Dedusting filters for industrial process plants

In order to design a dedusting filter correctly, several process parameters and the installation conditions must be taken into account. The ts-systemfilter team will be happy to support you personally. You can enter the parameters you know in advance using our enquiry form and we will clarify the rest in our conversation with you.

Select the design according to your application. The base filter contains the jet cleaning system, with the filter elements protruding into your container. With the top-mounted filter, the filter cartridges are placed in the filter housing and the filter unit is mounted on a silo using a flange or clamping ring and weld-in frame. With a funnel and rotary valve, the filter can function as a separator or be designed as a stand-alone unit with a collection container. Our mini filters can be used for aspiration, for venting pneumatic conveying systems or as safety filters. In principle, all filters can be supplemented with a police filter as a second filter stage. 

The volume flow of the process and the possible filter surface load result in the required filter area. Depending on the space requirement, select the series with its housing diameter. It is most economical to build upwards with a small series, as fewer filter elements are required. 

The filter surface load can be calculated using our slide rule. The lower the load, the better the expected residual dust values. Filter cartridges or filter bags can be used in all filters. Due to their compactness, we recommend cartridges, which work excellently in most applications. Filter bags are preferable for very sticky bulk materials such as milk powder. All common filter media on the market are available. Practical experience indicates the best filter medium for the respective application. Requirements for residual dust values, food suitability, chemical resistance or use in potentially explosive areas as well as the process temperature all play a role in the selection process. We can analyse the suitability of the medium for the bulk material in the laboratory in advance and are happy to support you in your selection. The most common media are made of polyester with or without PTFE membranes, with or without antistatic equipment, cellulose, polypropylene and polyphenylene sulphide for temperatures up to approx. 160 °C. 

In principle, the filter surface load must match the process parameters. If the load is too high in practice, the filter cannot work properly and malfunctions may occur. The properties of the bulk material to be transported or filtered also play a very important role. Whether filter cartridges or hose filters, a larger filter surface or a larger expansion space below the filter elements are more suitable and which direction of flow into the respective filter apparatus is required can depend on the process flow, the particles to be filtered and the conditions such as temperature and moisture content. 

For filter cartridges, we recommend selecting a filter surface load of approx. 1 m/s. The lower the sinking speed of the bulk material, the lower the load should be. Hose filters can be loaded with approx. 2-3 m/s. 

The volume flow of the process and the possible filter surface load result in the required filter  area. If the maximum filter area loading for your process is already known, you can calculate the required filter area using our slide rule. We would be happy to calculate the needed filter area for you. Enter your process parameters in our enquiry form or give us a call.  

Four weeks after initial commissioning, we recommend an inspection of the filter unit, during which the regular inspection and maintenance intervals should be determined. If the dedusting filter is operated in multiple shifts, shorter intervals should be selected than for single-shift or for only sporadic use. For most applications, annual maintenance is sufficient. 

For single-shift operation, we recommend replacing the filter elements after 2 years at the latest. Depending on the application, the service life of the filter area may be longer or shorter. There are dedusting filters where the star filters have been in use for over thirty years.

Dedusting filters are capable of removing a wide range of dusts and particles, including fine dust particles, fibrous materials, metallic and mineral dusts and toxic or harmful particles. Effectiveness depends on the specific filter type and the application environment.

We can capture many sizes of particles directly with our filter material, except below 1µ (micro), however these are also captured by the ‘filter cake’ that forms on the surface after some time during filtration.

Effective compressed air regeneration of the filter surface due to the design of the dedusting filter reduces the compressed air requirement. The use of a differential pressure control, which requires fewer compressed air pulses, also increases the energy efficiency of the system by reducing compressed air consumption. 

Well-maintained and functioning dedusting filters reduce the energy consumption of the process system due to less air resistance.

The dedusting filters from ts-systemfilter are characterized by their modular design, the housing parts are connected as standard by means of a clamping ring and a stable housing seal. We use seawater-resistant aluminium as the standard material. Stainless steel is of course available as an option.

The jet cleaning system with the control unit developed by ts-systemfilter is fully integrated in the filter head from series 05 onwards. With differential pressure control, the measuring sensor is automatically cleaned by means of a compressed air pulse.

When replacing the star filters, only the filter area is replaced as standard; the support tube is reused.

We have approval for category II 1D and II 1G (ATEX) on the modular system.

Our star filters have achieved service lives of over 40 years. We ensure that spare parts are available for decades.

There is no fixed time period, as this depends on the operating time of the system and the bulk material.

Our filter systems can usually be installed within an hour, depending on the respective series.

You can monitor the differential pressure on the display. If it fails, there is something wrong with the performance. The quality can be recognized by the residual dust content in the filter unit. If little residual dust is left behind, you have good filtration quality. For filter units with fans, the power requirement of the fan can be used as a measure. If there is a big difference between the current value and the standard value, you have less power in your filter unit.

Dust filters in which no ignition source can form are suitable for use in potentially explosive areas. At ts-systemfilter, every filter apparatus is assessed for its freedom from ignition sources and designed accordingly. Conductive or non-chargeable filter media play an important role in this. All installed components must be assessed. For use in Ex dust zone 20 or Ex gas zone 0, certification by a notified body is required in accordance with the European ATEX directive. The modular product range of filter apparatus from ts-systemfilter is certified by DEKRA. These dust extraction filters can be operated safely in all areas at risk of dust or gas explosions, with the protection class of freedom from ignition sources being applied. Optionally, the filter apparatus can be designed with the second protection class of explosion-pressure-shock-resistant construction. Depending on the size, a reduced explosion pressure of 2 bar is possible. Bulk materials with a KSt value of up to 400 bar*m/s may be filtered. Of course, the dust extraction filters can also be designed to be permanently pressure-resistant, usually for 10 bar.