How to save money, time and energy on dust collection?

Before starting your cost evaluation, it is important to make sure the filters you are considering for purchase will have adequate filtration efficiency and other characteristics needed to perform their primary function of air pollution control. There are listed Occupational Exposure Limits (OEL) for hundreds of dusts ranging from nonspecific or “nuisance” dust to highly toxic substances. 

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Tony SUPHINE Camfil, Farr APC Industrial Dust Collectors Technical Director When it comes to choosing filters for a cartridge dust collector, plant engineers and maintenance professionals sometimes regard these items as more or less of a commodity. If Filter A and Filter B both offer the same rated effi ciency and fill any special requirements – say, for example, the need for fire retardant media – then the lowest-priced filter would appear to be the better choice. In fact, the opposite may be true. But it requires a “Total Cost of Ownership” (TCO) calculation to know for certain. TCO helps you determine what it really costs to own your dust collector filters… and how to save money, time and energy by choosing the best filters for your application.

Before starting your cost evaluation, it is important to make sure the filters you are considering for purchase will have adequate filtration efficiency and other characteristics needed to perform their primary function of air pollution control. There are listed Occupational Exposure Limits (OEL) for hundreds of dusts ranging from nonspecific or “nuisance” dust to highly toxic substances. These limits are based on 8-hour time weighted average exposure. Further information on OELs can be found at https://www.hse.gov.uk//press//c.htm for the UK and other European counties have their corresponding authorities regulating the actual allowed levels.

For some dusts such as hexavalent chromium, a known carcinogen, the thresholds are as low as 5micrograms (0.005 milligram) per cubic meter. This is 10 times stricter than the limits for some other toxic dusts. Dust collectors need to be equipped with very high efficiency filtration media to meet such requirements. In addition, you also have to consider the environmental regulations. The new emissions requirements may require many plants to incorporate high efficiency filtration to ensure compliance.

How do you know if your dust collector filters will comply with emission thresholds? The equipment supplier should provide a written guarantee stating the maximum emissions rate for the equipment over an 8-hour OEL if you are recirculating the air back into the facility. Filter efficiency stated as a percentage is not an acceptable substitute, even if the supplier promises 99.9% efficiency. The authorities only care that the quantified amount of dust in the air is below established limits.

Also, what are the size(s) and shape(s) of the dust particles to be collected? Is the dust combustible? If the dust is combustible the entire system must comply to the ATEX regulations. This means that it’s not sufficient to buy single approved components: It is also required that you do an assessment of the system in accordance to directive /92/EC. Is the dust sticky or dry? These are just some of the characteristics that will also determine the best filter choice. Testing a sample of your dust is the only way to get an accurate picture of its properties. Dust testing is available from independent laboratories and many equipment suppliers.

HOW MUCH DOES A FILTER REALLY COST? Let’s assume you have identified the dust characteristics through testing, determined the required filtration efficiency, and narrowed the choice to two products with the same rated efficiency, Filter A and Filter B. Total cost of ownership (TCO) can now be applied to help you decide what filter to select. Similar in concept to life-cycle costing, CO incorporates a step-by-step evaluation process encompassing three categories: • Energy – the amount of energy required to operate the dust collector from day to day, including electrical costs, compressed air usage and CO2 emissions. • Consumables – the items that are replaced periodically throughout the life of the equipment • Maintenance and Disposal – the time it takes to service the equipment and the costs of disposing of the consumables.

If you are considering the purchase of a complete new dust collection system, you will have control over more of these variables, such as the selection of electrical components that impact energy use. But even if you are simply assessing what replacement filters to use in an existing dust collector, a TCO analysis can yield useful information and surprising results.

Figure 1 (next page) is a sample dust collection worksheet used to gather TCO data. Following is a more in-depth look at some of the key items that may be included in such a worksheet and how they impact TCO.

ENERGY Many factors influence a dust collector’s electrical energy consumption. Though there can be numerous electrical loads associated with a dust collector – timer boards, rotary airlock motors, etc. – the largest portion of the electrical load relates to the fan or blower required to move air through the system. It is important to understand that differential pressure losses are directly proportional to the amount of air moved through the system, and the amount of air in turn is directly proportional to the cost of electrical energy consumed by the fan. While ducting should be optimized at the time of installation to reduce the amount of pressure loss, we will focus on the energy control devices and filters which contribute to variable pressure losses during dust collector operation.

When running a dust collector with a constant speed fan (i.e., with no energy control device), the amount of air moving through the collector will vary during the service life of the filters. Why does this occur? When filters are clean and differential pressure is at its lowest, more air blows through the system than required, essentially wasting energy. As filters become loaded with dust, static pressure is increased and less air is moved as a result. Thus, filters use more energy in the early stages of service life and less in the final stages.

One way to reduce this problem is via a mechanical damper at the blower outlet. Depending on the type of filters used, periodic adjustment of the damper to regulate air flow can save an average of 250 Pa of static pressure over the life of the filter.

A far more effective approach is the use of a variable frequency drive (VFD) that electrically controls fan speed. When filters are new, speed is decreased to obtain the desired air flow. When filters become loaded, the fan is sped up to maintain a constant air flow. The electrical control is highly efficient in maintaining desired air flow, and energy consumption is greatly decreased. The use of a VFD has been proven to save an average of Pa of static pressure over the life of the filter. The added capital cost of installing a VFD on a dust collector will vary. However, the return on investment is typically under one year. Additional factors that impact energy use are:

• Premium effi ciency (IE3) vs. standard effi ciency (IE2) fan motors: Industrial electric motors are the single largest consumer of electricity in the U.S. Used to power a dust collector fan, a premium efficiency motor can pay for itself in reduced electrical power use and/or through rebates and incentive programs offered by many electric utilities. These motors run cooler and last longer, making them ideal for use with VFDs for optimum fan speed control and energy savings.

• High efficiency fans: When you specify a new system, you should make sure to specify a fan with an efficiency of at least 70% at the working point. A good industrial fan has up to 85% efficiency. The differences between fans are much bigger than between the motor classes, so there is a lot of potential here for energy savings.

• Compressed air usage: The amount of compressed air required to perform pulse-cleaning of filters and maintain a lower pressure drop is important to consider. Compressed air requirements will vary significantly depending on filter design. • CO2 emissions cost: Although this does not contribute tangibly to TCO, the amount of CO2 emissions from operation of a dust collector should be considered and stated as a cost impact on the environment.

CONSUMABLES, MAINTENANCE AND DISPOSAL The items in these two categories are straightforward and can be summarized as follows:

• Cartridge replacement – the amount of money spent on replacement filters alone. • Transportation cost – the amount of money required to have replacement filters delivered to the operation site. • Inventory cost – Typically, replacement filters are not received the day they are replaced in the system. This component is the amount of money required to carry inventory of replacement filters. • Labour cost – the cost of labour required for maintenance personnel to change filters. • Disposal cost – Depending upon the type of material being filtered, there is a cost associated with properly disposing of filters laden with process dust. If you are handling a hazardous dust, cartridge disposal costs may be higher. By reducing filter change-out frequency, associated disposal costs can be reduced. • Downtime cost – This will vary from facility to facility, but it refers to the amount of time in lost production due to shutting down the collector for a filter change. Clearly, when viewed on an annualized basis, all of these factors are largely dependent on the anticipated service life of the filter. The change-out schedule will determine how many filters you can expect to buy, transport, store and dispose, as well as the costs of labour and downtime associated with filter service.

TCO EXAMPLES The worksheet in Figure 1 compares two different filters, both containing standard media with standard cartridge filtration efficiency. Filter A, at a unit cost of €68, is a conventional dimple-pleat style cartridge filter. Filter B, at a unit cost of €90, is an open-pleat style cartridge filter designed for extended service life and lower pressure drop operation. Figure 2, the Life Cycle Comparison Report, uses data from the worksheet in Figure 1 to project the TCO of a new 16-cartridge dust collection system equipped with Filter B. Though it has a higher initial cost than Filter A, Filter B operates at a lower pressure drop over a longer period of time to save on energy use. The Energy Category in Figure 2 shows savings achieved by combining Filter B with energy-efficient electrical components. The use of a premium efficiency motor alone yields savings over a standard efficiency motor, but the best savings by far are realized with the combination of a VFD and premium efficiency motor – nearly €9,000 in projected savings over operating hours or one year.

NEW DUST COLLECTOR TCO EXAMPLE Projected Total Cost of Ownership Savings for 16-Cartridge Dust Collector using Filter B operating hours (one year)

Filter B also offers 50% longer service life, which translates into an additional €573.62 savings in consumable costs and €1,284.52 savings in maintenance and disposal costs. Added to energy reductions, the total cost of ownership savings per year = €10,812.41.

As noted earlier, TCO analysis can also be helpful with existing dust collectors. This was the case in a real-life application involving the metalizing of aircraft engine parts, in which the manufacturer was experiencing problems with plugging of fi lter cartridges in three identical dust collectors. “Filter A” – a conventional dimple-pleat filter with fire-retardant media – lasted only about 1,000 hours, necessitating frequent replacement.

The company decided to test a comparably rated “Filter B” (i.e., same efficiency but an extended life, low-pressure-drop open-pleat filter) in two of the three collectors. The filters lasted for 16 months or 5,280 operating hours before needing replacement. Figure 3 shows the TCO savings achieved by switching to Filter B. Based on a combination of field experience and analysis of the TCO data, the manufacturer switched all three collectors to Filter B and is now saving over €15,000 per year in maintenance and energy costs.

EXISTING DUST COLLECTOR TCO EXAMPLE Total Cost of Ownership Comparison Dust Collector Replacement Filter A vs. Filter B Actual Savings over 16 months (5,280 hours)

By now it should be clear that the lowest-priced dust collector filter is not necessarily the most economical or the most sustainable choice. TCO provides a useful tool for comparing the real costs of operating an existing dust collector with different filters, as well as a tool for evaluating the impact of energy-saving electrical components in the design of new and refurbished dust collection systems.

Market Insights on Monofilament Fabric Filter Cloth

Market Overview: The global nonwoven filter media market, which encompasses products like monofilament fabric filter cloth, has experienced substantial growth, rising from USD 7.45 billion in to USD 8.05 billion in . This upward trend is projected to continue at a CAGR of 8.11%, reaching approximately USD 12.87 billion by , according to Research and Markets. The increasing demand for efficient filtration solutions, driven by stringent environmental regulations and the need for better air and water quality, significantly influences market dynamics. Monofilament fabric filter cloth is particularly sought after for its durability and filtering efficiency, making it a preferred choice in various industrial applications, including automotive and water treatment sectors.

Regional Insights: The nonwoven filter media market is characterized by varying regional demands, with the Americas leading in consumption, particularly in the United States, where regulatory standards for emissions are stringent. This region's market growth is further supported by innovative advancements in filtration technologies. The Asia-Pacific region is also witnessing rapid growth, with a projected CAGR of 8.1% due to industrialization and heightened awareness of health and environmental issues. Countries like China and India are emphasizing the development of high-quality filter media, including monofilament fabric filter cloth. However, challenges such as fluctuating raw material prices and environmental concerns regarding nonwoven filter disposal remain critical issues that manufacturers must navigate to sustain growth in this evolving market landscape.

Types of Monofilament Fabric Filter Cloths

Using monofilament yarn creates a wide range of unique types of filter fabric filter cloths. Each type has a specific application area.

• Low-Density Monofilament Fabric Filter Cloths

  Low-density monofilament filter cloths have fewer fibers per inch, giving them a large open area. They allow for fast liquid flow and capture smaller particles. This design works well in places like water treatment plants, food and beverage production, and chemical manufacturing where filtering liquids quickly is essential.

• High-Density Monofilament Fabric Filter Cloths

  High-density options pack more fibers tightly together, creating a smaller exit point. While they let liquid pass through more slowly, they catch finer particles better. This makes high-density monofilament filter cloths suitable for uses that need to remove even tiny bits from liquids, such as in paint and pigment processing, semiconductor fabrication, or pharmaceutical filtering pipelines.

• Multi-Diameter Monofilament Fabric Filter Cloths

  Some filter cloths combine monofilament strands of different sizes. The blended diameters create a unique fiber surface that balances liquid flow and particle capture. Using multi-diameter monofilament filter cloths provides versatility in filtering performance for complex industrial processes. They can meet varying specifications within a single system.

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• White Mianol Filtration Strainer Bags

  A common type of filter bag is the white mianol strainers. They are made with monofilament material while most are made with multifilament material. Monofil filtration bags can filter out up to 5 microns and are typically used in liquid fine filtration applications.

• Coloured Mianol Filtration Strainer Bags

  Coloured mianol filtration strainer bags are typically used in liquid coarse and fine filtration applications. Coloured mianol strainers are often made with a larger micron mesh and are more visible in a working environment.

• Polyester Monofil Filter Cloths

  Monofil polyester filter fabric is made from a single, continuous synthetic fiber. Polyester monofil filter cloths are widely used for solid/liquid separation in the chemical, food and beverage, water treatment, and other industries.

• Nylon Monofil Filter Cloths

  Nylon (polyamide) monofil filter cloths offer excellent strength, elasticity, and abrasion resistance. They also have high resistance to oil and fat. Nylon monofil filter fabric is ideal for high-temperature filtration and demanding mechanical separation processes. It is also great for chemical resistance applications.

Specifications and maintenance of monofilament fabric filter cloth

• Material: The material used for monofilament filter cloths differs, with polyester being the most common. Other choices include nylon, polypropylene, and polyethylene.
• Filament Diameter: The size of the filament affects the cloth's strength and filtering precision. Generally, finer filaments allow for increased filtration precision, while thicker ones offer more durability.
• Weave Pattern: Cloths are usually woven into distinct patterns, each suited for diverse filtering tasks. A typical weave pattern is flat, while other variants are twill or leno. Each design results in a unique open area and particle capture efficiency.
• Fabrication area: This relates to the size of the pieces as well as any cut or seaming that may be required to make them fit into a specific filter device or apparatus.
• Temperature Tolerance: Some filter techniques require high heat or low-temperature tolerance elements. For instance, filter textiles for hot water extraction must have a high melting point.
• Chemical Resistance: It is essential to filter materials used in wastewater treatment or the food industry. The filter material must resist the chemicals passing through it, ensuring durability and effectiveness in various chemical environments.
• Filter Efficiency: The filter particle size and efficiency are critical when capturing certain contaminants. Some monofilament filter fabrics are designed to capture larger particles, while others are made to filter finer ones.
• Coating and Impregnation: Some monofilament filter cloths have surface coatings or impregnation to enhance their filtering capabilities, anti-static properties, water repellency, etc.

For optimal filtration performance and extended service life, proper maintenance of monofilament filter fabric is crucial:

• Regular dusting: Dust the filter cloth or use a vacuum cleaner to eliminate surface dust and debris.
• Avoid clogging: Ensure the filter holes do not clog by avoiding the trapping of substances that can close them. Use sealing substances to repel those likely to clog the filter.
• Periodic cleaning: Clean the filter cloth regularly based on use conditions. Use appropriate cleaning agents and methods to remove impurities and dirt.
• Stain treatment: Immediately treat stains on the filter material. The longer the stain remains, the more challenging it will be to remove.
• Edge and hole repair: Check the filter's damaged edges and holes regularly. Repairing or replacing them promptly to avoid further damage is essential.
• Storage cleaning: When storing the used filter cloths, ensure they are clean and dry to prevent mould and bacterial growth.
• Replacement: Replace the damaged or worn filter cloths. Continuously using damaged ones can affect the quality of the filtered liquid.
• Use environment: Consider the use surroundings of the filter cloth, such as temperature and humidity, and select suitable materials and maintenance methods.

Application scenarios for monofilament fabric filter cloth

Monofilament filter cloths have many uses in different industries.

• Food industry

  The food industry uses monofilament filter cloths for food and beverage processing. For example, they are used for solid-liquid separation when making juices, wines, dairy products, and cooking oils. The filter cloths help remove pulp, sediment, and unwanted particles, ensuring that only high-quality products are used for consumption. In addition to this, they are used for brewing beer filtration - both during the initial fermentation process and before bottling or canning. The precise filtration offered by monofilament filter cloths helps clarify the beer and eliminate any residual grains.

• Chemical and pharmaceutical industries

  In the chemical and pharmaceutical industries, monofilament filter cloths are used for liquid clarification and product recovery. The filter cloths separate crystals, precipitates, and impurities from valuable chemicals and solutions, thereby enhancing the purity and yield of chemical processes. They are also employed in the production of pharmaceuticals - such as antibiotics, hormones, and other medicinal compounds. The separation and filtration processes that use monofilament filter cloths are critical to meeting strict pharmaceutical standards and ensuring the safety and efficacy of final products.

• Water and wastewater treatment

  Monofilament filter cloths play a crucial role in water and wastewater treatment. They are used in microfiltration and ultrafiltration processes to remove suspended solids, bacteria, and other contaminants from water. This helps produce clean water suitable for different applications, including drinking, industrial use, and water reuse.

• Textile and dyeing industries

  Monofilament filter cloths are also used in the textile and dyeing industries for liquid filtration and dye separation. For instance, during the processing of fibers and fabrics, the filter cloths help eliminate undesirable colors, particles, and impurities from the water used, thus preventing damage to the equipment and end products.

How to choose monofilament fabric filter cloth

When it comes to choosing monofilament filter cloth, there are some key features business buyers should consider before purchase.

• Filtration requirements: This includes the types of particles or contaminants to be removed, the desired filtration efficiency, and the flow rate. Different applications may require varying mesh sizes and materials. For instance, a precise filtration task will need fine mesh, while a high-flow application will be suited to coarse mesh.
• Material compatibility: The fabric filter must be compatible with the chemical makeup of the solution or substance it will come in contact with. Certain chemicals can cause, damage, or degrade the filter, thereby, affecting performance. For instance, polyester filter cloth is commonly used for water treatment because of its resistance to a wide range of chemicals.
• Durability and tensile strength: Consider the filter cloth's durability and tensile strength. Withstanding the stresses of the filtration process and the physical demands of specific applications is important. For example, in demanding industrial settings, strong polyester still filter cloth is often used for its extraordinary tensile strength and durability. Make the filter's life longer and help reduce the need for frequent replacements.
• Ease of cleaning and maintenance: Pickup and maintenance ease can be an important consideration. If the filter cloth is difficult to clean or requires special maintenance, it may incur additional long-term costs. Some filter clothes are designed for easy cleaning, while others may require chemical cleaning.
• Cost-effectiveness: When it comes to large-scale business buying, the cost must also be considered. While choosing high-performance filter cloth may require a larger upfront cost, it can save money. This is through reduced cleaning, downtime, replacement, and maintenance expenses over the product's life span.

Q & A

Q1: What are the benefits of using monofilament filter cloths in industrial filtration processes?

A1: Monofilament filter cloths offer several advantages, including improved filtration efficiency, high flow rates, enhanced cake release, durability and longevity, resistance to clogging, chemical compatibility, temperature resistance, cost-effectiveness, and customization options.

Q2: Can monofilament filter cloths be used with different types of filters?

A2: Yes, monofilament filter fabric is versatile and can be used with various types of filters, including bag filters, plate and frame filters, tubular filters, drum filters, and string filters.

Q3: Are monofilament filter cloths easy to clean and maintain?

A3: Monofilament filter fabric is easy to clean and maintain. Regular cleaning prevents clogging and preserves filtration efficiency. Depending on the filtration application, filter cloths can be washed, back flushed, or subjected to chemical cleaning.

Q4: What factors determine the choice of monofilament filter cloth for a specific application?

A4: Consider the filtration quality, flow rate, particle size, chemicals to be filtered, the temperature of the process, and the budget.

Contact us to discuss your requirements of filter press fabric. Our experienced sales team can help you identify the options that best suit your needs.