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Home / Case Studies / Suspended OEM Dust Collector BORA for Mobile Platform at Refractory Materials Production Plant
R&D Project: Suspended OEM Dust Collector BORA for Mobile Platform at Refractory Materials Production Plant
Category: Completed R&D Projects
Client
Modern production of refractory materials and products for key industries:
- Ferrous and Non-ferrous Metallurgy
- Cement Industry
- Glass Industry
- Petrochemicals
- Production of a wide range of unformed refractory materials, from aluminosilicate to basic compositions, and products based on them.
- Engineering and consulting services in the design, installation, and operation of thermal equipment linings.
- Selection and supply of technological equipment for the installation and maintenance of linings.
- Comprehensive supply of refractory products.
Production Process
The complex for the production of unformed refractory materials includes:
- A line for the production of dry refractory mixtures, dense normal, low-cement, and ultra-low-cement concretes, shotcrete and mortars.
- A line for the production of dry refractory mixtures for blast furnace production, wet ramming and plastic masses.
- A line for the production of magnesia-based materials, shotcrete, and ramming masses.
- A raw material grinding section.
- A granulation section.
- A drying and sintering section.
- A crushing and classification section.
- A fine grinding section.
Problem
The production volumes are increasing, and a more intensive dust collection system is required in the manufacturing process. The challenge is that the dust collector needs to be placed within limited dimensions on a mobile trolley, which doses materials into special molds for the shaping of refractory products.
Task
The task involves designing, manufacturing, and installing a customized dust collection system for a mobile platform at a refractory materials production plant. The system should efficiently capture dust from four containers, each with a volume of 1m³, located on a trolley.
Current system component
The moving trolley is used for dosing materials into molds, without an air dust collection system.
Gas/Dust
The dust consists of tabular alumina, corundum, bauxite, and chamotte with the following particle size distribution:
- 2 to 5 micrometers: 20%
- 5 to 20 micrometers: 70%
- 20 to 100 micrometers: 10%
Initial Data
Client Communication
Client:
Good afternoon,
Please consider the possibility of manufacturing and supplying a bag filter with an impulse pneumatic regeneration system and provide a commercial offer with delivery timelines. Attached is an image of the weighing trolley on which the filter needs to be installed. The dust-laden air will be extracted from four containers, each with a volume of 1 m³, located directly on the trolley (as shown in the image), and from four similar containers that the weighing trolley will drive over during material unloading.
The available space for the installation of the filter and fan is as follows: length 3100 mm, width 1000 mm, height 850 mm.
Thank you.
Best regards,
Chief Mechanic
Please consider the possibility of manufacturing and supplying a bag filter with an impulse pneumatic regeneration system and provide a commercial offer with delivery timelines. Attached is an image of the weighing trolley on which the filter needs to be installed. The dust-laden air will be extracted from four containers, each with a volume of 1 m³, located directly on the trolley (as shown in the image), and from four similar containers that the weighing trolley will drive over during material unloading.
The available space for the installation of the filter and fan is as follows: length 3100 mm, width 1000 mm, height 850 mm.
Thank you.
Best regards,
Chief Mechanic
Weighing Trolley
Engineer Torch-Air:
Good afternoon, I am waiting for your clarification on this project regarding the number of connections and their diameters.
Client:
The number of connections is 8, with a diameter of 159 mm. Dimensions: length 2500 mm, height 850 mm, width 1000 mm.
Best regards,
Chief Mechanic
Best regards,
Chief Mechanic
Engineer Torch-Air:
For an accurate performance calculation, we need to know the cross-sectional area of all air intake zones (dusting zones).
Will the upper containers be covered with something? Where will the air intake be organized from?
How will the lower containers be closed off?
If we just take the cross-sectional areas of all the containers, the performance would be huge, around 3600 m³/h per container.
We won't be able to fit the bag filter with a fan in the dimensions 3100x1000x850.
If all containers are covered with canopies and the intake areas are no more than 0.3 m², then the total performance would be 8000 m³/h.
Will the upper containers be covered with something? Where will the air intake be organized from?
How will the lower containers be closed off?
If we just take the cross-sectional areas of all the containers, the performance would be huge, around 3600 m³/h per container.
We won't be able to fit the bag filter with a fan in the dimensions 3100x1000x850.
If all containers are covered with canopies and the intake areas are no more than 0.3 m², then the total performance would be 8000 m³/h.
Client:
The containers will be constantly covered with a solid sheet from the top, and loading will be carried out through holes in it. From the bottom, the container will be covered during unloading. The dimensions are slightly smaller than 2800x1000x850. The proposed performance is very large, which also requires a large fan. Since four containers are mounted on load cells, any additional vibrations from the fan will result in increased measurement errors, which is unacceptable. If we consider the option with loaded containers and perform a calculation assuming each container is 70% full? This would significantly reduce the volume.
Best regards,
Chief Mechanic
Best regards,
Chief Mechanic
Engineer Torch-Air:
Where and how is the dust (product) planned to be discharged?
Client:
The weighing container, after being loaded with raw material, stops above the mixer loading collector and discharges the material. At this moment, the rotary feeder of the filter will activate and unload the captured raw material into the same collector.
Engineer Torch-Air:
Good day, should both the rotary valve and the fan fit within the dimensions of 2800x1000x850?
Client:
Yes. The drawing is attached.
Best regards,
Chief Mechanic
Best regards,
Chief Mechanic
Drawing
Engineer Torch-Air:
I am unable to view attachments directly. However, if you describe the key details of the cartridge dust collector or provide more specifics, I’d be happy to help review it and offer feedback based on that
Сartridge dust collector
Client:
Could you please send the 3D model of this filter in SLDPRT or SLDASM format for insertion into my project?
Engineer Torch-Air:
I am attaching the file.
Client:
Is it possible to relocate the receiver and place it on the side?
Relocate the receiver on the side
Engineer Torch-Air:
Yes, it can be located on the side.
Client:
Please provide a commercial offer for the filter, its manufacturing time, and specify the motor power for the fan and rotary valve.
Engineer Torch-Air:
Cartridge filter
- Filtration area: 10 m²
- Fan power: 4 kW
- Shutter power: 0.55 kW
- Blowing power: 0.2 kW
Client:
Good afternoon,
Is it possible to make a bag filter? Also, I would need the cost of the filter.
Best regards,
Chief Mechanic
Is it possible to make a bag filter? Also, I would need the cost of the filter.
Best regards,
Chief Mechanic
Engineer Torch-Air:
Good afternoon, yes, but then the filtration area will be 5 square meters.
Client:
Got it. Thanks. We’ll be discussing it in the meeting at 1 PM today.
Best regards,
Chief Mechanic
Best regards,
Chief Mechanic
Engineer Torch-Air:
Good afternoon, thank you for your order. Please mark on the drawing:
- The location of the receiver side.
- The location of the dirty air inlet on the hopper.
Client:
I am attaching the diagram.
Best regards,
Chief Mechanic
Best regards,
Chief Mechanic
Diagram
Proposed Solutions
To address the client’s needs, we propose the use of a suspended OEM dust collector designed specifically for the mobile platform at the refractory materials production plant. Key features include:
- Efficient Filtration: Our dust collector utilizes a cartridge filter system with a filtration efficiency of up to 99.9% for dust particles as small as 2 microns.
- Compact Design: The collector is designed to fit within the client’s limited space dimensions (2800x1000x850 mm) while ensuring no additional vibrations that could interfere with the load cells.
- Customized Features: The dust collector can be fitted with a rotary valve and fan, with power ratings of 4 kW (fan), 0.55 kW (shutter), and 0.2 kW (blowing), meeting the client’s operational requirements.
- Seamless Integration: The dust collector is easy to install and operates effectively with the client’s existing system, ensuring high efficiency and minimal downtime.
Conclusion
Our dust collector has been operating at the customer's facility since 2021. During this time, the cartridge filter elements, which are consumables, have been replaced three times. The efficiency of the cartridge filter element is up to 99.9% dust filtration for particles of 2 microns and larger.
The filter is mounted on a trolley, which is constantly moving. Few companies in the air filtration market are willing to produce such equipment.
After approval with the customer, the dust collector was manufactured and delivered on time. It was installed by the customer's team with our company's consulting support. There have been no issues with the dust collector's operation.
Therefore, we can confidently say that the customer is satisfied with our product.
The filter is mounted on a trolley, which is constantly moving. Few companies in the air filtration market are willing to produce such equipment.
After approval with the customer, the dust collector was manufactured and delivered on time. It was installed by the customer's team with our company's consulting support. There have been no issues with the dust collector's operation.
Therefore, we can confidently say that the customer is satisfied with our product.
Best Dust Collectors for Refractory Materials Manufacturing Plant
We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
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