Filter Leak Test Using Perpendicular Aerosol Lances
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Solution Overview
Problem
Existing methods for determining the degree of separation and leak testing in filter arrangements are costly, maintenance-intensive, and fail to provide reliable information due to non-uniform aerosol distribution and turbulence in the gas flow, especially in filter housings with limited space or multiple filter elements.
Innovation Solution
The method involves applying a test aerosol uniformly across the entire cross-section of the filter element using lances perpendicular to the gas flow direction, ensuring even distribution and minimizing turbulence, with optional flow straighteners to maintain uniform flow conditions, allowing for reliable degree of separation measurement without continuous raw gas concentration monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a moving feed device is used to traverse the filter housing height, then the filter can be tested section by section, but the device becomes expensive and maintenance-intensive
Solution Approach 1:
The filter housing is divided into multiple test sections, with each section having its own stationary feed device and measurement system. This allows sequential testing of different height sections without requiring a complex moving mechanism, as each section is independently testable with simple fixed components.
Solution Approach 2:
The system uses the existing filter housing structure and flow paths to conduct tests in place, eliminating the need for external moving testing equipment. The stationary feed devices utilize the natural gas flow through each section to perform self-contained leak detection without requiring complex external mechanisms.
2Device complexity
If test aerosol is fed at a single point in the raw gas stream, then the feed device is simple, but the aerosol distribution becomes non-uniform and turbulence increases
Solution Approach 1:
The single-point feed is segmented into multiple feed locations distributed across the filter height. Each location has a simple stationary feed device that introduces aerosol locally, and the gas flow naturally distributes the aerosol uniformly across the test section without creating excessive turbulence.
Solution Approach 2:
Different locations along the filter height receive aerosol feeds tailored to their specific positions. The feed rate and positioning are optimized for each local section to ensure uniform overall distribution while maintaining simple feed device design at each location.
3Productivity
If the flow cross-section of raw gas stream is large, then the filter element is well-utilized, but the aerosol feed device becomes more complex to achieve even distribution
Solution Approach 1:
The large flow cross-section is divided into multiple vertical sections, each with its own simple stationary feed device. This segmentation allows the system to handle large flow areas without requiring a complex centralized distribution system, as each section independently receives and distributes aerosol through the existing gas flow.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces costs and maintenance by ensuring precise, reliable measurements of filter element performance with reduced risk of contamination and turbulence, providing consistent aerosol distribution and flow uniformity across the filter element.
Implementation Method 1
the aerosol being fed in by means of a distribution device of the feed device and several partial volume flows containing test aerosol being released into the raw gas flow from the distribution device, with the partial volume flows being fed into the raw gas flow at one point where a flow cross-section of the raw gas stream by a maximum of 20%, preferably by a maximum of 10% of an inlet cross-section of the filter element of the filter deviates
Data Source
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AI summary
The method involves introducing a test aerosol in a raw gas stream by a feeding unit (16) upstream of a filter element (9). The measurement of a particle or a determination of particle concentration in the flow direction behind the filter element is performed in a clean gas stream. The partial volume flows are delivered to a place in the raw gas stream, where a flow cross-section of the raw gas stream is as large as an inlet cross-section of the filter element of the filter arrangement (2). An independent claim is included for a device for determining the degree of separation and for executing a leak test in a filter arrangement for separation of dust and aerosols from a gas volume flow.