Dust collection systems and air filters for the minerals industry

The minerals industry works with a wide range of ores and stones - from asphalt to cement, gypsum to lime. Each of these materials present unique environmental challenges when it comes to filter technology for dust collection systems:

BWF Envirotec offers filter technology for dust collection systems for the air filter industry that focuses on productivity. Ensuring product quality and compliance with dust emission limits are central tasks for our industrial filters. Special requirements for industrial filters for dust collection systems include properties such as high abrasion resistance, dissipation of electrostatic charges and high chemical resistance.

Industrial dust collection systems for the minerals industry require special industrial filters

BWF Envirotec filters offer technically sophisticated solutions for any filter technology process. We offer an extensive range of industrial filters and services for dedusting various production processes.

We help our customers meet their production goals. To this end, we carry out industrial filter and dust analyses for all filter technology applications in our laboratories, recommend solutions for optimising filter systems and provide training courses on filter media, industrial filters and operating know-how in our Training Academy.

PM-Tec® and needlona® filter bags -
Filtration solutions for dedusting in the cement industry

  • Safeguarding product quality and complying with the dust emission limit values play a central role in dedusting in the cement industry. This equally applies to waste gases from cement kilns and exhaust air from silos, packing stations, mills and clinker coolers in dust collection systems.
  • Our high-performance filter bags ensure reliable, high availability in dust collection systems and fulfil the highest demands in dedusting exhaust air and flue gas.

That's how versatile our range of filters for the minerals industry is

  • needlona® (specially developed filters made of needle felt filter media),
  • MPS® (fine fibre needle felts with high air permeability and high dust separation),
  • ExCharge® (filter media safely dissipate electrostatic charge) and
  • PM-Tec® (ePTFE membrane industrial filter made of needle felt or glass fibre for fine dust filtration)

References for filtration systems in the minerals industry

Dust source
Filter medium of the dust collection system
Filter medium of the dust collection system
Location of the dust collection system      
Location of the dust collection system      
Number of filter bags
Number of filter bags
Inlet load g/Nm3   
Inlet load g/Nm3   
Temperature Continuous/Peak °C 
Temperature Continuous/Peak °C 
Cement industry - Clinker cooler
Filter medium of the dust collection system
needlona® NO/NO 551 CS52
Location of the dust collection system      
Iran
Number of filter bags
1,000
Inlet load g/Nm3   
20
Temperature Continuous/Peak °C 
160/200
Cement industry - Chlorine bypass
Filter medium of the dust collection system
needlona® PTFE/PTFE 704 MPS CS30
Location of the dust collection system      
Germany
Number of filter bags
1,200
Inlet load g/Nm3   
35
Temperature Continuous/Peak °C 
170-175/190
Lime, gypsum, clay industry - Shaft kiln
Filter medium of the dust collection system
needlona® PTFE/PTFE 704 MPS CS30
Location of the dust collection system      
France
Number of filter bags
572
Inlet load g/Nm3   
10
Temperature Continuous/Peak °C 
170-175/190
Lime, gypsum, clay industry - Rotary kiln
Filter medium of the dust collection system
PM-Tec® GL 750
Location of the dust collection system      
South Africa
Number of filter bags
6,532
Inlet load g/Nm3   
20
Temperature Continuous/Peak °C 
110-160
Cement industry - Rotary kiln
Filter medium of the dust collection system
PM-Tec® GL 750
Location of the dust collection system      
Brazil
Number of filter bags
7,800
Inlet load g/Nm3   
80
Temperature Continuous/Peak °C 
150/210
Asphalt industry
Filter medium of the dust collection system
needlona® NO/NO 401 CS17 AsphalTec
Location of the dust collection system      
France
Number of filter bags
480
Inlet load g/Nm3   
250
Temperature Continuous/Peak °C 
80/130

Advantages of our filter bags for your industrial dust collection system:

  • compliance with the strict emission limit values
  • high separation performance
  • good chemical resistance
  • resistance to high process humidity
  • excellent filtration characteristics
  • filtration of the finest dusts
  • easy cleaning
  • limited pressure loss

PM-Tec® and needlona® filter bags -
Convincing filtration solutions for every industrial filtration system

PM-Tec® and needlona® filter bags are custom-designed to suit the requirements of the dedusting process in the dust collection system. This provides you the optimum technical solution for your filtration system. We supply filter bags for every type of dust collection system and application together with the corresponding supporting cages.

Depending on the flue glass cleaning method, the high-efficiency filter media of the filter bag are enhanced with various surface, functional or protective finishes. These protect the filter medium even more effectively against harmful chemical and mechanical influences. Improved separation behaviour, effective cleaning, low residual dust emission and an extended service life of the filter bags in dust collection systems are thus achieved.

needlona® filter bags for industrial filtration systems

  • needle felt filter media made of all types of conventional polymer fibre
  • the fibre coating of the filter bag is applied to a strong supporting fabric, this makes the filter media extremely compact, dimensionally stable and mechanically resistant for long service lives under the most punishing conditions

PM-Tec® filter bags for industrial filtration systems

  • filter media made of needle felt or fibreglass fabric
  • with a laminated, high-efficiency ePTFE membrane
  • Very fine dust particles are already separated on the filter bag surface.

The right filter bag for every application in dust collection systems

BWF Envirotec Filter Filtration Silo Cement Conveying Equipment

Silo, packing station and conveyor systems

Silo filter, packing station and conveyor systems are charged with dry dust, mostly under ambient conditions. Consequently, a economically efficient needlona® needle felt made of polyester can be used. The additional Cementsurf® finish reduces the friction between dust and fibre, thereby not only increasing the degree of cleaning but also the service life of the filter bag in the dust collection system.

Cement mill, separator

High dust loads in dust collection systems from the cement mill or the separator require a resistant filter medium. An oil and water repellent CS17® finish is recommended in countries with a high relative humidity and ensures that the agglomerating dust is not only separated, but is also effectively cleaned from the filter bag. Addition of grinding aids imposes very high demands on the filter medium, as they prevent agglomeration of the cement dust in order to increase mill efficiency. Limited agglomeration behavior hampers dust separation to a considerable extent and therefore maximum-efficiency MPS® or PM-Tec® filter bags are used in dust collection systems.

BWF Envirotec Filter Filtration Cement Mill Seperator
BWF Envirotec Filter Filtration Coal Grinding Drying

Coal milling and drying

Since a drying process is involved in addition to milling, increase gas humidity is to be expected. This manifests itself in chemical attack on the polyester fibres due to hydrolysis, such that their resistance is weakened over the course of time. Consequently, BWF Envirotec combines the chemically more susceptible but mechanically stable polyester fibres with the chemically stable but mechanically weaker polyacrylnitrile fibres in order to achieve an optimum filter bag service life and high level of profitability with this compound medium. Owing to potential dust explosion, we recommend the antistatic ExCharge® filter medium for conducting static discharges.

Clinker cooler

The hot clinker dust emerging from the cement kiln is generally cooled with ambient air before further processing. Since they are applied in dry form and without harmful gasses, filter media for filter bags made of m-aramid can achieve long and economically efficient service lives. m-Aramide is characterized by greater sustained temperature resistance with low gas humidity, in addition to less mechanical wear through the effect of the abrasive clinker dust.

BWF Envirotec Filter Filtration Cement Clinker Cooler
BWF Envirotec Filter Filtration Cement Kiln Bybass

Furnace bypass

The currently increasing use of secondary fuels can for example increase the chlorine concentration in the exhaust gas and product to impermissible levels. By extracting a partial stream from the cyclone preheater followed by subsequent cooling, the harmful gases can be effectively separated in solid form by means of a filter bag. The high constant temperatures and corrosive gas and dust composition however require an extremely resistant filter medium. Filter media made of PTFE are perfect for efficient filtration in dust collection systems.

Cement kiln

The common method consists of a rotary kiln with an upstream cyclone preheater. Intensive material and heat exchange occurs here between the downwards flowing raw meal and the upwards flowing exhaust gas. In this manner, not only is the raw meal heated, but also binding of acid components contained in the exhaust gas occurs which might exert a chemical attack on the downstream filter bags. This absorption process is gaining in importance with increasing use of secondary fuels. Long service lives can be achieved with the very economically PPS filter bags at filter inlet temperatures of < 150°C. Filter bags made of polyacrylnitrile homopolymer are also suitable if owing to intensive heat recovery the filter inlet temperature can be reduced to constantly < 120°C and temperature peaks of > 140°C are avoided. A further reduction in costs can be achieved as a result. In case of higher tempratures, BWF Envirotec recommends use of high temperature fibre such as polyimide and fibreglass fabric.

BWF Envirotec Filter Filtration Cement Kiln

BWF Envirotec References
Filtration solutions for different industries

BWF Envirotec industrial filters are used in many other industries in addition to the mineral industry.

To other industries

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