i Origins and Selection of Filter Element Configrations Used in Dust Emission Limiting Systems $. Ramponi and G. Marchi, Italy Summary This article analyses the various configu: rations of fiter mada employed n dust extraction fiters using tho inetial eopara tion system and these dedicated to the conto of enissons generated during the handing ot buk or powdered haters. The report wil look at geometric contigu= ralions, construction matenals and oper: ating parameters, with special reference to the internal gaometry ofthe iter barrier and tho inertial properties of the product ‘The techniques used for tho selection of fiter media on the bass of the chemical physical characteristics of the product to handle ana the infow conditions will aso be ilustrated. Finally, special attention wil bbe dedicated to configurations currently under stu, 1. Introduction Up unl a few years ago, the handling of ‘bulk solids and powders not appertaining to any class of toxic o: harmful products was somewhat noglosted by the stan- dards controling harmful errissions and health and safety at work. The problem of Cconiaining these agents carne to light in the more industrialised countries durng the early eghties. The recent publication of European standards regarding the safety of machinery, and heath and safety at work, which according to the Troaty of Romo apply to all EC member countries, has aroused a great deal of ‘mutual interest on the subject. The introduction of increasingly severe standards to control emissons from dust handling piant has ‘ed to greater impor Sand Ranpont ara Gomano Marty, Canto eta even cr pr a Tel: 20505 46660, Fane +29 53546886, nsmersen pages 102 8 108 tance being attached to the develooment of techniques for protecting the environ: ment from pollutants. There are various systems in existence which can be adopted to contain pollution caused by the handing of bulk and powdored rato: tials. These plant systems include: « scrubbers (wet collectors) « electrostatic separators + centifugal separators «* fters with various support elements for the flter surfaces (bags. cartridges, ol: liptical bage, pockete, otc.) The filtration characteristics of the last systems in the above list are based on the inertia of the pariices transported by the flow of fui to be fitered. The most eticient of these, in terms of the cost/benefit ratio, are fiter systems made ‘up of modular elements. These machines basically consist of a chamber inside which siter elements are tocated to form a barrier to the fow of polutant, and a second chamber through ‘which the fitered air passes and where the fiter element cleaning systoms ae housed. Consideration will bo also gven to the backflow cleaning method which Uses compressed air: this method is with- ut doubt the most efficient and the most widespread. Fig. 1 shows a typical dust extraction fl The fitration efficiency of a dust extrac- tion device is represonted by the cureVolume 8 No, 1 JanuaryMarch 1996 showing the progress of the percent of the product retaned as 2 function of the granulematyy of the pollutant. Fig, 2 shows a typical offcioncy cure. 2. ABrief Description of the Inerti: Separation Process Dust rernoval using the inertial separation process 's based on the princple of a static element which opposes the flow of airand pollutant and blocks the mation of ‘he solid particles transported by the fled ‘teat This blocking effect is usualy pro- duced by special fore notworks arranged in sucha way as to create @ porous wall. This wall generates an impact and brak- ing mechanism which leads to the forma- tion of a subsequent outer layer and a. patial internal retention of the product. [AS a consequence, there is a tendency towards a progressive clogging of the fl- ter eloment, in particuar the outer sur- ‘ac0. In this case, the inortia of the solid- gas phase should be limited by increasng the surface area through hich te fluid passes, such that the vio- lence of the impact is reduced and the ‘ormation of the outer layer facitated. in ‘his manner, the probability of penetration by pollutants to the innor layers ofthe fl- tor clomont is reduced, asi tho statistical probability of the fiter barrier beng over: come. This phenomenon would, in fact, ‘reduce the effciency ofthe titration to en Unacceptable level Backflow cleaning allows the formation of permanent layer of product and con- tributes towards stabilising the operation ofthe fitration system with regard to sep- aration eficiency and head loss values. Filtration is nevertheless basicaly a su face action: ie. the iner floras of te fiter are rarely atfoctod, which oxplains tho rel ative thinness of the materais currently in The process takes place with a turbulent action, and as such its mathomatical do: scription entais a rather laborious proce: dure. It is however possible to use the somewhat similar uid dynamics method vwith dimensional analysis for a general description of the process, 3. Fundamental Parameters of Inertial Separation The eticiancy of the separation can be defined in cimersional analysis terms a a functon of the parameters which take into consideration the action of the inerta ‘oroes, tnictional forces and the effects of pressure and viscosity. ne = Flu, Re, Sth) 64 Fg.2 Tyce enceney cane. — E\xcn numbor: takes into account the pressure and fuid inertia Eu = Api: v2) ~ STOKES number: takes into account the inertia conditions and viscosity of the fuid Stk = pr-v oP/MD) Remotos number: takes into account the inertia conditons and friction in the fui Re=v- DN where 40 pressures density ofthe fluid velocity of the ftuid pt density ofthe pollutant d_ dimension of the polutant particles, ht dynamic viscosty of the fid D characteristic dmensions of the separator kinematic viscosity of the fluid. ‘These parameters can be used to set ud a system of equatons derived from the dimensional equivalence trom which the exponents of each value can be defined. ‘The completion of these analyses then requires comparison with laboratory tests, for the defition ofthe system constants. ‘The separation efficiency is, as aresuit, a functon of the folowing parameters: dgranulometry of the pollutent part clos. G specific weight of the separator ‘Sf thickness of the separator Df dimension of the filtres making up the separator Separation ticancy Geanvomoty irons) velocity of fuid fow density of the fis Pr density of the pollutant viscosity ofthe fui. Ne = Fld, G, Si, Df, pD, vp, Pr). Po density of these fibres v p 4. Origins and Develop- ment of the Various fer Element Configurations 4.1 Configurations 444 Bag The fiter bag is without doubt the oldest ‘and widest used configuration. Basically itconsists of a cyindrical surface of mod: ‘ost thicknoss. In this configuration, tho total area of the barrier exposed 10 the flow of polluted air is rather small. On the ‘other hand, ii does have the advantage of being suitable for almost any polutart ust, in that its smooth exterior surface ‘prevents partes of the product from be- coming trapped and therefore also ‘makes cleaning easier ‘One serous disadvantage of tis configu: ration is the smal flter area of each ele- ‘ment which drastically reduces the ratio between the fiter surface araa itself and the overall volume of the machine. The results are diseconorries in the manufac: ture of the various accessories, the sup- port structure and housing, etc 4.1.2 Cartridge ‘The cartridge configuration was devel- ‘oped to provide a solution to the need toincrease the fiter area while keaping the dimensions of the machino to minimum, The cartridge basicaly consists. of an ‘area of fabric of modest. thickness, pleated, and fixed toa rigid support to in: Ccroase the fiter surface area to that of the ‘oxternal dimensions of the fiter body. In this manner, the ratio between the fiter surface and the overall volume of the ma Cchine is increased substartialy, The re: Sut § the characteristic star type section. the more the angle between the sides forrring the point is reduced, the greater isthe fiter area for each size of element ‘The most serous disadvantage is the i compatibility of ths geometry with prod: Ucts having hygrescopic characteristics: Ccohesion, compaction. the presence of grease and ois, flaments and clots cause obstructions at the folds, reduce the fiter area and clog large areas of the element The impact velocty between sold and surface needs 10 be Imited in order 10 prevent this buld-up, especialy at the inner folds. In addition to the obvious ce- tetiotion problens, this effect also gradually reduces the fitration surface area and progressively worsens. the machine's performance. 4.4.9 Elliptical Bag This configuration was developed to ‘combine tho advantages of the bag with the need to increase the rato between the fitration surface and the overall vol- lume ot the fiter. The section of the ele- ‘Ment is generaly elipscidal in order to allow amore rational and compact Cconfguraticn of the volume of the ma- chine Fg 3: Poygonal her (coutacy ct WAM Spa 4.1.4 Pocket Tris system consists of very wide and thin fiter’alemerts: this coniiguration further increases the ratio between fitra- tion surface and overall volume. This charactoritic makes the pockets particu larly suitable for use on machnes requir ing @ very small outlet fiter stage such as wood machinng toos or bag openers. Tris configuration doos, however, have a few disacvantages: the poor rigidity of the large flat quadrengular surface requires a ‘Special internal structure for support and tensioning the surface, plus the product, ccan fall from one pocket onto the next during cleaning as the surfaces are par- allel and very close together. 4.2. Materials Used The materials used basically consist of bres woven and glazed to form 2 homog- ‘enous and reproducible network, the aim lf which is to form an effcient porous barrier against the pollutant. I the past, these fibres were of natural orgin (natural felts). Nowadays, most fiters ara manu- factured trom synthetic matorials: . polyester . polypropylene. Those two materials aro aloo available in various grades, generally speaking fom 300 to 600 g/m: the higher gades have better polutant intercepting qualities. The number of flores per unit volume in- creases and consequently so does the probabilty of activating the polutant sep aration mechanism. On the other hand, the higher grades also have the highest Fe hhoad lose cr, in other words, offer lower Permeabiity values for the ar 10 be fi- tered. The correct grade must therefore be selected in accordance with tre polu- ‘art, in order to obtain the best possible compromise between fiter efficiency and head loss. The filer element is also subjected to an inital phese of several hours operation without Geaning. Ths enables some fl- tered paricies to be incorporated in the filter labyrinth: ths is dofnod as "procoat ing’ and is done to increase the separa tion efficiency. Inertial separation generally produces a layor of product on the fltration surlace which gradually reduces the permeabily This layer is removed to a great extent by bbackvlow cleaning: this cleaning nowever 'S not 100% effeciive, and the fiter be- ‘comes progressively more clogged. AS a result, the head loss increases untila bal- anced situation is reached. The progress. of this gradual clogging can be controlled through testing: tho more or less asymp. totic progress of this phenomenon pro- vides precious information on the pertor- mance of the configuration used, and on the compatioilty of the separation system with the product to intercept. 4.3. Treatments Each of the materials mentioned ray re: {ure Teflon treating by impregnaton or ‘he application of a membrane: this treat ment alows @ very smooth impact sur- face layer to be obiained tree of any pro- trusions to which the pollutant can adhere. Antisiate treatment can also bo Pelygoral ter courtesy of WAM Spat 65carried cut to prevent the creation of paints of diferent electrostatic potental Detween the transported product, which 'S SUDject to electrostatic charges, and the separation element: diference in alectrostatic potential causes discrarges and sparks which are extremely danger- fous in dusty environments, above all for highly infammable powders. This anti- static treatment is based on the incorpo- ration of stainless steel fibre in the mesh In orde: to provide a contnuous conduc- tot. The entire structure of the dust ex- tractor must then be suitably earthed. 5. BA Selection Guidelines Product Coding ‘There sremany standards, European and otherwise, which classify buk products, according to mare or less complete cate- gates. The standard avaiable for Europe: 'S {SO 3435, iy hay, the standards inst- ‘ute has not yet issued a comparable document: the work was in fact started aporoxrmately 25 years ago by the,com- any WAM spa in order to be able to sat up models to forecast the performance of its_own products (mechanedl screw feeders, fiers, microdosers, valves, ex- tractors). On the bass of the information ‘supplied by the CEMA standard, a prod- ‘uct characterisation procedure was de- veloped and implementac and resulted in {an independent coding model. This work wil be continued by the SMP. Labora- {ores (one of the primary aims of which s the study of bulk material handling toch- ‘nology, the only one in taly) where the techniques have been perfected and standardised. The tota number of buk product samples craracterised to date is ‘over 2000, 80% of which have been studied on pilot plants to verity the mate- fial-machine interface. ‘The procuct code is 2 fundamental it strument for industrial applications, that it describes the chemical-physical ‘charastaristios ofthe prod.ct for hanling purposes and allows sutable precautors: {0 be taken against their particular char- acterstcs. “The parameters ar ~ apparent, vibrated and aosolute spe- cle weit ~ grenuiomety (SO grading) ~ fowabilty ~ abrasive power ~ other relevant characteristics (compac- ton, humidity, et.) This approach can therefore be used to select the configuration of the separator element once the product charactrstics are known, The progressive fed analyses. of the coding wil lead to the definition of 66 Youre: Table 1: Element configuration selection according to granulometry bin ewncee B Granuiomety | _Aoz-ao1s | _A0180-883 3833 Material polyester pobester polyester polypropyiene polypropylene: polypropylene or cartridges: mnfiguration ae bags, bags Configurat elliptical bags: eliptical bags: oliptical bags: pockots roots pockets ‘Table 2: Element configuration selgctoneccordng to fowabity Rowabaity 1 2 3 a index good flowable poor not flowability flowability flowable Material polyester polyester polyester polyester Polypropyiene | polypropylene | polypropylene | polypropylene Foon Teton Teton troormont coating — | coatog | carrigoo | contciges | canvgne tags ags vans bags Configuration alliotical elliptical eliptical elliptical bags ‘bags bags bags pockets | pockets | pocteis | pockets ‘Table &: Element configuration slecton according to abrasive power ‘abrasive 5 6 7 index slightly abrasive abrasive very abrasive ven povenir pobesie | pchestr polypropyene polypropylene polypropylene Recommended wearer | Teflon coating Teflon coating carages canuans in bags gS bags (Configuration elliptical bags: elliptical bags elliptical bags: Dockets poo ‘pockets the characteristics of the geometry, me- terial and treatmert of the filtration sur- faces. ‘The salcction must also tako into account the fitration speed determined by the po- luted fic flow, Example: A configuration of ftering elements for SORBITOL is required. This product is generally vansported pneuratcally in d- luted form, The fitration phase of the fuid Used therefore becomes an important part of the transport system. Product code: 73 AO,150 3 LXU 1. Granulometty (Table 1): allows tolora tion of all configurations and materials 2. Flowabity (3) (Table 2) recommends, care in selecting the configuration and ‘Table 4: Chemical compauibity Product | Polyester | Polyprop- vylene Strongacics | far ‘good Week acids | good | good Strong akai | very poor | good Weak alkali | poor | good Solvents, good | very poor Oricisers good | very poor Hydrotvss | good fair ‘Table 5: Technical compatability Temperature| <60°C | uptos0°C Poyprop-| polyester yleneee Table 6: Other relevant characteristics treatment: it is achisable to apply a Teflon finish to the fitration surfaces. 8. Aorasive power (6) (Table 3): no abra: ‘sive effects indieated 4, Hygroscopicity(U) and compaction 70) (able 6): these characteristics inai- cate the need to use configurations that do not involve the use of car- Characteristic Material | Treatment | Configuration bags Humidity > 159% pohester | Tattoncoating | eliptcal tags palyaropyene pockets Static eectrity bags generation all antisiatc | elipical bags pockets Viscosity Degracabity (2) Hygroscopicty (U) Tendency to form bags See rans | poet, | fHonestg | ity and flaments palypropylene a Presence of ois and greases (W) TTendoncy to compact () Table 7: Fitration speed tridgas ana confirm the need to apply aisuftace treatment. Filtration : tomy 5.2 Pockets and Pleated ost | ND” | a pectetes t canilges | canreiges Atprosont, ovoarch workisbing cared bags begs | bags | out into row materia for uso in eopara ; j ton bya, new methods of sutace fliptical | fitical —efiptcal | reatment andinew coniguratios for itr pockots | pockets | pockets | ements ln this respect, it ie vrorth mentioning the ‘configurations on which researchers in the sector have focused ther attention, Le. the pleated pocket, Tris configuration, whio stil having tho limitations of pleating mertioned previ ously, does alow the fitration surface of each element to be substantially in- creased, and asa resuk greatly increases the rato between fitration surface and machine volume. A problem sill tobe r2- Schuttgut Published 4 times per year For more information, please fax to: Trans Tech Publications Dr.-Ing. Reinhard H. Wohlbier Fax: +49 53 23 96 97 99 +49 53 23 96 97 96 Dust Control ‘solved 6 the realisation of the correct support for the fier element, as. the {def fition of the optimum profile of the in- ‘vidual element for obtanng tne best compromise between iter surtaces, leaning efficiency and fitration speed. 6. Conclusions ‘The report considers configurations o' fi- ter elements curtertly in use and, on the basis of product characterstes, indicates the rational procedure forthe salection of configuration, treatment and materals to vse. No mention is made of other more theoretical aspects which are subject 12 further study. Acknowledgements ‘The authors wish to thank Dr. Giant Vi- fins, Product Manager for the Fitration sector of WAM spa, for his valuable co- operation. References SRMP: Coding of buk materials and powders, SRMP: Theoretical and experimental documents on inertial separation WAM spa: Technical and commercial documents on fiters and titer elements. WAM: Dust fitation manual. Dioxevson, C.: Fiters and Fitration Hand- book; Elsevier Advanced Technology, Oxtord, 1994. ISO 9453: Continuous mechanical han dling equipment - Classficaton and standardisation of buk materials. EEC Directive 89/302 and subsequent amendments. EEC Drective 89/391 and subsequent amendments. A new German-language, technical journal, devoted to Mining & Quarrying, Processing, Conveying, Storing, Loading & Unloading, Transporting, Shipping & Recycling of powders and bulk materials. ‘Subscription prico: DM 184.00 + Postage or