Fabric filter
Rachmat Boedisantoso
Jurusan Teknik Lingkungan FTSP – ITS Kampus Sukolilo, Surabaya – 60111
TEKNOLOGI PENGENDALIAN PENCEMAR UDARA
Advantages of Fabric Filters
Very high collection efficiency
They can operate over a wide range of volumetric
flow rates
The pressure drops are reasonably low.
Fabric Filter houses are modular in design, and can
Fabric Filters (contd.)
Disadvantages of Fabric Filters
Fabric Filters require a large floor area.
The fabric is damaged at high temperature.
Ordinary fabrics cannot handle corrosive gases.
Fabric Filters cannot handle moist gas streams
Fabric Filters
Principle
The filters retain particles larger than the
mesh size
Air and most of the smaller particles flow
through. Some of the smaller particles are retained due to interception and diffusion.
The retained particles cause a reduction in
the mesh size.
The primary collection is on the layer of
Fabric Filtration merupakan alat kontrol udara yang paling umum dipergunakan
Fabric filter menggunakan filter yang terbuat dari nilon atau wol
Partikulat yang telah disisihkan/ terkumpul kemudian dibersihkan dengan mekanisme pembersihan tertentu.
Fabric filter juga disebut :
Baghouse
Fabric filter collectors,
Bag filters,
Fabric dust collectors,
Filter collectors,
Dust collectors,
Cloth collectors
keuntungan dan kerugian Fabric Filter :
Keuntungan penggunaan fabric filter adalah :
Efisiensi sangat tinggi, bahkan untuk partikel yang halus
Dapat dipakai untuk berbagai macam debu
Dapat untuk volume gas yang besar
Dapat beroperasi pada pressure drop yang rendah
Sedangkan kerugiannya adalah :
Memerlukan tempat luas
Bahan filter dapat rusak pada temperatur tinggi atau bahan
asam
Tidak dapat beroperasi pada lingkungan yang lembab
Fabric filter terdiri atas :
inlet,
outlet,
filter bag,
Mekanisme pengumpulan Fabric Filter pada umumnya ada tiga cara utama, yaitu :
Impaction, partikel memiliki gaya inersia yang terlalu besar untuk mengikuti aliran garis pada filter fiber sehingga tertumbuk pada permukaan filter
Interception, partikel mempunyai inersia yang sangat kecil (partikel yg lebih kecil). Partikel akan berada
pada aliran viscous, bergerak melambat dan menyentuh barrier dan berhenti
Diffusion, partikel lebih kecil dari 1 mikron berada pada kisaran gerak Brown, sehingga terjadi gerakan random yang akhirnya terintersepsi dengan dust
Proses Filtrasi Fabric Filter terdapat dua jenis
desain yang dapat digunakan yaitu:
Interior Filtration, partikulat dikumpulkan pada
bagian dalam dari bag filter. Gas yang
mengandung partikulat memasuki fabric filter melalui bagian bawah dari kolektor dan
diarahkan ke dalam bag dengan
menggunakan diffuser vanes atau baffle dan juga cell plate.
Exterior Filtration, partikulat dikumpulkan
pada bagian luar dari bag fliter. Proses
penyaringan berlangsung dari luar bag filter ke dalam bag filter.
Jenis Proses filtrasi ( kiri : Interior Filtrasi, kanan : Eksterior Filtrasi)
Terdapat beberapa cara pembersihan yang dapat
dipergunakan untuk menyisihkan partikulat yang menempel pada permukaan bag filter, tiga cara yang paling sering
digunakan adalah :
(i). Shaking
Mechanical shaking menggunakan motor yang dihubungkan dengan bag
Energi yang diperlukan rendah
Gerakan dan kecepatan tergantung endapan debu
Arah gerakan Horisontal atau vertical
Gerakan di bagian atas frame tempat bag diletakkan
Aliran gas berhenti saat dilakukan proses pembersihan
Shaker baghouse umumnya menggunakan interior filtration Diameter 15,2 – 45,7 cm ( 6-18 inch ) Panjang sampai 12,2 m ( 40 ft ) Lama pembersihan 30 dt – beberapa menit
Terdiri dari beberapa kompartemen
(ii). Reverse Air
Mekanisme yang paling sederhana
Aliran udara kotor dihentikan
Mengalirkan backwash air (udara bersih yang berlawanan arah)
Aliran udara bertekanan rendah
Debu akan jatuh ke hopper
Lama pembersihan 30 menit – beberapa jam Durasi pembersihan 10 – 30 detik
Terdapat ring dengan jarak 10 – 46 cm
Reverse air baghouse berdiameter 20 – 46 cm, dan
panjang 6,1 – 12,2 cm
Terdiri dari beberapa kompartemen
(iii). Pulse Jet
Disebut juga pressure jet cleaning
40 – 50% baghouse baru di Amerika
Menggunakan high pressure jet dari udara
Sistem exterior filtration
Menimbulkan shock wave
Pulse jet baghouse berdiameter 10,2 – 16,2
cm
Panjang umumnya 2,4 – 3,7, tapi dapat
Bahan bag house
Woven, terbuat dari benang, dipakai untuk
pembersihan energi rendah
Felted filter terdiri dari fiber yang dikompres
ke dalam mar dan dilekatkan pada woven
Ada yang terbuat dari bahan alam seperti katun atau wol
Temperatur lebih kecil dari 212oF atau 100oC Katun temperatur lebih kecil
Fiber sintesis
Nilon, orlon dan polyester tahan temperatur lebih tinggi
dan tahan terhadap bahan kimia
Nilon memiliki abrasive resistant yang paling tinggi
Polyester atau Dacron baik untuk menahan asam,
alkali dan abrasi dan relatif murah
Nomex buatan Dupont
Membran material terbuat dari berbagai jenis fiber yang disusun membentuk
membrane diantaranya adalah Gore-Tex membrane, jenis ini dapat
mereduksi emisi dengan baik, pressure drop yang relatif rendah, umur bag yang meningkat dan ratio air-cloth yang lebih tinggi
Design of Fabric Filters
The equation for fabric filters is based on
Darcy’s law for flow through porous media.
Fabric filtration can be represented by the
following equation:
S = Ke + Ksw
Where,
S = filter drag, N-min/m3
Ke = extrapolated clean filter drag, N-min/m3
Ks = slope constant. Varies with the dust, gas and fabric, N-min/kg-m W= Areal dust density = LVt, where
L = dust loading (g/m3), V = velocity (m/s)
Both Ke and Ks are determined empirically
Fabric Filters
Δ P Total pressure drop
Δ Pf Pressure drop due to the fabric
Δ Pp Pressure drop due to the particulate layer
Darcy’s equation
ΔPf Pressure drop N/m2
ΔPp Pressure drop N/m2
Df Depth of filter in the direction of flow (m)
Dp Depth of particulate layer in the direction of flow (m) μ Gas viscosity kg/m-s
V superficial filtering velocity m/min
Kf, Kp Permeability (filter & particulate layer m2)
60 Conversion factor δ/min V = Q/A
Q volumetric gas flow rate m3/min
Dust Layer
L Dust loading kg/m3
t time of operation min
ρL Bulk density of the particulate layer kg/m3
ΔP = ΔPf + ΔPp
Filter Drag S = ΔP/V
Areal dust density W = LVt S= k1+k2W
Parameter yang penting dan perlu
dipertimbangkan dalam merancang Fabric Filter diantaranya adalah :
(i). Pressure Drop
Dinyatakan sebagai pressure drop per unit
area sebgai fungsi dari karakteristik medium filter
Biasanya berkisar 2-4 inch
Dihitung dengan cara :
t V C k p V k p p p p f c f f c f 1 2 1
dimana :
pf = pressure drop sepanjang FF
k1 = resistensi FF (inch air /menit atau cm/menit),
merupakan fungsi dari karakteristik viscositas gas dan filter seperti ketebalan dan porositas (permeabilitas)
Vf = kecepatan filtrasi (ft/menit atau m/menit)
pf = pressure drop sepanjang cake dalam inch (cm)
k2 = resistensi dari cake (inch air /menit atau
cm/menit
C1 = dust loading (lb/ft3 atau kg/m3) ditentukan
secara experimen. Koefisien ini tergantung dari viscositas gas, densitas partikel dan porositas.
t V C k p V k p p p p f c f f c f 1 2 1
(ii). Kecepatan Penyaringan
Kecepatan penyaringan dinyatakan sebagai :
kecepatan merupakan kecepatan superficial filtering
A
Q
(iii). Performance Factor
Salah satu variable yang penting dalam
mendesain baghouse adalah ratio air to cloth (A/C) atau ratio udara terhadap bahan filter
A/C menggambarkan berapa banyak gas
kotor yang melewati permukaan filter dengan luas tertentu selama waktu tertentu.
Ratio yang tinggi berarti sejumlah besar
udara yang melewati fabric
Satuan cm3/detik/cm2 atau ft3/menit/ft2
Tergantung dari mekanisme pembersihan,
Problem
Estimate the net cloth area for a shaker
bag house that must filter 40,000 cfm of air with 10 grams of flour dust per cubic foot of air. Also specify the number of
components to be used and calculate the total number of bags required if each bag is 8 feet long and 0.5 feet in diameter.
The maximum filtering velocity for flour dust is 2.5 ft/min.
Solution
Step 1: Calculate total area and number of
components required: A = Q/V
Step 2:
Calculate the area of each bag: A = Π(d)l
Step 3:
Calculate the total number of bags required. Number of bags required = Total area / Area
30
2. Dividing Collection Devices
Filters and scrubbers do not drive the particles to a wall, but rather divide the flow into smaller parts where they can collect the particles.
2.1 Surface Filters
A surface filter is a membrane (sheet steel,
cloth, wire mesh, or filter paper) with holes smaller than the dimensions of the
31
However, one only needs to ponder the mechanical problem of drilling holes of
0.1-µ diameter or of weaving a fabric with threads separated by 0.1µ to see that
such filters are not easy to produce.
They are much too expensive and fragile for use as high-volume industrial air
32
Although industrial air filths rarely have holes smaller than the smallest particles captured, they often act as if they did.
The reason is that, as fine particles are
caught on the sides of the holes of a filter, they tend to bridge over the holes and
make them smaller.
Thus as the amount of collected particles increases, the cake of collected material becomes the filter.
33
The particles collect on the front surface of the growing cake.
For that reason this is called a surface filter.
The flow through a simple filter is shown schematically in Fig. 9.12.
35
If we follow the gas stream in Fig. 9.12
from point 1 to point 3 we see that the flow is horizontal and has a small change in
velocity because the pressure drop,
causing the gas to expand, and because the gas is leaving behind its contained particles.
36
In most industrial filters, both for gases and liquids, the flow velocity in the individual pores is so low that the flow is laminar.
Therefore, we may use the well-known relations for laminar flow of a fluid in a porous medium, which indicate
Here, k is the permeability, a property of the bed. (19) s Q p k A x
37
For a steady fluid flow through a filter cake supported by a filter medium, there are two resistances to flow in series, but the flow rate is the same through each of them.
We find:
Solving for P2, we get
2 3 1 2 cake filter -P = s P P P k k x x 2 1 3 cake filter = s s x x P P P k k
38
Then solving for vs:
This equation describes the instantaneous flow rate through a filter; it is analogous to Ohm’s law for two resistors in series.
The Δx/k terms are called the cake resistance and
the cloth resistance.
1 3
( )
(20)
[( / ) ( / ) ]
s
cake filter filter
p p Q v x k x k A
39
The resistance of the filter medium is usually
assumed to be a constant that is independent of time, so (Δx/k)filter is replaced with a constant α.
If the filter cake is uniform, then its resistance is proportional to its thickness:
1 1 cake cake cake mass of cake x area
volume of gas mass of solids removed area volume of gas
40
Customarily we define:
Here W is the volume of cake per volume of gas processed, which corresponds to a collection efficiency, η, of 1.0.
For most surface filters η=1.0, so the η is normally
dropped in the equation. Thus
Here V is the volume of gas cleaned.
1
cake
mass of solids removed volume of cake
W
volume of gas volume of gas processed
( ) and cake (21) cake s d x V x W W A dt
41
Substituting Eq. (21) for the cake thickness in Eq. (20), we
find
For most industrial gas filtrations the filter is supplied by a centrifugal blower at practically constant pressure, so (P1 -P3) is a constant, and Eq. (22) may be rearranged and integrated to 1 3 (P -P ) Q 1 dV = = = (22) A A dt [(V /kA+ ] s W 2 1 3 ( ) (23) 2 V W V P P t A k A
42
For many filtrations the resistance α of the
filter medium is negligible compared with the cake resistance, so the second term of Eq. (23) may be dropped.
The two most widely used designs of
industrial surface filters are shown in Figs. 9.13 and 9.14 (next and second slides).
45
For the baghouse in Fig. 9.13 there must be some way of removing the cake of particles that accumulates on the filters.
Normally this is not done during gas-cleaning operations.
A weak flow of gas in the reverse direction may also be added to help dislodge the cake, thus deflating the bags.
Often metal rings are sewn into filter bags at regular intervals so that they will only partly collapse when the flow in reversed.
46
Because it cannot filter gas while it is being cleaned, a shake-deflate baghouse cannot serve as the sole
pollution control device for a source that produces a continuous flow of dirty gas.
Typically, for a major continuous source like a power plant, about five baghouses will be used in parallel, with four operating as gas cleaners during the time that the other one is being shaken and cleaned.
Each baghouse might operate for two hours and then be cleaned for 10 minutes.
47
The other widely used baghouse design, called a pulse-jet filter, is shown in Fig. 9.14.
In it the flow during filtration is inward
through the bags, which are similar to the bags in Fig. 9.13 except their ends open at the top.
The bags are supported by internal wire cages to prevent their collapse.
48
The bags are cleaned by intermittent jets of compressed air that flow into the inside of the bag to blow the cake off.
Often these baghouses are cleaned while they are in service.
49
Example 15
The shake-deflate baghouse on a power
station has six compartments, each with 112 bags that are 8 in. in diameter and 22 ft long, for an active area of 46 ft2 per bag.
The gas being cleaned has a flow rate of
86,240 ft3/min.
The pressure drop through a freshly
cleaned baghouse is estimated to be 0.5 in. H2O.
50
The bags are operated until the pressure drop is 3 in. H2O, at which time they are taken out of service and cleaned.
The cleaning frequency is once per hour.
The incoming gas has a particle loading of 13 grams/ft3.
51
The collection efficiency is 99%, and the filter cake is estimated to be 50% solids, with the balance being voids.
Estimate how thick the cake is when the gags are taken out of service for cleaning. What is the permeability, k, of the cake?
52
Solution:
The average velocity coming to the filter surface:
The 5 is used here because one of the six
compartment is always out of service for cleaning.
vs is commonly referred to as the air-to-cloth ratio, face velocity, or superficial velocity.
3 2 86240 / 3.35 1.02 (5)(112)(46 ) s Q ft min ft m A ft min min
53
If the filter remains in service for 1 hour before
cleaning and vs is constant, the 1 square foot of bag will collect the following mass of particles:
3 2 2 60 13 3.35 0.99 (1 ) 7000 0.369 1.80 s m gr lbm ft min c t h A ft gr min h lbm kg ft m
54
The thickness of the cake collected in 1 hour is
Taking 2 3 3 3 3 / 0.369 / (2 / )(0.5)(62.4 / / ) 5.9 10 0.071 . 1.8 m A lbm ft g cm lbm cm ft g ft in mm
0, we can solve Eq. (20) for k,
filter x k 5 2 2 2 2 12 2 13 2 (3.35 / min)(0.071 /12 .)(0.018 )(2.09 10 / / )( / 60 ) ( ) (3 . )(5.202 / / . ) 7.96 10 7.40 10 s x ft ft in cp lbf s ft cp min s k p in H O lbf ft in H O ft m
55
Compare this with values found in ground water flow:
The calculated permeability of this material is roughly the same as that of a highly permeable sandstone. #
12 2 11 2 (7.96 10 ) 0.75 1.06 10 darcy k ft darcies ft
56
This calculation shows that the collected is about 1.8 mm thick.
If the cleaning were perfect, this would be the cake thickness.
However, it is hard to clean the bags
completely, and in power plant operation it is common for the average cake thickness on the bags to be up to 10 times this
57
One of the advantages of the pulse-jet design is that it cleans the bags more thoroughly, allowing a higher vs, at the cost of a somewhat shortened bag life.
Fig. 9.15 (next slide) is a set of typical results from tests of collection efficiency for this kind of filter.
59
If the superficial velocity increases, the
efficiency falls; for a superficial velocity of 3.35 m/min the outlet concentration is
about 20 percent of the inlet concentration.
The particles that pass through such a filter do not pass through the cake but
through pinholes, which are regions where the cake did not establish properly (Fig.
61
The pinholes are apparently about 100 µ in diameter, much too large for a single particle to block because there are rarely 100-µ particles in the streams being
treated.
When the superficial velocity is high, more pinholes form.
62
Example 16
Estimate the velocity through a pinhole in a filter with a pressure drop of 3 in. of
water.
Assuming that this is the pressure drop
corresponding to the curve for 0.39 m/min on Fig. 9.15, that the steady-state
penetration at that velocity is 0.001, and
that the pinholes have a diameter of 100 µ, estimate how many pinholes per unit area there are in the cake.
63
Solution:
The flow through the pinhole is best described by Bernoulli’s equation, from which we find the average velocity:
Here the (area ∙velocity) of the pinholes must be 0.001 times the
(area ∙velocity) of the rest of the cake. Hence
1/ 2 1/ 2 2 3 2 2 2 2(3 ) 249 0.61 (1.20 / ) 21.5 / pinholes P in H O Pa kg C kg m in H O Pa m s m s 2 7 2 0.001 0.001 (0.39 / ) 3.0 10 (21.5 / )(60 / ) pinholes s cake pinholes A m min m A m s s min m
64
Each pinhole has an area of A =
(100 10-6 m)2 (π/4) = 7.85 10-9 m2, so there
must be
The calculated velocity through a pinhole is (21.6 x 60) /0.39 = 3300 times the velocity through the cake.
7 2 9 2 3.0 10 38 pinholes/m # 7.85 10 m
65
2.2 Depth Filter
Filters do not form a coherent cake on the surface, but instead collect particles
throughout the entire filter body are called depth filters.
The examples with which the student is probably familiar are the filters on filter-tipped cigarettes and the lint filters on many home furnaces.
66
In both of these a mass of randomly
oriented fibers (not woven to form a single surface) collects particles as the gas
passes through it.
In Fig. 9.17 (next slide), we see a particle-laden gas flowing toward a target, which we may think of as a cylindrical fiber in a filter.
68
To determine whether a particle bumps into the target or flows around it, we can compute the relative velocity between particle and gas using the appropriate equivalents of Stokes’ law.
That task was first undertaken by
Langmuir and Blodgett, and Fig. 9.18 (next slide) conveniently summarizes the
mathematical solutions for the small
70
To see how they obtained Fig. 9.18,
consider a single particle in a turning part of the gas stream as shown in Fig. 9.19 (next slide).
72
In Fig. 9.19, the appropriate velocity to use in Stokes’ law is not the overall stream velocity but rather the difference in y-directed velocity between the particle and the gas stream.
Generally, the gas stream will have a larger velocity in this direction than the particle, so
3
(
)
y drag y gas y particle
73
The resisting (inertial) force of the particle is
If there are no electrostatic, magnetic, or other forces acting, then these two forces are equal and opposite, so 3 6 y particle y inertial d F ma D dt 2 18 ( )
y particle y gas y particle
d
dt D
74
Rearrange,
Δt is the time available for the y-directed forces to
move the particle around the garget, which must be proportional to the time it takes the main gas flow to go past the target.
2 18 (24) ( ) y particle y gas y particle d t D
75
This time = Db/v, where Db is the diameter of the barrier, so we may substitute in Eq. (24), finding
Ns is the separation number, which appears on the horizontal axis in Fig. 9.18.
It is equal to the diameter of the barrier divided by the stokes stopping distance.
2 1 2 18 1 (25) ( ) y y particle b y y gas y particle s d D D N
76
Some authors call Ns the impaction parameter or inertial parameter.
In Eq. (25) we can see that if the integral on the left is a large number (a low value of Ns), then there is plenty of time and
force for the flow to move the particle
around the target and the target efficiency (ηt) will be low.
77
Example 17
A single, cylindrical fiber 10 µ in diameter is placed perpendicular to a gas stream that is moving at 1 m/s.
The gas stream contains particles that are
1 µ in diameter and the particle concentration is 1 mg/m3.
What is the rate of collection of particles on the fiber?
78
Solution:
If all the particles that start moving directly toward the fiber hit it, then the collection rate would be equal to the volumetric flow rate approaching the fiber times the concentration of particles:
If we catch them all, we will collect 10-8 g/s for every
meter of fiber length.
5 3 3
8
maximum possible rate = (1 / )(10 )(10 / ) 10 / / b D c m s m g m g m s
79
The actual amount caught will be this number times the target efficiency.
The separation number is
From Fig. 9.18, we see that for cylinders this value of Ns corresponds to a target efficiency of about 0.42, so we would expect to collect about 0.42 10-8
g/m/s. # 3 6 2 5 5 (2000 / )(10 ) (1 / ) 0.617 (18)(1.8 10 / / )(10 ) s kg m m m s N kg m s m
80
Example 18
A filter consists of a row of parallel fibers
across a flow, as described in Example 17, with the center-to-center spacing of the
fibers equal to five fiber diameters.
What collection efficiency will the filter have for the particles?
Assume that the fibers are far enough
apart that each one behaves as if it were in an infinite fluid, uninfluenced by the
81
Solution:
From Example 17, ηt = 42% for a single fiber.
If the fibers are spaced five fiber diameters apart, then the open area is 80%, and the blocked area is 20%.
So,
Collection efficiency = (target efficiency) (percentage blocked) = 42%20% = 8.4% #
82
Example 19
A filter consists of 100 rows of parallel fibers as described in Example 18,
arranged in series.
They are spaced far enough apart that the
flow field becomes completely uniform between one row and the next.
What is the collection efficiency of the entire filter.
83
Solution:
ηoverall = 1 - poverall = 1 - (pindividual)n
= 1 - (1-0.084)100 = 0.9998 #
These three examples show, in idealized form, what goes on within depth filters.
Most such filters do not have an orderly array of parallel fibers; the filter medium consists of a tangled jumble of fibers in a random orientation, making up a thick mat.
84
In depth filters that diffusion leads to small particle collection in addition to that
computed above by impaction.
Friedlander developed a theoretical
equation, with constants determined by experiment, for the case of diffusion
collection of particles from a gas steam flowing past a cylinder under
circumstances where impaction was negligible.
85
Most of the published data could be represented by
where all the terms are as defined previously, Di is the diffusivity and ν is the kinematic viscosity.
The first term on the right is for diffusion collection, where as the second is for collection by noninertial contact (interception) 2 / 3 2 1/ 2 1/ 2 3/ 2 1/ 6 1/ 2 1/ 2 6 3 (26) i t b b D D D D
86
Example 20
Repeat Example 17 for particles having a diameter of 0.1 µ. Take into account
impactions, diffusion, and interception.
Solution:
In this case Ns is (0.1)2 = 0.01 times the previous value, or 0.0062, for which, from Fig. 9.18 we can read ηt ≈ 0.
From Fig. 8.1, we can read that the
diffusivity is about 6 10-6 cm2/s = 6 10 -10 m2/s.
87
So
The diffusion term is (0.0086 / 0.00025) = 34.4 times the interception term.
Table 9.3 (next slide) shows the effect of changes in velocity and particle diameter on the collection
mechanisms. 10 2 2 / 3 7 2 1/ 2 5 2 5 1/ 2 1/ 2 5 2 1/ 2 5 3/ 2 6(6 10 / ) 3(10 ) (1 / ) (1.49 10 / )(10 ) (1 / ) (1.49 10 / ) (10 ) 0.0086 0.00025 0.0088 0.9% # t m s m m s m s m m s m s m
89
There is some particle size at which there is a minimum collection efficiency.
Typically, this size is in the range 0.1 to 1 µ, which is the size most likely to be
90
2.3 Filter Media
For shake-deflate baghouses, the filter bags are made of tightly woven fibers
(surface filter), much like those in a pair of jeans.
Pulse-jet baghouses use high strength felted fabrics, so that they act partly as depth filters and partly as surface filters.
91
Filter Fabrics are made of cotton, wool, glass fibers, and a variety of synthetic fibers.
Cotton and wool cannot be used above
180 and 200oF, respectively, without rapid deterioration, whereas glass can be used to 500oF (and short-time excursions to
92
In addition the fibers must be resistant to acids or alkalis if these are present in the gas stream or the particles as well as to flexing wear caused by the repeated
cleaning.
Sumber:
Control of Primary Particulates by Hsin
Chu, Professor, Dept. of Environmental Engineering, National Cheng Kung
University, Taiwan
Technology for Air Pollution Control by