Dust Collector Leak Detection and Running Cost Reduction by Triboelectric Dust Monitor

Industrial dust collectors often suffer from invisible filter bag leaks that lead to increased running costs, material loss, and unplanned maintenance.

This application explains how triboelectric dust monitoring enables early detection of filter bag leakage, supports predictive maintenance, and allows operators to reduce dust collector running costs by using filter bags until the end of their service life.

At a certain factory, during the process of collecting metal powder, the dust concentration was periodically monitored by isokinetic measurement analysis. Despite this, there were many leaks. Each time, they had to shut down operations and clean the dirty worksite .

Furthermore, because location of the leak inside the dust collector could not be identified, all filters (filter cloths) were replaced .

Due to this situation, they were worried that they wanted to improve the working environment as much as possible and reduce the need for unnecessary filter replacements.

Solution

Triboelectric Dust Monitor provides real-time continuous monitoring for dust concentration and detects dust leakage immediately when it happens.

It detects even small amount of dust leaking out from small crack of filter bag and it's possible to identify damaged filter bags where the signal of Dust Monitor and backwash pulse timing is synchronized.

Finally, it is possible to realize running cost because those filter bag can be used at the end of lifetime as predictive maintenance.

It is possible to observe dust leakage trend by recoding concentration signal output (DC4-20mA) from Dust Monitor.

   * Above trend chart is dust concentration signal when backwash pulse is applied.

Continuous measurement (0.1-1000mg/m3) in place of human observation.

Alarm output before regulated value.

Running cost reduction possible as filter bags can be used until the end of lifetime.

Dust concentration compensation (approximation) function mode available.

Approximated value compensated by input factor can be output.(Compensation factor adjustable from 0.1 to 2.0)

Matsushima Measure Tech Triboelectric Dust Monitor is automatic measurement instrument complied with JIS standard (JISB7996).

Correction coefficient is quite high (0.969) and almost replaceable with isokinetic measurement system.

Achieved by the technology

It replaces a human and continuously monitors 24 hours a day.

It is possible to reduce maintenance work such as cleaning work for dust leakage, etc. because it tells you before dust leaks.

It detects even minute leaks (0.1mg/m3 or over) when filter begins to break, and it is possible to prevent the valuable raw materials leak.

Inside of dust collector is divided into multiple rows and backwashed in row order.

Leakage during backwashing appears as a trend for each row, so there is no waste by replacing only the filters in rows with a large amount of leakage.