Reduce the frequency of bag filter cloth replacement and cut costs!
In the line manufacturing powder for a chemical company, there are two bag filter dust collectors for drying and cooling. Various countermeasures have been implemented, but none have resulted in satisfactory products, leading to concerns about maintenance effort, costs, and safety. Issues: 1. The filter media for drying is at high temperature and low humidity, which poses a risk of static electricity accumulating and causing sparks that could lead to fires. 2. Even when using static electricity countermeasure filter media, the charge level remains high, and there have been near-fire incidents. 3. The filters for cooling become wet due to condensation of the powder, and even with pulse cleaning, the clogging of the filter media is not resolved, necessitating frequent replacements. 4. Although high water-repellent filter media have been used, they perform well immediately after replacement but do not last as long as expected.
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Based on the points below, we have proposed alternative products for each application. For dryers: The electrostatic countermeasure filter material that you have experience with, which incorporates carbon fibers, has some issues with conductivity. Due to the weak nature of carbon, it can occasionally break due to pulsing, leading to a decrease in performance. - We suggest changing the conductive fibers from carbon to stainless steel, creating a filter material that won't break even under stress, while also increasing the initial conductivity and minimizing performance degradation. For coolers: The filter materials coated with fluororesin on the surface or laminated with fluororesin breathable membranes initially had very low pressure loss after installation, but their effectiveness decreased more quickly than expected. We will select filter materials that can maintain water-repellent effects for a longer duration. - Upon examining used filter materials that showed a decline in water-repellent effects over a short period, we found that the dust being collected was very hard and highly abrasive, causing the water-repellent treatment to wear off. - Since surface treatment alone cannot solve this problem, we propose products that have water-repellent treatment incorporated into the filter material itself.
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