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Ceramic Fiber | Filter Media A Breakthrough in “In-Situ” Filter Cleaning By Dick Nixdorf, President & CEO, Industrial Ceramic Solutions, LLC Figure 1. All ceramic fiber media at 300X magnification 8 • February 2010 • www.filtnews.com T oday’s global economy has placed industry in developed countries at a competitive disadvantage with developing countries in the areas of labor costs and environmental regulations. The answer to maintaining market share and reasonable profit margins is reducing manufacturing costs and minimizing environmental compliance expense. Industrial process efficiency improvements usually require higher operating temperatures. Lower emission control expenses require a need to replace outdated pollution control systems with innovative filtration technologies. Temperature dependent industrial manufacturing requires increasing the process exhaust temperature beyond the limits of the current cellulosic or polymeric filtration equipment. The standard solution in moving to a higher temperature exhaust is a thermal oxidizer system. This technology is similar to a catalytic converter on a car. A ceramic or metal honeycomb is coated with a precious metal catalyst that converts emissions to harmless gas products at a temperature above the catalyst reaction temperature. Most industrial process exhausts do not reach this catalyst reaction temperature. Therefore, additional heat must be added by burning large volumes of natural gas to increase the process exhaust stream to the catalyst reaction temperature as it passes through the ceramic honeycomb. These costs for natural gas can range from $100,000 to $5 million/year, depending on the size of the exhaust stream. An additional penalty is high CO2 emissions. One answer to these high operating costs is a patented, dual-layer, wet-laid,
nonwoven ceramic fiber filtration media trademarked ThermoPore TM . HOW “IN-SITU” CLEANING WORKS This alternative, commercially available, ceramic fiber filter media and its ceramic frame components will operate to temperatures up to 1,200˚C to accommodate high processing and exhaust temperatures. The filter media shown in Figure 1 is 95% efficient at removing organic and carbonaceous particles down to 0.1 microns. The ceramic filter media can, further, be coated with a precious metal catalyst to destroy all combustible hydrocarbons and VOC’s at temperatures above 400˚C. In circumstances where industrial exhaust steams operate below this temperature at the filtration equipment location, the ceramic fiber media can capture the particulate over a period of time, regardless of the exhaust temperature. When the filter cartridge(s) reach a designed particulate loading, as determined by backpressure measurements, the filter cartridge(s) are cleaned in a periodic mode to combust the captured particulate to a harmless CO2 and H2O gasses at an elevated temperature. The clean filter is then returned to its filtering task in the process stream. In many cases the filter cartridges can be individually cleaned, in place, without moving to a separate filter cleaning station. The natural gas expense required for this cleaning is less than 5% of that consumed by a thermal oxidizer. The preferred concept is to trap particulate over a long period of time without applying auxiliary heat to the exhaust stream, followed by cleaning at a high temperature for a short period. A typical operating sequence for a ceramic fiber cartridge emission system is filtration for eight hours, followed by a 30 minute high temperature cleaning cycle. The filter systems are designed to trap a given quantity of particulate to reach a designated backpressure. Upon reaching the selected backpressure, the cartridge assembly is exposed to a hightemperature cleaning cycle. During the cleaning cycle, the temperature of the filter cartridges is raised to the particulate oxidation state. The filter is cleaned. Any pollutant exhaust gases evolved from the filter system, during this cleaning cycle, are directed through an auxillary catalyst coated ceramic fiber exhaust chimney filter to assure that no hydrocarbons or VOC’s escape to the atmosphere. OTHER ADVANTAGES The ceramic fiber filter media is very efficient at removing particulate from the exhaust stream. There usually is no visible smoke from the plant exhaust. Figure 2 shows the efficiency of a filter cartridge servicing a high particulate diesel engine application. The light color bar is the particle count prior to the filter and the dark bars represent the particle count www.filtnews.com • February 2010 • 9
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