Keywords
Failure rate
Bathtub curve
Bag filter efficiency
Madhab’s hat curve of reliability
How to Cite
Abstract
This thesis presents a comprehensive study on the failure rate, reliability, and collection efficiency trends of bag filters in a cement plant over 15 years. Bag filters are vital pollution control equipment used in various industries, including cement plants, to maintain environmental compliance. Understanding their performance and failure patterns is crucial to ensure efficient and reliable operation while adhering to stringent pollution control standards. The research findings reveal that the failure rate trend of bag filters closely follows the bathtub curve, with an initial high failure rate, a period of lower failures, and a subsequent increase in failures as the equipment nears the end of its life cycle. Reliability trends align with Madhab's Hat curve, exhibiting higher reliability during the first 10 to 12 years of operation, followed by a decline in reliability. The collection efficiency of bag filters declines as the equipment ages, with the efficiency decreasing from 99.998% in the early years to 95.05% in the 15th year. This emphasizes the importance of maintenance and retrofitting for older dust collection equipment to maintain high collection efficiency. The study concludes that the typical life span of bag filters ranges from 10 to 15 years, after which major maintenance interventions are necessary to minimize failure rates. The research provides valuable insights for maintenance engineers, design engineers, and reliability engineers, enabling them to improve the performance of pollution control equipment, such as bag filters, reverse air bag houses (RABH), and electrostatic precipitators (ESP), to meet the pollution control standards set by regulatory authorities.
References
Jena MC, Mishra SK, Moharana HS. Experimental investigation on maximizing conveying efficiency of belt conveyors used in series application and estimation of power consumption through statistical analysis. Environ Prog Sustain Energy. 2023; 42: 1-11. https://doi.org/10.1002/ep.14031
Jena MC, Kumar MS, Moharana HS. Effect of particle size on collection efficiency of ESP and RABH: A Case Study. Aerosol Sci Eng. 2019; 3: 75-87. https://doi.org/10.1007/s41810-019-00045-2
Jena MC, Kumar MS, Moharana HS. Air pollution from cement plants: Case Study on particulate matter in Bihar, India. Environ Claims J. 2020; 32: 221-32. https://doi.org/10.1080/10406026.2020.1714200
Khalaf AB, Hamam Y, Alayli Y, Djouani K. The effect of maintenance on the survival of medical equipment. J Eng Des Technol. 2013; 11: 142-57. https://doi.org/10.1108/JEDT-06-2011-0033
Jena MC. A study on reliability, validation of bath tub curve and concept of Madhab’s hat curve of reliability. Scholedge Int J Multidiscip Allied Stud. 2015; 2(5) 43-52.
Chandra A. Performance determination of ESP systems based on PG Tests at DVB IP station unit-5. Delhi: CES. IIT; 2002.
Xia S, Duan L, Wang J, Ji R. Effect of the surface treatment process of filter bags on the performance of hybrid electrostatic precipitators and bag filters. Atmosphere. 2022; 13: 1294. https://doi.org/10.3390/atmos13081294
Feng Z, Pan W, Zhang H, Cheng X, Long Z, Mo J. Evaluation of the performance of an electrostatic enhanced air filter (EEAF) by a numerical method. Powder Technol. 2018; 327: 201-14. https://doi.org/10.1016/j.powtec.2017.12.054
Patnaik A, Anandjiwala RD. Investigating reasons for filter bag failure and developing a method to improve its life span. Chem Eng Technol. 2015; 39: 529-34. https://doi.org/10.1002/ceat.201500282
Morcos VH. Performance analysis of industrial bag filters to control particulate emissions. Energy. 1996; 21: 9-14. https://doi.org/10.1016/0360-5442(95)00087-9
Liu X, Shen H, Nie X. Study on the filtration performance of the baghouse filters for ultra-low emission as a function of filter pore size and fiber diameter. Int J Environ Res Public Health. 2019; 16: 247. https://doi.org/10.3390/ijerph16020247
Li W, Shen S, Li H. Study and optimization of the filtration performance of multi–fiber filter. Adv Powder Technol. 2016; 27: 638-45. https://doi.org/10.1016/j.apt.2016.02.018
Patnaik A, Anandjiwala RD. Reasons for filter bag failure and method development to improve its life span. Chem Eng Technol. 2016; 39: 529-34. https://doi.org/10.1002/ceat.201500282
Zhu Y, Li J, Xu P. Filtration characteristics of a new hybrid electrostatic bag-house system. Chin J Environ Eng. 2011; 5: 2091-4.
Ardkapan SR, Johnson MS, Yazdi S, Afshari A, Bergsøe NC. Filtration efficiency of an electrostatic fibrous filter: Studying filtration dependency on ultrafine particle exposure and composition. J Aerosol Sci. 2014; 72: 14-20. https://doi.org/10.1016/j.jaerosci.2014.02.002
Zíková N, Ondráček J, Ždímal V. Size-resolved penetration through high-efficiency filter media typically used for aerosol sampling. Aerosol Sci Technol. 2015; 49: 239-49. https://doi.org/10.1080/02786826.2015.1020997
Bao L, Musadiq M, Kijima T, Kenmochi K. Influence of fibers on the dust dislodgement efficiency of bag filters. Text Res J. 2014; 84: 764-71. https://doi.org/10.1177/0040517513509853
Humphries W, Madden JJ, Miceli M. The effect of particle precharging on the performance of a fabric filter collecting lead smelter dust. Aerosol Sci Technol. 1984; 3: 381-95. https://doi.org/10.1080/02786828408959026
Choi H-K, Park S-J, Lim J-H, Kim S-D, Park H-S, Park Y-O. A study on the characteristics of improvement in filtration performance by dust precharging. Korean J Chem Eng. 2002; 19: 342-6. https://doi.org/10.1007/BF02698426
Lyu C, Liu JX, Sun X, Yu ZH. Enhancement of filtration performance of fibrous filter for unipolarly charged coal-fired fly ash. J Northeast Univ Nat Sci. 2021; 42: 1335-40. https://doi.org/10.12068/j.issn.1005-3026.2021.09.017
Li H, Wang Z, Ye Y, Wang Z. A model analysis on the pulse-jet cleaning performance of electrostatically stimulated fabric filtration. Powder Technol. 2016; 291: 499-505. https://doi.org/10.1016/j.powtec.2016.01.004
Hasolli N, Park YO, Rhee YW. Filtration performance evaluation of depth filter media cartridges as function of layer structure and pleat count. Powder Technol. 2013; 237: 24-31. https://doi.org/10.1016/j.powtec.2013.01.002
Dai GP, Wei YD, Zhang BS, Shi MX. Failure analysis of filter bags within the bag filter in HDPE unit and its improvements. Petrochem Equip. 2009; 38: 89-91.
Humphries W, Madden JJ. Fabric filtration for coal-fired boilers: nature of fabric failures in pulse-jet filters. In: Filt Sep. 1981; 18: 503.
Lin Z, Li J, Chen D-R, Wu Q, Ma Z, Wu D. Improved performance of the opposing pulsed-jet cleaning by annular-slit nozzles for pleated filter cartridges. Sep Purif Technol. 2022; 303: 122233. https://doi.org/10.1016/j.seppur.2022.122233
Other Causes of Baghouse: Filter Failure dust collection blog https://www.baghouse.com/category/dust-collector-troubleshooting/ (Accessed on November 4, 2023).
benefits of a well-maintained dust collection system. https://www.baghouse.com/2023/11/28/5-benefits-of-a-well-maintained-dust-collection-system/ (Accessed on December 2, 2023).
Dust collector troubleshooting guide. https://www.baghouse.com/2011/02/04/dust-collector-troubleshooting-guide/ (Accessed on December 2, 2023).
Chudnovsky BH. Electrical equipment life expectancy, aging, and failures. Electrical Power Transmission and Distribution, 2012. https://doi.org/10.1201/b13012-6
Bathtub curve. Wikipedia, last edited on 21 June 2023, at 17:53 (UTC). Available at https://en.wikipedia.org/wiki/Bathtub_curve
Reliability analytics tool kit. Available from https://reliabilityanalyticstoolkit.appspot.com/
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Copyright (c) 2023 Madhab C. Jena, Sarat K. Mishra, Himanshu S. Moharana