Prof A Mukhopadhyay

National Institute of Technology, Jalandhar, India

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Background

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A filter medium is any material that, under the operating
conditions of the filter, is permeable to one or more components
of a mixture, solution, or suspension, and is impermeable to the
remaining components.

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 Fabric Filters in Liquid Filtration

Filtration of aqueous fluids

1. Water treatment plants
2. Water desalinization
3. Water discharge treatment plants
4. Industrial process streams
5. Industrial chemicals
6. Drinking water filtration
7. Beverage filtration
8. Filtration of aqueous foods (Sugars, Food processing
plants)
9. Medical filtration applications (Blood filters, Vent filters,
Contamination barriers)
10. Pharmaceutical applications
11. Swimming pool filters
12. Aquarium filters A MUKHOPADHYAY, NIT JALANDHAR 7
Filtration of hydrocarbon fluids

1. Industrial hydrocarbon processing (Petrochemicals,

Resins (solvent base), Lacquers)
2. Aviation and diesel fuel filtration
3. Hydraulic fluids
4. Machine tool coolant and cutting oil filtration
5. Edible oil filtration
6. Engine filtration

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Broadly filtration process contributes to
the followings
Purity of product,
Imbibing functional performance (e.g., clean
room for tissue culture)
Saving in energy
Improvement in product and process efficiency
Protection of machine/instruments and their
components
Recovery of precious materials
Environmental pollution control
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Filtration for Purity of product in Pharmaceutical Industry
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Auto air filter
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Recovery of precious material: Smelter before installation of equipment to
collect silica fume. Toady, in the U.S., no silica fume is released – it is all
captured and used
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Worst Air Pollution Scenario: When Pulse Jet Bag Filter Fails To
Work
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Modern manufacturing facilities contain equipment, such as machines for welding, grinding and
cutting, along with CNC machine tools for turning, grinding and milling for example, that give off oil
mist in the production environment when operating.

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Performance numbers were:
• Average inlet: 28.3 mg/m³
• Average outlet: 0.001 mg/m³
• Efficiency: 99.999%
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Different filter media with activated carbon
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Illustration of cartridge respirator filter structure
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 It can absorb up to 500 times of its own weight of pure water
and even under pressure resist release of the absorbed water
Super Absorbent Polymer (Sodium Polyacrylate)
Due to the extraordinary water absorption properties the super
absorbent polymers (SAPs) are used widely in diapers, training pants,
adult incontinence products and external feminine hygiene products,
as well as agricultural andA MUKHOPADHYAY,
gardeningNITapplications.
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Super absorbent textiles for Filtration – water extraction

Key application areas:

Aviation – water and particulate removal from aviation fuel
Automotive – water and particulate removal from diesel
Oil – water and particulate removal from wide range of oils
and waste oils.

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Removal of mist (liquid droplet)NITthrough
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Candle type demister
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 Coalescing Media/Separators

• Mechanisms of separation by porous filter

media:
– Coalescence by means of depth filtration

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• Mechanisms of separation by porous filter media:
– Separation by means of surface filter

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Schematic of a fuel filter/separator
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Filter / gel behaviour under stress
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Extraction through tea bag
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Electro-filtration
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 Bactericidal Enzyme HEPA Filter In Food Industry

Mechanism of Lytic Enzyme

The primary characteristic of enzyme filter is to positively extinct the captured
microorganisms with the lytic action immobilized enzymes to the filter, which
leads to a solution of preventing a deterring secondary contamination.
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Mechanism of Particle Separation

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Single Fibre Filtration mechanisms

Diffusional Fiber
deposition

Streamlines (air
moving
Inertial trajectory)
impaction

Direct Capture by Charge on the

electrostatic fiber surface
interception forces

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Pores in Nonwoven fabric

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 An industrial filter operates under the mode of surface
filtration; retaining particle inside the structure by depth
filtration deters the performance of filter.

Surface filtration Depth filtration

Particle shape is important 41

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Surface Depth loading filter
loading filter
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 Surface-loading filter Depth-loading filter

Dust cake Filter media Dust particles Filter media

• Low Density
• Dust air side with low porosity like
membrane • High porosity space for dust
• Small pores, low thickness loading
• Supporting structure with high • Progressive pore size distribution
porosity and high mechanical strength from dust to clean air side
• For higher dust loading • For lower dust loading
• Cleaning required • Cleaning not required
• Energy requirement high • Energy requirement less
• For industrial use • For clean room application
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Comparison of depth and surface filtration
Aspects of Depth filtration Surface filtration
comparison
Field of HVAC and process air Process air and de-dusting
application technology technology
Mechanism Separation of particles within Separation primarily by media
filter media; filter has to be surface; cleaning is necessary
replaced when clogged
Material Voluminous nonwoven, Compacted nonwoven, porosity is
characteristics porosity is in general high (90- low (45- 80%); mass/unit area =
99%); mass/unit area = 50 – 80 – 1000 g/m2, type of fibre
800 g/m2 , type of fibre depending on application
depending on application
Typical Concentration < 5 mg/m3 Concentration > 5 mg/m3
parameters Air velocity = 0.2 – 4 m/s Air velocity = 0.005 – 0.05 m/s
Pressure differential = 20 – Pressure differential = 1000–
600 Pa 3000 Pa
Temperature = -200C – 600C Temperature = 200C – 2500C
Filter media Filter mats, rigid filters, Filter bags, filter cartridges, filter
pocket filters, filter cartridge, plates, filter candle
EPA/HEPA/ULPA filterNIT JALANDHAR
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3. Pore sizes and shape is determined by fibre arrangement
and its consolidation. The size of pores is usually large
compared to the size of the particles filtered-unlike sieve or
some membrane filter.

Complete blocking Bridging filtration

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 Depth straining mechanism

Depth retaining mechanism

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Depth loading filters

Turbo machinery Pocket filter

HVAC systems

Automobile air filter Automobile oil filter

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Surface loading filters

Welding Heavy duty

applications oil filters

pharmaceutical
industry

Used in compressor
industrial bag filter

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 CAKE FILTARTION

Cake filtration is perhaps the most widely used filtration system

in industry. In cake filtration, the solid material separated from
the liquid accumulates on the surface of the medium so that,
after a short initial period, the deposited solids form a cake
through which the liquid must pass.

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Application of Atmospheric Air filters

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 Air Contaminants

Pesticides Diesel Soot Virus Tobacco smoke Radioactive Bacteria Atmospheric Coal dust Pollen Carbon black Beach sand
(0.001 m) (0.01-0.1 (0.005-0.3 (0.01-4 µm) fallout (0.5-10 Dust (1-100 (10-1000 (20-10000 (100-10000 µm)
m) µm) (0.1-10 µm) µm) (0.001-30 µm) µm) m)
m)

Filtration Strategies
REVERSE
OSMOSIS ULTRA FILTRATION PARTICLE FILTRATION
NANO FILTRATION MICRO FILTRATION
Ionic Molecular Macromolecular Micro-particle Macro-particle
0.001 0.01 0.1 1 10 100 1000 10000

Chemical Capture Mechanical Capture and Electrostatic

Capture

Applications

Facemask NIT JALANDHAR

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 Cleanroom
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Semiconductor Cleanroom
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Cleanroom for Tissue Culture
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Cleanroom for operation Theater
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In Aerospace

Dispersion of Microbial Aerosols in Passenger Cabins - Effect of

Different FilterNITEfficiencies
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Cleanroom Classification

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Application of Ventilation and other Atmospheric Air filters
[In many cases High Efficiency Particulate Air (HEPA) filter are
used]
•Pharmaceutical
•Bio technology
•Chemical industry
•Nuclear air ventilation
•Medical industry
•Food industry
•Automotive industry
•Nanomaterials
•Space industry
•Military equipment
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Classification of depth-loading filters according to EN 779 and EN 1822
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Classification of HEPA filter

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A filter with higher airflow resistance requires more energy
consumption to push airA MUKHOPADHYAY,
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filter.
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* Media velocity reduces at second and third stage due to
pleating of the structure
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Filter for cleanroom
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Ways to increase dirt holding capacity

Increase the surface area of the medium

Use a prefilter

Gradient density filter media

Use bulkier and thicker media

Use of charged media

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Fiber Formation Technologies

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Physical Characteristics of Commercial Nanofiber Webs:
Comparison to Melt blown and Spun bonded Webs

Fiber type Fiber size range Fiber surface Weight range

(microns) area (m2/g) (g / m2)
Nanofibers 0.05 80 0.02 – 0.5
Melt blown fibers 2 2 5 – 200
Spun bond fibers 20 0.2 8 – 350

However, manufacturing of nanofibres at commercial and

economical scale has not yet been realized.

Using finer fibre at downstream for HEPA and Upstream for

Industrial Gas filtration. If there is chance of delamination
during pulse jet cleaning, then it can be sandwitched
between woven fabric.
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 Fine fibres can also be produced using different process.
Fibres such as bi-component fibres, which have large number
of island fibres, can be produced and could be useful in
making finer denier fibre fabrics.

Island fibres

Evolon… The Next Generation

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(Fibre Separation through water-jet)
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Bicomponent Fibers

PPS

PET

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Bicomponent Fibers

3 denier 0.19 denier

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Islands-in-the-sea As-spun Fiber

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Shape factor

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Surface area of the 4DG fiber is 2.3-2.8 times that of a
round cross-sectioned polyester fiber of the same denier.

4 DG Fibre
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Electrostatic enhancement of fabric filter

There are three principal charging processes:

• Triboelectric charging,

• Corona charging,

• Induction charging

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Corona Charging on Media
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Electret Fibre
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Induction Charging
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In pseudo-electret filters, the polarity of the dc voltage can be reversed
periodically every few minutes, and in this case the electric field can be
restored at almost twice the magnitude because of the combination of the
imposed voltage with the potential due to the accumulated charge.

Pseudo electret
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• Use of electrostatic precipitator

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 Innovation in HEPA Filter

• Improvefilter life.
• Improve dust loading capability.
• Reduced maintenance.
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Atmospheric Air filters
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Atmospheric Air Filters
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Filter with activated carbon for HVAC application
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Nonwoven filter medium with activated carbon for gas
adsorption (REM)
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PLEKX® adsorption medium wherein an activated carbon
layer sandwiched between two nonwoven layers
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Composition of the composite media HVAC
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Physical Properties of Major Type of Absorbent

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Purafil Triple-Blend Media removes the widest variety of odors and
gases from applications where jet fuel fumes, diesel exhaust and
automobile emissions are present. The Purafil chemisorptive
process remove contaminant gases by means of adsorption,
absorption, and chemical Areaction.
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Pollutant emissions from diesel-engine vehicles

The composition of diesel

exhaust gases

Harmful products are generated due to the air–fuel ratio, ignition

timing, turbulence in the combustion chamber, combustion form,
air–fuel concentration, combustion temperature etc

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 Controlling through
Diesel oxidation catalyst (DOC)
Diesel particulate filter (DPF)
Selective catalytic reduction (SCR)

Through ammonia injection enables high separation efficiency

for toxic nitrogen oxides (NOx) and other harmful gases.

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ndustrial Gaseous Pollution and Health Impac

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The most important particle formation mechanisms in
air pollution sources include the following:
Physical attrition/mechanical dispersion
Combustion particle burnout
Homogeneous and heterogeneous nucleation
Droplet evaporation

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Relative size of common filtered particles

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Impact on Health
Lungs are anatomically structured to bring large quantities of
air (on average, 400 million litres in a lifetime) into intimate
contact with the blood system, to facilitate the delivery of
oxygen.
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 Hindustan Times February 14, 2016

“Air pollution is the fourth-highest risk factor for death globally and
by far the leading environmental risk factor for disease (heart
disease, stroke, lung cancer, bronchitis, emphysema and acute
infections)”.
Air pollution caused more than 5.5 million people die prematurely in
2013, with more than half of those deaths in India and China, 1.6
million people in China and 1.4 million people in India in 2013.”
Air pollution caused more than 9 million people die prematurely in
2015, with more than half of those deaths in India and China, 1.8
million people in China and 2.5 million people in India in 2015.”
Extraction from
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https://www.theguardian.com/environment/2016/feb/12/air-pollution-dea
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Impact on Health

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Occupational Hazards / diseases due to expose industry and
polluted air

Silicosis (Silico-tuberculosis) Asbestosis 
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 Coal worker’s
Byssinosis Pneumoconiosis

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Body defense mechanism for particles above 2.5 µm

Nose hair

Movement of cilia sweeps mucus upward and

help removing particles above 2.5 µm
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Particulate size with associated depth
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Body defense mechanism for particles below 2.5 µm

Very small particles can enter into the blood stream by hydrostatic
pressure. Number concentration of the particles in the environment plays
a vital role.

Lung tissue has an abundant blood supply that can carry toxic
substances and their metabolites to distant organs.
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Industrial Gas Filtration

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Gaseous and particulate pollution
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Clean Environment
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Controlling Mechanism for Industrial Dust Emission

Gas-borne dust particles may be collected by out of the several

techniques, viz.,
 Settling chamber (using gravitational effect)
 Baffle Chamber (using inertial impaction) Removal of coarse
particles, i.e.,
 Cyclone (using centrifugal principle) above 20 μm

 Electrostatic precipitator
 Fabric filter Removal of coarse as well as
fine particles less than 10 μm
 Wet scrubber
Arguably the most efficient and versatile is the fabric collector,
especially when processing very fine particles typically in the
range of 0.1 – 10 μm , which are slow to settle and by virtue of
their greater light scatter, more visible to the naked eye.
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Outlet Inlet

Dust
Settling chamber
Outlet
Inlet

Baffle
chamber Dust Cyclone
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Multi-cyclone
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Electro-cyclone
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 Uses of Cyclone and Multi-cyclone

 Uses principle of Centrifugal force (F) to collect coarser particles. F is

proportional to mv2/r, i.e.,
Force α Mass x (Velocity)2
Particle radius
 Commonly used to remove relatively large particles from gas stream.

 Cyclone often used as Pre-cleaner (followed by bag house / ESP).

 As a Pre-cleaner often designed to remove 80% of particles that are greater

than 20 µm in diameter.

 No moving parts, Relatively inexpensive to construct

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Mechanical separation ofJALANDHAR
particles before bag filtration
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 Electro Static Precipitator (ESP)

Main Components: Emitting Electrode Assembly , Collecting Electrode Assembly,

Transformer-Rectifier Sets, Voltage Controllers , Rapping System, Material
Conveying System A MUKHOPADHYAY, NIT
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Working Principle
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Electrostatic Precipitators - Discharge Electrodes

For low dust loads &

C en trelin e
coarse particles

For fine particles &

Tang ential medium dust loads

For very high dust

loads & high
D o u b le D ensity
resistivity dust
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Pip e & Sp ike Ty p e D isch arge E lectro d es
Two types of electrostatic precipitators:
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parallel-plate (a), tubular (b)
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Electrically energized cyclone (electrocyclone)
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 Remove
Liquid droplets such as
sulfuric acid mist
Combustible particulate,
Particles that are sticky in
nature.

A wet electrostatic precipitator (WESP or wet ESP) operates

with saturated air streams (100% relative
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Wet Scrubber

Probably, scrubber is the

only pollution control device
that can effectively and
economically remove dust
and gas at the same time.
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Sustainability issues of industrial bag filtration process

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General application of particulate control system

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Mechanical/Reverse jet filtration System

Inside to outside filtration; (a) Filtration (b) Reverse jet

cleaning and dust dislodgement
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Mechanical shaker baghouse
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Reverse jet arrangement
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A typical set-up for industrial pulse-jet filter unit
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Municipal Solid Waste Incineration Coal-fired Industrial Boiler
16 MW – 65,000 ACFM 110,000 ACFM

Utility Boiler
500,000+ ACFM

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Bags with cage
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 High pressure low volume

Siemens pulse-jet filter (HPLV)

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 High pressure low volume

Industrial pulse-jet bag house (HPLV)

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 Medium pressure medium volume

Fitting of blow pipe

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 Medium pressure medium volume

Pulse-jet filter unit (MPMV)

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 Low pressure high volume

PJFF ACI

ESP

Pulse-jet filter unit (LPHV)

TOXECON Set-up designed by Electric Power Research
Institute, USA and ADA - Environmental
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 Internal clean air manifold
–Three arm arrangement
–Continous rotation at 1 rpm
–Clean up to 40 bags per pulse
•One manifold per bundle
–Up to 1,600 bags per bundle
•Direct access to bags/cages
–NO pulse pipes to remove

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 Low pressure high volume

Cleaning arm directs air flow. When the

cleaning arm and bag segments are correctly
aligned, air nozzles fire directly into the bags.
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 Air pressure
Filtration during cleaning

Pmax
P

Time Time
Time Time

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 ΔPmax

Unstable

Stable
ΔPR

Residual pressure
drop

Pressure drop characteristics with time

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Clean-on-demand mode
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Clean-on-time mode
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Emission through fabric filter
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Designing of Filter Media for

Industrial Gas Filtration

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Designing of Filter Media

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Properties required for Filter Fabrics for Liquid Filtration
Machine-orientated Application-orientated Filtration-specific
properties properties properties
I. Rigidity I. Chemical stability I. Smallest particle
II. Strength II. Thermal stability retained
III. Resistance to III. Biological stability II. Retention efficiency
creep/stretch IV. Dynamic stability The structure of filter
IV. Stability of edges V. Absorptive media
V. Resistance to characteristics Particle shape
abrasion VI. Adsorptive Filtration mechanisms
VI. Stability to vibration characteristics III. Resistance to flow
VII. Dimensions of VII. Wettability Porosity of media
available supplies VIII. Health and safety Permeability
VIII.Ability to be aspects IV. Dirt-holding capacity
fabricated IX. Electrostatic V. Tendency to blind
IX. Sealing/gasketing characteristics VI. Cake discharge
function X. Disposability characteristics
XI. Suitability for reuse
XII. Cost
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A MUKHOPADHYAY, NIT JALANDHAR 165
Basic manufacturing of filter fabric
Manufacturing of nonwoven filter through three basic processes;

A MUKHOPADHYAY, NIT JALANDHAR 166

 Basic manufacturing of filter fabric

Manufacturing of nonwoven filter through three basic processes;

A MUKHOPADHYAY, NIT
(a) Needle felting, (b) Spun-bonding, (c) Spun-laceing (hydro-entangling)
JALANDHAR
167
 1. Fibre selection: Resistance to Various Air Filtration
Conditions

A MUKHOPADHYAY, NIT JALANDHAR

168
Hint : E = Excellent, G = Good, F = Fair, P = Poor.
Continued…

A MUKHOPADHYAY, NIT JALANDHAR

Hint : E = Excellent, G = Good, F = Fair, P = Poor. 169
 MATERIAL FOR HIGH
TEMPERATURE
FILTRATION

HIGH CERAMIC METAL

PERFORMACE
FIBER

PPS RIGID FLEXIBLE METAL FIBER

(190°C/200°C) (WOVEN AND FELT
NONWOVEN) (530◦C)
HIGH (10000C)
POYIMIDE DENSITY
(240°C/260°C) SINTERED
(10000C)
METAL FIBER
(600◦C)
PAN LOW
(1400C) DENSITY
SINTERED
(1000◦C)
METAL
ARAMID POWDER
(200°C/220°C) (540◦C)

GLASS
(260°C/288°C)

BASALT
FIBERE
(6000C/6500C) A MUKHOPADHYAY, NIT JALANDHAR 170
Hot Gas Filtration

A MUKHOPADHYAY, NIT JALANDHAR 171

Sintered metal powder

Sintered metal fibre

A MUKHOPADHYAY, NIT JALANDHAR 172
2. Role of fibre fineness on filtration
1. Filtration is a surface property
2. Finer fibers have more retention than same volume of
coarser fiber.

A MUKHOPADHYAY, NIT JALANDHAR 173

 Regular fibre Micro Fibre Nano fibre
Size (micron) 20 2 0.05

Specific surface 0.2 2 80

area (m2/gm) A MUKHOPADHYAY, NIT JALANDHAR 174
3. Fibre Individualization and Uniformity

Non-uniform web and fibres in group

A MUKHOPADHYAY, NIT JALANDHAR 175

4. Role of fibre cross sectional shape

A MUKHOPADHYAY, NIT JALANDHAR 176

Surface area of the 4DG fiber is 2.3-2.8 times that of a
round cross-sectioned polyester fiber of the same denier.

4 DG Fibre
A MUKHOPADHYAY, NIT JALANDHAR 177
 Thru-air Bonded
5. Degree of Consolidation
Higher Bulk

Stitch
Bonded

Spunlace

Needle
Punched

Spunbond
NONWOVEN FABRICS
Calendar
Bonded
Lower Bulk
A MUKHOPADHYAY, NIT JALANDHAR 178
A MUKHOPADHYAY, NIT JALANDHAR 179
A MUKHOPADHYAY, NIT JALANDHAR 180
Needle Arrangement

181
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Sequence of machine for needle punched filter media

A MUKHOPADHYAY, NIT JALANDHAR 182

 Fabric with and
without pinhole

Particle penetration during filtration

A MUKHOPADHYAY, NIT JALANDHAR 183
 Typical cross section of Needle Felt

Good surface collection of the dust on the flue gas side

A MUKHOPADHYAY, NIT JALANDHAR 184

Spunlace (Hydroentangling) process

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Hydro-entanglement Jets

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Mechanism of Hydro-entanglement Process

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Multi-stage Hydro-entangling Unit

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Schematic diagram of Spunbond nonwoven

A MUKHOPADHYAY, NIT JALANDHAR 189

Pleated Filter Element
A MUKHOPADHYAY, NIT JALANDHAR 190
6. Pore structure of textile material

A MUKHOPADHYAY, NIT JALANDHAR 191

Total Voids ( C)

A MUKHOPADHYAY, NIT JALANDHAR 192

Voids and porosity

A MUKHOPADHYAY, NIT JALANDHAR 193

A MUKHOPADHYAY, NIT JALANDHAR 194
Pore throat
Minimum diameter of continuous or connected pores is commonly
referred to as pore throats 

Where, d1 = throat diameter

d2 = average diameter
d3 = entry or exit diameter
S = surface of pore
V = volume of pore

Schematics of a pore in fibrous network

A MUKHOPADHYAY, NIT JALANDHAR 195

Pore sizes and shape is determined by fibre arrangement and
its consolidation. The size of pores is usually large compared
to the size of the particles filtered-unlike sieve or some
membrane filter.

A MUKHOPADHYAY, NIT JALANDHAR 196

Pore shape and equivalent particle size concept

• Hygroscopic particles are

heavier and easy to capture
than non-hygroscopic particles

• Free flowing vs agglomerating

nature of particles
A MUKHOPADHYAY, NIT JALANDHAR 197
7. Fibre Orientation and Alignment of Pore

Spunlace Nonwoven Spunbonded Nonwoven

Needle Punched Nonwoven

A MUKHOPADHYAY, NIT JALANDHAR 198
Tortuosity of pores
Tortuosity factor : It is defined as the ratio of the
actual length followed by a streamline to the
thickness of the filter bed.
Tortuosity factor  = ( lc / l )
 = Tortuosity
l = Thickness of porous
medium
lc= Length of pore path

A MUKHOPADHYAY, NIT JALANDHAR 199

Special shape of needle board – angled needle
penetration:

A MUKHOPADHYAY, NIT JALANDHAR 200

201

Challenges to Industrial Gas Filter

A MUKHOPADHYAY, NIT JALANDHAR

1. Efficient filtration of fine particles
Requirement for lower PM2.5 emission which necessitate compact fabric, whereas it will also lead to higher
differential pressure.

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A MUKHOPADHYAY, NIT
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Use of membrane or coating
Due to the extreme thickness (12–75 μm) of the membrane, it is
essential to combine it with a suitable substrate either by special
adhesives or, where appropriate, by flame bonding.

One most popular micoporous PTFE membrane is chemically inert

and can withstand high temperature (2600C).

A MUKHOPADHYAY, NIT
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PTFE microporous film (Magnification 500 times)
JALANDHAR
Hot melt laminating with engraved roller
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Recently use and benefits of ultra-high molecular weight polyethylene
(UPE) is also reported. UPE based membranes, with their microfibrillar
structure, bridge the gap between membranes and non-wovens. Foam
layer can also be used on nonwoven fabric.

Electron photomicrographA MUKHOPADHYAY,

ofJALANDHAR
a foam NIT layer on a nonwoven fabric
206
Unlike membrane coating is applied in a single process over
the fabric. Slightly higher fabric resistance during first few
month.

PTFE microporous film Surface of a typical porometric film

(Magnification 500 times) or coating showing the micropores
A MUKHOPADHYAY, NIT
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 Thermo-bonded fabric Microscopic coating

Microscopic coating Microscopic coating

SEM image of thermo-bonded fabrics and media with

microscopic coating
A MUKHOPADHYAY, NIT JALANDHAR 208
Use of layered fabric concept

Cross section hydroentangled composite with meltblown layer (HYCOFIL®) [By

courtesy of Sächsisches Textilforschungsinstitut e.V. (STFI), Chemnitz, Germany]
A MUKHOPADHYAY, NIT
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Mechanical Separation

Perforated mail box

Different types of dust entries

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Cascadair
A MUKHOPADHYAY, NIT
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Expandiffuse™ 
A MUKHOPADHYAY, NIT
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Combination of Cyclone and Fabric Filtration

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Use of Hybrid Filter
Electrostatic precipitator may be used in line or may be
embedded with fabric filtration system.

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Hybrid Filter

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A MUKHOPADHYAY, NIT
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A MUKHOPADHYAY, NIT
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 PJFF ACI

ESP

Pulse-jet filter unit (LPHV)

TOXECON Set-up designed by Electric Power Research
Institute, USA and ADA - Environmental Solutions, USA
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ADVANCED HYBRID™ filter system
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Multi-Stage Collector
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Bag filter with assistive
A MUKHOPADHYAY, NIT ESP 221
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Advanced electric
A MUKHOPADHYAY, NIT fabric filter
222
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Advanced electric fabric filter
A MUKHOPADHYAY, NIT
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A MUKHOPADHYAY, NIT
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Nonwoven filter medium with
A MUKHOPADHYAY, NIT reinforced scrim
225
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Anti-static bag

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 Level of Filtration Velocity
The relatively low values of face velocity are typical for fabric
filter.

Single Fibre Filtration Mechanisms

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Role of Fibrous Assembly

Mechanism of surface filtration. (a) Complete blocking

filtration; (b) Bridging filtration
A MUKHOPADHYAY, NIT
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Depth filtration: (a) Depth straining mechanism,
(b) Depth retaining
A MUKHOPADHYAY, NIT mechanism
229
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 Particle type Filtering velocity
(m/min)
Carbon black 1.5
Alumina 1.8
Wood flour 3

Higher velocity leads to shorter filer life and greater emission.

Lower velocity signify larger filter unit.
A MUKHOPADHYAY, NIT
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Pleated needle punched filtered media
Reduce velocity, thus reduce emission
A MUKHOPADHYAY, NIT
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Dust settlement
Online vs offline filtration

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 Control of Can Velocity

QOut QOut

V1 V2

QIn QIn

A MUKHOPADHYAY, NIT
233
Same air to cloth ratio
JALANDHAR
How to verify the “can velocity”?

Side view Q
Q Q
V 
A  d 2 
V ( x  y )   n  
 4 
Q
y
Tube sheet With:
dimensions n = number of bags
d = bag diameter
d

x = tube sheet length

x

y = tube sheet width

Q = Air flow

A MUKHOPADHYAY, NIT
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Scheme of a Stationary Panel Filter with Moving Suck-off Nozzle
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Air flow through multi-drum filter
A MUKHOPADHYAY, NIT
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Cleaning Control Sequence
 Recommended cleaning sequence
Typical cleaning sequence Recommended cleaning sequence

 Example of recommended cleaning sequence for a dust

collector with 17 bag-rows and 10 timer positions:

A MUKHOPADHYAY, NIT
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Level of cleaning

Filtration and Protection of Primary dust layer

Initial Dust layer Final dust deposit

Clean fabric
deposition of deposit on the when increase of
dust in surface of the pressure drop
interstitial pores fabric acts as calls for cleaning
filter media of fabric
238
Challenge for optimizing pulse parameter
(Pulse pressure, pulse duration, pulse cycle)

Lower Pulse intensity

Higher efficiency
Gaseous absorption by dust cake
Greater differential pressure hence higher energy requirement

Higher pulse intensity (only 10-15% energy is for cleaning)

Lower energy requirement

Damage of filter bag due to flexing and membrane rupture
Greater depth filtration leads in reduction in life
Lower efficiency,
A MUKHOPADHYAY, NIT
239
Introduction of sonic energyJALANDHAR
to clean the bag
Comparison of the operating costs of a conventional jet-pulse baghouse filter with a ProJet
megaR filter in offline operation mode and a ProJet megaR filter in online operation mode.

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Particle penetration at the time of cleaning
A MUKHOPADHYAY, NIT
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Use of conditioning agent for a fresh bag

With Initial dust cake of conditioning agent, the fabric is protected

from particulate, while still allowing air to pass through the dust
cake A MUKHOPADHYAY, NIT
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JALANDHAR
Change in plant operational strategies

The ammonia-injection process could provide effective

control of sulfur dioxide from coal-burning power plants.
Further, it can make particles larger in size which are easy
to capture.

A MUKHOPADHYAY, NIT
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2. Hot Gas Filtration

If these gas streams can be cleaned at elevated temperatures

and pressures, then processes can be made more efficient in
terms of energy and more integrated in terms of process
technology.
Lowering temperature by ambient air leads to increase in gas
volume; therefore larger fabric filter with increased cloth area is
A MUKHOPADHYAY, NIT
required for efficient filtration JALANDHAR
performance. 244
A MUKHOPADHYAY, NIT
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A MUKHOPADHYAY, NIT
246
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 MATERIAL FOR HIGH
TEMPERATURE
FILTRATION

HIGH CERAMIC METAL

PERFORMACE
FIBER

PPS RIGID FLEXIBLE METAL FIBER

(190°C/200°C) (WOVEN AND FELT
NONWOVEN) (530◦C)
HIGH (10000C)
POYIMIDE DENSITY
(240°C/260°C) SINTERED
(10000C)
METAL FIBER
(600◦C)
PAN LOW
(1400C) DENSITY
SINTERED
(1000◦C)
METAL
ARAMID POWDER
(200°C/220°C) (540◦C)

GLASS
(260°C/288°C)

BASALT
FIBERE
(6000C/6500C) A MUKHOPADHYAY, NIT JALANDHAR 247
Sintered metal fibre

Sintered metal powder

A MUKHOPADHYAY, NIT JALANDHAR 248
 Pinholes

Damage of filter media at high temperature

A MUKHOPADHYAY, NIT JALANDHAR 249
Damage of filter media at high temperature
A MUKHOPADHYAY, NIT JALANDHAR 250
Composite nonwoven with P84 fibrous batt with P84 Scrim
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3. Size of filter unit

A MUKHOPADHYAY, NIT
Design of cartridge (spun boded) dust collector
JALANDHAR
252
Damaged filter bag
A MUKHOPADHYAY, NIT
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Pleated needle punched filtered media
A MUKHOPADHYAY, NIT
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 Long bag technology up to 15 m
Minimal footprint
Lower maintenance costs

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4. Control of Temperature and Moisture

Burn of bag by spark or high-temperature particles

Two methods that may minimize corrosion are: (1) reheating
the gases to above their dew point, or (2) using materials of
construction and designs that allow equipment to withstand the
corrosive conditions.
A MUKHOPADHYAY, NIT
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5. Control of particulate and gases simultaneously

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The pollutants SO2 and HCℓ are removed by using sodium bicarbonate (NaHCO 3) or calcium hydroxide [Ca(OH)2] as
sorbent, whereas in the presence NH 3 and O2, NOx is catalytically converted to N2 and H2O by passing through the
catalytic filter elements.

Schematic principle ofA MUKHOPADHYAY,

the dry flue NIT gas cleaning system
258
JALANDHAR
Through Sorbent Injection
Pulse-jet filtration process is also extensively used for
simultaneous control of gaseous emission. In general for
removal of gaseous pollution during coal combustion, the
following techniques can be used.
Injection of an alkaline slurry in [Ca(OH)2, NaHCO3] a spray
dryer with collection of dry particles in a fabric filter.
Dry injection of alkaline material into the flue-gas stream
with collection of dry particles in a fabric filter.
Addition of alkaline material to the fuel prior to or during
combustion
Out of the above, spray-drier-filter systems for the
simultaneous removal of SO2 and fly ash from industrial boilers
becomes very common.
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 Need to develop
new technique,
suitable sorbent,
and new catalyst
A MUKHOPADHYAY, NIT
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Structure of the catalytic filter element
A MUKHOPADHYAY, NIT
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 Using Non-Thermal Plasma
Technology based on non-thermal plasma (NTP) is expected
as a new energy source to activate chemical reaction in gas
phase, especially in gaseous pollutant treatment reaction. Non-
thermal plasma is characterized by the fact that the electron
temperature is very high whilst the ion and neutral molecular,
i.e., the gas temperature is low.

A MUKHOPADHYAY, NIT
Schematic illustration of the electrode system
JALANDHAR
262
6. Longer filter life (Most often life is decided by
extent of filter clogging/ depth filtration)

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A MUKHOPADHYAY, NIT
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Principal representation of the cleaning overpressure
decrease during ageing
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A MUKHOPADHYAY, NIT
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A MUKHOPADHYAY, NIT
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Damage due to cage
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7. Challenges in separation of difficult particles

Fabric filtration system is quite versatile as it can handle large

varieties of dust differing in physical and chemical
properties.

Separate/ handle difficult particles like particles with strong

adhesion forces - Paint particles
Light and fluffy particles – Asbestos fibre
Abrasive particles – SiC, Alumina
Particles with high reactivity - Dye particles
Hot particles - SiC
Nanoparticle with adverse gas properties - Flame synthesis
of TiO2 or SiO2 A MUKHOPADHYAY, NIT
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JALANDHAR
Contd…

Mixtures of solid and liquid particles in the aerosol – Tar

collection
Particles with low sticking efficiency - Sugar
Particles causing fire hazards/explosion - Coal, rubber

Particles causing blinding of pores – Milk powder

Filtration at high temperature is also possible with
appropriate textile material – Fly ash

Particles with one or more of these properties occur in a wide

variety of applications
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8. Fibre offering more chemically and hydrolytic
resistance with/without temperature.

9. Material to have more abrasive resistance [e.g., use of

Aramid/P-84 but it is costly; Alternative Strategy:
Lower the velocities (ACR, Inlet Velocity, Can Velocity)]

10. Challenges to reuse the filter bags after its lifetime.

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A MUKHOPADHYAY, NIT
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273

Related Issues and Development

Pollution Prevention vs. Pollution Control

Waste Management Techniques

A MUKHOPADHYAY, NIT JALANDHAR

1. Change in process philosophy: Change in process
philosophy (advent of fluidized bed combustion in coal fired
power plant). Fluidized bed combustion results in less SO2
and NOX emission (by lowering incomplete combustion by
10%) than pulverized coal fired boiler. Prevention is
frequently more cost effective than control.

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2. Change in plant operation (coal washing,
injection of ammonia vapour)
Physical cleaning of coal through washing and beneficiation can
reduce its ash and sulfur content, provided that care is taken
in handling the large quantities of solid and liquid wastes that
are generated by the cleaning process. washing, which can
reduce ash content by upto 40%.

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 3. Alternative Fuels and Raw Materials

Reduces or eliminates the hazardous materials that enter the

production process. It reduces waste treatment costs.
The use of low volatile coals in place of high volatile
coals has proved most effective in eliminating smoke and
the substitution of low sulfur fuels for high sulfur fuels has
reduced the SO2 discharges quite appreciably.
Use of gaseous fuel (LNG) which are low-ash fossil fuels
contain less noncombustible, ash-forming mineral matter
and thus generate lower levels of particulate emissions.
Use of biomass as fuel

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Use of biomass as fuel: In Germany, in many places the
power fuelled by brown coal, has been reconfigured as a
biomass incineration plant. With this plant, the wood used
is exclusively for energy production through combustion,
and comprises low-grade wood varieties from forests, fast-
growing species plantations, remnants from the wood-
processing industry and scrap wood.

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4. Recovery and reuse of waste
Recovery of expensive powder
Waste materials Industrial End use
sources
Fine cement dust Cement plant Paint production in paint
industry, Composite in
polymer industry
Silica dust Smelter for the Composite in plastic
production of industry
ceramic and
silicon metal
Ferrosilicon dust Smelter for the Expensive abrasion
production of powder
ferrosilicon alloy NIT
A MUKHOPADHYAY,
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278
Recovery of precious material: Smelter before installation of equipment to
collect silica fume. Toady, in the U.S., no silica fume is released – it is all
captured and used
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 Reuse of Waste

It is an effective way for waste management. It assists the

manufacturer to achieve sustainability targets through the re-
use of valuable resources currently available.

Coal fly-ash consists primarily of silica, alumina and iron (in

addition to multiple toxic elements like mercury) that mean
that in some applications, it can be used as a partial
replacement for energy-intensive Portland cement used in
concrete.

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Contd…
• The cement producers include some of the non-
hazardous by-products from other industries as their raw
ingredients while making new cement, e.g., fly ash
resulting from the production of electricity, mill scale
resulting from steel making, and foundry sand resulting
from metal castings.
• Cement kiln dust can be used in road base and soil
stabilizing agent.

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Efficient end use of waste material from Industry

Waste materials Industrial sources End use

Foundry sand Foundries and Soil Asphalt concrete, bricks

(Silicates SiO2) remediation & pavers, concrete

Roasted pyrite Metal surface treatment in FDA-approved for use in

(Iron oxide Fe2O3) metal industry cosmetics, used as a
pigment

Gypsum from gas Incineration process and Used in civil construction,

desulphurization, Foundries cement production
Chemical gypsum (Sulfur)

Fly-ash and Crushed sand Metal castings and Additive in cement for
(Si-Al-Ca-Fe) Foundries Concrete production,
Cement clinkers
production
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5. Recycling of collected waste

Recycling indicates use of a waste as an effective substitute

for a commercial product or as a raw material in the
manufacture of a product. This will cause;
Reduction of waste, landfill or dumping,
Substitution for virgin resources and
Reduction in associated environmental costs of natural
resource exploitation.
In Iron and steel industries, approximately 60% of the
baghouse dust is oxides of iron and zinc. It also contains
other metals such as aluminum and magnesium, lead,
chromium etc. The baghouse dust can be recycled for zinc
recovery. A MUKHOPADHYAY, NIT
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283
Aluminium recycling is the process by which scrap aluminium
can be reused in products after its initial production.
Recycling scrap aluminium requires only 5% of the energy
used to make new aluminium which either must have to be
mined from bauxite ore and then refined using the Bayer
process.

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6. Use as a source of energy/raw material

Waste heat boiler from municipal and medical waste incinerator

A MUKHOPADHYAY, NIT
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7. Waste segregation and disposal

It signifies isolating hazardous waste from nonhazardous waste,

avoiding contamination of wastes with water.

It has the following advantages:

Safely minimize the potential of hazardous waste for release into

the environment.
Waste segregation and disposal can be a simple and effective
pollution prevention technique applicable to a wide variety of waste
streams and industries.
The practices for segregating wastes include isolating hazardous
waste from nonhazardous waste, avoiding contamination of wastes
with water etc. Disposal involves the transfer of a pollutant to the
environment in air, solid waste, or water.
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Waste segregation and disposal

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 Be
pr com
ef
er ing
re
d lea
st

Waste Management Hierarchy

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Many new designs differing in construction and raw material
have come up and are continuously evolving. The main
issues for such developments are:

Filtration efficiency
Flow resistance
Filter life (resistance to blinding/plugging, improved
resistance to thermal, chemical, hydrolytic and oxidative
degradation)
Size
Greater storage/dirt holding capacity, wherever applicable
Optimum cleanability
Specific performance characteristics (absorption of gases,
anti-bacterial, anti-microbial oil/water repellant, static
dissipating, spark resistant, abrasion resistant)
Lowest cost vs. performance/benefit
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In addition, current world, social, economic and
environmental conditions have created a new set of
requirements to add to the above:

Disposability/recyclability
Sustainability
Green impact in production (minimal environmental
impact)
Energy savings

All these requirements have impact on industry, its producers

and their products are still, to a degree, unknown, but
major media manufacturers are already moving to meet
these objectives and toA MUKHOPADHYAY,
capitalize
JALANDHAR
on them as well.
NIT
290
Thank You
A MUKHOPADHYAY, NIT
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JALANDHAR
A MUKHOPADHYAY, NIT
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A MUKHOPADHYAY, NIT
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