October, 2020
No. 540

MARKETS

 Asia Will Account for More Than Fifty Percent of Fabric Filter Purchases This Year

 The market for fabric filters for air pollution and in-plant control is down this year. The shrinkage is coming primarily in Europe and the U.S. with Asia showing modest gains. The coronavirus pandemic is largely to blame.

 The closure of coal-fired power plants will continue in Europe and the U.S., but the market will continue to grow in Asia due to tighter particulate emission regulations. Fabric filters will be selected over electrostatic precipitators for many Asian coal fired plants. The use of dry scrubbing and fabric filters instead of wet scrubbers is a factor in some countries.

 Tighter regulations are also helping suppliers of dust collectors for mechanically generated dust (as opposed to products of combustion).  Donaldson received a Blue Sky award in China which has some of the world’s toughest emission standards.

 East Asia accounts for 50 percent of the market. NAFTA has shrunk to just 15 percent of the total.

 The value added starts with resins, cellulose fibers or glass fibers which are processed into filter media. This media is then converted into bags or cartridges. These cartridges are placed in dust collectors. These collectors are part of systems with fans, motors, controls and connecting ductwork.  Since bags are replaced every two years or so, the aftermarket is very substantial.

 The system companies are becoming more involved in aftermarket sales. In fact, in China air pollution system suppliers are encouraged by the government to build and operate facilities for the plant owners. The motivation is to assure compliance with emission standards.

 There are three types of companies participating in this market:

·         Media and bag companies

·         Equipment and system companies

·         Integrated companies

A further segmentation is between those making standard collectors and those making engineered and generally larger collectors. A large power plant dust collector could exhaust 4 million CFM. In contrast a small welding fume collector could exhaust a few hundred CFM.

 GE at one time was an integrated company. It owned a large bag manufacturer (BHA) and with Alstom was a leading supplier of large dust collectors. Today GE has lost most  of its market value and is exiting the coal business. It sold BHA to Clarcor which in turn was acquired by Parker Hannifin.

In contrast Fujian Longking is the largest supplier of dry scrubbing systems in the world. Its revenues have grown by 30 percent in the last four years and  were 10.8 billion CNY in in 2019. Net income before taxes showed a similar growth to 1 billion CNY. Net income rose to 850 million CNY

Parker Hannifin is now an integrated company making media as well as equipment and systems. Clarcor industrial filtration revenues at the time of acquisition by Parker were over $800 million.

 Donaldson has annual dust collector sales of $400 million.  It has an installed base of 160,000 units and 32,000 aftermarket customers. It is the world leader in the production of standard dust collectors. 

 In 2000 it introduced a nanofiber media for engine filters as well as dust collectors and has sold  1 billion ft2 of this media.

 It makes its own membrane media, Tetratex^®. This PTFE membrane is laminated to needled  polyester to create a high efficiency media used in pulse jet filters. It also buys filter media from just two media companies.

 Lydall has been focusing on the dust collector media market. First it acquired Southern Felt from Andrews. Lydall  then acquired Gutsche in 2016. Gutsche supplies non-woven media with much of its sales in EMEA but also has a factory in China. 2016 sales were $50 million of which dust collection was $40 million. In the latest quarter Lydall dust collector media sales including Texcel, Southern Felt and Gutsche were $30 million. So annual dust collector media sales are about $120 million.

 BWF remains a larger supplier than Lydall with both media and bag making operations. The privately held company has 1800 employees and 15 production sites around the world.  Revenues are $300 million.

 There are a number of variables which will impact the markets by region, industry, and media type. the McIlvaine company is continually analyzing the market in Fabric Filter and Element World Market. http://home.mcilvainecompany.com/index.php/markets/air/n021-world-fabric-filter-and-element-market

 Bob McIlvaine can answer any questions about the report. His email is rmcilvaine@mcilvainecompany.com and his cell is 847 226 2391.

 Filter Media Market Will Be Large but Volatile

 The segments of the filtration industry which use non-woven and membrane filters were $60 billion in 2019. If the lowest true cost choices relative to the coronavirus are selected the market will grow to $80 billion in 2022. This represents an increase of 33 percent over the 2019 revenues.

 Coronavirus variables have the biggest effect on the mask, local air and HVAC purchases. Given the lowest true cost path the media purchases for masks would be over $5 billion. The media purchases for local air and HVAC would be $4 billion. Media purchases for other filtration applications would be over $21 billion.

 The lowest true cost analysis recognizes the fact that most virus transmission is through small aerosols. As a result, highly efficient masks and filters represent the lowest true cost.

 Media suppliers are investing in production lines which will be depreciated over many years. So, the market past 2022 is of high interest. The future markets are dependent upon:

·         choice of the lowest true cost program or the choice the U.S. and Brazil have taken

·         the timing and impact of vaccines and therapies

·         the impact of the next pandemic, influenza and air pollution

·         the development of new media with higher performance attributes

·         existing capacity versus demand at any point in time.

The filtration media suppliers are facing the challenge of a very volatile market. The 2021 market could vary from $20 to $35 billion. By 2024 the market could vary from $23 billion to $44 billion.

 Media suppliers will be well advised to continually adjust forecasts in each application and geography.  Some applications such as rotating equipment have much more certainty than masks.

The same media which can be used in masks and HVAC filters has applicability in gas turbine intake filters, dust collectors, and liquid cartridges.

Growth in gas turbine inlet filters and dust collection will be much more predictable than media for fan filter units and local air systems.

 Media efficiencies will change substantially from this 2019 split.

 The COVID impact will likely lessen but air pollution and influenza concerns will insure a continuing market.

 The Mcilvaine Company has custom reports on filter media and multi-client reports on each filtration application. Details are found at www.mcilvainecompany.com  Bob McIlvaine can answer any questions at rmcilvaine@mcilvainecompany.com or 847 226 2391.

 Air Filter Market Will Grow but By How Much?

 The suppliers of air filters and media are producing at capacity around the world. With the new evidence showing that most COVID transmission is through small aerosols there is the potential for the market to expand at an unprecedented rate in the next year. There are two questions. How big is the potential? Can the filter and media companies meet the increased demand? Most of the demand will be in F9 and H10-17 high-efficiency media. This is presently just a small fraction of the total air filter market.

 In terms of applications the only one not impacted by COVID is the gas turbine inlet. But even for this application the trend is toward higher efficiency.

 McIlvaine has analyzed the benefit of high efficiency filters. Even though the highest benefit occurs in 2021 when the pandemic is at its peak, there is a substantial value in future years just based on indoor and outdoor pollution and influenza.

 In the U.S. in recent years there have been very few high efficiency filters installed.

 Another pressure is the very large requirement for high efficiency media for masks.

 There is less question about gearing up to increase filter production by 100 percent or more than there is the filter media. Sine the demand for high efficiency masks will likely soar it will be challenging to produce enough meltblowns just for masks. The question is then whether microglass, nanofibers, versions of spun bond, and membranes can be produced in sufficient quantity to greatly increase the high efficiency filter production. 

 McIlvaine has been surveying filter manufacturers who in general believe it can be done but that it will be challenging. The biggest obstacle is the risk that a big investment will not be profitable due to a market which will shrink with as the pandemic is brought under control.

 Even though there will be justification for higher efficiency filters after the pandemic, this is not sufficient to justify the investment. The likely course of action is that only a portion of the justifiable investment will be made initially.

 Many lives could be saved if 100 percent of the justified investment could be made in 2021. But without government support the investment will be more gradual. It will only approach the amount justified as it is seen that there will be a continuing market.

 This opportunity is being continually assessed in Air Filter Market and Supplier Program. Click here to view a video description or Click here for the power point display.

GAS TURBINES

 Nanofiber Media has Advantages for Gas Turbine Intake Filters

 NXTNANO is a technology company specializing in mass production of nanofibers for extensive end use applications including air and microfiltration media, microporous breathable films, micron rated venting films, life sciences/pharmaceutical medias, and performance apparel. The company does extensive custom development and manufacturing for industry partners wanting proprietary nanofiber technologies for specific applications and industries.

 Owning an extensive trade secret portfolio for its process, along with numerous patents and pending for products, NXTNANO is now developing relationships with companies, industries and markets that can benefit from its unique technology skill set.

 NXTNANO nTEX medias are the choice in some of the toughest turbine environments on earth. From the frigid cold, to scorching heat, and salt-laden costal applications, they have medias to cover what you need where you need it. nTEX is available in nanofiber treated cellulose blends or synthetic bases in efficiencies from F8-E10+. Their proprietary hydro and oleophobic nanofiber stops fine particulate and even low surface tension liquids from penetrating.

 nTEX NP003 - F9 Synthetic Filter Media

 NP003 Specifications at a Glance

 §  Construction: Nanofiber over polyester nonwoven (pulsable surface filtration)

§  Efficiency: F9 / MERV 15 

§  Air Permeability:

§  30 ft³/min/ft² (CFM) @ 0.5 in. H₂O (ASTM D737) U.S.

§  140 l/dm2/min @ 200Pa (DIN 53887) Germany

§  15 cm³/cm²/s @ 125Pa (JIS L 1096 A) Japan

§  Basis Weight: 120 GSM

§  Finish: Standard

§  Available Widths: 25.9 – 82.0 inches (657 – 2030 mm)

§  Process Data: Designed for rotary pleating — pre-& post-heat recommended

 AAF Can Fit E12 Filter into High Velocity Filter Housing

 In the offshore environment, ambient air is heavily contaminated with sea salt aerosols, salt in solution, fog and mist. Industrial processes such as drilling, grit blast, mud burn, and gas turbine and supply vessel exhaust fumes further contaminate the ambient air quality.

 In the majority of offshore gas turbine applications, high-velocity air intake filtration systems are standard, historically utilizing low efficiency bag filters. These bag filters provide inadequate protection against the highly contaminated ambient air, resulting in air compressor blade fouling, corrosion, erosion, turbine blade damage and the requirement for frequent offline water washing. This can lead to irreversible damage, unplanned gas turbine shutdowns and potential engine failure.

 N-hance is a gas turbine filtration system for use in the offshore oil and gas sector. For many years, operators have been told it is not possible to install EPA E12 filtration in high-velocity filter housings. The advice has been to upgrade to larger, costlier filter housings offshore to avoid sub-micron particle penetration and offline water washing remaining a regular occurrence.

 N-hance provides EPA E12 efficiency within existing high-velocity filter housing with no increase in differential pressure. This will optimize gas turbine performance, availability and reliability, resulting in more efficient, productive and profitable assets.

 It can also:

·         Eliminate frequent offline water washing

·         Increase fuel efficiency

·         Eliminate hot end corrosion

·         Retain power output

·         Extend engine life

·         Reduce CO2 emissions

Hengst Group Provides Customized Gas Turbine Intake Filter Solutions

 Nordic Air Filtration and Delbag are air filtration solutions specialists, with both brands members of the Hengst Group.

 Their unique protection systems for turbomachinery systems have been used across the world for decades. They supply filter solutions for new filter houses through original equipment manufacturer (OEM) partners to be installed on GE, Siemens, Alstom, Turbomach, Solar and many other gas turbines around the world.

 Both Nordic and Delbag rely on multiple manufacturing sites in the northern hemisphere, stretching all the way from North America in the west across Europe to Asia in the east for manufacturing their products.

The group provides a complete range of static and cleanable filters, covering the new ISO16890 standard classification from ePM1 to coarse and filter classes G3 – F9, according to EN 779. Apart from the coarse and fine dust filter products, their range also includes a number of HEPA filters for filter classes up to U15 to EN 1822.

 They offer customized solutions based on the environment, application or the available space. Their air intake filters are individually designed for specific air inlet filtration requirements from the replacement of filter elements to extending and optimization of the filtration system.

 Nordic and Delbag filtration solutions are designed to perform in adverse conditions. They offer a comprehensive range of filter combinations for compressors and turbomachinery air filtration systems. The filters can be exposed to extremely cold, arid, moist or sandy conditions.

 In regions with relatively low dust concentration, a multi-stage static filter system consisting of a pre-filter (a pocket filter) and a fine filter (a filter element) is the most practical solution. A droplet separator is integrated for climates with long periods of high humidity while a coalescer filter is recommended in offshore applications and wet outdoor zones such as coastal areas.

 WASTE PROCESSING

 Andritz to Supply Flue Gas Treatment Systems for the Integrated Waste Management Facility (IWMF) in Singapore

 ANDRITZ has received an order from Keppel Seghers to supply flue gas treatment systems for the IWMF Phase 1 WTE (Waste-to-Energy) facilities in Singapore.

 IWMF and the Tuas Water Reclamation Plant (Tuas WRP) — collectively known as the Tuas Nexus — will be the world’s first integrated waste and water treatment facility to be conceptualized and planned from the ground up. IWMF Phase 1 and the TWRP are scheduled for completion in 2025. Once completed, IWMF Phase 1 will be able to treat:

·         2900 tons per day of incinerable waste;

·         250 tons per day of household recyclables collected under the National Recycling Programme;

·         400 tons per day of source-segregated food waste; and

·         800 tons per day of dewatered sludge from the Tuas Water Reclamation Plant

 ANDRITZ’s scope of supply for the four WTE lines in IWMF Phase 1 includes the design and supply of flue gas treatment equipment such as fabric filters, HCl and SO₂ scrubbers, ID fans, low-temperature economizers with steam gas reheaters, steel structures, flue gas ducts, tanks and silos, and advisory services.

Using ANDRITZ equipment at IWMF Phase 1 will help Singapore achieve its sustainability goals because it will be able to meet the highest environmental standards and reduce the emissions from incineration of 2900 tons per day of incinerable waste.

 A Keppel Seghers-led consortium was selected by Singapore’s National Environment Agency to develop and build (on EPC basis) the WTE and materials recovery facilities as part of the IWMF Phase 1 development for Singapore. ANDRITZ was chosen as the consortium’s key supplier for the flue gas treatment system due to its track record with dry, semi-dry and wet technologies for industrial flue gas cleaning as well as its advanced energy recovery solution using heat recovery from flue gas in the low temperature range.

 HWD Recycling Kft. Focused on Clean Air at Their Recycling Plant

 In the plant of HWD Recycling Kft. in Hungary bad or used electronic products are collected and processed which cause hazardous dust. With the Nederman dust collection solution in place they are getting a cleaner and safer workplace as well as reduced energy cost.

 HWD Recycling Kft. collect and process bad or used electronic products from the public, public groups and manufacturing companies in accordance with environmental standards and requirements. The main profile of HWD is the professional dismantling and processing of equipment, air conditioners and industrial refrigerators as well as storage of aluminum and copper raw material extracted from waste free from external influences until further processing.

 The recycling plant uses various grinding/crushing systems to process the waste. During grinding, dust is generated in the grinders/crushers and in areas of the conveyor belts, which is detrimental to health and processing equipment. Furthermore, aluminum dust is generated during the process and, as all fine air materials, poses risks of explosion if they are not taken care of.

 Nederman has decades of experience in combustile dust handling and in this case a low vacuum solution was installed including an ATEX certified Nederman FMCZ8A filter unit with a15 kW Combifab fan, inverter and arms with the necessary safety components. Explosion Isolation Flap Valve  in the suction branch and explosion diverter was installed for return air in blowing branch.

 BIOMASS

 TTL Supplies Filter Media for Biomass Incineration Plant

 Technische Textilien Lörrach has supplied a filter for the dedusting of a biomass incineration plant.

 A filter medium made of PTFE and Polyimide fibers is successfully being used in a dust collector of a biomass incineration plant. The warranty term of 24 months was fulfilled, and the filter bags continue to work to the satisfaction of the plant operator. In order to achieve a protection against sparks, they applied a fleece of special oxidized fibers on the needlefelt surface.

 Example of the use of a PTFE and PI mix felt, 750 g/m², with PTFE surface coating and FBP fleece

 Sumitomo SHI FW Awarded CFB Boiler Modernization Project in Austria

 Sumitomo SHI FW (SFW) has been awarded a contract by SAPPI Europe to modernize an existing circulating fluidized bed (CFB) boiler, which will result in a 30 percent CO₂ emissions reduction at the Gratkorn Pulp & Paper mill.

 SFW will design, supply and erect the project, which includes modifications to the lower furnace, new heat shift system, biomass feeding system, bottom ash extraction system, and emissions control system, as well as dismantling and commissioning. The modernization will allow the plant to completely shift from coal  to multiple sustainable and renewable fuels. The new emissions control system include bag filters and selective non-catalytic reduction (SNCR), which will ensure the plant meets the newest Best Available Technologies (BAT) standards, especially regarding dust and NO_x emissions.

 “SFW’s mission is to help our customers achieve their climate targets efficiently and cost-effectively. With this project, Sappi will be one step closer to achieving their decarbonization commitments, while reaping the benefits of reliable energy supply and extending the lifetime of their current assets”, says Kari Kohvakka, SVP Service at SFW.

 The project will be completed at the end of 2021.

 IRON AND STEEL

 ArcelorMittal Zenica Completes Two Major Environmental Investments to Cut Dust Emissions

 ArcelorMittal Zenica has marked the completion of two major environmental investments that will contribute to improved air quality.

 A second hybrid filter has been installed in the sinter plant, cutting dust emissions from sinter machine no. 6 below 10 mg/Nm3, a level which is well within European Union standards as well as being far below the 50mg/Nm3 legal limit in Bosnia & Herzegovina.

 In 2017, ArcelorMittal Zenica became the first steel plant in the world to have industrial-scale hybrid filtration technology installed in its sinter plant.

 The ceremony also marked the completion of the installation of the secondary dedusting system in the  BOF Steel plant, a €5.1 million project. The process of putting the entire system into operation, and testing the equipment, is currently underway and on course for completion before the end of 2020. ArcelorMittal Zenica worked with Italian engineering company Ekoplant on the project.

 The company is also in the process of installing new gas boilers for a new combined heat and power plant that will provide greener energy to the city of Zenica, as part of a joint venture with the city of Zenica that is being built with EBRD financing. This will result in an 80 percent reduction in SO₂ emissions from the plant, which is Zenica’s sole external provider of heating during the winter.

 With 2350 direct jobs and more than 12,000 indirectly dependent on the company for employment through more than 400 local supplier companies, ArcelorMittal Zenica is one of the country’s biggest economic generators.

 COMPANY NEWS

 Donaldson Introduces Rugged Pleat Baghouse Dust Collector

 Donaldson Company, Inc. has introduced the Donaldson Torit^® Rugged Pleat (RP) baghouse industrial dust collector. The collector is designed to capture heavy and abrasive dust inherent to woodworking, mining, grain processing and other industries.

The new RP baghouse collector features Donaldson’s SuperSep^™ inlet which pre-separates up to 97 percent of the dust before it hits the filters and the PerfectPulse^™ cleaning system focuses cleaning energy directly over the filters, supporting long life. With its new Ultra-Web^® Spunbond filters, the collector is capable of providing up to 94 percent fewer emissions as compared to baghouses equipped with standard 16-oz singed polyester bags, which makes it ideal for heavily regulated industries and operations that recirculate conditioned air in their facilities.

 “The Rugged Pleat baghouse collector offers unrivaled performance and efficiency,” said Joe Kiolbasa, Product Manager in the Industrial Air Filtration division of Donaldson. “This new technology will help facility managers tackle air quality and occupational health and safety issues, while providing a lower total cost of ownership over the life of the collector.”

The new RP baghouse dust collector utilizes 44 percent fewer filters than traditional baghouse collectors, resulting in a 72 percent reduction in change-out times. In keeping with Donaldson’s commitment to providing comprehensive filtration solutions, the RP baghouse includes the iCue^™ connected filtration monitoring service which allows customers to remotely monitor, manage, and optimize the operation of the dust collector.

 Scientific Dust Collectors Announces the New Baghouse Results of ASHRA Standard 199 Testing

 Scientific Dust Collectors (SDC) has completed its ASHRAE Standard 199 Test Lab and recently completed testing on SDC’s Reverse Pulse Jet Baghouse Collector. Ashrae 199 is an objective method of testing the performance of an industrial pulse cleaned dust collector. This standard is a significant test in the dust collection industry. The purpose of this standard is to provide a performance matrix by which an industrial dust collector can be measured. The standard test consists of six well-defined test procedures. This standard test measures and documents emissions, differential pressure and compressed air consumption. Scientific Dust Collectors appears to be the first baghouse manufacturer to provide these test results to the industry. The results achieved are excellent and speak for themselves. SDC is pleased to share all 36 pages of the detailed results. Contact David Wick at dwick@scientificdust.com.

 Valmet to Invest in Filter Fabric Manufacturing in India

 Valmet has decided to invest in filter fabric manufacturing in Pune, India in order to better serve its customers and improve delivery times of filter fabrics to the Asia Pacific and Middle East areas.

 The investment includes manufacturing equipment for filter fabric production. The new unit will start operation in the second quarter of 2021.

 “This investment gives us the necessary assets to further develop our services close to customers and strengthen our position in the market. It also ensures our capacity for the coming years to deliver filter fabrics that respond to customer needs for maximized reliability and optimized performance of their production process,” says Tero Kokko, Vice President, Fabrics Business Unit, Valmet.

 Valmet is one of the leading suppliers of filter fabrics and industrial textiles globally. Valmet’s filtration offering covers filter fabrics and felts for the mining and chemical, pulp and paper, dry filtration and laundry industries.

Xiamen Runjia Group Focuses on Filter Bags and Dust Collector Accessories

 Established in 2005, Xiamen Runjia Group is a member of China Environmental Protection Industry Association and an ISO 9001:2008 international Quality Management System Certification Enterprise. The company focuses on the production and sale of air filter bags, liquid filter bags, filter elements, filter cartridges and dust collector accessories and other filter products.

 In order to meet the dust removal needs of enterprises in different working conditions, the filter materials of Runjia Co. have always been made of a variety of synthetic fibers. According to the unique properties of each fiber, the infinite combination of various fibers is carried out. At present, their products are widely used in metal and non-metal smelting, cement, asphalt, waste incineration, power, chemical industry, ceramics, tobacco, food processing and other industries.

The company has introduced advanced production equipment, imported high-quality filter materials, advanced processing technology, rigorous production process control, extensive professional technology and many years of rich application experience, so that their products are well received by customers at home and abroad.

 Back to Fabric Filter Newsletter No. 540 Table of Contents