R&D Project: OEM Baghouse for Air Filtration of Sodium Chloride (NaCl) Dust According to the Customer's Technical Specifications
The project for developing an OEM BagHouse system for air filtration from sodium chloride (NaCl) dust presents a unique engineering challenge. The interest in this project is driven not only by the complexity of the technical solution but also by the widespread use of NaCl across various industries.
Its unique natural resources—including deposits of rock salt and bischofite—a wide range of raw materials for high-value products, proximity to key transportation hubs and markets, and significant innovation potential (with its own research and production center and collaborations with leading scientific institutes) enable the company to gradually diversify its product line.
Products manufactured by our client:
- Solid caustic soda (technical granulated 99%, technical tabletized, reagent-grade sodium hydroxide).
- Liquid chlorine (in cylinders, containers, and tank cars).
- Hydrochloric acid (synthetic technical, from chlorinated organic production off-gases, technical inhibited).
- Suspension polyvinyl chloride (PVC).
- Chlorinated paraffins.
- Edible salt.
- Magnesium chloride.
- Magnesium hydroxide and oxide.
- Sodium hypochlorite.
- Pool chemicals.
- Household chemicals.
- Food additives: E 524 (caustic soda), E 528 (magnesium hydroxide), E 530 (magnesium oxide), E 511 (magnesium chloride).
Initial Data
Interesting Aspects of Sodium Chloride (NaCl)
- Chemical Stability and Reactivity: Sodium chloride is a stable yet reactive substance that can participate in chemical reactions under certain conditions, such as with strong acids or at high temperatures. This makes its processing particularly interesting from a chemical engineering perspective.
- Hygroscopicity: NaCl has the ability to attract and retain moisture, which is crucial to consider when designing air filtration systems, especially in high-humidity environments.
- Abrasive Properties: Despite its seemingly harmless nature, fine NaCl particles can have an abrasive effect on equipment. This necessitates the use of specialized materials and technologies to minimize wear and tear.
Applications of Sodium Chloride:
- Food Industry: NaCl is the most well-known and widely used food additive, serving as both a preservative and a seasoning. Its presence in food production processes is virtually unavoidable.
- Chemical Industry: Sodium chloride is a key raw material for producing chlorine and caustic soda through electrolysis, as well as other chemical compounds.
- Road Maintenance: In countries with cold climates, NaCl is used for road treatment during winter to prevent icing.
- Water Treatment: Sodium chloride is used in desalination and water softening systems.
The development of an air filtration system for capturing NaCl dust requires a comprehensive approach, considering both the physical and chemical properties of salt, as well as safety and efficiency requirements. This project not only highlights the importance of innovative solutions in environmental safety but also demonstrates a deep engineering approach capable of ensuring the durability and reliability of industrial equipment in challenging operational conditions.
Commentary by Michael Klepik, CEO of Torch-Air
I am proud to share with you our latest achievement at Torch-Air – the development of the OEM BagHouse air filtration system for capturing sodium chloride (NaCl) dust. Our team has carefully monitored every aspect of this project, striving for excellence at every step.
Creating this system was a challenge that we gladly accepted. Sodium chloride, or simply salt, can be a tricky contaminant, especially due to its hygroscopic nature and ability to corrode materials. We selected special materials to address these challenges, ensuring the durability and reliability of the system. Our BagHouse Blizzard filters, made of high-performance fabric, effectively capture the finest salt particles while maintaining air flow efficiency.
This project was made possible thanks to close collaboration between our team and the client, who provided clear technical requirements. We believe this is not just another air filtration system, but a step forward in innovation and customized technological solutions. With each such project, we become better, finding new ways to improve the efficiency and safety of our systems.
Thank you for choosing Torch-Air. We look forward to new projects and the opportunity to once again exceed your expectations!
Client Communication
We submitted a request for the Dust Collector Baghouse Blizzard last year, and I am attaching the proposal for it.
Please update the commercial offer.
I forgot to include the current questionnaire for the air filtration system, please use it as a guide in your work.
I kindly request that you provide a response to our request no later than May 24, 2024, by 05:00.
Best regards,
Material and Technical Support Department
Questionnaire:
Name of equipment/product and/or systems | Gas cleaning and dust removal equipment |
Type, brand, model (analog or equivalent) | From the manufacturer of the drawing, technical specifications, questionnaires, etc. |
Technological positions | 34.1 – Bag filter 34.2 – Centrifugal fan 34.3 – Screw conveyor |
Construction and dimensions of equipment | Must meet the requirements of the approved technical conditions for connecting the facility, as well as the technological, architectural, and structural solutions of the approved design and working documentation. |
Documents | Project Appendix 3 to the project |
Purpose and/or application of equipment/product and/or systems | Air filtration from NaCl dust |
Maximum weight of a single unit of equipment/product and/or system (net) | According to the equipment passport |
Maximum total weight (gross) | According to the equipment passport |
Maximum overall dimensions (projected dimensions) | The maximum overall dimensions of the equipment must meet the requirements of the technological, architectural, and structural solutions of the approved design and working documentation. |
Location of pipe connections | No specific requirements |
Overall installation drawing | To be clarified during the approval process |
Mass-dimensional, rigging, installation schemes, etc. | To be developed by the Contractor |
Characteristics | Aspired air quality composition: Edible salt (NaCl) that meets all standards and hygiene safety requirements. Quantitative composition: up to 1g NaCl per 1m³ of air Granulometric composition of the solid phase of the product connected to the aspiration system: 0.0…0.063 mm – 0.2%; 0.063…0.1 mm – 0.3%; 0.1…0.16 mm – 2.2%; 0.16…0.2 mm – 3.41%; 0.2…0.315 mm – 23.75%; 0.315…0.4 mm – 31.46%; 0.4…0.63 mm – 38.48%; 0.63…1.0 mm – 0.2%; Over 1.0 mm – 0%. |
Equipment composition | Bag filter with pulse cleaning, fan |
Performance: | Air volume: at least 1800 CFM Material temperature at the inlet: ≤ +50°C Material humidity at the inlet: 0.05-0.1% Material density: 2165 kg/m³ Bulk density of material: 1060 kg/m³ Airflow speed: 15 m/s Ambient temperature: +15 to 30°C Relative humidity: up to 75% |
Design life | The service life of the main equipment components should be at least 20 years |
Mean time between failures | Mechanical equipment: at least 2000 hours Hydraulic equipment: at least 2000 hours Mean recovery time: no more than 100 hours Service life between repairs: at least 6 months |
Operating modes of the equipment/product and/or system | Continuous operation mode, 330 days per year, 7920 hours per year |
Requirements for unification and typification of products | No requirements |
Installation frequency and duration of maintenance and repair | The maintenance and repair schedule during the warranty period should not exceed 20 working days (160 hours) per year. |
Additional operational requirements | The supplied equipment/products and/or systems must be new, produced no earlier than 2024 (not used, not refurbished, not exhibition samples). The technical characteristics specified by the manufacturers should be maintained throughout the entire service life of the equipment. The installation of sensors and control devices ensuring safe operating conditions should be provided. Acceptable noise requirements: up to 80 dB. Materials used in the manufacture of equipment and parts in contact with the product must meet the requirements of steel used in the food industry, with corrosion resistance. Equipment protection against corrosion according to the operating conditions – medium-aggressive exposure. |
Requirements for materials, spare parts, special tools, and devices necessary for installation | Materials, spare parts, special tools, and devices necessary for installation are provided by the manufacturer as part of the supply of the technological complex. |
Requirements for materials, spare parts, special tools, and devices necessary for commissioning | Installation should be carried out using standard tools. |
Other requirements | General requirements for the mechanical part of the equipment: Factory assembly of drives First filling with preservation oils and lubricants Installation marking for assembly The equipment should be shipped with the maximum possible degree of assembly. Pipe connection loads: All connections must ensure process tightness and exclude leaks into the environment. |
Power supply group, power sources, and type of current (AC, DC) | AC current Use of switchgear (manufacturer) to be agreed with the customer; Electric motor IP-55; Control cabinets execution, no lower than IP-54 |
Frequency and allowable deviation from nominal | Frequency: 50 Hz |
Voltage and its allowable deviation from nominal | Voltage: 380V |
Automation class/degree requirements | The equipment must be equipped with an automatic control, alarm, and shutdown system for safe operation. The control and alarm system must be installed in separate control cabinets. The control cabinets housing for sensors and electronic components must provide a degree of protection no less than IP54. |
Supplied measuring and automation equipment | Must go through the approval process with the Customer. |
Requirement for service provision, if necessary | The customer performs the equipment installation at their own expense. The Contractor provides commissioning, adjustment, and supervision services (at their own expense). The Contractor provides service maintenance throughout the entire warranty period (at least 3 years) at their own expense. |
We have updated the technical and commercial proposal (TCP). We have increased the filtration area and also added new purchased items — a slide gate and a big bag discharger, which you requested. I have reflected all your requests in the proposal. What we have now is a fully OEM BagHouse that we are developing specifically for you. I hope it will meet your expectations.
I kindly ask you to consider the possibility of concluding the contract.
Please include the delivery to Miami in the cost.
Also, I request that you add the drawings and a more detailed description to the invoice.
Best regards,
Material and Technical Supply Management
- Carbon steel
- AISI 304
- AISI 316
Best regards,
Material and Technical Supply Management
Characteristics Data:
- Airflow Capacity, CFM: 1,800
- Filtration Area (max), sq ft: 646
- Filter Housing Material: AISI 304 Stainless Steel
- Filter Media Material: Nonwoven Needle Felt
- Air to Cloth Ratio: 2.78 CFM/sq ft
- Operating Temperature in Filter, °F: Up to 302
- Inlet Dust Concentration (max), g/ft³: Up to 4.26
- Outlet Dust Concentration (max), mg/ft³: 5-10
- Compressed Air Pressure, psi: 70-100
- High-Pressure Fan (Explosion-Proof Design): Included
- Rotary Feeder: Included
- Slide Gate for Bulk Bags: Included
- Supports, Ladder: Included
Proposed Solutions
- Enhanced Filtration Area: Expanded to ensure high-efficiency air cleaning and compliance with all performance specifications.
- Durability and Material Selection: The filter housing is made from AISI 304 stainless steel, ensuring excellent corrosion resistance and long-term durability. Special attention is given to the abrasive properties of NaCl dust, with reinforced materials to minimize wear.
- Slide Gate and Big Bag Discharger: Added as per the customer’s request, these components are designed for ease of operation and efficient bulk material handling.
- High-Performance Filtration Media: Nonwoven needle felt material is used to optimize dust capture while maintaining airflow efficiency.
- Explosion-Proof Fan Design: To ensure safety in hazardous environments, the system includes a high-pressure fan with explosion-proof design.
- Continuous Operation Mode: The system is designed for continuous operation, running 330 days a year, meeting the client’s requirements for high productivity with minimal downtime.
Conclusion
The gas cleaning and dust removal equipment was developed and manufactured in strict accordance with technical specifications and dimensional requirements. The system is equipped with all necessary tools and accessories for installation and commissioning, which were carried out within the time frame set by the project.
The system's capacity is no less than 1800 CFM, taking into account all the requirements for the qualitative and quantitative composition of the aspirated air. The equipment operates continuously for 330 days a year and has demonstrated high reliability and efficiency, running for two years without significant issues.
The system fully complies with US tolerances and standards, including OSHA and EPA requirements. This guarantees the safety and high environmental performance of processes at the customer's facility.
All system components are made from materials compliant with the food industry, ensuring required corrosion resistance and airtight connections. This ensures long-term operation and minimizes technical maintenance, as confirmed by the planned periods between repairs and mean time between failures.
We thank the customer for their trust in Torch-Air and guarantee continued support and service throughout the entire operational life of the equipment.
Best Baghouse Solutions for Air Filtration of Sodium Chloride
Vladimir Nikulin
