Air filters
CYCLONE COMBINED PELLET SEPARATOR:
A completely new design is proposed for three high performance cyclone separators to be installed in Lithuania for the production of pellets The new design optimizes the flow and maximizes the effective filtration area of the filter bags More than fifteen designs were considered to obtain the optimal solution Dust was modeled to predict the decantation rate and to prevent dust accumulation A state of the art advanced turbulence model was used
THE LARGEST AIR FILTER IN EUROPE:
We designed a new air filter for a steel mill in Poland, resulting in the largest of its kind Flow Control Engineering was hired from the beginning to make the design This is essential to avoid problems from the outset This way, reducing consumption from 3 6 to 2 MW The filtering fans were balanced by up to 1 5 with consequent savings of filtering material by 15 The spark suppressor was designed for a controlled current There were no added costs for design of special parts or excess material thanks to the detailed engineering of Flow Control Engineering
OPERATING PROBLEMS (filter bags burning):
The largest electric arc furnace plant of the Mediterranean had, since its inception, a problem of burning of the sleeves as a result of the sparks. A quick analysis showed that the spark suppressor was not working correctly. In addition, the flow asymmetry overloaded some filter compartments. We redesigned the system at a minimum cost ensuring long term, trouble free operation. Consequently, resulting in savings worth up to 250,000 euros/year in maintenance, in addition to the costs of related fines. The air in the city is cleaner now.
OPERATING PROBLEMS OF A CEMENT FILTER (filter bags breakage)
A cement filter exhibited a systematic breakage of its sleeves resulting in a cost of 100 000 euros per year to their manufacturer The filter replaced an older one that also did not work properly, ever Our analysis identified the problem in one week The problem was in the location of the filter, so that would affect any filters that were installed However, the solution required a lot of work because there were many restrictions including heated ducts, deflectors, etc The newly designed device was installed in only one day and with a budget under 5000 euros No further breakdowns, resulting in the correction of a problem that had lasted for twenty years As a result, a lot of money was saved and the manufacturer stopped paying penalties
FILTER OPTIMIZATION (a healthy environment in the city):
We were called by the most advanced steel mill in Europe to collaborate in the installation of a new furnace This was a very demanding project from the point of view of filtration, given the proximity of the plant to a large city After six months of work we achieved a design that met the requirements and, once manufactured, the operating data showed deviations of less than 2 5 The air around the steel plant meets the environmental requirements for healthy living for citizens.
