Filtration

Reducing Dust Collector Maintenance and Energy Costs in the Cement Industry | Case Study

Cement Factory Reduces Maintenance and Energy Costs with BHA PulsePleat Filters_Cement-Factory_Parker Industrial Gas Filtration and Separation DivisionIn industrial manufacturing, the need for frequent, costly maintenance is often the stimulus that compels equipment operators to search for a better solution. Time is valuable, and hours spent on maintenance activities could be put towards other responsibilities. 

This was the case when a cement company searched for a solution for the short life expectancy of the filters used in its Fuller pulse jet dust collector connected to and OSEPA high-efficiency separator. 

Cement Company Reduces Maintenance and Energy Costs with BHA PulsePleat Filters - Download Case Study - Parker Industrial Gas Filtration and Generation Division

 

 

Download the full case study, "Finding the Right Filter to Realize Savings and Avoid Costly Upgrades", to get the details on how BHA® PulsePleat® Pleated Filter Elements reduced energy and compressed air consumption costs at a cement factory.      

 

 

The problem

The company was realizing a useful life of its process dust collection filters of only two years, due to a combination of issues: Velocity of the dust in their systems was rendering the membrane material on their filter bags useless. This was allowing for bleed through to the depth of the polyester filter bag, causing an increase of operating differential pressure to over 8 inches (203mm). The high operating differential pressure led to an increase in measured emissions from the system.  

The original system was designed to handle an air flow of 61,000 cubic feet per minute. This called for 975 installed filters. Each filter was made of 16-ounce (500 grams) polyester PTFE laminated felt. The dimensions of each filter were 6.25 inches (158.75mm) by 144 inches (3,658 mm). This resulted in a total filtration area of 19,134 square feet (1,779 square meters.) The air to media ratio was 3.1:1.

 

The solution

Cement Company Reduces Maintenance and Energy Costs with BHA PulsePleat Filters - BHA Pulse Please Filter Elements on Pulse Jet Dust Collector - Parker Industrial Gas Filtration and Generation DivisionThe search ended when the company replaced the existing conventional bags and cages with Parker OSEPA BHA® PulsePleat® filter elements (PFE). PFEs offered the opportunity to increase total filtration area while reducing the physical space required. The same number of elements were installed but they were reduced in length from 144 inches to 57 inches. The spun-bound polyester media, set in a pleat, with molded urethane end-caps required no tube sheet or collector modifications. Due to the pleat design, the total filtration area was increased by 75 percent to 33,590 cubic feet. This reduced the air to media ratio to 1.8:1.  

 

Results

After several months of operation, the cement company realized a number of savings and benefits, including:

  • More than $14,000 annual savings in compressed air consumption.
  • A 2 tph increase in production.
  • A 55 percent reduction of differential pressure while maintaining the full flow requirement of 61,000 cfm.
  • A 200 percent increase in filter bag life — equivalent to more than five years.
  • The shorter element design eliminated the velocity issues and degradation of the filter media.
  • The air to media ratio was reduced to 1.8:1.
  • The total filtration area was increased by 75 percent.


Conclusion

By installing PFEs, the cement company avoided the high costs of modifying their existing equipment or adding a new dust collector. The company has realized full production capability with lower emissions, lower differential pressure, reduced energy costs and less compressed air consumption as well as longer filter life.

To learn more about BHA dust collection products, watch this video:

 

 

Cement Company Reduces Maintenance and Energy Costs with BHA PulsePleat Filters - Download Case Study - Parker Industrial Gas Filtration and Generation DivisionFor more details on how Parker BHA® PulsePleat® Pleated Filter Elements reduced energy and compressed air consumption costs in this application, please download the full case study, "Finding the Right Filter to Realize Savings and Avoid Costly Upgrades".   

 

This blog was contributed by the Filtration Technology team, Parker Industrial Gas Filtration and Generation Division

 

Related content

BHA® Pleated Filter Elements Improve Dust Collection for the Foundry Industry

Compressed Air Treatment Solutions for Today's Manufacturing Plants 

Filtration Technologies and Key Markets

 

 

 

 

 
Categories
Recent Posts by Author

Reducing Dust Collector Maintenance and Energy Costs in the Cement Industry | Case Study

In industrial manufacturing, the need for frequent, costly maintenance is often the stimulus that compels equipment operators to search for a better solution. Time is valuable, and hours spent on...

BHA® Pleated Filter Elements Improve Dust Collection for the Foundry Industry

Business growth creates new challenges. This is the case for plant engineers and maintenance managers responsible for the efficient operation of the most common form of dust collection equipment...

Improving Power Plant Gas Turbine Performance in Harsh Desert Environments

Gas turbine performance is affected by the environmental challenges of a specific power plant installation. In a recent project located in the Middle East, a filtration solution to protect the turbine...
Comments

Have a question about Parker products or services? We can help: Contact Us!

Comments for Reducing Dust Collector Maintenance and Energy Costs in the Cement Industry | Case Study


Please note that, in an effort to combat spam, comments with hyperlinks will not be published.

Leave a comment





Captcha