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BAG HOUSE FILTER MONITORING - COMPLIANCE MONITORING FOR PROFIT

A Bag House Monitoring System which meets dust emissions regulatory requirements, avoids significant environmental incidents, and generates a return on compliance monitoring equipment.

FilterMonitor - software for optimised bag house performance

With a Zeta 5000 installed just down-stream of the bag house, FilterMonitor, ETR-Unidata´s bag house monitoring system, can signal:

  • the onset of deterioration, and
  • the bag house compartment, and row in that compartment, in which the deteriorating bag is located

The Zeta 5000 is so accurate and has such a fast response time that this is achieved without the need for a continuous emissions monitor in each compartment of the bag house, potentially lowering both capital and maintenance and manning costs for large arrestment plant installations.

THE BENEFITS

Improved bag house filter monitoring leads to lower operating and maintenance costs, by allowing:

  • Longer periods between bag change-outs
  • Shorter inspection times and thus shorter scheduled downtime
  • Tighter control of emissions, because it measures the performance of each individual bag row, not just the stack (and while overall emissions might be below the levels which would result in a reportable environmental incident, one row might be allowing material product loss)
  • Better scheduling of preventative maintenance, as a better understanding of the rate at which bags deteriorate is developed
  • Reduced health and safety concerns arising from in-bag-house maintenance time.

Improved ability to predict the bag house´s performance also:

  • minimizes the likelihood of an unexpected catastrophic filter failure and a reportable environmental incident, and
  • reduces the likelihood of damage from escaped dust to nearby bags. The savings in a large bag house can be considerable.

 PROSPECTIVE RETURN

The benefits from increased output easily out-weigh the costs of the bag house monitoring system. For example:

  • A 1.0% increase in plant availability over a year will provide an incremental 3.65 days output, assuming a 365 day year
  • A 0.1% reduction in product losses will automatically generate an extra 0.365% of product annually

For a plant with annual revenues of ₤1,000,000 these results would mean increased operating revenues of ₤13,650 per annum at very little incremental cost.

Many if not most operators will find that their daily revenues are high enough to cover the cost of FilterMonitor with the Zeta 5000 within in just one year, if the system allows just one extra day of output. With the addition of savings on filter bag purchases and man-hours employed on maintenance, the financial case becomes compelling.

Compliance monitoring can now be achieved, essentially at no capital cost, as an adjunct to investment in improved process control.

ZETA 5000 ENABLING TECHNOLOGY

  • A bag house monitoring system such as this requires a very responsive continuous emissions monitor:
  • The minimum detection level of the continuous emissions monitor must be not greater than the emissions allowed by the bag, which can be below 0.1mg/M3
  • The continuous emissions monitor´s response time must be both rapid and not “dampened” by averaging over too long a period. Generally, tribo-electric continuous emissions monitors are more heavily dampened than those employing light-based technology, to avoid false emissions alarms associated with their short-term volatility. As they generate signals quite slowly (perhaps two per second compared to the twenty per second performance of the Zeta 5000), their dampening period must in any event be at least ten times longer than that required for the Zeta 5000. The greater sensitivity of Zeta allows identification of the deteriorating bag house row from just one monitoring point, at the exit.

RETROFITTING

FilterMonitor can be retro-fitted to any existing Zeta 5000 installation.

BAG HOUSE FILTER MONITORING - COMPLIANCE MONITORING FOR PROFIT Downloads:

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