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07/18/2006
Donaldson Filter Components Ltd
7 The Parks
Newton le Willows, WA12 0JQ, England
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Jenny Nash
+44 (0) 1942 711711
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FOR IMMEDIATE RELEASE
DONALDSON MEMBRANES STOPS FIRE DAMAGE CAUSED BY FLYING SPARKS AT GERMAN STEELWORKS
Donaldson Membranes has proved that perseverance pays by solving a stubborn filtration problem caused by sparks at a major steelworks in Germany.
The need for increased air volume was achieved via the shortening of the pipeline between the furnace and the filter unit to achieve reduced pressure drop.
As a result, the plant’s CEAG Reverse Air Filter House was located very close to the electro steel furnace but the filter media employed did not provide a barrier to spark damage, resulting in permanent fire damage to the lower part of the sleeves.
The problem was intensified by a need for increased air volume, proximity to the furnace, limited fan capacity and no fitted spark arrestor. Therefore in 1998 it was decided to replace the 3,456 sleeves, 216 in 16 chambers, with new ones manufactured from a media providing higher air flow – but the new media gave rise to even more spark damage.
In 1999, the plant manager contacted Fasse Filter, whose expertise lies in the selection of filter media to meet application needs and the manufacture of tailor-made filter bags for individual systems.
Fasse Filter supplied a high temperature resistant filter media but the price was unaffordable.
In early 2000 the steelworks contacted Donaldson Membranes Germany and again Fasse Filter to draw upon their combined expert experience of production and application knowledge. Together they installed trial sleeves manufactured from #6254 Tetratex High Efficiency Woven Fibre Glass.
Donaldson Membranes’ high performance laminates offer superior dust cake release, low pressure drop, higher air flow, and high efficiency, making Tetratex® an excellent choice for filtration and other applications.
The resulting sleeves were high quality and did not stretch, however there was still small spark damage. Also, for a complete installation it was still too expensive but a delivery of 16 trial filter bags was made nonetheless.
Meanwhile in 2001, a competitor suggested they could supply a heat and spark resistant fabric sleeve at a lower cost. Trails were commenced with this filter media, however they proved that the fibres where not suitable for this type of tensioned filter bag and the trials were concluded in Spring 2002.
Finally in 2003, one of the plant personnel remembered the Donaldson Membranes filter media that he had nicknamed the “Golden ones” - the 16 trial bags made completely from #6254 Tetratex High Efficiency Woven Fibre Glass.
After analysis of the trial filter bags at Donaldson Membranes, the textile strength and membrane remained unaffected after one and a half years, approximately 9000 - 10.000 h. There was slight damage in small areas inside but the glass fabric also remained intact.
So Fasse Filter was again asked to come up with a solution that could prevent spark damage but at a more competitive price. Fasse Filter suggested a bi-component sleeve, which would be less costly, and in consultation with Donaldson Membranes recommended the incorporation of the popular #6254 Tetratex Ultra High Efficiency Woven Glass fabric. Finally, 216 sleeves were installed on trial and following excellent results, the whole filter house was equipped with the sleeves until today.
Only minor spark damage has occurred since the installation, and for added protection, the system is now optimised to operate in such a way that the
chambers are switched off when electro dipping commences.
The steelworks’ plant manager is delighted to have finally found the answer to the spark damage problem. He said: “It took us an incredibly long time to find an acceptable solution. We spoke to so many people and the longer it took the more confused we became. From today’s viewpoint I must say that in future we will
rely upon the companies that we know can solve the problem, Fasse Filter and
Donaldson Membranes.”
Holger Fasse, MD at Fasse Filter, said: “Difficult applications such as this require assessment over a period of time involving more than one trial in order to meet all requirements – in this case a media capable of providing a barrier to fire damage from sparks but which was not prohibitively expensive. We met the first criteria very early on and were able to fulfil the second when we were called back to assess the situation. We are delighted to have found a definitive filtration solution for this on-going problem which has proved both effective and affordable, and also offers the additional benefits of Donaldson Membranes’ Tetratex product, such as extended filter life and energy savings. This application demonstrates that it is wise to
develop and maintain a constant working relationship with manufacturing
partners who have the required expertise and who can follow the project
through to a successful conclusion.”
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