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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








Industries
We are living in an age where industrialization is at the core of the framework of our existence and it is almost impossible to alienate ourselves from its repercussions. The only way to create long lasting solutions for a cleaner environment is to study the various industries, their entire supply chain and their pollution requirements in depth.

Over the years, we have worked hard towards creating a deep understanding of the various industries and their contribution to pollution. This has enabled us to create innovative solutions for them as a responsible entity of our society.   


Cement
The cement industry, for obvious reasons, creates enormous amount of dust during the process of making, and their producers are making considerable efforts to reduce the dust emissions in air with a better approach.

Pollution in Cement Manufacturing

Air pollution generated during the cement manufacturing consists primarily of particulates from the raw and finished materials, and fuel combustion by-products. The traditional way of controlling emissions from sources other than the kiln usually involve capturing the dust using a hood or other partial enclosure and transporting it through a series of ducts to the collectors. 

For this purpose, in the cement industry, there is a need for various types of dust collectors based on the factors such as particle size, dust loading, flow rate, moisture content and gas temperature.

The need for better technology

Today’s cement manufacturing facilities provide comprehensive solutions to challenge dust collection needs by combining advanced emissions control technology with proved application expertise. Keeping all the processes running, producing a quality product in a timely manner and meeting EPA emission standards has become a challenge for the cement industry.

Solutions for the Cement industry 

Dust is a byproduct that cannot be done away with in the process of cement manufacturing. It is produced during the quarrying of material, and then during grinding, burning, cooling, conveying, storage, packing and dispatch processes. 

Filter systems are installed at various stages to control the uncontrolled dust emissions. However, this has a disadvantage as enormous quantities of exhaust gas have to be dedusted during the cement manufacturing process. 

In the cement industry, fabric filters (bag filters) and accessories have been established as the most important types of process filter. 

There is a clear trend towards bag filters, which enable compliance with lower emission limit values and are practically independent of operating conditions and plant starting and stopping phases. 

Masturlal Fabrichem offers solutions through superior high quality filtration products with over 40 years of experience in the cement industry. We remain deeply engaged in, and understand the objectives of the cement producers. Our thorough understanding of the industry makes us create products that make a positive impact not only on the company but the industry as a whole. 





Thermal Power

Power plants are the veins of a nation that are the drivers of economic development. But to create power, there are a range of pollutants that are generated from coal-fired and coal co-fired power generating plants and some are more specific to a particular technology.

Pollution in Thermal Power Industry

The primary emissions to air from the combustion of fossil fuels or biomass are sulfur dioxide (SO2), nitrogen oxides (NOX), particulate matter (PM), carbon monoxide (CO), and greenhouse gases, such as carbon dioxide (CO2).

Depending on the fuel type and quality, mainly waste or solid fuels, other substances such as heavy metals (i.e., mercury, arsenic, cadmium, vanadium, nickel, etc.), halide compounds (including hydrogen fluoride), unburned hydrocarbons and other volatile organic compounds (VOCs) may be emitted in smaller quantities, but may have a significant influence on the environment due to their toxicity and/or persistence.

The need for better technology

To keep air pollution under control in Thermal Power Plants, various measures can be taken. For example, choice of fuel and measures to increase efficiency of plant. The fuel itself can be a major point of reduction of pollution, its quality, type, efficiency etc. can help decrease pollution.

As mentioned above, the pollutants in a Thermal Power Plant are quite toxic in nature and can lead to various human health problems.

Solutions for Thermal Power Industry

Fabric filters bags are a solution that remove dust from a gas stream by passing the gas through a fabric and leaving the dust on the surface of the fabric. The fabric filter is therefore not sensitive to dust resistivity.

However, the fabric filter is more sensitive to contamination due to the barrier- like nature of the dust removal. It is thus important to choose the material of the bag as well as the gas temperature and gas conditions.

Masturlal Fabrichem provides a wide range of filtration solutions needed for long experience spanning technologies, materials knowhow and the applications for Thermal Power Plants.





Metal
In metal production, there are several harmful gas compositions which are a serious threat to the quality of air. Processing in metal smelters involve extraction of various metals from ore to create more refined metal products. Metals include copper,iron, steel, nickel, lead, zinc, silver, cobalt, gold, cadmium, etc. Metal Smelting specifically involves heating the ore with a reducing agent such as coke, charcoal or other purifying agents. Primary smelting processes mine ore and concentrates, whereas secondary smelting processes recover scrap.

Pollution in Metal Smelter 

Extractive metallurgical and smelting processes can be highly polluting activities. It has been found that smelting processes emit high quantities of air pollutants such as hydrogen fluoride, sulfur dioxide, oxides of nitrogen, offensive and noxious smoke fumes, vapors, gases, and other toxins. As well as, a variety of heavy metals: lead, arsenic, chromium, cadmium, nickel, copper, and zinc. The processes of extraction of metal such as pickling also use large volumes of sulfuric acid. 

Inhaling such harmful gases or particles produced during metal extraction could be highly harmful for humans and can cause chronic diseases. Sudden exposure can cause irritation to eyes, nose and throat. Prolonged exposure can cause heart and lung problems and even death. Accumulation of toxic elements in organisms can cause kidney and liver problems, gastrointestinal tract issues, joint pain, as well as nervous, respiratory and reproductive system damage.

The need for better technology 

It is possible in modern smelters to operate them at very low emission levels, however this can be costly and many plants do not meet the standards. 

New technologies are playing an important role in reducing or even preventing smelter pollution. Older smelters emitted most of the sulfur dioxide generated, and now almost all of it is captured prior to emission using new technologies, such as electrostatic precipitators, which capture dust particles and return them to the process.




Infrastructure
Pollution in Infrastructure

The asphalt manufacturing process consists of drying and heating aggregate (crushed rock, gravel, reclaimed asphalt pavement or sand) and filler (dust, fly-ash, lime or baghouse fines) and combining them with approximately 5% by weight of heated bitumen.

The two types of asphalt manufacturing plants are batch plants and drum-mixing plants. Particulate emissions generated from batch or drum-mixing plants are typically collected in a cyclone followed by a baghouse or wet scrubber.

The need for better technology

There are various kinds of emissions and pollutants at infrastructure facilities ranging from solid residue to liquid pollutants and gaseous emissions. At most facilities, fabric filters are used to control emissions from dryers. Other controls used include mechanical collectors and scrubbers. Emissions from aggregate handling and transfer typically are controlled with fabric filters or scrubbers.

Solutions for Infrastructure

Masturlal Fabrichem understands and appreciates that asphalt plants cannot function and be profitable if the baghouse is not running optimally. Being in the industry with over 40 years of experience that has knowledgeable staff and field presence, you are sure to get the most beneficial advice in reducing pollution caused in the industry. 




Waste Incineration
Pollution in Waste Incineration Industry 

The combustion of any substance will generate byproduct emissions that could be released to the air. The following air emissions are usually the main concerns associated with incineration facilities: metals, especially mercury, lead, and cadmium; organics such as dioxins and furans; acid gases such as sulfur dioxide and hydrogen chloride; particulate matter such as dust and grit; nitrogen oxides (which are ozone precursors); and other substances, such as carbon monoxide.

The need for better technology

People exposed to emissions directly by inhaling contaminated air, or by ingesting or having skin contact with contaminated soil and dust are at more significant risk than inhaling emissions from MSW incineration facilities. Exposure can also occur indirectly by eating foods that have been contaminated with these substances. In addition to human health, plants and animals could also be adversely affected by emissions from incineration facilities. 

Solutions for Waste Incineration Industry

The major air emission control technologies available with Masturlal Fabrichem for incinerators are fabric filters. Fabric filters, also known as baghouses, are extremely effective in controlling emissions of metals and organic compounds that attach to fine particulates. Fabric filters also consist several cylindrical bags that filter emissions.

These types of waste incineration plants are subjected to close environmental scrutiny because they are located in heavily populated areas, with neighbors that closely monitor the effectiveness of the filtration and scrubbing process. 

Masturlal Fabrichem a recognized supplier in baghouse and dust collector filters, installation, parts and services, has proven products and services that can handle the common and site specific problems of this industry like:

  • Premature baghouse filter failures
  • High pressure drop or drag resistance
  • Emissions
  • Hopper or silo bridging & buildup
  • Heavy corrosion of baghouse floors & walls
  • Reverse air/pulse jet systems
  • Corroded cages





Biomass
Pollution in Biomass industry

The dust generated by biomass plants is primarily fly ash. These types of plants can pose a threat to the environment because they are typically located in heavily populated areas.

The need for better technology

Burning biomass causes hazardous air pollutants to be emitted in the air, and can cause cancer or other serious health effects, such as reproductive effects or birth defects, or adverse environmental effects.

The HAPs emitted in the greatest quantities by burning biomass include the organic HAPs styrene,acrolein, and formaldehyde, and the acid gases hydrofluoric acid and hydrochloric acid. Biomass burners commonly emit ten tons or more of the acid gases and from one to five tons of organics each year.

Solutions for Biomass industry

Fabric filters or baghouses are generally considered the most effective means of emissions control for particulates filtration. They can show control efficiencies upwards of 99%. They are installed at some mid-sized facilities and many utility-scale facilities.  

Masturlal Fabrichem, a major supplier of fabric filter products and relevant accessories can effectively tackle filtration problems of this industry like :  

  • Premature baghouse filter failures
  • High pressure drop or drag resistance
  • Emissions
  • Hopper or silo bridging & buildup
  • Heavy corrosion of baghouse floors & walls
  • Deteriorated shaker/reverse air systems
  • Corroded cages





Spent Wash
Pollution in Spent wash Manufacturing

In India, there are major wine, beer and industrial alcohol producers that have plants in Uttar Pradesh, Maharashtra, Tamil Nadu, Madhya Pradesh and other parts of the country. These plants produce alcohol by using mainly molasses as a raw material, these molasses contains 7-8% glucose, which is converted to alcohol by the process of fermentation. 

Molasses are first diluted by adding water then yeast is added in the diluted molasses solution and fermentation process takes place. As the process goes up, glucose is converted into ethyl alcohol and carbon dioxide. This carbon dioxide is removed in the gaseous form, which is collected separately.
 
The need for better technology

The distillery sector comes under one of the seventeen categories of major polluting industries in India. Large volumes of dark brown coloured wastewater known as “spent wash” is created which generates critical problem of environmental pollution in many countries. 

High temperature of the wastewaters may instantaneously kill fish and other aquatic organisms, thus destroying the flora and fauna of a river, when the wastewaters are discharged into it. Due to decomposition of soluble and suspended organic matters present in the wastewaters, high BOD (Biochemical Oxygen Demand) and COD (Chemical Oxygen Demand) of the wastewaters results, causes rapid depletion of the oxygen content of the water, thus creating a foul smell. This further promotes growth of nuisance organisms and can render the stream totally unfit for propagating fish life and for the purpose of drinking, personal hygiene, recreation and other purposes. The distillery effluents, when drained into a water source, make it susceptible to the propagation of harmful microbes. Thus creating serious biological hazards like the generation and propagation of water borne diseases. To prevent this, the effluents of the distillery are either treated or utilized profitably.

Solutions for the Spent Wash industry

India is a major producer of sugar in the world and contributes substantially to economic development. Bagasse and molasses from the sugar factory are also economically more important. Bagasse is used in the production of paper, electricity and also as a fuel in boilers whereas Molasses is used as a cheap source for alcohol production in distilleries by fermentation method. 

Through experiments, it has been found out that spent wash is very useful in increasing the yield of several crops and improving the soil characteristics like pH, Ec and nutrient availability. However the effect of raw distillery spent wash in different concentration on the growth parameters, sugarcane production, soil fertility status and ground water quality are lacking.

Masturlal Fabrichem is a supplier of filtration products for hazardous gases and wastewater,which gets collected separately and are cleaned and purified.. 





Carbon Black
Today’s carbon black facilities seek the need to be more efficient with tight operating expenses as well as meet EPA regulations. Dust collection equipment/bag houses play an important role to the overall production, no matter what type of grade is produced. Technology advancements over the years have allowed plants to extend filter life while increasing production rates and decreasing the equipment downtime. 

The need for better technology 

This process controlled industry requires most efficient filter media. Carbon black has a strong warming effect both in the atmosphere, and when it lands on snow, ice caps and glaciers, where it absorbs the sun's heat, reduces reflectivity and causes widespread and faster melting, causing sea level rise and other climate changes.

Because carbon black remains in the atmosphere for only a few days - unlike other greenhouse gases, which may remain in the atmosphere for over a century; reducing carbon black emissions should be among the most effective near-term strategies for slowing global warming which may also avoid some of the most imminent climate change tipping points.
 
Carbon black comes from diesel engines, industrial smokestacks, residential cooking, heating stoves and geographically most carbon black that falls in the Arctic comes from North America, Europe and Asia.Thereby it is also a leading cause of respiratory illness and death and controlling these carbon black emissions will save lives and help improve the quality of health around the world. 

Solutions for Carbon Black Industry 

Below is a list of common problems in which we have supplied filtration expertise to solve problems:

  • Opacity
  • High differential pressures
  • Premature bag failure
  • Insufficient amount of cloth area
  • Oil exposure of filter surface
  • Chemical attack
  • Temperature excursions





Chemical
Pollution in Chemical Industry

This is one industry which is responsible for a large amount of pollution. The primary effect of chemical industry on environment and on the lifestyle is due to the pollution, arising from the industrial activities, resulting in gas emissions, wastewater polluting the natural ponds and underground water, solid and slurry waste and further polluting the soil, if not treated. 

One source of air emission is the sulfur dioxide, resulting from the combustion of coke, oil products or natural gas, when desulfurization is not sufficient. Since it is catalyst poison, careful desulfurization is required.

Another source of pollution is nitrogen dioxide, resulting from partial oxidation of atmospheric nitrogen at combustion of reforming fuel, as it happens at the combustion of any fuel. Additional part of nitrogen dioxide is obtained from partial oxidation of the produced ammonia. 

The need for better technology

Chemical pollution presents a host of dangers to both humans and wildlife. Toxic chemical spills can cause immediate, short-term devastation to the environment and anyone exposed to the substances. However, much more insidious is the long-term effects of chemical pollution, which can harm those far away from the initial source of contamination and over a much longer period.

Solutions for Chemical Industries 

Masturlal Fabrichem is in the chemical, odor and particle control filtration processes and produces the most powerful and efficient filtration products and relevant accessories for industrial purposes.

Having created a wide range of filtration bags each of which reacts to a specific pollutant. Masturlal Fabrichem have also considered the efficiency and safety of chemical filtration systems ideal for various circumstances. 





Oil and Gas
Pollution in Oil & Gas Industry

Oil & Gas industry comprises of two types of applications:- 
- Upstream applications
- Downstream applications

The Upstream applications covers water injection filtration, crude oil filtration, diesel filtration, whereas the downstream application covers, gas turbine air filtration, gas turbine oil filtration, etc. The downstream application also covers oil and gas refining, which relies on the effective operation of complex processes with absolute filtration applications.

Field gas is processed to remove solids, deformable and liquid contaminants prior to its gas separation process. This involves multi-stage separators, coalesces and particulate filters bags.

The need for better technology 

One major factor that accounts for the processing, quality and environmental impact of petroleum is the composition of the natural gas and crude oils. Air pollution consists of fugitive emissions, mainly methane, as well as from storage. Exhaust combustion emissions are generated from compressors, pumps, drill engines and engines of servicing vehicles. Gas flaring is the major source of combustion emissions where the major source of secondary emissions is the water separated from the natural gas and crude oil.

Water pollution in the petroleum industry comes from uncontrolled leaks and spills, and also during transportation of crude oil and products. Solid wastes containing varying amounts of different pollutants are thereby generated from particular processes or as sludge in storage tanks.

Solutions for Oil & Gas Industry 

As world demands on oil and gas continue to grow multifold, Masturlal Fabrichem helps keep your systems at top production levels with a complete range of continuous emission monitoring, particulate-opacity monitoring, combustion control, process analysis and control, cross-stack gas analysis and portable gas equipment solutions. 





Food Processing
Pollution in Food Processing Industry 

Food processing projects involve the processing and packaging of fruit and vegetables, meat products, fish and shell fish, dairy products, grains and beverages production. It includes refinement, preservation, improvement of product, storage, handling, packaging and canning. The processing may involve receiving and storing raw or partially processed plant, animal or other food materials; processing the raw materials into finished products, packaging and storing the finished products. Since the existing environment within which they operate is the only one we have, shared by both the consumers and operators of other sectors of the economy.Therefore there is the need to ensure the preservation of the environment in as natural and ecologically balanced as possible for the use of all. 

The need for better technology 

A number of factors which are responsible for food contamination are as follows :

  • Various vegetables may get contaminated with toxic bacterial strains (from irrigation water, groundwater, or soil) which may only be destroyed by processing the polluted food at high temperatures.
  • Plants (vegetables, crops, or trees) get contaminated with the environmental pollutants along with water and nutrients through their roots. Air pollutants also enter the plants through roots after being first deposed on the ground with precipitation water. 
Solutions for Food Processing Industry

Masturlal Fabrichem has a wide variety of dust collectors that can be applied in the food processing industry ranging from small bin vents to large baghouses customized to meet the specific needs for each type of food product. Dust collectors or ‘material separators’ in the food industry keep the product in the process stream through use of a bin vent collector, preventing the loss of valuable ingredients and removing a potential waste stream.

Food processing applications produce dusts on both the upstream and downstream sides of the process. Upstream nuisance, pre-process, and out of plant sources can require dust collection. While downstream the production processes, and other internal process plant sources drive the need for dust collectors. The types of processes found in the food industry may include:

  • Mixing
  • Conveying
  • Screening
  • Packaging
  • Drying
  • Blending
  • Extruding
  • Weighing




Textile

The textile industry is concerned with production of yarn, majorly the manufacturing of cloth. This process creates enormous amount of dust during the process of making, and their producers are making considerable efforts to reduce the dust emissions in air in a better approach.

Pollution in Textile Industry

The major pollutants in the process of textile manufacturing is the exhaust air that comprises of wax, fiber particles and oil that can clog the exhaust and lead to excessive cost of filter disposal and replacement.

There is also blue smoke that is released during textile manufacturing, which causes less VOC pollution, but has a high priority in getting separated effectively. The released smoke can have a hazardous effect on the neighborhood.

The need for better technology 

The process of cloth manufacturing is a tedious process, one in which the raw material has to go through a number of chemical processes such as sizing, desizing, scouring, mercerizing, bleaching, dying, printing, and finishing. A number of chemicals are used for the same, and hence waste water collected after these processes is alkaline in nature and contains high amounts of BOD, COD, TDS and alkalinity.

Apart from this, the industry also generates air pollution with dust, lint etc. that can cause respiratory problems in the workers leading to chronic lung diseases.

Solutions for Textile Industry

Advanced filtration solutions to filter and recycle water that is used in textile manufacturing can reduce water pollution. Such applications include filtration for size recovery, filtration and reverse osmosis for bleaching and scouring process streams, filtration and evaporation for mercerizing streams and filtration and reverse osmosis for dyeing streams.

Masturlal Fabrichem offers energy efficient solutions for the separation of waste air composites and solutions to combat water pollution using advanced filtration mechanisms. 





Paper
Pollution in Paper Industry

The typical paper mill uses a vast amount of energy, water and wood pulp in an extremely complex series of processes, using modern and sophisticated controls technology to produce a sheet of paper - a process which generates an extensive amount of dust.

Creating paper out of wood or pulp involves several complex processing steps in which the raw materials are chemically treated. This producegases that have the potential to cause corrosive damage to the surrounding machinery and equipment. That is why they are classed as contaminanted gases. Particularly at risk are sensitive areas such as electronic equipment, control rooms, process control systems and compressors. The negative effects of the corrosion of the copper and silver components of these devices include a loss of process efficiency, additional maintenance costs, expensive repairs and unplanned downtime.

Need in Paper industry

The environmental impact of paper production is important to note since it has many negative effects. Here are some of them:
  • 40% of the world’s commercially cut timber is used for the production of paper.
  • Pulpwood plantations and mills endanger natural habitats.
  • Over 30 million acres of forest are destroyed annually.
  • The pulp and paper industry is a big contributor to the problem of deforestation and is partly to blame for the endangerment of some species that live in the forests.
The life cycle of paper is damaging to the environment from beginning to end. It starts off with a tree being cut down and ends its life by being burned – emitting carbon dioxide in the atmosphere.Paper production uses up lots of water. A4 paper requires 10 liters of water per sheet.

Most of the materials in landfills are made of paper. When paper rots, it emits methane, a greenhouse gas. When it is burned or composted, carbon dioxide is released.

Pulp and paper mills discharge water that is riddled with solids, dissolved organic matter called lignin, alcohol, inorganic material such as cholates, chlorine and metal compounds. All of this contributes to soil and water pollution.

The paper industry is the 5th largest consumer of energy in the world. It consumes upto 4% of the world’s energy. To produce 1 ton of virgin paper, it is estimated that 253 gallons of petrol is used.

Solutions for Paper Industry

Masturlal Fabrichem provides a variety of filter cartridges, pleated bags and flat cell panel filters suitable for the paper industry and the type of dust, it generates. They develop customized solutions specifically for the needs of the paper industry. These ensure effective and efficient gas-phase filtration to permanently remove contaminant corrosive gases from the air. 

They offer everything from a single source: from on-site pollutant analysis to the selection of filter products or permanent ongoing monitoring.They also provide reliable protection against corrosion by contaminant gases that are released during the main process steps in papermaking:

  • Lignin removal
  •          Bleaching
  •          Wastewater treatment




Iron and Steel

The Iron & Steel Industry has a variety of pollution associated with it. Apart from the waste materials that include solid, liquid and gases produced during the metal extraction/ creation processes, it is not surprising that the industry also produces considerable noise pollution.

The emissions from this industry have a direct and considerable impact on not only the immediate but also far-reaching consequences on the environment in general including climate change, global warming and the melting of the ocean’s ice.

Since the consumption of iron and steel in our world has become considerably large, there is also a large amount of energy consumption by this industry.

Due to increasing environmental concerns associated with industrial waste, companies must now incorporate waste management and prevention strategies into their industrial processes. Pollution prevention includes the design of products and processes that will lead to less waste being produced by manufacturer or the end user.

Solutions for Iron & Steel Industry

The need of hour is for Iron and Steel manufacturers to include waste management practices and create pollution prevention strategies even if it means to design new product/processes that will help reduce the industry’s lasting impact on the environment.

Below is a list of common problems to which we have applied our filtration expertise:

  •           Ore beneficiation
  •           Pig iron production
  •          Oxygen steel making
  •           Rolling mill
  •           Cogeneration
  •           Electric arc furnace




Aluminium
The Aluminum industry is considered a process-controlled industry, but it is heavily regulated for particulate emissions. Alumina dust is very fine and abrasive, and requires state-of-the-art filter media. The industry spends a great deal of capital on baghouse maintenance and equipment that monitors baghouse performance. We provide a well-rounded industry concept individually geared toward the application. 

Solutions for Aluminum Manufacturing

Masturlal Fabrichem is a supplier of hundreds of baghouses ranging from very small to very large units. Below is a list of common problems in which we have supplied filtration expertise to solve problems:

  • Opacity
  • Chemical attack
  • Filter abrasion
  • High differential pressures
  • Thermal degradation
  • Insufficient cloth area




Copper
The main environmental issues for the primary copper production are the potential emissions to air. Emissions like dust,metals/metal compounds and sulphur dioxide which are derived from roasting and smelting sulphide concentrates or by using sulphur-containing fuels or other materials. The formation of dioxins in the presence of chlorine is also a potential source of hazard. 

Solutions for Copper Manufacturing 

Masturlal Fabrichem is a leading supplier of gas filtration for this industry. Filter requirements range from mining, transportation, crushing, flotation, leaching and smelting of copper. Due to the presence of sulfate and nitric acid, this industry requires filter products which are resistant to specific chemical/acid attacks.

Below is a list of common problems to which we have applied our filtration expertise:

  • High differential pressure
  • Acid/Chemical attack
  • Temperature excursions
  • Opacity
  • Hopper evacuation problems




Zinc
Zinc smelting and product recovery are challenging applications because of the chemical makeup of the gas stream, temperature excursions, and characteristics of particles and dust cake. Environmental control and process control are equally important in this industry, ultimately investing a great deal of capital in order to attain the best results. 

Solutions for the Zinc Manufacturin

Below is a list of common problems to which we have applied our filtration expertise:

  • Poor dust cake release
  • Opacity
  • Temperature excursions
  • Insufficient cloth area
  • Premature bag failure
  • Hopper evacuation
  • Spark holes




Lead
Lead is a hazardous metal and they require independent and self-evaluated safety requirements in their manufacturing process. They also require to minimize down-time due to safety and production concerns. 

The types include pulse-jet, shaker, reverse air, and horizontal cartridge units which are all very prominent in the industry. High performance filter products like expanded PTFE membrane, micro-denier are all used to maximize the operation. 

Solutions for Lead Manufacturing 

Below is a list of common problems to which we have applied our filtration expertise:

  • High differential pressure
  • Opacity
  • Insufficient cloth area
  • Hopper discharge
  • Temperature excursions




Ferro Alloy
Ferro Alloy industry requires high-temperature filter fabric due to the processes involved in metal extraction. Major pollutants include large particles of dirt, dust and pieces of wood/ charcoal and coke along fine particles. The gases may contain harmful sulphurous products, toxic metal oxides, carbon monoxide and other organic gases. 

Solutions for Ferro Alloys Manufacturing 

Below is a list of common problems to which we have applied our filtration expertise:

  • Temperature excursions
  • Dilution air dampers
  • Hopper evacuation
  • Hood capturing inefficiencies
  • High differential (start-up)
  • Increased smoke volume




 
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?