4:
A Ferro Silicon Producer in Alabama
Filter flow resistance (pressure drops) have been significantly reduced, allowing for increase in system gas flow of approximately 20% which has allowed for the increased furnace production. Producer can now operate at a higher furnace power rate, which in turn allows for increased capacity and improved product quality.
5:
A Ferro Silicon Producer in Norway
Installed GORE® membrane filter bags. Operation at twice the flow and grain loading and at a lower pressure drop, 5.9" w.g. (150 mm) as opposed to 7.87" w.g. (200 mm).
7:
AOD Vessel
The baghouse differential pressure dropped to a maximum of
5 to 6 inches w.g. The gas flow and productivity of the vessel
increased dramatically.
8:
Bag Pulse Jet Top Load Collector
After three months operation at 50 psi pulse pressure, the pressure drop across the filter cartridges was maintained below 4.5" w. g., at 15,000 to 18,000 acfm system airflow. The cyclone has prevented any spark damage to the cartridges, the design of which allows for installation and removal times one-third that of the original filter bags.
10:
Calcium Hypochloride
After installation of GORE™ all ePTFE bags and optimization of
system setting by Gore technicians, filter emissions dropped to
near zero for remainder of bag life.
11:
Carbon Black
With the use of GORE™ filter bags the airflow was increased
by over 20%, the pressure differential across the collector
was reduced by over 50% (with higher airflow) and a baglife
of 3 years could be achieved.
14:
Catalysts
GORE™ Filters increased baglife to over 24 months.
15:
Cement Finish Mill, Conventional Mechanical Separator
The GORE® membrane filter bags operated consistently at 4-5" w.g. at an air-to-cloth ratio of 5.0:1. Through the use of GORE® membrane, mill production increased 8% to 90-92 tons per hour, as better mill sweep was achieved. The energy and maintenance costs were substantially reduced over conventional bags.
16:
Cement Finish Mill, High Efficiency Separator
The first set of GORE® membrane filter bags operated consistently at 5" w.g. at an air-to-cloth ratio of 5.1:1. Mill production increased to an average of 105 tons per hour with an emission rate of 0.002 grains/cubic foot. The first set of GORE-TEX® membrane filter bags were installed for 3.25 years and were replaced with a second set of GORE® membrane filter bags.
17:
Cement Kiln
Since installation, the filters have been operating at a differential pressure of 6" w.g. and are cleaning on-line. The pulse pressure is set at 4 bar (approximately 60 psi) and the filter bags are cleaning based on a photohelic gauge 2.5 times an hour. Since installation, none of the filter bags have been replaced. There are no visible particulate emissions.
18:
Cement Kiln
The complete project (from concept to final commissioning) took place within nine months, costing under two million U.S. dollars. This included obtaining permits, consultant work, and a six-week shut down to complete the retrofit. The second set of bags consistently operate in the 3-4" pressure drop range and clean on demand with 50 psi averaging every six hours.
19:
Cement Kiln
The first set of GORE® membrane filter bags lasted six years. Emission levels decreased by 75% after installing GORE-TEX® membrane filter bags. The differential pressure decreased by 50% across the baghouse. Airflow increased from the design flow rate of 154,000 acfm to 226,000 acfm with an air-to-cloth ratio of 2.25:1.
20:
Cement Kiln
Since installation, the baghouse has operated above the design airflow with a consistent differential pressure of 4" w.g. The emissions have been tested at 0.0025 gr/acf which, at design airflow, equates to under 4 lbs/hr.
21:
Cement Kiln
During March 1997, a new Fuller reverse air baghouse was installed and equipped with GORE® membrane/acid resistant fiberglass fabric (10 oz/yd2) filter bags. Since installation, the baghouse differential pressure is less than 3.5" w.g. The floors of the clean air plenums are free of dust. There are no visible particulate emissions.
22:
Cement Kiln / Raw Mill
Due to the success of this ESP/baghouse hybrid on both kilns, a technical paper was written on the application, co-authored by Gore and the Director of Engineering from the customer. A write-up of this application has also been published in international cement trade journals, as well as having been presented at several conferences.
23:
Cement Kiln / Raw Mill
Installed only 78 GORE® membrane filter bags in each compartment, approximately 76% of the total designed number of filter bags. After installation of GORE® membrane filter bags, the plume was still evident; however, the plume was now detached with a bluish appearance.
24:
Chemicals – Powder Paint Coatings
Flex-Kleen collector; vertically hung top load. Spun-bonded polyester cartridges (quantity of 264), 5.563" outside diameter x 40" long; 20,000 acfm, air-to-cloth ratio of 3.0/1
29:
Electric Arc Filter
By removing the U Tube cooler pressure loss the plant was able
to open the canopy hood dampers more.
30:
Electric Arc Foundry Furnace
When the grain loading was high and air volumes low, the GORE® membrane was able to handle the high grain loading conditions. During the boil phase, the air volume pushed the air-to-cloth ratio past 7:1 with a very fine fume. Again GORE® membrane filter bags handled the conditions with no problems.
31:
Electric Arc Furnace
The baghouse differential pressure dropped to a maximum of
5 to 6 inches w.g. The gas flow and productivity of the vessel
increased dramatically.
32:
Electric Arc Furnace
Bag failures stopped since the GORE™ ePTFE membrane and the fiberglass backing material are not subject to hydrolysis and resist spark damage.
33:
Electric Arc Furnace
With the new high temperature membrane filter media, required
dilution air from the canopy hood is reduced and furnace suction
pressure is consistently maintained, reducing furnace fugitive
emissions.
34:
Electric Arc Furnace
The baghouse differential pressure decreased due to more
effective bag cleaning. As a result, the melt shop gas flow increased
by 20% without adding more baghouse compartments.
35:
Electric Arc Furnace
Thermal degradation of filter bags has been eliminated. The pressure differential across the baghouse was decreased by two inches. A 30 percent increase in airflow was measured through the system. This increase in airflow has virtually eliminated the smoky conditions in the melt shop. Baghouse emissions are one-tenth permitted levels.
37:
Emission Control System – Industrial Paper-Fired Boiler
Gas flow of 15,264 acfm at 420°F has been maintained with 4.5" DP across the bags. Mass emissions measured at only 22 percent of the allowable limit. Bags have not been retensioned because cake build-up on the bags has been eliminated.
40:
Ferroalloy
Eliminated the need for sonic horns and dramatically decreased
baghouse pressure drop.
41:
Ferrochrome
System optimization and installation of GORE® membrane filter
bags resulted in improvements to the baghouse and overall production process.
42:
Ferrosilicon
Extraction at the furnace has increased above the design.
43:
Flash Dryer New York (One MikroPulsaire Baghouse)
Production restriction and short bag life. The existing baghouse was experiencing rapid buildup of DP to 10+" in 3-4 months. Particle penetration in the conventional media was the main problem with particle size ranging from 1/2 to 2 microns. Downtime affiliated with frequent bag changeout was also a production loss problem.
44:
Flex-Kleen Collector
GORE® Filter Cartridges were used in a Flex-Kleen collector to solve the problem of chronically plugged cartridge pleats.
45:
Fly Ash Handling; Circulating Fluid Bed Boiler
Pressure drop is reduced to 2-3" w.g. Bag life increased to 11 months. Major savings in bag and labor costs were realized. It was observed that with GORE® membrane filter bags, the system moved more fly ash than before. Also, the bags recovered several times from filling up the baghouse with fly ash. Subsequently, dumping frequency into the storage silo had to be doubled. Now, both collectors use GORE® membrane filter bags.
46:
Fly Ash – Industrial Coal-Fired Boilers (2)
Fly ash – industrial coal-fired boilers (2). Griffin pulse jet collector (1,260 bags) – gas flow: 60,000 acfm at 350ºF; air-to-cloth ratio: 4.8 cfm/ft2; inlet load: 0.2-5.5 gr/dscf; particle size: 25% <= 3.0 µ.
47:
Food Additives
Cleaning measures were significantly reduced and high pressure
drops were eliminated.
48:
Food Nutrition
After installation of GORE™ High Durability Filters plant
engineers reported much lower emissions and pressure drop
reduction to 3,5 millibars.
49:
Fumed Silica
Use of GORE™ filter bags allowed the plant to convert the
secondary filter into a primary one which increased production by one third.
55:
Hydrated Silica
Using GORE™ High Durability Filter Bags emissions were significantly
reduced and much lower pressure drops were achieved.
56:
Ladle Metallurgy Furnace
Filters have been operating since September 1997. Emission results were recorded at 0.0002-0.001 gr/dscf, which is less than the permitted level. Also, the filters can be cleaned at optimal pressures and intervals without bleed-through or emissions spikes.
57:
Ladle Metallurgy Furnace
Filters have been in use since September 1997. Emission results were recorded at 0.0002 gr/dscf -0.001 gr/dscfm-less than the permitted level.
58:
Ladle Treatment System Baghouse
The system now runs with a consistent airflow of 41,000 acfm and compartment pressure drops of 4.5 - 6.5" H2 O. The customer is able to run two ladles simultaneously, increasing metal throughput.
59:
Lead Oxide (PbO) Barton Process
Original set of GORE® membrane filter bags were in service for more than three years and were removed during a planned maintenance shutdown. Emission levels measured less than required by standards/regulations during this operational period.
60:
Lead Reverberatory Furnace
GORE® membrane/GORE® fabric filter bags eliminated premature bag replacement in a lead reverberatory furnace application.
61:
Light Weight Aggregate Kiln
Since start-up, the fan has been able to operate with the damper 87% open. The differential pressure maintains between 3 and 4" w.g. There have been no filter bags removed since installation and there are no visible particulate emissions.
62:
Lime Kiln, Suspend Kiln
Baghouse is running higher than design airflows (almost 30~40%) with differential pressures across the inlet flange to outlet flange from 160~170 mm w.g. The cleaning system is a pulse-jet style using compressed air at a pressure of 5~5.5 bar.
64:
Magnesium Furnace Baghouse
After the GORE® membrane filter bags were installed, emissions through the bags ceased. The initial set of bags continues to provide excellent filtration performance after more than 10 years of service.
65:
Magnesium Furnace Baghouse
After the GORE® membrane filter bags were installed, emissions through the bags ceased. The initial set of bags continues to provide excellent filtration performance after more than 10 years of service.
66:
Medical Waste Incinerator at a Seattle, WA Medical Center
Since the GORE® membrane filter bags were installed in April 1991, the pressure differential across the baghouse remains below 3 inches w.g. before cleaning. After one complete cleaning cycle, the pressure differential is reduced to 0.5 inch of w.g. The cleaning air pressure is set at 40 psig and the cleaning cycle is actuated once every two days.
67:
Medical Waste Incinerators With a Waste Heat Boiler
Since the GORE®membrane filter bags were installed in April 1991, the pressure differential across the baghouse remains less than three inches w.g. before cleaning. After one complete cleaning cycle, the pressure differential is reduced to 0.5 inch of w.g.
69:
Multiple Industrial Coal-Fired Boilers
Customer achieved full load airflow with a 6" DP across tubesheet which allows systems to run at a full steam load (1.3 MM lb steam). Tests of filters at 6-mo. intervals reveal good retained strength and flexibility, good permeabilities, and no dust penetration or bleed-through. Average bag life has been 96 months with one trial compartment at 123 months.
70:
Multiple Spreader Stoker Boilers Provide Steam For Two 55 MW Generators
At full load, the GORE® membrane filter bags provide a baghouse pressure drop of 6.0" before cleaning and 4.0 - 5.0" after cleaning. This is maintained with a 50 psi pulse pressure and a 45-90 minute cleaning cycle. The low baghouse pressure drop allows boiler draft to be maintained at -0.10" with a 66% open I.D. fan damper setting.
71:
Municipal Waste Incinerator – West Germany
Emission measurements in February 1987 were 0.0004 gr/cf for line 1. The outlet rate was 2.5 times less than any other lines. (Measurements were performed after 9,200 operating hours/17 months.) Cost savings in compressed air usage have been substantial.
72:
Open Silicon Metal Furnace – Norway
The baghouse has been running at 6" w.g. since late 1984 with no failure. The air-to-cloth ratio is 3.28/1.00, with test runs up to 5.48/1.00. The pressure drop was decreased one-third while doubling the air-to-cloth ratio, eliminating the need for the capital investment and time delay of installing a second baghouse.
78:
Pigments
With the application of hydrolysis resistant GORE™ filter bags,
bag-life was enhanced from 6 months up to 4 years.
79:
Platinum
After only half a year of operation, the amount of collected and
recycled dust added up to about 1 kg – worth more than the
SINBRAN® filters had cost.
80:
Platinum Flash Dryer
Gore completed the bag change and rewelded in 48 hours to minimize downtime. The visible emissions from the stack were eliminated. Weekly bag changeouts were also stopped. The plant was able to eliminate the production bottleneck, while the filter operated at a low pressure drop of 100 mm (3.94") w.g.
81:
Platinum Flash Dryer
Gore completed the bag change and rewelded in 48 hours to minimize downtime. The visible emissions from the stack were eliminated. Weekly bag changeouts were also stopped. The plant was able to eliminate the production bottleneck, while the filter operated at a low pressure drop of 100 mm (3.94") w.g.
82:
Pneumatic Transport of Fly Ash to Silo
Manual cleaning not required to maintain constant negative pressure in the system. Pressure drop is low and controllable via pulse cycle. Compressed air requirements reduced. No extra maintenance required.
83:
Polyvinylfluoride
With installation of GORE™ Acid Resistant Aramid Felt filters
pressure drop was stabilized at 1.000–1.500 Pa.
85:
Precipitated Silica
With better hydrolysis resistance provided by the GORE™ Acrylic
Filter Bags, and an optimized process, the bags lasted longer
and lowered investment costs.
86:
Primary Lead Sinter Production
The bag life improved, while baghouse down-time, maintenance
costs, and stack emissions have all been drastically
reduced.
87:
Primary Smelting of FESI Products
After 1 year of operation the GORE® membrane filter bags are still evacuating the working area completely and at a controlled pressured drop of approximately 200 mm w.g. (At installation and start-up the customer removed the inlet duct construction that we placed in the middle of the collector and over its entire length.
88:
Pulverized Coal-Fired Utility Boiler
Design airflow achieved. Bags cleaned on demand at 6" w.g. SO2 scrubber costs reduced by over $12,000/month (less reagent used and less fuel for reheat). Installed second set of GORE® membrane filter bags. During annual outages, the first and second set of GORE® membrane filter bags were replaced after 20 months and 36 months respectively, even though the bags had not failed.
89:
Purification on an Electric Arc Furnace (60T)
To date, 7.5 years life for the GORE® membrane filter bags (filter bags are being replaced due to an increase in operating temperature: GORE® membrane/polyester felt filter bags replaced by GORE® membrane/fiberglass filter bags). This replacement was completed during the fourth quarter of 1989. The mechanical shaking was eliminated; therefore, there has been no more mechanical wear or detachment of the filter bags.
90:
PVC Emulsion Resin Spray Dryer (Aeropulse)
Aeropulse pulse-jet collector (1,800 bags); gas flow: 56,000 acfm at 140°F; air-to-cloth ratio: 3.3 gross:3.9 net; inlet loading: 8.7 gr/acf; particle size: less than 5.0 mm.
92:
PVC Plastics
Process was made more efficient by running both grinders into
a single baghouse with possible cost savings over time.
94:
Rail Unloading Collector Handling Coke
GORE® membrane/heavy duty polyester felt filter bags were installed. Emission levels were met and exceeded, and no blinding occurred. The bags have been operating successfully for more than three years.
95:
Rail Unloading Collector Handling Coke
GORE® membrane/heavy duty polyester felt filter bags were installed. Emission levels were met and exceeded, and no blinding occurred. The bags have been operating successfully for more than three years.
96:
RCRA & TSCA Permitted Hazardous Waste Incinerator
The GORE® membrane filter bags operated for 1 year at approximately 6 inches w.g., and cleaned down to 2 inches w.g., using 60 psig cleaning air. The cleaning system would cycle approximately once every two to eight hours, depending on the content of the waste stream. No loss of burn time was experienced during the year.
99:
Secondary Lead Metal Production
GORE® membrane filter bags improved bag life to three to four
years, while baghouse down-time, maintenance costs, and
stack emissions have all been drastically reduced.
100:
Secondary Lead Production
High-temperature, chemically inert GORE® membrane filter bags
allowed the plant to raise the baghouse operating temperature
and stay above the acid dew point, resulting in much less corrosion
and wet dust cakes.
101:
Secondary Lead Smelter (Shaft Furnace)
After two years of continuous operation all emission tests in the GORE® membrane filter bag are <1 mg/Nm³. The flow is controlled at a maximum and the pressure drop is still below 100 mm w.g.
102:
Secondary Lead Smelter – Ventilation System
The GORE® membrane filter bags have been in continuous service since installation. Pressure drop across the filter media is 2-3" maximum. Shake cycle frequency is once every 1-1/2 hours for 10 seconds.
104:
Silicomanganese
System optimization and installation of GORE&ref; membrane filter
bags resulted in improvements to the baghouse
and overall production process.
106:
Silicon Metal
The baghouse differential pressure decreased resulting in increased
gas flow without expanding the baghouse.
109:
Specialty Glass
The pressure build-up above the dosing scales was effectively
eliminated by the GORE™ filter bags.
110:
Spreader Stoker; 10,000 acfm
Pressure drop has been reduced to 5" w.g., allowing full rated steam production (60,000 lbs/hr) to be attained. With GORE-TEX® membrane filter bags, compressed air pressure has been reduced to 50 psi and the time between cleaning is 300% greater. Visible emissions have been reduced. Bag life increased to 18-24 months.
111:
Stack Gas Cleaning Downstream From a Coal-Burning Boiler
No manual cleaning has been necessary to maintain a controlled and low pressure drop and maximum gas flow. Despite hours of poor combustion, the GORE-TEX® membrane filter bags have reconditioned themselves, and the pressure drop and flow values have returned to normal.
112:
Stainless Steel Electric Arc Furnace
Pressure drop reduced to 5" H2O. Meltshop is clean. Bag life longer than five years. Customer saves 30,000 pounds sterling (approximately $45,000) per inch of reduced pressure drop.
113:
Steel – 4th Hole Evacuation of Electric Arc Furnace (60T)
Gore's proposal was accepted. Airflow was measured at 176,550 acfm (300,000 m³/h) at 480ºF (250ºC) with a gross air-to-cloth ratio of 2.2/1 and a net of 2.6/1 while maintaining a differential pressure of 4.7" w.g. (120 mm) and 5.5" w.g. (140 mm) respectively. The customer was satisfied with the airflow and saved the cost of a new baghouse and fans.
114:
Steel Electric Arc Furnace
Pressure drop has been reduced to approximately 4-5" H2O at an actual net air-to-cloth ratio of 2/1. Even after several system upsets, system airflow has increased 50 percent (over 400,000 cfm). The meltshop atmosphere is very clean, with visibility near 100 percent. The customer has saved several million dollars by eliminating the need to buy a new baghouse.
115:
Steel – Electric Arc Furnace – 70-ton EAF
Start-up was successful, with sufficient draft to evacuate the furnace. The majority of this draft was from the GORE® membrane-filter-bag-outfitted baghouse, and the operational differential pressure was 5.2" w.g. (133 mm). The start-up also used a precoat to protect the GORE® membrane from potentially damaging hydrocarbons.
116:
Steel Scrap Melting Electric Arc Furnace
System operation began in November 1995. After initial dust evacuation system problems, the system has settled into smooth operation with low pressure drops (less than 175 mm w.g.). The emission requirements have been met, even with the system start-up problems.
120:
Thermal Decontamination Incinerator
The first set of GORE® membrane filter bags lasted two years, with an average pressure drop of four-five inches H2O. Full gas flow was maintained throughout the life of the bags. No thermal attack was reported. Strict emissions code of 0.0026 gr/acf was met for the life of the bags. A second set of GORE® membrane filter bags was installed in September 1985. The bags are still in use.
121:
Thermal Desorption soil Remediation Unit
Compliance testing done six months after startup, revealed an outlet emission level approximately 15% lower than the required maximum particulate emission limit.
122:
Three Lime Kilns
Baghouse is running higher than design airflows (almost 30%) with differential pressures across the bags ranging from 70~100 mm w.g. Cleaning is with reverse air fan.
123:
Titanium Dioxide
Bag life was increase to 3,5 years and pressure drop was
stabilized at 1.000 Pa throughout life of filters.
124:
Titanium Dioxide
By replacing generic membrane filters with GORE™ Acid Resistant
Filters, and optimizing airflow, life was extended to 9–12
months with continuous system operation.
125:
Titanium Sponge Vapor Recovery
Bag life was increased to as much as five years. The non-stick characteristics of GORE® membrane prevented the development of globules on the surface of the bags. Airflow has been maintained at acceptable levels for needed production rates.
126:
Titanium Sponge Vapor Recovery
Bag life was increased to as much as five years. The non-stick characteristics of GORE® membrane prevented the development of globules on the surface of the bags. Airflow has been maintained at acceptable levels for needed production rates.
134:
Waste Oil and Filtration Sludge Incinerator
The customer achieved a 30-month bag life with the first set of bags even though process upsets (electric failure, hopper fill-ups, leaking access door, etc.) occurred during the first 14 months of operation.
135:
Waste Solvent Incinerator – Kentucky
Drastically reduced emissions virtually eliminated emission-related down times and dewpoints. Bags were installed on Sept. 9, 1982 and were removed in April 1984. Bags were guaranteed for 13 months, but were used for 19 months. |
