Case Studies

Case Study: Improving Efficiency: How Fabric Selection Reduced Boiler Bag Filter Emissions by 50%
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Background:

A large industrial facility, operating a high-temperature coal-fired boiler system, faced significant challenges with particulate emissions from its bag filter system due to change of fuel from Coal to Biomass. The emissions were consistently measured at 100 mg/m³, which exceeded regulatory limits and created environmental compliance issues. The facility was required to reduce particulate emissions to meet stringent environmental standards, avoid fines, and improve its sustainability practices.

Problem Statement:

The facility’s boiler system was emitting particulate matter at a rate of 100 mg/m³, exceeding regulatory limits and creating environmental concerns. The Existing filter bags were no longer performing at optimal levels, especially in capturing fine dust particles under the high-temperature conditions of the boiler. The facility's goal was to reduce emissions to less than 50 mg/m³ or lower by switching to a more efficient filtration material

Solution:

After a detailed assessment of the existing system and exploring various options, the following solution was implemented:

1. Assessment of the Existing Bag Filter System:
  • A comprehensive audit of the bag filter system revealed that the exiting filter bags had begun to lose their filtration efficiency over time due to the high operating temperatures and chemical exposure within the boiler environment.
  • The bags were found to have inadequate dust release capabilities, resulting in clogged filters and an increased pressure drop across the system, which further compromised their efficiency.
2. Selection of Special Filter Bags:
  • The facility opted to replace the existing bags with Special - Filter Bags . This special coating is known for its superior filtration efficiency, non-stick properties, and resistance to high temperatures. These bags offer better fine particle retention, improved dust release during cleaning cycles, and a longer service life, making them ideal for challenging boiler conditions.
  • The Bags where made of Imported material of high quality .
3. Installation of the New Filter Bags:
  • The installation of the new filter bags was carried out during scheduled maintenance downtime to minimize disruption to the plant's operations.
  • The bag filter system’s settings were adjusted to optimize the performance of the new bags.
4. Post-Installation Monitoring :
  • Once the new filter bags were installed, Real-time particulate monitoring was employed to assess the effectiveness of the new filter bags in capturing fine particles.

Results:

  • Dramatic Emission Reduction: The change filter bags resulted in a significant reduction in particulate emissions from 100 mg/m³ to just less tahn 50 mg/m³, an 50% decrease. This improvement helped the facility meet and exceed regulatory emission limits, avoiding potential fines and improving its environmental compliance status.
  • Better Environmental Impact: The substantial reduction in particulate emissions contributed to improved air quality in the surrounding area. This also aligned with the company’s sustainability goals and demonstrated their commitment to environmental responsibility.

Conclusion:

By upgrading filter bags facility was able to achieve a dramatic reduction in particulate emissions, from 100 mg/m³ to less than 50 mg/m³, meeting and exceeding regulatory compliance. This case study highlights the importance of selecting the right filtration technology for high-temperature and chemically demanding applications, and demonstrates the significant benefits that come with investing in advanced filtration solutions.

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