Product category:
Air handling: Dust + Fume extraction
News Release from: Donaldson Membranes | Subject: Tetratex Release #5102 in Turkey
Edited by the Processingtalk Editorial
Team on 20 September 2005
Filtration media change for cement plant
in Turkey
The employment of Donaldson Membranes Tetratex Release filtration media has increased production at a Turkish cement plant, where a bottleneck at one of the mills was slowing down the cement process
The employment of Donaldson Membranes Tetratex Release #5102 filtration media has substantially increased production at a Turkish cement plant, where a production bottleneck at one of the mills was slowing down the cement process The efficient operation of its mills is vital to maintain its position, therefore a swift and cost-effective solution was required
This article was originally published on Processingtalk on 11 Mar 2008 at 8.00am (UK)
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In addition, because the cement process at the mill uses an automated system comprising state-of-the-art technology, only premium products can be incorporated to resolve emerging problems.
Following a careful evaluation of the mill's production system, Donaldson Membranes recommended the use of Tetratex Release #5102, a 100% Polyester Needlefelt Filter Media employing the economical, high performance Tetratex Release ePTFE Membrane, for 2,500 filter bags, to be manufactured and installed by German specialist Fasse Filter.
The Fasse Filter expertise lies in the provision of filterbags which are tailor-made for individual systems with the highest precision, having sourced precisely the right filter material to meet the application needs.
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Donaldson Membranes, experts in the manufacture of expanded microporous PTFE membranes, films and laminates, can meet the needs of vital applications in a cross-section of markets
As a market-leading producer of filterbags and FIBCs for most applications, Fasse Filter is experienced in handling ePTFE-laminated filter media at all stages of the production and installation process.
Together with Donaldson Membranes the company is renowned for solving problems within filtration applications throughout the world.
An inspection of the mill's cement process revealed that the emission rate and pressure drop of the filterbags was too high.
The existing filterbags were made from a standard Polyester Needlefelt, with a high air permeability of 100-250 l/dm2min, weighing 450-500 g/m2.
The parameters of the filter system were a flow rate of 176500m3/h, with a differential pressure of 197mmwg, cleaning pressure of 6 bars with a time-controlled system.
An order was agreed for Fasse Filter to supply and supervise the installation of 2,500 replacement filterbags, with a snapring bottom, each manufactured from Tetratex Release #5102 filter media.
Tetratex Release is an economical, high performance, surface filtration PTFE membrane, which is laminated onto a variety of substrates for pulse jet baghouse applications, and acts as a primary dust cake requiring no precoat before or during operation.
Tetratex Release is thermally bonded onto the following needlefelts: Polyster/Epitropic anti-static, Polyester, Acrylic and Aramid.
By limiting fine particle penetration Tetratex Release delivers high capture rates, whilst preserving the filter substrate integrity and maintaining optimum airflow at a reduced pressure drop - resulting in higher air-to-cloth ratio, extended bag life and energy savings.
In addition, its anti-adhesive surface decreases the need for cleaning.
Tetratex Release membrane is thermally stable up to 325C, is manufactured from PTFE Floropolymer resin, a chemically inert material - and results in near zero emissions for particles larger than 3 microns.
Designed specifically for applications such as this one, where an enhanced needlefelt surface finish is required for dust cake release, Tetratex Release has far superior collection efficiencies compared to conventional coated needlefelts.
Filtration Efficiency and Fractional Efficiency Graphs.
For this application Donaldson Membranes recommended Tetratex Release #5102 Polyester Needlefelt Filter Media, with an air permeability of 50-100, weighing 500 g/m2.
An order for the required 3,000 m2 of media required for 2,500 filterbags was dispatched to Fasse Filter.
Fasse Filter then manufactured the filterbags to a tailor-made specification.
This involved welding the filterbags lengthwise to minimise the needlestitches, and the previous filterbag dimensions were changed to fit the existing cages perfectly.
Holger Fasse, MD at Fasse Filter, said: "We manufactured 2,500 bespoke filterbags and, in addition to the basic specification, supplied these filterbags with a 50mm reinforcement at the bottom part to prevent damage which is most typical of the type of filterbags previously installed".
After the new filterbags had been in operation for four weeks, substantial improvements were recorded.
The flow rate had increased to 179500m3/h, whilst the differential pressure had decreased to 131mmwg and the cleaning pressure could be reduced to 5 bars.
The plant manager was delighted to report that Donaldson Membranes and Fasse Filter had succeeded in reducing the pressure drop by a third, eliminating all visible emissions and removing the bottleneck, thereby increasing production - and profits at the plant.
Mr Fasse added: "Our customer was extremely satisfied with the results and it quickly became apparent that the investment in new filterbags would pay for itself within a relatively short space time due to the savings in pressurised air, energy, maintenance costs and increased output".
Tetratex Release #5102 is just one of the many high performance products amongst the Donaldson Membranes range of Tetratex filtration medias, which are employed in a wide variety of industrial applications including: cement; incineration; metallurgical; chemical; pharmaceutical; food; plastics; fine chemicals and paint.
Tetratex Release offers enhanced needlefelt surface finish, providing higher efficiency and superior dust cake release than other coated materials.
Donaldson Membranes supplies four efficiency levels of Tetratex membranes: Tetratex; Tetratex Release; Tetratex High Efficiency Membrane; and Tetratex Ultra High Efficiency Membrane.
Manufactured from 100% PTFE Polymer resin, Tetratex membranes are chemically inert and thermally stable up to 325C.
The filtration membranes exhibit on average more than 100 million pores per cm2.
Tetratex membranes deliver the highest particulate capture rates, unrivalled dust cake release, extended filter bag life and energy savings.
Tetratex membranes can be bonded onto a variety of substrates, including woven, spun bonded and needlefelt materials, which are used in pulse jet, reverse air and cartridge type dust collectors and filter baghouses.
"The process equipment and conditions will determine the selection of the most suitable substrate for the application of Tetratex filter media, and a variety of points must be considered," said Donaldson Membranes Industrial Filtration Product Manager George Byrne: "Continuous service operating temperature and peak excursions must not exceed the advised maximums for the selected substrate, and the chosen substrate must have the ability to withstand excessive or undue degradation due to the presence of acids, alkalis and oxidising agents at the process operating temperature.
"Some substrates will suffer degradation if high humidity is present at the process operating temperature".
Mr Byrne continued: "The type of filter unit must also be taken into account, with regard to cleaning method and pressure, filter bag construction and cage configuration.
In the case of a retrofit, as with the Turkish application, history of the existing installation should also be considered".
Commenting on the case study in Turkey Mr Byrne said: "Tetratex ePTFE membranes are used in many parts of the cement process, giving improved airflow throughout, which translates into increased production rates, as proven by the high performance of the media used in Turkey".
He added: "It is also important to note that Tetratex ePTFE membranes have become a significant market player as the fabric and technology of choice in the replacement of electrostatic precipitators (ESP) with baghouse filters in the kiln de-dusting process".
Donaldson Membranes, part of Donaldson Company, a leading worldwide provider of filtration systems and replacement parts, provides a total customer support service from its new UK offices in Newton-le-Willows, with further offices located in Europe, America and Asia.
An internationally respected manufacturer of expanded microporous PTFE membranes, films and laminates, Donaldson Membranes is a technology-driven company committed to satisfying customer needs through innovative research and development.
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