Particulate filtration systems, such as baghouses and cartridge dust collectors are critical for the industrial productivity and process control. They are equally important for employee health, plant safety, and compliance with the EPA and OSHA regulations.
Regulatory compliance and process improvement are business challenges. Therefore, focusing on bag leak detection for emission monitoring and solids flow monitoring for process control applications is important, particularly where accurate detection and monitoring will help companies to improve operations, reduce operating cost, prevent emissions to meet environmental requirement and embrace the importance of EHS.
Cement producers are challenged to meet EPA regulations without interrupting production while striving to improve profitability in a competitive cement market.
Typical sensors and controls for baghouses are often basic and do not provide intelligent control or preventive insight into the process. Time-consuming manual inspection of filters and baghouse components become necessary. This can require a shut down or extend an outage. The historical EPA requirement for an opacity monitor in the stack provides
little value toward preventive and proactive emissions control.
To fully monitor and optimize the kiln filtration systems and overall plant production, our integrated sensing and control can provide intelligent differential pressure control, optimized filtration and pulse cleaning, actionable diagnostics, and advanced particulate monitoring, which utilizes charge induction sensing.
A smoothly running baghouse is critical for asphalt production to keep road paving on schedule. Therefore, planning filter maintenance ahead of time and meeting compliance with low maintenance is necessary.
Due to the batch processing with high
moisture and sticky particulates, most of the existing system were repeatedly unreliable. False alarms significantly hampered production with frequent maintenance.
Field and time tested, we can offer a complete reliable solution for particulate monitoring for hot mix asphalt processes. Complete with diagnostic features, our solution can help to even locate filter leaks by row at the hot mix baghouse, enabling the plant to replace only the damaged filters thus, saving time and expensive filter replacement costs. This enable the staff to focus on production and proactive baghouse maintenance before major problems ensue.
Raw carbon black production processes are extremely harsh and demanding. Temperatures can reach 760°C. Moisture is used to control quality, and SO2 presents corrosion issues.
For particulate monitoring, the concentrated black powder complicates opacity and any light scatter device operation. Therefore, for any type of instrument, carbon black processes are among the most challenging.
Our particulate monitoring technology offers carbon black producers the best available solution to prevent tenacious emissions while minimizing instrument maintenance, repair/refurbish costs, and unplanned down time. Our baghouse control and diagnostic systems and software can also provide significant operational ROI opportunities and further your process and compliance optimization. With proactive, high-quality product support, we allows producers to focus on core operations and improve profitability.
Calcium Carbonate Mining
With the EPA regulations, mineral producers are required to monitor and report filter differential pressure (DP) and pulse pressure, and to conduct Method 22 visual emission inspections twice daily on every dust collector/baghouse.
Leading mineral producers can gain a competitive edge by investing in technology, including intelligent control and sensing tools to drive production and operational efficiency.
Weoffer a turn-key solution to meet the EPA regulations with numerous improvements to operations and provide long-term value by reducing energy use, diagnostic on solenoids/valves and filter leak location by rows, reduce maintenance, prevent downtime and increase safety.
At Iceland’s largest aluminum smelter, located in a pristine glacial fjord, air flow through the stack is 2.8M CFM after being treated by two Gas Treatment Centers (GTC), each consisting of a 12-compartment baghouse with a total of 23,020 individual filters. The challenge for this plant was to keep particulate emissions as low as possible while minimizing downtime and expenses to maintain the baghouses.
Our Particulate Matter Continuous Emission Monitoring System (PM CEMS) was installed alongside an optical forward scatter PM CEMS in the common outlet of each baghouse to monitor total particulate for regulatory compliance.
Site comparison proved that we can provide a superior leak detection below 1 mg/m³ with similar mass linearity and superior baseline measurement. It operates without the need for calibration or lens alignment with at least 6 times longer maintenance interval.
Rolled Aluminum Producer
Increasing production at a large facility comes with challenges. With commitment to the community and environment, such a large facility would have to take proactive steps to ensure their baghouse processes and stacks complied with US-EPA MACT standards.
US-EPA MACT filter leak detection regulations for secondary aluminum require adhering to quality assurance (QA) testing as specified in EPA-454/R-98-015 Fabric Filter Bag Leak Detection Guidance. The required tests include a zero, span, and response to actual PM injection.
With our internal circuitry to automate these tests, data is recorded in the instrument. The design and accuracy of our self-test systems meet internationally recognized EPA standards including ASTM D7392 and EN 15859. Automatic QA means reduced labor costs and prevent recording errors. In addition, reports are generated automatically further saving time.
Acid Discharge at
Catalyst Producer Plant
The world largest chemical companies for catalyst producer which is used at the refineries in the manufacture of diesel and gas petroleum was tasked to analyze their rising costs and downtime associated with powder processing baghouses at their catalyst facilities.
Several of their plants had reported a significant increase in emergency outage hours and rising operational costs due to baghouse problems. Acid discharge caused by their baghouse upset conditions resulted in damage to process equipment structure.
Our solution of tightly integrated control of the cleaning system resulted is a reduce downtime, enabling plants to prevent excess emissions and product loss, protect downstream equipment, significantly reduces compressed air consumption, reduce replacement costs and reducing the employee exposure to hazardous particulate and confined spaces.
The final Return on Investment (ROI) data showing an improved process efficiency and plant cost saving.