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Comparison P84® vs. Chinese PI Fibres

Evonik Fibres GmbHPage | 2

Operating Experience - P84 and Chinese

PI fibres in the same Baghouse

Cement Kiln/Raw Mill Filter Sichuan 3200 tpd

• 4536 bags (130mm x 5200mm), 9629 m²

• A/C ratio: 0,96 m/min

P84® in operation for 7 years (2006-2013)

• Dp stable @ 6-7 mbar during the entire bags life

• Emissions < 10 mg/Nm3 during the entire life

• Low total costs and almost 100% availability of the bag house.

PI CN installed in 2013

• Dp increased from 6 mbar to 8-10 mbar within 2 years due todust penetration

• Additional costs of RMB 500.000 in comparison to P84 during thefirst 2 years (app. 20% of the costs of a set of bags – more thaninitial savings on the bag costs)

• Expected life <<7 years (Dp and emissions will become limiting)

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Italcementi IFTR

P84® versus Chinese PI Bags

Test 3

December 2015

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Italcementi FTR – Calusco Italy

Main features of IFTR:

Installed on a cement plant

Kiln / Cooler FF - Coanda nozzles for HPLV cleaning

Multi-compartment FF (10);

IFTR with 2 test lines with dedicated fans and flow rate controller;

Heat tracing included;

Automatic valves on gas return to automatically isolate the lines

Reduced numbers of curves

Return line in the clean gas chamber – smaller fans

ΔP measured in the bags cover boxes for maximum accuracy

Calibration tests started recently

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Schematics of the Filtration Test Rig

Bag Filters in

Baghouse

Seperate cleaning

for test bags

Seperate Fans for test bags

Flow Control

Pressure,

Temperature

Recording

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Test 3: P84 vs Chinese PI

1. Bag 1 P84

2. Bag 2 Chinese PI

New test bags for Test 3 were installed during the September 2015 outage:

1. P84 130 l/(dm2 min) @ 200 Pa

2. Chinese PI 140 l/(dm2 min) @ 200 Pa (Yi felt Z08Z41-000-5/0)

Ageing procedure applied for Test 3:

• 2000 cleaning cycles, at 2.2 bar and 1.2 m/min filtration velocity

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Test 3: Operating Parameters

Ageing: 2000 cleaning cycles at 2.2 bar pulsing pressure

and 1.2 m/min filtration velocity (06-10/11/2015)

Actual Test (11/11 – 23/11/2015, off line, 26/11 - 01/12/2015)

Pulse pressure: 3.2 bar

ΔP control mode: 1.0 kPa – 1.1 kPa

Filtration velocity: 1.04 m/min

Equivalent flow: 140 m3/hour

Pulse time: 100 ms

Min time between pulses: 10 sec

Max. no. of pulses (trip): 10

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0

200

400

600

800

1000

1200

1400

60000 60500 61000 61500 62000 62500 63000 63500 64000 64500 65000

Dp

[Pa]

daytime [s]

Bag1

Bag2

Pressure Drop Before Ageing

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FV: 1.04 m/min

Pulse P: 3.2 bar

ΔP: 1.0 - 1.1 kPa

Test Parameters

Test 3: Results – P84 vs Chinese PI

0

20

40

60

80

100

120

140

160

180

200

1 2 3 4 5 6 7 8 9 10 11 12 13

Pulses

/ day

P84

Chinese PI

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0

200

400

600

800

1000

1200

1400

10000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000

Dp

[Pa]

daytime [s]

Bag1 18.11.15

Bag2 18.11.15

Pressure Drop after Ageing

Bag 1 = P84

Bag 2 = chinese PI

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2 X BAGS - BAG FILTER ΔP POWER CONSUMPTION / COST COMPARISON

Bag House

Bag Type (surface) Yilun P84

Average Pressure Drop (ΔP) kPa 0,88 0,713

Actual Volume Flow m3/s 167 167

Fan effciency (typical) % 80 80

Motor effciency (typical) % 94 94

Drive efficiency (typical) % 85 85

Power consumption KW 229,5 185,9

Power Consumption per day (24 hrs) kW*h 5508 4463

Power Consumption per year (8000hrs) kW*h 1834159 1486086

Price of power Euro / kW*h 0,06 0,06

total fan power costs per year €/a 110.050 € 89.165 €

Power cost difference / year Euro / year 20.884 € 23%

Energy Consumption and Cost Comparison

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Pressurized Air

Bag House

Bag Type P84 Yilun

Barometric pressure mbar 1013 1013

Pulse tank pressure bar (g) 4 4

Absolute pressure bar (abs) 5,0 5,0

Pulse valve size 2 1/2" 2 1/2"

Flow coefficient (Kv) - [20oC & 101.3

kPa] Nm3/ hour 70,3 70,3

Pulse time ms 200 200

Volume per pulse - [20oC & 101.3 kPa] dm3 (litre) 148 148

Number of bags per bag house 3300 3300

Number of bags per pulse pipe 20 20

Number of pulse valves per bag house 165 165

Pulse rate / bag (FTR)

pulses /

hour 2,875 5,83

Total air consumption - [20oC & 101.3

kPa] m3/hour 70,1 142,1

Power consumption / hour KW 9,7 19,6

Power consumption /day KW 232,2 470,9

Price of power

Euro / KW

hour 0,06 0,06

Power cost / day Euro 14 € 28 €

Power cost / year (90% availability) Euro 4.577 € 9.281 €

Power cost difference / year Euro -4.704 € 49%

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Pay Back Time of the P84 Bags

P84 Yilun Difference

Bag Investment [€/m²] 20 16 20%

Investment costs [€] 200000 160000 40000

Annual Fan Power Costs [€] 89165 110050

Annual Pressurized Air Costs [€] 4577 9281

93742 119331 25589

Pay Back Time [years] 1,56

Assumptions

Plant Size: 10000m²

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Test 3: Conclusions – P84 vs Chinese PI

The P84 filter bag performed better than the Chinese PI material

The number of pulses required to maintain the ΔP within the pre-set

range (1.0 – 1.1 kPa for both bags) was found to be about 25% lower for

the P84 bag.

The mean Dp for the P84 bag is approx. 23% lower than the mean Dp of

the Yilun bag. This results in a 23% power saving

Power saving in fan power and pressurized air consumption lead to a

payback time of just 1,6 years based on a price difference of 20%

between P84 and Chinese PI

Examples from the industry show that the superior filtration performance

of P84 also leads to a longer bag life