Improving Fabric Filtration Efficiency with ePTFE* Membrane

expanded Polytetrafluroethylene

2005 by General Electric Company. All rights reserved

What is ePTFE membrane?

A microporous membrane laminated to traditional filtration fabrics. The PTFE membrane consists of a web of overlapping fibrous strands that form millions of air passages, much smaller than the particulate, for an extremely porous filter surface. Because the membrane is a PTFE derivative, its surface is slick; bag cleaning is more complete with less energy.
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How does ePTFE improve filtration?

Slick surface = Improved filter cleaning Surface barrier = Prevents bag blinding Improved airflows = Lower differential pressure Resistance to moisture in the gas stream Higher load / steam production

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What is PTFE membrane?

Enhanced fine particulate collection Superior clean-down of the filter Longer bag life Resistance to moisture in the gas stream

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ePTFE manufacturing
The fine powder is blended with an extrusion aid, often referred to as the lubricant. The mixture of powder and lubricant are pre-formed into a cylindrical shape. The pre-form is placed in the extruder and extruded through a die into tape. The tape is calendared into the desired thickness. The lubricant is removed by drying. The tape is then stretched into the desired width to make membrane.
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Lamination process

ePTFE Membrane

BHA-TEX

Base Fabric

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ePTFE filtration facts

Average membrane pore Size 0.5 - 1 micron, effective pore size much smaller. Traditional woven/felts typically have a 20 micron pore size. Can fit approximately 1000-2000 pores across the tip of a ball point pen. 100 million pores per square centimeter.
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1000 microns

BHA-TEX magnified 2500 times

This dot represents 1 micron particle. The web-like structure collects submicron particulate, yet allows air to pass through.

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Surface v. depth filtration

Depth Filtration
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Surface Filtration
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Depth v. surface filtration

A conventional filter bag collects particulate in the depth of the fabric.

airflow

Dust gets trapped in the fabric

airflow

Cross section view standard felt bag (used)

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Depth v. surface filtration

An ePTFE filter bag collects particulate on the surface of the membrane.

airflow

BHA-TEX membrane Dust collects on surface and is easily cleaned off

Dust does not penetrate the fabric

airflow

Cross section view BHA-TEX laminated bag (used)

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Increased air volumeextended bag life

Normal Bag Changeout

High P Decreased Production

P Conventional Felt/Woven

BHA-TEX Advantage

BHA-TEX
Increased Airflow TIME
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Extended Bag Life Continued Production

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BHA-TEX demonstration

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Red smokebomb filtration comparison

Standard fiberglass: depth filtration

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BHA-TEX: surface filtration

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The membrane advantage

Emissions gr/ACF 0.040 0.035 0.030 0.025 0.020 0.015 0.010 0.005 0.000 Standard filter media 0.0397 gr/ACF (92mg/m3) BHA-TEX filter media 0.0006 gr/ACF (1.3 mg/m3) Test conditions: New fabric 0.6 micron (average) 5:1 air-to-cloth ratio (1.52 m/min filter rate) 10 grains/ACFM grain loading

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PTFE membrane provides excellent dustcake release

Without PTFE

With PTFE

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Depth filtration
Collection side Back side

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Surface filtration
Collection Side Back Side

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 BHA-TEX

Bi-Component Laminated Polyester Felt

What is Bi-Component Lamination?

Membrane is bonded to a sheath rather than a singed fiber Lamination occurs across a larger number of smaller bond sites The result: Extremely durable & efficient ePTFE filter media

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Bi-component lamination

With Bi-Component point lamination, the BHA-TEX membrane is bonded to the sheath surrounding the fiber creating a more durable and pliable fabric filter.

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Conventional ePTFE lamination

50x magnification

Conventional membrane lamination to a singed polyester causes large bond points that lead to restricted airflow.
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Bi-component lamination
50x magnification

Bi-Component lamination technique allows for more numerous, yet much smaller bond points, and increased airflow.
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Industry-specific Applications for BHA-TEX

Cement industry
Coal mill collector Finish mill collectors High efficiency separators Kiln Bypass collectors Silo Belt transfer points
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Cement industry
Coal mill collectors Advantages: Reduces differential pressure Reduces lost product Increases bag life

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Cement industry
Finish Mill Collectors High Efficiency Separators Advantages: Improves airflow Reduces differential pressure Reduces product loss Potential increases to production
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Cement industry:
Kiln & Bypass Collectors Advantages: Improves airflow - reduces buildup Improves collection efficiency Increases bag life

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Cement industry
Silo Belt transfer points Advantages: Improves efficiency Extends bag life Reduces maintenance

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Food / Pharmaceutical industry

Problems: Sticky dust is a frequent problem Food grade products required; strict guideline adherence Solution: BHA-TEX is USDA approved for direct contact components BHA-TEX is used in the processing, drying and conveying of: Food additives Pill coatings Sugar Dried milk & eggs Protein

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Food industry
Applications: Sugar collection Mixers Additives Pneumatic transport Silo venting

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Chemical industry
BHA-TEX can help solve problems that often come with an increased demand for higher production rates, higher quality products, lower emissions and reduced product loss. BHA-TEX has been successful in improving collectors in the manufacturing of: Soaps Herbicides / Pesticides Detergents Fertilizers

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Paints / Pigments industry

These manufacturers create some of the most difficult dust particles to collect. The dust contains a high volume of submicron size particles. BHA-TEX membrane provides 99.99+% efficiency for the collection of fine particulate, such as: Carbon Black Toner TiO2 Cosmetics

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Plastics industry
Spray drying is an integral process in the manufacture of plastics. These systems experience unique problems and heavy dust buildup. The smooth surface of BHA-TEX is ideal for process collection in plants producing: PVC Polypropylene Polyester Polystyrene Polyethylene

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Steel industry
Common trends: Shorter tap-to-tap times Accomplished by: Increased transformer size Oxy-fuel burners Foamy slag Water-cooled panels

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Results on baghouse performance

Increased dust generation Emissions inside melt shop Need for more ventilation air Higher temperature

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Plant schematic

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Steel industry
Furnace Coal Auxiliary

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Steel industry
Furnace Advantages: Increases air volume Reduce energy consumption Reduction of emissions

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Steel industry
Coal Advantages: Increased production Improve collection efficiency

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Steel industry
Auxiliary Advantages: Extends bag life Reduce differential pressure Survive upset process conditions

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Alumina industry
Carbon Crushing Advantages: Collection of fine particulate Prevention of bleed through & blinding Venting Bauxite Transfer Points Advantages: Reduces differential pressure due to better release of sticky particulate
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Combustion industry
Issue: Potential for very fine particulate Problem: Can bleed through conventional filter media Result: Emissions & decreased air permeability. Issue: Potential for high moisture levels Problem: Agglomeration on bags impedes cleandown Result: Reduced air permeability, high diff. pressure BHA-TEX has been successful improving operation of baghouses in the following applications: Boilers / SDAs / SCRs Flyash & Coal Material Handling
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Case History:
Unit 1 Coal Fired Boiler Golden Valley Electric Association Healy Station Fairbanks, Alaska

Golden Valley Unit 1 baghouse

12 Compartment Reverse Air Unit Standard Fiberglass Bags: 11.5 379 x Sub-Bituminous Coal (7,800 BTU) Continuous cleaning to maintain full load Waste Coal (6,100 BTU) - Even continuous cleaning couldn't maintain full load

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Possible solutions
Upgrade I.D. fan (1998) New standard fiberglass bags (1998) Evaluated addition of two new compartments New BHA-TEX ePTFE Membrane bags (1999)

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Pressure drop comparison standard fiberglass v. BHA-TEX ePTFE membrane

Fiberglass at 1 Year Base Fabric Membrane at 1 Year

4 2

2 4

Dustcake

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Operating comparison
Standard Filter Bags Average Pressure Drop Steam Production Cleaning Frequency Cleaning Duration Reverse Air Fan Use 9 -10 92 - 100% of Design Capacity Continuous to 20 Minute Intervals 30 Seconds (Reverse Air & Horns) Continuously In Service ePTFE Filter Bags 5 7 100% Design Capacity 2 Hour Intervals 3 Seconds (Horns) 2 Hours Total per Month

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Fan curve
Static Pressure vs. Air Volume
14 (356mm) 12 (305mm)

Static Pressure

Air Volume

80% of Designed Capacity

Designed Capacity

Difference Between Static Pressure of 2 Locations

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Questions?

Thank you.