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Innovations

Over the last four decades, Masturlal Fabrichem has created filtration solutions for industries across various disciplines. Our solutions have helped solve various filtration related problems and have won the loyalty of our clients over the years. 

Here we share with you a few of our success stories along with the primary issues in different industries and how we created solutions for the same.

Cement

Application: Cement Mill Application

Study & recommendation of suitable quality of filter bags for Cement Mill application 

Major challenges and problem identification:

  • Higher differential pressure across the bag house.
  • To avoid rain water ingression in clean air plenum as there was no shed at the top of the bag house.
Technical Considerations:

Selection of filter bags quality suitable for moist heat conditions. 

Innovations for problem identification and implementation of solution: 

Our team collected the operating data and based on operating conditions, we suggested installing of 100% Acrylic filter bags instead of existing 100% Polyester filter bags to avoid hydrolysis effect.

After installation of filter bags, pre-coating on filter bags was optimised with process dust and cleaning cycle.

Light weight shed has been constructed by customer on top of the bag house to avoid rain water ingression in the bag house as per our recommendation.

Filter bags' life was extended from 6 months to 24 months from the date of commissioning with the new set of bags.





Thermal Power

Application: Study & recommendation of suitable design of filter bags to improve the overall performance of hybrid type bag house system in order to achieve :

  • Pressure drop below 1500 pa
  • Emission ≤ 30 mg/Nm3
Major Challenges and problem identification: 

The customer was not prepared to go for higher quality of filter bags than the existing quality and was looking for filter bags made from 100% PPS fibers due to cost competitiveness over polyamide combination filter bags. 

Oxidation on filter media causes reduction in its tearing strength. Improvement in filtration efficiency of filters bags and reduction in clogging of filter bags was also a major problem.

Technical Considerations:

It was difficult to achieve desired performance by using 100% standard design of PPS filter media. Now the task was to optimize filter bag designs without compromising on quality and marginal impact on cost.

PPS Fiber

Innovations for problem identification and implementation of solution: 

The Masturlal Fabrichem team visited the site and studied the operating condition of the bag house and also carried out an analysis of used filter bags for physical properties. Advanced analysis was arranged at our principal laboratory facility and it was found that chemical degradation had occurred in the filter media properties specially the tearing strength of the filter media due to the oxidation effect.

After thorough analysis of the existing quality of filter bags, operating condition and cost constraint, Masturlal Fabrichem developed filter bags made from a combination of standard fiber with micro fine and trilobal fibers to improve the filtration efficiency and also to ensure minimal clogging in filter bags which was due to filter media structural design. 

To reduce the effect of oxidation on filter media, we recommended to pre-coat the filter bags with precipitated homogenous calcium carbonate to form uniform protective cake on collection side of filter bags. We also recommended pre-coating after long shutdowns.

PTFE Coating

All filter bags were installed in the presence of our service team accompanied by a customer representative to ensure quality of installation. 

After start-up, the cleaning cycle was optimized according to DP mode and now the system is running successfully with the desired performance parameters. 






Metal
Application: Steel Plant (SMS application)

Study of bag filter system for suggesting appropriate quality of filter bags to suffice the requirement of fluctuations in operating temperature from 130 Deg. C to 220 Deg.C at Inlet. 

Major challenges and problem identification: 

The quality of filter bags should be robust to handle temperature fluctuations without compromising on performance parameters.
Major challenges are as follows :-

  • Avoid damage to filter bags due to change in the operating temperature.
  • Increase of mechanical life of filter bags from existing life of 6-12 months.
  • Increase in overall efficiency of the complete system. 
  • Optimization of water spray arrangement over the duct used to suppress the temperature. 
Technical considerations: 

  • Selection of filter media which can sustain a fluctuating range of operating temperature without compromising on emission levels and differential pressure.
  • Enhancing the life of filter bags with an increase in filtration and cleaning efficiency thereby reduction in cleaning frequency.

Innovations for problem identification and implementation of solution: 

The Masturlal Fabrichem team collected the operating data and studied the problem of fluctuation in the operating temperature thoroughly. Based on the operating conditions, we suggested using 100% P-84 filter bags having multi-lobular fiber structure with special anti-adhesive PTFE based finish thereby increasing filtration/collection and cleaning efficiency.

    
P84 Felt


 P84 Fiber

After installation of filter bags, cleaning cycle has been optimized and cleaning pressure has been reduced by 25%. Selection of filter products has reduced use of water spraying arrangement in the circuit.Overall efficiency of the total system has been increased considerably. 





Textile
Application: Coal Fired Boiler

Need for an enhanced mechanical life from existing set of filter bags through suitable selection of filter media.

Capacity: 12 tons.

Existing Bag Life: 6-7 months

Major challenges and problem identification:

  • To provide an improved mechanical life of filter bags considering the existing parameters.
  • To avoid random failure of the bags at various locations.
  • To provide a cost effective solution along with the performance.
  • The filtration efficiency of the system should not be hampered.
Technical Considerations:

  • Selection of an appropriate filter bag is required right from the selection of the filter fiber quality.
  • Enhancement of life of filter bags by achieving less mechanical wear and tear of the filter fabric.
Innovations for problem identification and implementation of solution:

The existing used sample of filter bag (damaged) was collected and sent to our principal lab for destructive/root cause analysis and to find out the exact reason for random failure of bags during the operations.

The complete operating data of the system was collected and studied; both design and existing parameters were taken into consideration.

Based on the data and the analysis report which showed:

  • Excessive frequent cleaning 
  • Scrimless material has lower mechanical strength than bag material with scrim. The higher mechanical strength and dimensional stability of scrim supported bags will reduce the risk of mechanical damage.
  • The air permeability of the scrim less material is relatively higher which allows the dust to penetrate into the felt easily. Once the dust enters the felt, it will cause abrasion and increased mechanical wear. Denser material with an air permeability of 150l/dm2 @ 200Pa, or less, would allow a lower and stable pressure drop due to reduced penetration of dust into the felt and reduces the mechanical wear.
  • Further reasons for mechanical damage (like damaged cages) cannot be excluded. Due to a few damaged bags, neighboring bags would also be damaged and contaminated with dust if not replaced immediately.

Recommendation:

Taking into consideration the overall conditions, joint discussions with our expert technical team and the analysis report, we came to a conclusion that a compact design of filter media with combination of two fibres, PPS + P-84 micro is required. ( That is collection side needled with micro fibres of 1.2-1.7 dtex And back side with fibres of 2.3 dtex for support of cages)

This combination of filter media was treated with anti-adhesive chemical finish which helped in moisture repellency during the operation. The entire lot was replaced with our recommended/suggested quality that is PPS+P-84 in 560 GSM weight with an anti-adhesive finish.

Results:

  • Less pressure differences across the bag filters
  • Frequent and random failure of the bags issue was not observed
  • Less breakdowns/stoppages
  • Service life time was 24 months
  • Cleaning of bags with less compressed air
  • Overall efficiency of system was improved
  • Customer was satisfied
Optical expertise/microsopy - Cross section of needle felt








Filtration
If we go back to the origin, we find that oxygen was formed on earth. It was not always there. It has taken almost 2.45 billion years for oxygen to settle in to the atmosphere. But how was it formed in the first place? At that time, earth had abundance of flora. And the tiny organisms called the blue-green algae intiated the Great Oxidation Event (GOE) using sunlight and carbon dioxide to exhale oxygen. It has taken nature millions of years to create the air we breathe. And it has taken us only 100 years to contaminate it.

Our world today is in danger. In danger from the very air that surrounds it, the water that flows through it, the land that it is and the noise added by man-made activities.

It is not possible to look at the filtration challenge individually for air, water, land and noise. To improve the overall quality of life of the citizens, we have to understand the entire challenge as one. This is mainly because all the different types of pollutions are intricately connected in a closed cycle where everyone, inculding us humans are also affected by these.

To understand this more clearly, consider the air emissions from all the industries. The pollutants that are soluble in water get mixed with rain water and come down on earth again, while the suspended particles float in the air that we breathe. The rain water fills up our lakes, ponds, rivers and the seas which is used for irrigation. There are industries that add to the water pollution directly by releasing polluted water in to the river or sea. The chemically contaminated water when used for irrigation gets absorbed by the plants as well as the earth. The fertility of the soil also gets affected. This in turn requires us to use more artificial fertilizers. The food grown using the polluted water and in the polluted soil is what we humans eat. Over the years we are seeing the results of this viscious cycle with the rise in diseases and decline of human health as a whole. We have to understand that we are just one small part of the entire ecosystem but are the biggest influencers of the same system. We are gradually deteriorating not only our own well-being but of all the living organisms in this ecosystem.

There is only one way to reclaim our world, with the help of the right filtration solutions. Masturlal Fabrichem believes that environmental change is possible, and we are at a stage where every little step towards reducing environmental pollution can help us achieve our goal of a cleaner environment.


Understanding Pollution
Our ecosystem has undergone massive destruction. Industrialization, technological innovations and lifestyle changes have had various implications on our atmosphere. Its contamination and any physical, biological or chemical alteration are termed as pollution. 

Our rivers are replete with streams of toxic waste, our land is piling up with trash and our city skies are hidden in smog. Much damage has been done to our environment. Long term exposure to pollution can lead to diseases and eventually, even the death of environment the way we know it today. 

The need of the hour is to help build a healthy environment for us to thrive in. Measures are being taken by the Regulatory bodies in India by creating strict guidelines to follow such that pollution by various means is kept under control. 

The Ministry of Environment & Forest (MoEF) has launched the Charter on "Corporate Responsibility for Environmental Protection (CREP)" in March 2003 which has regulatory norms for prevention and control of pollution through various measures including waste minimization, in-plant process control & adoption of clean technologies. The Charter has set targets concerning conservation of water, energy, recovery of chemicals, reduction in pollution, elimination of toxic pollutants, process & management of residues that are required to be disposed off in an environmentally sound manner. 

It is our sincere endeavor at Masturlal Fabrichem to support all such entities to save our environment from further destruction. Our products are made with world-class materials and help various industries keep their pollution contribution under control. 



Air Pollution
It goes without mentioning that air is one of the most important entities for sustainability. However, the air that surrounds us today is bereft of purity. A nation-wide programme to monitor the quality of ambient air known as National Air Quality Monitoring Programme (NAMP) has been set up by the Central Pollution Control Board(CPCB). Under N.A.M.P., four air pollutants viz., sulphur dioxide (SO2), oxides of nitrogen as NO2,suspended particulate matter (SPM) and respirable suspended particulate matter (RSPM / PM10) have been identified for regular monitoring at all the locations. 

Air Pollution Control

If you look around, you will see change happening this very moment. Modernization paved the way for new technologies and with it, a completely new way of living emerged where machines are as much a part of our lives as is nature. While this was to make our lives easier, it has not reflected very well on our environment. To satisfy the increasing demand of goods, supply has to catch up and so, new factories are set up. These factories and industrial spaces all emit hazardous gases causing irreversible air pollution. 

While we are now accustomed to a certain way of life and cannot alter that completely, what we can do is to ensure that our businesses do not cause as much damage to the environment. This can be done by air pollution control methods that help prevent the world around us from deteriorating further. 

Masturlal Fabrichem is completely devoted to the cause of air pollution control. Our products and services are designed to help curb the effect of air pollution created in factories, industrial spaces and businesses. We believe that with the right kind of measures, we can together, significantly contribute to keeping the air we breathe clean and pure..






Water Pollution
Water pollution is a recent development and can be credited entirely to recent developments in industrialization. As opposed to earlier, when people were more concerned at least with their immediate environment, today there is a growing lack of empathy for the environment.

Over two thirds of Earth's surface is covered by water; yet our oceans, rivers, and other inland waters are being "squeezed" by human activities. To monitor water pollution in India, the Central Pollution Control Board (CPCB) established a nationwide network to monitor the quality of water across all states and UTs. The data received indicates that organic and bacterial matter due to the discharge of domestic housewater mostly in untreated form in urban centres continues to be critical for the water bodies. The municipal corporations are not being able to treat the load and the water bodies do not have adequate water for dilution, leading to water borne diseases. 

To understand the repercussions of water pollution, imagine pouring a cup of black ink into a river. One would say that the ink would quickly disappear into the river’s much larger volume of clean water. But the ink’s particles would still remain in the river water, even if in a very low concentration that one would not see the difference. At such low levels, the ink would not pose a real problem. But consider gallons of such ink being poured into our water bodies, over a period of time. The implications could be poisonous to the health of the environment. 

Fortunately, the damage from water pollution is often reversible.

Water Pollution Control

The easiest way to control water pollution is by the dilution of water. The pollutants are to be treated chemically and converted into nontoxic substances. Radioactive wastes in water can be removed by oxidation of ponds. 

Industrial and domestic wastes must be limited to the smaller ponds, and the larger ponds should be avoided. Waste, in the presence of sunlight and organic nutrients may lead to a large growth of bacteria which can act on the waste matter to reclaim the water which can be used in making fertilizers as it would be rich in phosphorous, potassium and nitrogen and for irrigation and factory purposes.





Land Pollution
Land pollution is often the most neglected, as the severity of its outcomes cannot be perceived immediately as air or water pollution. The decreasing forest covered land, rapid industrialization, expansion of cities and the population explosion has put immense pressure on our land and its resources. The Central and State Authorities, among others, believe that there is a need to encourage industries to recycle and reuse waste materials as far as practicable in order to minimize the discharge of wastes into the environments.  

While permitting the discharge of effluent and emission into the environment, State boards have to take into account the assimilative capacities of the receiving bodies. It is not going to be too late before land pollution becomes one of the biggest battles mankind would have to fight for its survival.

Land Pollution Control

To control pollution of land one has to understand the sources and the natural cycle. Each point in the cycle needs to be addressed differently but consistently in order to prevent land pollution. Regulating the various man-made activities stringently is one way of achieving this. But this alone doesn’t work. It is important for citizens and industrialists to understand their role in this entire process. Pro-active measures taken towards eliminating the pollution will work better than the regulatory as it brings more precise control and not averaged. 

For starters, the limited use of fertilizers and pesticides is essential. Grazing must be controlled and forest management should be done properly. Then, afforestation and reforestation must be done. In areas of wind erosion wind breaks and shields must be used. The soil binding grass must be planted and the large trees must be placed along the banks. The industrial wastes must be dumped in the low lying areas. There is a definite technique of cropping which does not allow the weeds to settle on the fields. The mining ways must be improved along with their transportation.





Noise Pollution

Noise pollution has become so much a part of our urban cityscape, that we do not realize when everyday sounds start creeping in on us and become unwanted noise. Noise that tends to disrupt the natural rhythm of life makes for one solid pollutant.

Modern life has made it difficult to escape noise. Even electrical appliances at home have a constant hum or beeping sound. By and large, lack of urban planning increases the exposure to unwanted sounds. This is why understanding noise pollution is necessary to curb it in time.

Owing to this, the Government set up The Noise Pollution (Regulation and Control) Rules in 2000. These rules address issues such as vehicular noise control, use of loudspeakers, permissible noise levels in industrial and residential areas, restriction of noise in silence zones and give rights to authorities as well as people to register a complaint if the rules are not abided by. 

Noise Pollution Control 

There are many methods which help to control the noise pollution. Firstly, the source of noise should be checked and kept under control. The path of transmission of sound must be stopped and the receiver of noise must be safe guarded. Secondly, noise pollution created by traffic must be reduced near the residential homes, educational institutes and hospitals. We must also ensure that all vehicles are maintained properly to reduce noise caused by them. Industries and factories, must be built away from residential spaces to protect human beings from noise pollution. But above all, people should be made more aware of the hazards of noise pollution and each one should check if they are contributing to noise pollution in their vicinity.





 
Innovations
Over the last four decades, Masturlal Fabrichem has created filtration solutions for industries across various disciplines. Our solutions have helped solve various filtration related problems and have won us the loyalty of our clients over the years.

Here we share with you a few of our success stories along with the primary issues in different industries and how we created solutions for the same.
How we helped a mega cement plant achieve complete pollution control?