghouse differential pressure but did not appear to accelerate the buildup of residual material.     

Development of a photoreactive fabric filter for simultaneous removal of VOCs and fine particles

A fabric filter sampling system was manufactured by using a UV lamp and a plate-shape sample fabric coated with titanium dioxide (TiO₂) sol to develop a photoreacting fabric filter capable of simultaneously removing dust particles and volatile organic chemicals (VOCs) from contaminated air streams. Variations of pressure drop across the fabric as well as toluene vapor removal efficiency were investigated and examined with respect to various conditions such as the injection duration of dust-laden gas, the photocatalyst particle size, the toluene vapor load, and the photocatalyst load. Again, variations in air permeation and the tensile strength of fabrics with the photocatalyst load were measured and examined to determine the appropriation of nonwoven fabric as a supporter for the photocatalyst. The toluene removal efficiency of this new generation fabric filter was manifestly significant, and a possible deficiency in removal efficiency would be solved through the appropriate design and serial arrangement of a multichannel photoreactor consisting of fabric media coated with the photocatalyst.     

清灰效率对炷状陶瓷过滤器的影响

研究了脉冲清灰效率对过滤过程的影响。假定粉尘结构在过滤和清灰中不变的条件下 ,对清灰效率的影响进行了分析。发现在一定的启动压降下 ,存在着一个最佳的清灰效率 ,即在 90 %～ 95 %之间。由于在运行的前几个循环中 ,粉尘压降、残留粉尘压降以及粉尘厚度、残留粉尘厚度存在较大的变化 ,因而在开始的几个循环中 ,不宜采用相同的清灰时间间隔     

气固错流移动颗粒床过滤器压降特性研究

研究了错流移动颗粒床过滤器操作压降与过滤介质特性、表现过滤气速、颗粒层移动速度和床层粉尘沉积量之间的关系。结果表明，无粉尘沉积时，床层压降可以用Ergun方程计算。颗粒层移动速度的变化并不会造成床层压降的显著变化。除尘过程中，床层内粉尘沉积量随气体中粉尘浓度的增大、颗粒层移动速度的减小而增加，同时将导致床层压降的显著增大。错流移动床除尘操作压降可以用带修正项的Ergun方程计算，其修正项为比沉积率和颗粒层空欧率的函数。在实验数据范围内，该方程的计算结果与实验数据最大偏差小于15％。     

循环过程中陶瓷滤材内粉尘沉积规律实验研究

The penetration and deposit of particles within the medium is thought to be one reason that the residual pressure drop of the rigid ceramic filter increase with cycle number. In this study, the change in the microstructure of a single layer ceramic filter candle during filtration-cleaning cycle was observed by scanning electron microscope (SEM) and the resistance property of the filter was monitored accordingly. The experimental results show that there exists a serious dust deposit within the filter medium, especially at the surface region. This should be responsible for the decrease of the filter permeability. The deposit law of dust in the filter medium during filtration-cleaning cycle was then studied by measuring the deposit depth, the deposit amount, the particles distribution within the medium, the size distribution of deposited particles, and so on. Particles migration and fine particles penetration were found to be the main reasons, for which dust deposit within the filter medium became aggravated with cycle number. Based on a differential form of Ergun equation, an expression for the pressure drop of a used ceramic filter was developed with a good agreement with experimental results. Then, the effect of dust deposit on the residual pressure drop was studied at the different face velocities and dust sizes. It was found that face velocity and dust size significantly influence dust deposit within filter medium, and then the operation performance of the filter.     

Die Abscheidung von Partikeln aus Gasen in Faserfiltern

Particle collection by fibrous filters . Technically employed fibre filters can be classified according to their construction and application in two major groups: deep bed filters and fabric filters. Approaches to the calculation of the collection efficiency for both types of filters start from a clean nondusted filter layer. From this one examines only the initial state, which is especially critical, while the degree of collection as a rule becomes better with increasing dust accumulation. Various models are available for the calculation of the pressure drop. The initial pressure drop for deep bed filters can be calculated with the help of the resistance model. Especially important are those estimates, which for purification filters describe the pressure drop or the gas flow with increasing dust accumulation, because these equations can serve directly for the dimensioning of filter plants. Of courese, characteristic permeability values for filter fabric and dust layer must be determined beforehand. The possibilities and problems of these calculations, as well as open questions, will be discussed.     

Experimental study on the treatment of volatile organic compound vapors using a photoreactor equipped with photocatalyst‐coated fabrics

In this study, methods were developed to enlarge the scope of traditional applications of titanium dioxide (TiO₂) and to increase the value of felted fabric by allowing volatile organic compound (VOC) degradation as well as dust filtration in a photoreacting fabric filter. In the past, when a V–Ti mixed catalyst was used, the application of felted fabric as a support material for the catalyst was difficult because the active temperature of the catalyst ranged from 250 to 400°C. Thus, in this study catalyst‐coated felted fabric was manufactured at normal temperature conditions, and then fundamental de‐VOC performance tests were conducted under irradiation condition to develop a fabric filter having a de‐VOC function in addition to a dust‐filtration function. Toluene vapor was selected as a sample VOC because it poses health hazards, has been widely used as an organic solvent, and has been known as a compound that is difficult to dissociate. To manufacture and use a fabric filter that degrades VOC_S, and removes dust particles through using photocatalyst‐coated fabrics and light sources, optimum operating conditions were obtained by observing the degradation attributed to varying the toluene‐vapor flow rate, the initial toluene concentration, flue gas humidity, TiO₂ loading onto the surface of the fabric, and the intensity and wavelength of a near ultraviolet light lamp. To keep the flue gas humidity at a relatively constant level, a system to automatically control the humidity was constructed. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 3174–3179, 2004     

Distributions of age, thickness and gas velocity in the cake of jet pulsed filters—application and validation of a generations filter model

Different imperfections are observed with jet pulsed filters. They manifest themselves most obviously in the curve of the pressure drop versus time. A convex pressure drop curve indicates cake compaction. But jet pulsed filters frequently show a concave rise of the pressure drop curve. This phenomenon is due to a strongly nonuniform cake area load on the filter and it is generally attributed to incomplete cake removal. Incomplete cake removal takes place when only a fraction of the total filter area is cleaned at the end of a filter cycle or when patchy cleaning prevails. Patchy cleaning means that a jet pulse removes the entire filter cake of only a fraction of the exposed filter area except for a thin adhesive dust layer.In this paper a filter model is proposed in which the different classes of cake thickness are understood to result from different cake generations. A cake becomes one generation older when it survives the jet pulse cleaning at the end of a filtration cycle, although the area that is occupied by the cake on the filter medium is diminished by the jet pulse.This generations filter model can be used to find the distributions of age, thickness and gas velocities in the cake from steady-state operational data. The steady-state, periodic model provides a complete basis for the simulation of heterogeneous gas/solid reactions in the cake of jet pulsed filters.In the model intermediate cake build up during the cleaning procedure is considered. There redeposition of removed filter cake also takes place, and its extent is estimated. The model can also serve to determine from macroscopic process data, if the cleaning system of a filter installation operates in the undesirable mode of patchy cleaning.Experiments from a pilot plant for dry flue gas cleaning are presented and the generations filter model is validated with the experimental data.     

Improvements to dust filtration through acoustic agglomeration and atomization

Based on the theories of acoustic agglomeration and dust wet removal, an experimental apparatus was constructed to study the combined effects of acoustic agglomeration and atomization humidification in the pretreatment process to analyze the filtration performance of filter material. According to the concentration of coal-fired fly ash chosen in the experiments, the proper amount of atomization humidification and the proper sound pressure level (SPL) were determined. Under the relative humidity (RH) of 69% and with SPL in the range of 100 dB to 135 dB, the removal efficiency of fly-ash, the compressibility of the fly-ash particle layer on the filter media, and the performance of pulse filter cleaning were studied. The results indicate that the combined effects of sound fields and atomization humidification can effectively remove PM₁₀ and PM_2.5, and change the interaction and movement of particles, which can improve the pore structure of the fly-ash particle layer and increase the porosity of the dust layer. The results also indicate that with the proper amount of atomization humidification and appropriate SPL, the joint acoustic-atomization pretreatment can delay the filter material blocking, which reduces the pulse filter cleaning frequency and extends the filter cleaning cycle. It can also reduce the residual resistance after filter cleaning and prolong the operating lifetime of the filter media.

© 2017 American Association for Aerosol Research     

陶瓷过滤管表面粉尘层清除过程的图像分析

Based on the analysis of high-speed video images, the detachment behavior of dust cake from the ceramic candle filter surface during pulse cleaning process is investigated. The influences of the dust cake loading,the reservoir pressure, and the filtration velocity on the cleaning effectiveness are analyzed. Experimental results show that there exists an optimum dust cake thickness for pulse-cleaning process. For thin dust cake, the patchy cleaning exists and the cleaning efficiency is low; if the dust cake is too thick, the pressure drop across the dust cake becomes higher and a higher reservoir pressure may be needed. At the same time there also exists an optimum reservoir pressure for a given filtration condition.     

Fabrication of cordierite filter by in-situ solidification for high temperature dust collection

Cordierite ceramic filters have been shown a potential candidate for a high temperature dust collection, owing to its very low thermal expansion coefficient characteristic as an attribute of excellent thermal shock resistance. It is preferable that a design of porous cordierite filter should have low pressure drop with high permeability while keeping the structural integrity. This study describes a simple and direct approach for fabricating a porous cordierite filter with honeycomb-type structure by introducing various non-through holes into mechanically foamed slurry, which is subsequently in-situ solidified by polymerization reaction. The gelcasting cordierite-based slurry was mechanically foamed in nitrogen-filled chamber. The resulting foamed slurry was cast directly into circular molds equipped with a cover having different number of pins. The gelled-bodies were carefully dried at 25 °C with a controlled humidity, followed by sintering under optimized condition. The dust collection performance, pressure drop, and gas permeability were evaluated as a function of the number of non-through holes in porous cordierite. Based on the results of the tests, the holey porous cordierite filter offered a better filter design for dust collection application.