ระบบเครื่องวัดฝุ่น DynaCHARGE เป็นเครื่องวัดฝุ่นที่ดีที่สุดสำหรับผู้ผลิตผงฝุ่นเขม่าดำ หรือ Black carbon

DynaCHARGE™ Handles Tenacious Carbon Black Outperforms Competing Charge & Optical Systems

นักอนุรักษ์สิ่งแวดล้อมพยายามนำเสนองานวิจัยเกี่ยวกับความรุนแรงที่เกิดขึ้นของผงฝุ่นเขม่าดำ หรือ Black carbon ในหลายๆด้าน
แต่ก็ต้องยอมให้กับประสิทธิภาพการวัดฝุ่นของเครื่องวัดฝุ่น ระบบกรองฝุ่น DynaCHARGE ที่สามารถป้องกันผงฝุ่นเขม่าดำ หรือ Black carbon และป้องกันการปล่อยมลพิษที่ตกค้างสู่ชั้นบรรยากาศได้ที่ดีสุด

ระบบเครื่องวัดฝุ่น DynaCHARGE เป็นเครื่องวัดฝุ่นที่ดีที่สุดสำหรับผู้ผลิตผงฝุ่นเขม่าดำ หรือ Black carbon ในการป้องกันการปล่อยมลพิษที่ตกค้าง
กรมควบคุมมลพิษ ให้ความหมายผงฝุ่นเขม่าดำ หรือ Black carbon ว่า อนุภาคหรือผงเขม่าที่เกิดจากกระบวนการเผาไหม้ต่างๆ see more...

Challenge

“Long-term reliability in processes where most other devices have failed.”

Raw carbon black production processes are extremely harsh and demanding. Temperatures can reach 1400°F, moisture is used to control quality, and SO2 presents corrosion issues. For any type of instrument, carbon black processes are some of the most challenging to be found.

For particulate monitoring, the concentrated black powder complicates using opacity and light scatter devices. Carbon black is also conductive, which challenges triboelectric and other charge-sensing instruments that use a sensing probe that must remain electrically isolated to function properly.

In addition, the US-EPA has been tightening regulations and increasing enforcement within the industry.

Two carbon black producers experiencing ongoing issues with unreliable measurements, the potential for unforeseen shutdowns, costly refurbishing of sensing elements, and poor support from existing suppliers, wanted to take proactive steps to further ensure compliance and improve their operations. They contacted FilterSense for a better solution.

Solution

“For 1.5 years, DynaCHARGETM has not required cleaning or maintenance.”

While FilterSense was confident its DynaCHARGETM induction technology would be a reliable solution, both producers wanted to prove it first hand.

Plant A set up a test of DynaCHARGE against a competing charge-sensing device and an optical PM CEMS. After initial run time, the plant performed a comparison
to increased emissions by creating leaks in baghouse filters.

Plant B wanted proof of long-term reliability. Having previously tested and ruled out an optical monitor, this plant purchased DynaCHARGE and compared it against their existing charge-sensing systems for over a year. The existing devices required weekly to quarterly cleaning and required frequent costly refurbishing. Side-by-side installations were set up on four processes: the dryer drum, the reactor, the main unit filter, and the process filter.

DynaCHARGETM sensor installed and performing reliably in the outlet of a dryer drum (foreground). FilterSense engineer observing control unit (back).

 

Results

Plant A
The test team engineers for Plant A reported they made a unanimous decision to recommend FilterSense. This was based on the performance of DynaCHARGETM against the competing products (Figure 1), low maintenance, and the quality proactive support by FilterSense.
They added that while the optical system was “very sophisticated, it was cumbersome, required costly/complex installation, more maintenance, and was simply not practical for installation at this plant and other company facilities.”

Plant B
Project engineers here found similar response data but substantial reliability differences. For one process, the plant had not performed cleaning on the DynaCHARGE for over 1.5 years while the other system was requiring cleaning every week. For the other three processes, DynaCHARGE was also not cleaned for over 1.5 years while the other systems required cleaning every 3-4 months. There were also no signs of any need to refurbish the DynaCHARGE sensors.

While response was indeed similar, DynaCHARGE did show some higher resolution, low-level measurement capabilities (Figure 2).

The DynaCHARGE PM 100 PRO systems installed have full automatic device health checks and automatic EPA self testing. This provides the plant with even further confidence.

“Unlike FilterSense, the other sensors required cleaning quarterly, and sometimes weekly!”

FilterSense engineer commissioning DynaCHARGETM PM 100 PRO.


“The decision by the team was unanimous. We have selected FilterSense.”

Figure 1 -- Plant A: Low-Level Response Testing

Figure 2 -- Plant B: Dryer Drum Comparison

Benefits
DynaCHARGE systems offer carbon black producers the best available solution to prevent tenacious emissions while simultaneously minimizing instrument maintenance, repair/refurbish costs, and unplanned down time.

FilterSense B-PACsTM (baghouse control and diagnostic systems) and FilterWARETM central HMI/SCADA solutions provide significant ROI opportunities towards further preventive process and compliance optimization.

Proactive, high-quality support allows producers to focus on core operations and improving profitability.