Installation, maintenance and overall performance of pulse valves in dust filtration systems
IEN Europe: What should a plant operator look for when choosing a dust collection system?
Samuel Olive: First of all, high peak pressure. Maximum pressure determines the speed and force of the burst of compressed air emitted by a pulse valve when it cleans the filters of a dust collector. Pulse valves that quickly reach high peak pressure increase the efficiency of the dust collector’s overall performance. The ASCO™ Series 355B Power Pulse Reservoir System offers the highest peak pressure and flow performance on the market.
Second, a fast valve response time. Pulse valves that open and close quickly not only improve filter cleaning, they also use less compressed air.
Last, easy installation and maintenance. Facility operators should consider the investment in installation and labor costs when choosing a dust collection system. The more complex the valves in a dust collection system, the more time and labor they will consume when installing or removing for annual maintenance. One way to save even more time is to Emersonis patented Quick assembly clamp connection, making installation and maintenance quick and easy. The quick-fit clamp is featured on the ASCO Series 353 Pulse Solenoid Valve.
Dismantling and/or installing the valves can take time. Can you tell us more about the Quick Mount Clamp feature?
Compared to other connection types, the Quick Mount Clamp reduces installation time by 60%. This is especially important considering that installation is time consuming for original equipment manufacturers (OEMs) and end users. Conventional valves have threaded or dresser connections. Quick-tightening connection valves connect to piping easier and faster than threaded and straightener fittings and require no special tools or additional sealing.
When specifying pulse valves, it is important to consider the complexity of the installation process. Do they require special tools? Do they have a lot of coins? The more complex the valves are to install, the more time and labor they consume.
What is the role of a pulse valve in a dust collection system?
When a dust collector is in operation, it attracts dust particles to its filters. As the particles accumulate, they compress into cakes. These cakes can clog the filters, reducing the effectiveness of the dust collector. To remove dust particles from the filters, pulse valves periodically blow compressed air, which sends a shock wave through the filters. When the shock wave hits the dusty cakes, they crumble from the filters. Therefore, pulse valves are essential to the system. Without them, dust cakes will continue to build up and reduce the effectiveness of the dust collector. An example of these critical valves is the ASCO Series 353 Pulsing Solenoid Valve. High product flow rates, higher peak pressure, and fast response time provide optimal filter cleaning performance while using less air.
How do pulse valves improve dust collector performance?
Reliable pulse valves help reduce emissions, energy consumption and operating costs. Compressed air can be expensive for process facilities, and plants with multiple dust collection systems can use a lot of it. How long the valve is open determines the amount of compressed air used. Choosing a pulse valve with fast response times results in less compressed air consumption compared to pulse valves with slower response times. Pulse time can be reduced by having a more efficient way to use air as well. Additionally, dust collection systems rely on pulse valves to clean the filters. Without pulse valves, dust would continually clog the filters, leading to downtime and higher operating costs.
What efforts does Emerson support to reduce the carbon footprint?
At Emerson, we have a three-part sustainability framework, Greening of, Greening by and Green with. It’s part of Emerson’s goal to help support and foster our customers’ decarbonization and environmental sustainability efforts, which we call Greening By. Part of this is achieved through energy-efficient solutions, such as the 355B Series Power Pulse Reservoir System and 353 Series Pulse Valves. The high peak pressure and fast valve response time these solutions provide can reduce compressed air consumption. This, in turn, reduces the energy used by the compressor to produce the air and carbon emissions. Compressed air savings can be substantial when multiplied across an entire plant.
In addition to compressed air savings, providing a high pressure pulse can reduce the number of pulses required to effectively clean filters and thus extend filter life, increasing filtering efficiency and reducing the waste generated by the replacement of the filter itself. This also reduces maintenance and purchase costs.
Can you tell us about any successful applications the ASCO Series 353 Pulse Solenoid Valve has been part of?
We have installed the Series 353 Pulse Valve around the world and the positive results are overwhelming. This includes OEMs manufacturing laser cutting and dust collection solutions as well as end users with applications such as carbon black manufacturing and steel mills, particularly in the Asia-Pacific region. We have also had great success with applications in the rubber manufacturing and chemical industries. Our extensive portfolio of dust collection equipment and global footprint enables our customers to supply components from a single source, including explosion-proof solenoid valves and pressure vessels. Our products are capable of delivering consistent results in standard applications such as cement or less common applications such as biomass plant cleaning.
Do you foresee any technical developments in terms of dust filtration systems? Are the number of applications using them increasing?
Digital transformation is changing all businesses, including dust removal applications. Better understanding of the technical parameters of dust collection equipment and improved automated control will ultimately lead to reduced emissions, more efficient plant operation and reduced maintenance.
In response to the trend to reduce the complexity of manufacturing and plant operations, influenced by the need for high production levels despite labor shortages, it will be increasingly valuable to have simple and complete solutions that reduce labor time and complexity.
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