ANFA Nonwoven conference 2019

PPS Trilobal Fiber for BagPPS Trilobal Fiber for Bag Filter Application

Toshihiko TokumaruTOYOBOTOYOBO Life and Industrial Fibers Department2-8, Dojima Hama 2-chome, Kita-ku, Osaka, 530-8230, JAPAN

Tel: +81-6-6348-3607, Fax: +81-6-6348-3602November 8th 2019November, 8 , 2019

Corporate ProfileAs of March 31 2019As of March 31 ,2019

Company name TOYOBO CO., LTD.

Established May 1882June 1914

: Establishment of Osaka Boseki

: Start of Toyobo, Incorporated

Capital stock \ 51 7 billion

y ,

merger between Mie Boseki and Osaka Boseki

N b f E l

Capital stock \ 51.7 billion

Head Office 2-2-8, Dojima Hama, Kita-ku, Osaka, Japan

Number of Employees 9,572 (consolidated)3,092 (Nonconsolidated)

URL https://www.toyobo-global.com/

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マスタ タイトルの書式設定Bases for Marketing and Sales, Group Manufactures

TOYOBO U S A INC

TOYOBO CHEMICALS EUROPE GMBH TOYOBO (SHANGHAI) CO., LTD.TOYOBO AUTOMOTIVE TEXTILES (CHANGSHU) CO., LTD.

TOYOBO (SHANGHAI) BIOTECH CO., LTD.SPINREACT S.A.U.

TOYOBO U.S.A., INC.

TOYOBO (THAILAND) CO., LTD.TOYOBO INDUSTRIAL MATERIAL (THAILAND) LTD

TOYOBO (TAIWAN) CO., LTD.

SANTOYOKO (HONG KONG) CO., LTD.

TOYOBO KOREA CO., LTD.

Arabian Japanese Membrane Company, LLC

TOYOBO KUREHA AMERICA CO., LTD.

TOYOBO INDUSTRIALMATERIALS AMERICA, INC.

TOYOBO MEXICO,S.A. DE C.V. INDUSTRIAS UNIDAS, S.A.

TOYOBO INDIA PRIVATE LTD

TOYOBO INDUSTRIAL MATERIAL (THAILAND) LTD.TOYOBO CHEMICALS (THAILAND) CO., LTD.TOYOBO SAHA SAFETY WEAVE CO., LTD.

TOYOBO DO BRASIL PARTICIPACOES LTDA.

TOYOBO TEXTILE (MALAYSIA) SDN. BHD.PT. TOYOBO MANUFACTURING INDONESIA

PT. SHINKO TOYOBO GISTEX GARMENTPT. TOYOBO INDONESIA

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Business Segments

HealthcareTextiles & Trading

Films &

Functional Polymers Industrial Materialsg

4

Airbag

Industrial Materials

Airbag

High Performance FibersAirbag fabrics

Lif d I d t i l M t i l

PBO fiber

“ZYLON”Ultra-high-strength polyethylene

“IZANAS” Life and Industrial MaterialsIZANAS

Bag filters

“PROCON®”3D spring-structured fiber

“BREATHAIR”5

Filter bags for pulse-jet systems Dust collector examples for coal fired power stations

Dust collector

ESP or Filter Bags

＜South Africa CFB Power Station＞

Filter bags for pulse-jet systems Cake layer

Clean Gas

ide

SideGas Clean Gas

Clean Gas

Scrim

Filtr

atio

n S

Cle

an G

as S

SF C

< PPS Filter Bag : Cross Section >Gas Filter bag

＜Pulse-Jet Filtration＞

Pulse jetClean Gas Clean Gas

< Top of PPS Bag Filter>

PPS Fiber

＜PPS Fiber＞Filament Fiber

PPS

Ｓ

n

Staple Fiber<Poly-p-phenylene sulfide>

It is a material formed only from the Benzen ring and Surfido.

The combined energy of Phoenillen and Sruffid The combined energy of Phoenillen and Sruffid is large. And it is highly crystallized.

Therefore, this fiber is excellent in heat resistance and chemicals resistance.

There is little water dissolution.

PROCON (PPS) 1.3 1.7 2.5dtex Trilobal

PROCON 1.3dtex△

＜TOYOBO＞PROCON Trilobal

＜Regular PPS＞

＜Fig.1 Fiber Surface of PPS Staple Fiber＞

327( 2/k )PPS 1.0dtex

300

350

(m2/kg) P R O C O N

PROCON 1.7dtex△(1.87dtex△)

327(m2/kg) (1.19dtex)

200

250

urface A

rea (

P P S○

Trilobal

PROCON 2 5dt △

272(m2/kg)

280(m2/kg)

100

150

Su

PPS 2.2dtex○

PROCON 2.5dtex△(2.41dtex△)

PROCON Trilobal Fiber has high

100

01234

Fiber Titre (dtex)

206(m2/kg)

260(m2/kg)PROCON Trilobal Fiber has high surface area.

Filter bag for pulse-jet system The residual pressure behavior of pulse-jet filtration

Clean Gas Clean Gas Pulse jet

ide

SideGas Clean Gas

Scrim

Filtr

atio

n S

Cle

an G

as S

SF C

re d

rop

Residual pressure drop

Pres

su

Residual pressure drop

Cycle time

Time

y

PPS Trilobal / VDI 3926 （ISO 11057） Result

＜VDI Test Condition＞ T t D t 5 / 3(3 5 P l NF)＜VDI Test Condition＞ Test Dust：5g/m3(3.5μm, Pural NF)

A/C ：2m/min、 Temp.：160

Number of cycles： 30+10,000(Ageing)+10(Stabillization)+2h(1,000Pa)

Lab.TestNeedle feltSamples

Weight(g/m2)

Thickness

( )

Air Permeability (JIS)(cc/cm2･

Dust Emission (mg/m3) Cycle time (sec) Residual Pressure

drop (Pa)After 30 Measuring After 30 Measuring After 30 Measuring

< TOYOBO Data (Relative Comparison) > Japanese Needlefelt Maker

Samples (g ) (mm) (cc/cm2･

s)cycles

1,000Pa1,000Pa,

2hcycles

1,000Pa1,000Pa,

2hcycles

1,000Pa1,000Pa,

2hPROCON

2.5T Trilobal-100% 580 1.88 9.1 1.15 0.28 662 185 102 431PROCON 578 1 92 6 9 0 94 0 11 583 275 125 3421.7T Trilobal-100% 578 1.92 6.9 0.94 0.11 583 275 125 342PROCON

2.2T○ Round-100% 612 1.89 10.7 1.38 0.57 577 121 103 458

PROCON2.5T Trilobal-100% 532 1.95 148 2.06 0.36 411 65 62 421

PROCON 553 1 74 136 2 32 1 00 392 47 76 467

<EU Customer Data> (l/dm2 min at 2 mbar)

PROCON2.2T Round-100% 553 1.74 136 2.32 1.00 392 47 76 467

Dust Emission / VDI 3926 （ISO 11057）

<Fig.1 Dust Em ission>

1.2M easuring 1,000Pa 2h after ageing(10.000cycles) and stabillization(10cycles)

0.8

1

mg/m

3)

○(TO YO B O )

2.2T ○-100%

0.4

0.6

st Emission (m ○( )

△(TO YO B O )

○(EU C ustom er)

△(EU C ustom er)

○(C om pany A)

1.0T○-20% B lend forfiltlation side + 2.2T○

0

0.2

Dus 2.5T △-100%

1.7T △-100%

P R O C O N

B lend

0.5 1 1.5 2 2.5 3 3.5

Fiber Titer (dtex or T)

Trilobal showed the high filtration efficiency.

Cycle Time/ VDI 3926 （ISO 11057）

＜Fig.2 C ycle Tim e＞

( ) ( )

300

350

400○（TO YO B O ）

△（TO YO B O ）

M easuring 1,000Pa 2h after ageing(10.000cycles) and stabillization(10cycles)

1.7T △-100%

P R O C O N

150

200

250

cle Time (sec)

2.5T △-100%

50

100

150

Cyc

2.2T ○-100%

P P S (R ound)

0

1 1.5 2 2.5 3

Fiber Titre (dtex or T)

Simulation of flow velocity distribution＊Software：Fluent 18.0(ANSYS/USA)

0 0.01 0.02 0.03 0.04 0.05 m/s

＊Software：Fluent 18.0(ANSYS/USA)2 Dimensions Isothermal Steady-state Analysis

＜Round PPS (Regular)＞＜Trilobal PPS (PROCON)＞

2m/min(0 033m/s)(0.033m/s)

VDI

＜Velocity Down Area (Blue) without fiber＞＜PROCON＞ (μm2) ＜Regular＞ (μm2)1.3T Trilobal 360 (36%↑) 1.0T Round 2321.7T Trilobal 431 (34%↑) 1.5T Round 2852.5T Trilobal 515 (35%↑) 2.2T Round 333

＊ Bl A l h 0 015 / ( 0 9 / i )＊ Blue Area：less than 0.015m/s (=0.9m/min)

Simulation of Particle Collection

＜Round PPS (Regular)＞Particle:3.5μm(VDI)

＜Trilobal PPS ＞Particle:3.5μm(VDI)

2m/min→ +

3 5 m

2m/min→+

3 5μm Porosity: Porosity:3.5μm

N=5N=5

3.5μm

＊Random Configuration (Layout) (N=5)

Porosity:73.5 %

Porosity:73.4 %

fluctuation

N=5

fluctuationfluctuation

N=5

Dust layerDust layerDust layer

＜Dust Leak through Needlefelt＞

Leak DustLeak DustLeak Dust

Round PPS (R egular PPS)

TrilobalPPS (PR O CO N )

Round PPS (R egular PPS)

TrilobalPPS (PR O CO N )

Round PPS (R egular PPS)

TrilobalPPS (PR O CO N )Initial Cake layerInitial Cake layerInitial Cake layer

1.3T Trilobal (Layer or Blend)

＜1.3T Trilobal Layer 20wt%)＞ ＜1.3T Trilobal Blend 20wt%)＞

2.2T Round50 %

1.3T Trilobal 20 %2.2T Round 30 %

2.2T Round80 %

1.3T Trilobal20 %

2 m/min＋

3.5μm(VDI)

3.5μm

Tortuosity（Next page)1 41(Layer) > 1 15(Blend)

Porosity:73.5 %

1.41(Layer) > 1.15(Blend)

Simulation： flow velocity distribution

0 0.1 0.15 0.21 0.29 0.34 m/s

＜Round PPS (Regular)＞＜Trilobal PPS ＞

Tortuosity

＊Random Configuration (Layout) (N=5)

Tortuosity=L/C

L：Length of the curveLL

Air

Tortuosity1 9(Trilobal) > 1 7(Round)

C：Distance (Thickness) of Needlfelt+ Particle

1.9(Trilobal) > 1.7(Round)

CC

2.5T Trilobal / Needlefelt (Japanese Companies)

VDI：1.3T Trilobal(20ｗｔ%) Layer / 2.2T Round

PROCON 1 3dt △PROCON 1 3dt △

1.3T Trilobal 20％1.3T Trilobal 20％

PROCON 1.3dtex△

327(m2/kg)

PROCON 1.3dtex△

327(m2/kg)

＊This Sample was Produced by actual Needlefelt process in Japan

W i ht Thi h A P2.2T Round

80%2.2T Round

80%PPS 2.2dtex○PPS 2.2dtex○

W eight

(g/m 2)

Thichness

(m m )

A .P

(c/cm 2・s)

1.3T Tri.20% /2.2T○80% 519 1.9 15.4

2.2T R ound-100% 532 1.8 15.7

＜Dsut Em ission (VDI)＞

0.4

)

＜C ycle Tim e (VDI＞

240250

30023%

Im provem ent

206(m2/kg)206(m2/kg)

0.17

0.3

0.14

0.2

0.3

mission (mg/

m3)

4 1%Im provem ent

53%Im provem ent

84

195

150

200

250

ycle T

ime (se

c)

2 1%Im provem ent

0.1

0

0.1

2.2T Round 1.3T Trilobal20% 2.2T Round 1.3T Trilobal20%

Dust Em

7 084

0

50

100

2.2T Round 1.3T Trilobal 20% 2.2T Round 1.3T Trilobal 20%

Cy

2.2T Round 1.3T Trilobal 20%

Layer

2.2T Round 1.3T Trilobal 20%

Layer

TOYOBO CustomerLayer Layer

TOYOBO Customer

Reference 1) PPS Trilobal

＜CFB, South Africa＞Filter Bag： TPPS Trilobal (10-20%)

High Temperature Filtration Conference in 2008 http://www.eskom.co.za/OurCompany/PhotoGallery/Pages/Eskom_Power_Stations.aspx

Reference 2) Trilobal

＜CFB, Australia 660MW x 2＞Filter Bag：PROCON 2.5T Trilobalg2.5T Trilobal／PTFE Scrim／2.2T RoundUnit 5,6 ： 40,000 bagsBag Life： min.32,000 (hours)Pulse Jet-on LineOperating Temp.：150 (max. 180 )O2 ： ?H2O ： 7.1 (vol%)SOｘ ：150 (ppm)NOｘ ： 380 (mg/m3)ACR ： 1.2 (m/min)Emission： 4 (mg/m3)

Bag Life： 2.5T Trilobal +2.2T Round (lower △P) ＞ 1.0T Round+2.2T

Thank you