In December, the EPA reached consent agreements stemming from Clean Air Act claims with 3 major carbon black manufacturers, where the plants agreed to invest $300 million collectively in state-of-the-art pollution control technologies. This resolution once again reinforced the importance of reliable particulate emission monitoring technology. Although carbon black stacks and baghouse dust collectors are some of the most challenging applications, carbon black manufacturers have been using Auburn FilterSense continuous particulate emission monitoring systems for years to help improve production and proactively stay in compliance and avoid fines.
Non-Optical PM CEMs, CPMS, and BLDS for Baghouses
With process temperatures that can reach 1400º F, carbon black production is extremely harsh and demanding to say the least. Additionally, moisture and corrosive sulfur dioxide create further challenges to instrumentation.
The process conditions and tenacious black powder cripple opacity monitors and light scatter PM CEMS and PM CPMS devices. It is also a highly conductive material, which presents a challenge to triboelectric / particle charge particulate monitors and Bag Lead Detection Systems (BLDS) which although non optical use a sensing probe that need, to remain electrically isolated to operate properly. Auburn FilterSense triboelectric / charge induction technology and sensor designs are unique and proven capable to operate reliably in carbon black manufacturing processes. Auburn FilterSense customers experience low level particulate measurement (<1 mg/m3) and long maintenance intervals of 6-12 months vs 1 to 4 weeks with optical and other triboelectric devices.
With the US-EPA tightening regulations and increasing enforcement within the carbon black industry, it is important for plants to evaluate ways to meet their compliance requirements efficiently and while simultaneously improving plant operations. Auburn FilterSense particulate monitors can include internal EPA QA checks and internal data logging to automatically ensure adherence to regulations and also proper operation of the instrument. Along with available PC Software, the data that is being monitored can be easily stored and made accessible to all key stakeholders including the environmental team for their reporting, maintenance team for maintenance planning, and plant engineers for process optimization. This avoids the difficult process of gathering data from different sources and combining them into a unified report saving time and eliminating the opportunity for error.
Further compliance assurance and simplification as well as significant process control and optimization improvements can be achieved by installing a full baghouse performance control and diagnostic system, such as the Auburn FilterSense B-PAC. These systems provide intelligent control of process differential pressure, full insight of filter media performance (including locating the onset of filter leaks by row) and real time condition monitoring of pulse-jet diaphragms and solenoids. Additional return on investment is gained by extending filter life and greatly reducing compressed air loss.
Although it is a difficult application, highly effective and reliable particulate monitoring is available for the carbon black industry. Auburn FilterSense's technology not only helps companies meet their compliance requirements, but can also help to improve operations.
Contact us today if you would like to discuss you application.