Innovative baghouse design technology
Highly dependable fabric filter solutions
Whether you require an entire baghouse system design from ventilation point to the outlet stack, or simply the design and key parts of the fabric filter, FLSmidth will work with you to find the most cost-effective filtration solution possible. The FabriClean is just that solution.
To help you meet increasingly stringent environmental requirements, we are continually pushing the limits of what our fabric filters can achieve. With the FabriClean, this means more efficient operation and increased life of the filter bag, which ultimately results in significant energy savings and lower total cost of ownership. Reduced equipment weight and footprint are also integral to the FabriClean’s design, improving the baghouse’s emission reduction capabilities and minimising its construction time and shipping costs. This all translates to lower CAPEX expenses for your business.
Highlights of the FabriClean include our sophisticated gas and dust distribution system, perfect bag-to-cage match, and the convenience of on-line maintenance. Our fabric filter design focuses on long bag lifetime, minimal maintenance and reliable, cost-effective operation, all aimed at providing you with a dependable, long-term, and money-saving solution.
But how does the FabriClean work so efficiently? The FabriClean’s Pulse Jet fabric filter consists of rows of circular filter bags suspended from a tube sheet, which separates the dirty and clean gas chambers within a compartment. Each bag has an internal wire cage, which supports the filter bag and prevents collapse.
Dust-laden flue gas enters the filter inlet manifold through the existing ductwork. Dust from this gas is then collected on the outer surface of the filtration media, allowing only clean gases to pass through and into the top section above the tube sheet. The gas then moves on to the outlet ducting and stack.
The dust collected during this process is removed from the filter bags by pulses of compressed air. The cleaning is initiated by a differential pressure measurement when a predetermined level of resistance across the filter is obtained. During cleaning the dust falls into the hoppers, which is then cleared out via the dust discharge system.
A breakthrough in baghouse efficiency
- Increased efficiency with pre-separation of dust
- The FabriClean’s unique gas distribution system, in combination with a pre-separation of dust, reduces the dust load on filter bags, resulting in fewer cleaning cycles and minimised compressed air consumption.
- Increased filter bag lifespan
- With fewer bag-to-cage contact points in the proprietary cage design, the FabriClean saves you money in the long run by reducing flex fatigue and increasing the filter bag lifespan.
- Smaller equipment footprint
- By minimising the need for bag and cage replacement, the FabriClean’s long filter bag technology contributes to lower operating and maintenance costs overall
- Reduced energy consumption
- Pulse duration, interval, and pressure are all automatically adjusted by the Smart Pulse Controller®, which further minimises the use of compressed air.
A different kind of fabric filter
Unique gas distribution screens
The FabriClean filter’s unique gas and dust distribution system offers greater flexibility and an optimal filter size for any medium to high gas flow. When a filter is cleaned on-line, the direction of the gas flow in the compartment is very important. The FabriClean filter’s gas flows predominantly down along the bags, which minimises the risk of dust re-entrainment. Dust-laden gas enters the inlet duct from the process equipment and flows through the inlet damper into the individual compartments containing the filter bags. The gas velocity is lowered significantly in the gas distribution chamber, which leads a substantial amount of the dust to drop out directly into the hopper. This reduces the dust burden on the filter bags, which in turn increases the filter bag lifetime.
A uniform flow across the distribution screen is ensured by baffle plates and an upward gas flow. The gas and the remaining dust will then pass the screens and be distributed across the entire bag area, with the dominating gas velocity being downwards. This results in a significant decrease in the amount of pulse air required to clean the filter bags, which reduces your power consumption and extends bag life.
Advanced Control System
Our SmartPulse Controller® ensures a smoother operation and increases the lifetime of your filters. This control system incorporates a variety of features that help operate the filter at a minimum cost and ensure identification of any malfunctions, so they can be dealt with quickly and effectively. The control system is designed for both serial and parallel interfaces to the plant control system as well as field components (valves, dampers, instruments). Serial communication is often used, as this system is more cost-effective in terms of both material and time.
Long Filter Bag Technology
By manufacturing our filter bags with the highest quality materials available, we have been able to greatly improve their lifespan. Each filter bag incorporates a stainless steel snap ring sewn into the top of the bag which, when fitted, locates securely in the tube sheet and provides a more efficient seal. Bag replacements will become less frequent, which enables a smaller equipment footprint and reduced overall maintenance costs.
|Typical bag material||Continuous temperature|
|Polyester, PES||135 ˚C (275 ˚F)
|Polyphenylene sulphide, PPS, PROCON®, TORCON®||190 ˚C (374 ˚F)
|Aramid, m-Aramid, MAR, NOMEX®||200 ˚C (392 ˚F)
|Polyimide, PI, P-84®||245 ˚C (473 ˚F)
|Polytetrafluorethylene, PTFE, PROFILEN®, RASTEX®, TEFLON®||260 ˚C (500 ˚F)
|Fiberglass, GL||260 ˚C (500 ˚F)
Proprietary Cage DesignOur star-shaped cage design also contributes to improving bag lifetime by minimising wear. To support the fabric of the bag, a mild steel wire (or stainless steel) cage is provided. The cage is designed to support the fabric evenly, which restricts flexing and abrasion of the filter bag while allowing optimum dust release at the time of cleaning. The cage comes standard without joints, but can be offered with a split joint if required. Depending on your choice of fabric, each cage consists of either 10 or 16 evenly spaced vertical wires which are, in turn, attached to horizontal bracing rings placed at appropriate intervals along its length.
Simple Inlet/Outlet Duct LayoutThe FabriClean’s clever design also makes for simpler installation, maintenance and parts replacements. Inlet and outlet dampers are used to isolate the filter compartments during maintenance periods. If necessary, it is possible to close the outlet damper only to carry out off-line cleaning. For personal safety, a mechanical locking device is supplied to lock the dampers in the closed position.
“I’m very satisfied that FLSmidth stayed with us until this job was completed successfully. Despite the challenges of the project, Jbel Oust Cement is now enjoying significantly lower dust emissions from the plant.”