1. Houston Material Handling Society October 2008 Baghouse Cleaning Control Presented by: T.J. Winalski

2. Copyright 2008Page 2 Agenda Baghouse Cleaning Control Particulate Monitoring Diagnostics Overview

3. Copyright 2008Page 3 Baghouse Basics Baghouses can be very efficient in collecting particulate Media – many media types for different processes Pressure Loss (Drop) of a baghouse is function of: –Baghouse Design –Media Type –Air Flow –Dust Layer Thickness Cleaning Media – All media needs to be periodically cleaned to maintain acceptable pressure drop Cleaning is controlled either by Time OR Differential Pressure

4. Copyright 2008Page 4 Pulse Jet Baghouse

5. Copyright 2008Page 5 Baghouse Basics Ensure cleaning air supply is sufficient (flow/pressure) Cleaning air supply should be clean and dry Keep air to cloth ratio at acceptable levels Avoid condensation in baghouse

6. Copyright 2008Page 6 Agenda Baghouse Cleaning Control Particulate Monitoring Diagnostics Overview

7. Copyright 2008Page 7 Cleaning Pulse – The Beat of the Baghouse

8. Copyright 2008Page 8 Depth vs. Surface Filtration – Filtering Mode Conventional Media Membrane Media Depth filter media e.g. PPS felt Membrane

9. Copyright 2008Page 9 Solenoid Activation: Current Timer Board –Controls Solenoid ON Time and OFF Time –OFF Time Adjustable off time 3-600 seconds Stand Alone of through Other Device

10. Copyright 2008Page 10 How does your baghouse heart beat? istockphoto.com

11. Copyright 2008Page 11 Types of Cleaning Modes Time Only Pulse On Demand Single Set Point Hold

12. Copyright 2008Page 12 Pulse on Demand – 30 days DP (“ WC) Days 4122028 2 4 DP

13. Copyright 2008Page 13 Single Set Point: Hold 4.0” WC DP

14. Copyright 2008Page 14 Single Set-Point: Hold 4.7” WC DP Pulse Rate

15. Copyright 2008Page 15 Single Set-Point: Hold 4.0” WC DP Pulse Rate

16. Copyright 2008Page 16 Single Set Point: Hold 6.5” WC - 12 days DP Particulate

17. Copyright 2008Page 17 IntelliPulse – Single Set-point Control DP Pulse Rate

18. Copyright 2008Page 18 Single Set Point Hold Control: 1 day Pulse Rate DP

19. Copyright 2008Page 19 Single Set Point Hold = Even Filter Cake/Constant Air Flow

20. Copyright 2008Page 20 Single Set Point Hold - Benefits Constant Air Flow Through the Baghouse Minimum Compressed Air Use – for Cleaning Maximum Filter Life Reduced Maintenance due to longer component life Lowest Particulate Emissions

21. Copyright 2008Page 21 Single Set Point Hold – Total Pulse Count

22. Copyright 2008Page 22

23. Copyright 2008Page 23 Single Set Point Hold Actual Electricity Savings from Compressed Air

24. Copyright 2008Page 24 Comprehensive Cleaning Controller Functionality Cleaning Modes Off Time –Once Through –Cycle Down Pressure –Single Set Point Hold –POD Full Solenoid Control – Easily Selectable and Adjustable Multi-Row Pulsing Pattern Pulsing Pulse Control for Each Individual Solenoid

25. Copyright 2008Page 25 Single Set Point Hold Control - Benefits Steady Differential Pressure by Maintaining Filter Cake Constant Air Flow through Baghouse Lowest Particulate Emissions Optimum Operating Costs –Maximum Media Life –Lowest Compressed Air Usage –Optimum Fan Volume –Minimize Maintenance Costs through longer life of components

26. Copyright 2008Page 26 Requirements of Today’s Technology: Performance Reliability Flexibility Information Communication Comprehensive Cleaning Control Integrate Particulate Sensing Integrate Differential Pressure Sensing: Tube DP or Non-Clogging DP Transmitter Integrate I/O’s Ethernet/Fieldbus Communication

27. Copyright 2008Page 27 27 Non-Clogging Differential Pressure Transmitter

28. Copyright 2008Page 28 Inches of H 2 O Time (sec) -2 0 2 4 6 8 10 Flange – to Flange  P Compartment  P provides insight: 35 minutes Cleaning frequency Variation in  P amongst compartments Some compartments are taking more flow Differential Pressure Monitoring

29. Copyright 2008Page 29 Agenda Baghouse Cleaning Control Particulate Monitoring Diagnostics Overview

30. Copyright 2008Page 30 Integration of Particulate Monitoring

31. Copyright 2008Page 31 Sensor Technology – Protected Probe

32. Copyright 2008Page 32 Particulate Emissions Pulse Rate

33. Copyright 2008Page 33 Particulate Emissions Filter Media Change

34. Copyright 2008Page 34 Particulate Monitoring with Broken Bag

35. Copyright 2008Page 35 Particulate Monitoring - Cement Kiln

36. Copyright 2008Page 36 Particulate and DP – over 6 days DP Particulate

37. Copyright 2008Page 37 Particulate and DP – 1 day DP Particulate

38. Copyright 2008Page 38 Particulate Emissions: High Resolution Particulate DP

39. Copyright 2008Page 39 Particulate Monitor - Locations

40. Copyright 2008Page 40 Particulate Emissions – Maintenance Tool

41. Copyright 2008Page 41 Proactive Maintenance Tool: MicroFractures DP (“ WC) Days 4122028 2 4 DP Particulate

42. Copyright 2008Page 42 Agenda Baghouse Cleaning Control Particulate Monitoring Diagnostics Overview

43. Copyright 2008Page 43 Which would you prefer?

44. Copyright 2008Page 44 Diagnostic Capability Instrumentation is the window into the process Failed Solenoids Failed Diaphragm (header pressure) Failed Filter by Row (particulate) Process Conditions – high DP, low Header Pressure, air temperatures, moisture, fan vibration, bearing temperatures, etc.

45. Copyright 2008Page 45 Typical Baghouse

46. Copyright 2008Page 46 PARTICULATE SENSOR Passive Sensor Protected Probe Technology Mounted in clean air duct DELTA P SENSOR Non-Clogging Type for reliable maintenance free measurement Mounted on Dirty Side Accurate Reliable Measured Differential Pressure Quick Clamp Connection COMPRESSED AIR SENSOR Checks compressed air (gas) header pressure Mounted in the compressed gas manifold

47. Copyright 2008Page 47 Bag Row Leaks Particulate Failed Individual Solenoid Failed Individual Diaphragm Header Pressure Compressed Air (Gas) Differential Pressure Read Locally Or On HMI Diagnostics

48. Copyright 2008Page 48 Visualization

49. Copyright 2008Page 49 Conclusion Comprehensive Cleaning Control Operate as a Stand Alone Controller (harsh industrial environments) Operate out of the box for any baghouse, bin vent to 80 row baghouse Reliably Monitor Particulate Emissions Communicate with a HMI

50. Copyright 2008Page 50 Questions, Discussions, Applications

51. Copyright 2008Page 51 THANK YOU !!

52. Copyright 2008Page 52 MICS Platform Power Supply IntelliPulse Triac Modules Tube Type DP Module I/O Modules Particulate Modules Fieldbus Communications Internal DataLogging (removable SD Card) Comprehensive Graphic Display

53. Copyright 2008Page 53 Cleaning Control/Diagnostic Technology Modular Instrument Control System – adds functionality as required Basic Control System Remote I/O’s installed at baghouse (minimize installation)