Coal Age

JUN 2013

Coal Age Magazine - For more than 100 years, Coal Age has been the magazine that readers can trust for guidance and insight on this important industry.

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operating ideas continued lector's space requirements so it can be installed in locations where tight quarters complicate the placement of other systems. The mesh-like material also filters better and lasts longer— while consuming less energy—than conventional filter bags. The new filters allow a smaller size fan to move air through the elements, helping to reduce the overall power consumption of the collection system. "The old unit had a large footprint, and it was too close to the emergency reclaim area," Cason said. "A smaller, high-efficiency insertable unit gives us back that space and does a better job of filtering the air." The unit features a pulse cleaning system, which uses a short burst of air sent back through the filter to dislodge accumulated material. Filter changes are a no-tool procedure from the clean side of the dust collector. "These new insertable air cleaners can eliminate many of the problems seen with central 'baghouse' collection systems, including long runs of ducting, large enclosures, difficult maintenance and high power consumption," said Dan Marshall, product engineer, Martin Engineering. "They help solve airborne dust problems by keeping fine particles in the load or returning them to the material stream." The new line of insertable units was developed to handle the heavy dust concentrations and air volumes arising from material transfer points. They are designed to remove 99.9% by weight of all dry particulates 0.5 micron and larger (based on a time-weighted average of a properly installed, operated and maintained unit). The automated "reverse jet" cleaning sequence facilitates continuous operation, keeping filters working effectively with a mini- June 2013 mum of compressed air. The small integrated fan runs only when the conveyor is operational, further improving energy efficiency. "These systems eliminate the need for installing or maintaining ductwork, and there's no haulage or cleanup costs for waste disposal since fugitive material is contained within the process," Marshall said. "One of the most popular features with operators is the clean-side access for inspection and filter change-outs. It's a quick and easy process, saving further on time and maintenance costs." Also contributing to the air cleaner's smaller footprint is a modified transfer chute, with modular hood-and-spoon components to better manage material flow, and a stilling zone to reduce turbulence. The engineered flow chute employs special geometries that capture and concentrate the material stream as it travels through the chute. Every design is tailored to suit the specific material characteristics and conveyor systems of the individual customer, rather than using stock products and attempting to make them work. Transfer chutes provide the dual benefits of minimizing aeration and preventing buildup within the chute, particularly important when dealing with combustible materials. Asked to summarize the results of the upgrades, Stuart said, "For me, not having those clean-up and repair battles is a huge relief. And the whole area is a cleaner, safer working environment." "No question that the system has paid for itself. We used to spend a lot of time making adjustments and repairs, but since the install, the system has been essentially maintenance-free," said Janis. "It doesn't matter what kind of coal we run, or whether the coal is damp from rain or completely dry. The fines are contained." 53

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