Filter bag sdl presentation v3
description
Transcript of Filter bag sdl presentation v3
31 March 2011
Bongi Cindi
SD & L – Filter Bag Presentation
ContentsContents
• Filter Principle of Operation Filter Principle of Operation
• Advantages and Disadvantages Over ESP’sAdvantages and Disadvantages Over ESP’s
• Filter Types and Filter Cleaning MethodsFilter Types and Filter Cleaning Methods
• The Thermal Power Fabric Filter Plant ComponentsThe Thermal Power Fabric Filter Plant Components
• Fabric Filter Plant CAPEX ComponentsFabric Filter Plant CAPEX Components
• Fabric Filter Plant OPEX ComponentsFabric Filter Plant OPEX Components
• Related Industries in South AfricaRelated Industries in South Africa
• Way ForwardWay Forward
• Filter Principle of Operation Filter Principle of Operation
• Advantages and Disadvantages Over ESP’sAdvantages and Disadvantages Over ESP’s
• Filter Types and Filter Cleaning MethodsFilter Types and Filter Cleaning Methods
• The Thermal Power Fabric Filter Plant ComponentsThe Thermal Power Fabric Filter Plant Components
• Fabric Filter Plant CAPEX ComponentsFabric Filter Plant CAPEX Components
• Fabric Filter Plant OPEX ComponentsFabric Filter Plant OPEX Components
• Related Industries in South AfricaRelated Industries in South Africa
• Way ForwardWay Forward
Filter Principle of OperationFilter Principle of Operation
• Gases (and also liquids) are separated from dispersed particles by passing it through a fabric “medium” with a large surface area
• Particles that are not able to penetrate the medium will be retained on its surface, forming the so-called “filter cake”
• The filter cake is equally important to the actual filtration process as the medium.
Source: Klingspor and Vernon, 1988Source: Klingspor and Vernon, 1988
Advantages
• Filter systems are the main alternative for Electro Static Precipitators (ESP’s) systems
• Offer very high collection efficiencies of typically above 99%, over rather large size ranges
• Performs well in high electric resistivity ashes
Advantages
• Filter systems are the main alternative for Electro Static Precipitators (ESP’s) systems
• Offer very high collection efficiencies of typically above 99%, over rather large size ranges
• Performs well in high electric resistivity ashes
Advantages and Disadvantages Over ESP’sAdvantages and Disadvantages Over ESP’s
Disadvantages
• Larger pressure drop
• The low allowable gas velocity making them larger than ESP plants
• High capital expenditure than ESP’s
Disadvantages
• Larger pressure drop
• The low allowable gas velocity making them larger than ESP plants
• High capital expenditure than ESP’s
Eskom Position
• Currently Eskom power stations has mix of ESP’s & fabric filter plants (FFP’s)
• Based on the effectiveness of the filter bag technology to reduce emissions, Eskom is planning to embark on fleet to replace all ESP’s with FFP’s
• There are immediate capex opportunities to localise on the fabrication and installation of FFP’s
• There are opex opportunities for industrialisation of the filter bag fibre
Eskom Position
• Currently Eskom power stations has mix of ESP’s & fabric filter plants (FFP’s)
• Based on the effectiveness of the filter bag technology to reduce emissions, Eskom is planning to embark on fleet to replace all ESP’s with FFP’s
• There are immediate capex opportunities to localise on the fabrication and installation of FFP’s
• There are opex opportunities for industrialisation of the filter bag fibre
Filter Types and Filter Cleaning MethodsFilter Types and Filter Cleaning Methods
1. Reverse air cleaning1. Reverse air cleaning
2. Pulse-jet cleaning2. Pulse-jet cleaning
3. Shake/deflate systems3. Shake/deflate systems
Source: Soud, 1995Source: Soud, 1995
The Thermal Power Fabric Filter Plant ComponentsThe Thermal Power Fabric Filter Plant Components
Source: HitachiSource: Hitachi
Fabric Filter Plant CAPEX ComponentsFabric Filter Plant CAPEX Components
Design
Civil
• Foundations
• Columns
• Structural Steel
Mechanical
• Bags, Fabric & Support
• Housing & cladding
• Collection hoppers
• Discharge devices
• Filter cleaning device
• Fans & ductingElectrical• Motors• Cables• C&I• Switchgear
Design
Civil
• Foundations
• Columns
• Structural Steel
Mechanical
• Bags, Fabric & Support
• Housing & cladding
• Collection hoppers
• Discharge devices
• Filter cleaning device
• Fans & ductingElectrical• Motors• Cables• C&I• Switchgear
Opportunities
To maximise local content on fabrication and installation
Opportunities
To maximise local content on fabrication and installation
Fabric Filter Plant OPEX ComponentsFabric Filter Plant OPEX Components
Fibre Material
Bag filters made of fabric fibre materials, textile, plastics and ceramics
Factors determining process quality are removal efficiency
Fibre Material
Bag filters made of fabric fibre materials, textile, plastics and ceramics
Factors determining process quality are removal efficiency
Surface morphology of new fiber at 3,000x magnificationSurface morphology of new fiber at 3,000x magnification
Surface morphology of new fiber at 7,500x magnificationSurface morphology of new fiber at 7,500x magnification
Surface morphology of used fiber at 3,000x magnificationSurface morphology of used fiber at 3,000x magnification
Surface morphology of used fiber at 7,500x magnificationSurface morphology of used fiber at 7,500x magnification
Fabric Filter Plant OPEX Components……… contdFabric Filter Plant OPEX Components……… contd
Fibre MaterialFibre Material
Typical fabrics used for bagsTypical fabrics used for bags
GenericName
FiberMaximum temperature Acid
ResistanceAlkali
ResistanceFlex abration
resistanceRelative
cost
Continuous Surges
°F °C °F °C
Natural fibercellulose
Cotton 180 82 225 107 poor excellent average 0.4
Polyolefin Polypropylene 190 88 20093
excellent excellent good 0.5
Natural fiberprotein
Wool 200 93 250 121 good poor average 0.8
Polyamide Nylon 200 93 250 121 poor to fair excellent excellent 0.6
Acrylic Orlon® 240 116 260 127 very good fair average 0.7
Polyester Dacron® 275 135 325 163 good fair excellent 0.5
Aromaticpolyamide
Nomex® 400 204 425 218 fair very good very good 2.0
Fluorocarbon Teflon® 450 232 500 260 excellentexceptpoor forfluorine
excellentexceptpoor for
trifluoride,chlorine,
andmoltenalkalinemetals
fair 6.7
Glass Fiberglas®or glass
500 260 550 288 good poor poor to fair 1.0
Polymer P84® 450 232 500 260 good fair fair 2.5Polymer Ryton® 375 191 450 232 excellent excellent good 2.5-4.0
Sources: McKenna and Turner 1989 and Greiner 1993.Sources: McKenna and Turner 1989 and Greiner 1993.
Fabric Filter Plant OPEX Components ……… contdFabric Filter Plant OPEX Components ……… contd
Fabric Manufacturing process• Woven fabrics:- filters are made of yarn with a definite repeated pattern
• Felted fabrics:- filters are composed of randomly placed fibers compressed into a mat and attached to loosely woven backing material
• Membrane filter:- is a special treatment where a thin, porous membrane (expanded polyfluorocarbon) is bonded to the scrim, or support fabric.
Fabric Manufacturing process• Woven fabrics:- filters are made of yarn with a definite repeated pattern
• Felted fabrics:- filters are composed of randomly placed fibers compressed into a mat and attached to loosely woven backing material
• Membrane filter:- is a special treatment where a thin, porous membrane (expanded polyfluorocarbon) is bonded to the scrim, or support fabric.
Cross-section of filter at 25x magnificationCross-section of filter at 25x magnification
Opportunities
All needling of fabric to be localised
Opportunities
All needling of fabric to be localised Source: freepatentsonline. Source: freepatentsonline.
Fabric Filter Plant OPEX Components ……… contdFabric Filter Plant OPEX Components ……… contd
Bag Manufacturing processBag Manufacturing process
Welding of filter cageWelding of filter cage Filter cageFilter cage
Filter BagFilter Bag
Final ProductFinal Product
Bag stitchingBag stitching
Typical industrial applications for baghouses
Shaker Reverse-air Pulse-jet
Screening, crushing, and conveying of rock products Low temperature steel applications Metal working Mining operations Textiles Woodworking processes Chemical industry Food industry Coal-fired boilers
Cement kilns Lime kilns Electric steel furnaces Gypsum calcining Ore smelters and roasters Sintering plants Rock dryers Foundries Carbon black Magnesium oxide kilns Coal-fired boilers
Pharmaceuticals Food industry Woodworking Sinter plants Metal working Foundries Textiles Chemical industry Coal-fired boilers Asphalt batch plants Municipal waste incinerators
Related Industries in South AfricaRelated Industries in South Africa
Filters are used in many other SA industries to aggregate volumes for industrialisation of filter bags
Filters are used in many other SA industries to aggregate volumes for industrialisation of filter bags
Way ForwardWay Forward
Eskom is looking at Industry to provide input into the fabric filter bag (FFB) strategy, especially on the process around
manufacturing of the bags
Eskom is looking at Industry to provide input into the fabric filter bag (FFB) strategy, especially on the process around
manufacturing of the bags
ENDEND