Filtration

Foundry Improves Throughput and Reduces Maintenance Costs | Case Study

Foundry Improves Throughput and Reduces Maintenance Costs | Case Study - Molten-Metal-Foundry - ParkerIn today’s foundries, facilities engineers and maintenance personnel are challenged with effectively balancing increases in throughput with reductions in costs. Maintaining the optimum performance of baghouses is a critical area of focus as they can have a significant impact — either positive or negative — on the output of a foundry.  

 

FoundryLearn how a U.S. foundry venting multiple processes with a shaker baghouse solved high differential pressure, short bag life, costly maintenance and reduced furnace airflow problems. Download the case study.

 


The problem

A foundry located in the U.S. was experiencing high differential pressure and short filter bag life in their baghouses, resulting in costly maintenance and problems with reduced furnace airflow. Specifically, the 3-compartment Bahnson Hawley/Norblo shaker baghouse did not provide adequate airflow to the four induction furnaces, a scrap pre-heater system, and a mag inoculation station it vented. The filters were blinding with fine particulate, and the resulting high-pressure drop across the collector reduced the original design airflow of 40,000 CFM to 28,000 CFM. 

The foundry knew they needed expert advice on how to solve these issues before it was too late. They turned to Parker because of the company’s deep experience in air filtration design and equipment. Parker’s specialists determined that a system like the one installed at the foundry required a design air volume of 55,000–60,000 CFM — well beyond the capabilities of the old shaker-style baghouse. 


The solution

Parker’s engineering team designed a pulse-jet cleaning conversion for the existing housing incorporating the high efficiency of BHA®PulsePleat® filter elements. In the design, the existing housing had the maintenance-intensive shaker mechanisms and thimble tubesheet removed and retrofitted with a flat tubesheet for installing the top-loading BHA®PulsePleat® filters from inside a walk-in clean air plenum. The design called for only 336 BHA®PulsePleat® filter elements to meet the calculated design air volume at a 4:1 air-to-cloth ratio.

 
Optimized dust collection

Foundry Improves Throughput and Reduces Maintenance Costs | Case Study  - BHA Pulse Pleat Filter Element - Parker HannifinBHA® PulsePleat® filter elements can revitalize your dust collection system, by solving the most common baghouse problems: lack of capacity, short filter life, and low efficiency. PulsePleats can increase the filtration surface area in your present baghouse system facilitating higher throughputs, longer life, and higher efficiencies. Benefits include:

  • Increased volume at a lower differential pressure.
  • Operate at appreciably higher filtration efficiencies.
  • Spunbond medias using EPA/ETV verified media from the EPA.
  • Better cleaning efficiency and faster return to operating airflow.
  • Achieve filtering efficiencies of 99.99362% for PM 2.5 compliance.
  • The one-piece design eliminates the need for filter bags, cages, and accessories, plus easier removal.
  • Reduced downtime and maintenance costs.
  • Elimination of inlet abrasion in filter bags.
  • Optimized collector due to higher CFM throughput.
  • Up to 400°F (204°C) maximum operating temperature.

 


Results

The foundry decided to move forward with Parker Hannifin’s recommendation. The system was installed to the design specifications and the improvements quickly proved worthy of the investment. Some of the key findings included:

  • The baghouse consistently operated at the design air volume with differential pressure between 4”-5” w.c. 
  • Compressed air for pulse-jet cleaning of the filter elements ran at 60 PSI, 40% below normal pulse-jet collectors. 
  • Based on this system’s performance improvements, the foundry upgraded other baghouse systems with BHA® PulsePleat® filter elements. 


Conclusion

Effective business management starts with identifying inefficiencies and implementing real-world solutions that provide maximum benefits through increased production and reduced operational costs. By installing Parker’s innovative BHA® PulsePleat® technology, this foundry reduced furnace airflow problems, extended bag filter life and reduced high maintenance costs.

Foundry Improves Throughput and Reduces Maintenance Costs | Case Study - download the case study - Parker HannifinTo learn more about the application, download a copy of the case study “
US foundry venting multiple processes with a shaker baghouse solved high differential pressure, short bag life, costly maintenance and reduced furnace airflow problems.” 

 

This blog was contributed by the Industrial Gas Filtration and Generation Team.

 

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