The design of a dedusting or product filter is based on clearly defined process parameters. In addition to the pure volume flow, the raw gas load, product properties, explosion characteristics, emission requirements and installation situation are particularly important.
Our goal is a reliable, energy-optimised and compliant solution - individually designed and manufactured.
The type of application describes the process environment in which the filter is used. It primarily defines the expected raw gas load and thus forms the basis for further design.
Process type
Aspiration (low raw gas load)
Dedusting (average raw gas load)
Pneumatic conveying (high raw gas load)
In the next step, the boundary conditions on the system side that are decisive for dimensioning and design are recorded: Volume flow and load spectra, temperature window and the selected cleaning method. These parameters directly influence the filter area requirement, the design of the fan/compressed air system and the operating behaviour (Δp curve, cleaning intervals).
2.1 Volume flow
2.2 Temperature
2.3 Operating pressure ratios
2.4 Cleaning method
Once the process parameters have been determined, the basic design shape is defined.
This is where the decision is made as to which „structure“ will support the technical solution.
The product properties essentially determine whether Cartridges, bags, filter plates or membrane elements can be used.
Critical properties
Why not every product is suitable for cartridges and filter plates
Pleated filter elements offer a high specific filter area in a compact design.
Boundaries arise with:
Consequences:
In such cases, filter bags or membrane elements are more economical, despite higher initial investment costs.
The filter element is selected not only according to design (bag, cartridge, etc.), but also according to Filter medium, surface finish and membrane lamination if necessary. These determine the degree of separation, cleaning behaviour, differential pressure stability and resistance to temperature, humidity, oil or chemical stress.
5.1 Filter types
Bag / pocket filter
Typical use:
Pneumatic conveying and dedusting with high raw gas loading, agglomerating dusts
Micropore filter plates
Typical use:
Dedusting with medium raw gas load, limited installation space, dry dusts
Filter cartridges
Typical use:
Aspiration with low raw gas load, limited installation space, dry dusts
Sinbran elements
Typical use:
Fine dust applications with high emission requirements
Depth filter / final filter (e.g. HEPA)
Typical use:
Final filtration after pre-separator/dedusting filter, clean gas/safety stage
5.2 Choice of surface finish
Depending on the product and process requirements, filter media are specifically equipped:
Membrane lamination (e.g. PTFE membrane)
Hydrophobic / oleophobic finish
Polyimide fibres
Antistatic design
Abrasion-resistant or chemically resistant media
The right combination of Design, filter medium and surface finish is decisive for service life, energy consumption and operational safety.
The requirements for the clean gas quality define the necessary degree of separation and the possible need for additional safety or final filter stages. A distinction must be made as to whether the cleaned air is discharged into the open air or returned to the work area.
6.1 Exhaust air to the outside
6.2 Recirculation mode
In the case of combustible dusts or gases, an explosion protection assessment is mandatory. The necessary protection concept is defined on the basis of the zone classification and the explosion-relevant material data - in terms of design, organisation and system technology.
Zoning (dust)
The zone categorisation defines the requirements for electrical and mechanical components as well as for constructive protective measures
Relevant characteristics
These characteristics determine:
Constructive protective measures
The explosion protection concept is defined on the basis of the characteristic data:
Pressure shock resistant design
The enclosure is designed for a specific explosion overpressure (e.g. up to Pmax).
Advantage: No pressure relief to the outside required.
Disadvantage: High design effort and use of materials.
Pressure relief for reduced explosion pressure (explosion venting)
In the event of an explosion, the pressure is reduced via defined Rupture discs or flameless systems is discharged in a controlled manner. This significantly reduces the explosion pressure in the filter.
The key design parameter is the:
The relief area is dimensioned in such a way that:
Please note:
Explosion suppression
A sensor system recognises the rate of pressure increase and injects extinguishing agent into the housing before the maximum pressure is reached.
Advantage:
Disadvantage:
Explosion decoupling
Prevents the flame or pressure from spreading to neighbouring parts of the system (e.g. pipelines).
Typical decoupling types:
The selection is made depending on:
Result of the ATEX assessment
The combination of:
leads to a defined protection concept in terms of:
Housing design
Pressure relief or pressure shock resistance
Decoupling
Earthing concept
Selection of ATEX-compliant components
The design of a filter is not a standard procedure, but the result of a systematic evaluation of process type, volume flow, pressure ratios, design, filter technology, emission requirements and explosion protection.
The multitude of these influencing factors shows that a generalised standard solution rarely does justice to the actual operating conditions. An inadequately designed filter solution leads to high energy consumption, reduced service life with high maintenance requirements and unsafe processes.
Only the technically consistent combination of these parameters leads to
We analyse your application in a structured manner along these steps and develop a Customised and manufactured filter solution - technically safe, economically optimised and reliable in the long term.
Send us your process data - we will check your application and find the optimum solution together.
Invest two minutes and in just two working days you will receive the right system design for your project as the basis for our initial consultation.
We can advise you on customised filtration solutions for processing milk powder. Do you need quick help with the selection and design of a filter for your application?
Simply enter your details in the form and we will get back to you within the next 2-3 working days.
The right filter system is a decisive factor for the safety of machines, processes, product safety and the health of your employees. Errors in the filter configuration can have a decisive impact on these factors. Only specialists work for us; our modular systems have been tried and tested in industry and are of the highest quality.
Pascal Wieland
Pascal Wieland
Key Account Manager and Product management
Tel +49 7159 8069-25
Mobile +49 162 3017787
pascal.wieland@bg-filtration.de
