Improve energy efficiency by monitoring dust collector systems in real time

Emerson’s ASCO DPT Control System provides superior monitoring, optimising dust collector system performance and increasing uptime

Emerson’s latest ASCO^TM DPT Control System optimises the performance and improves the efficiency of filtration and dust collector systems by providing accurate and reliable low-level particulate monitoring, early warning leak detection, enhanced cleaning control and real-time diagnostics. The connected system serves as a cost-effective, scalable and purposeful step toward a facility’s digital transformation.

Using traditional sensing technology, low-level leakage is hard to detect in environments with high operating pressure, high humidity or oil and steam. The advanced signal processing of the DPT Control System helps ensure accurate, low-level measurement and detection of particles of less than 1 milligram per cubic meter in harsh, high-pressure (maximum 7 bar) and high-humidity applications, like those found in the cement, power plant, incineration, finishing aluminum and chemical industries.

“The digital transformation of the process industry is underway and connected facilities around the world are seeing the valuable sustainability and operation cost reducing benefits that real-time monitoring and diagnostics deliver,” said Stephan Cocciardi, director of marketing and global strategic accounts with Emerson’s discrete automation business. “The sophisticated monitoring capabilities of the ASCO DPT Control System can help facilities detect issues and prevent problems that would otherwise waste energy and accrue unplanned downtime, resulting in a more efficient and reliable dust collection system.”

By closely monitoring dust collector systems in real time, the DPT Control System can help users locate and address leaks before they become issues, improving energy efficiency and compressed air consumption savings. The loop-powered sensor enables intrinsically safe monitoring of difficult-to-access points of the filtration system, including coil, diaphragm and filter bag. The system’s condition monitoring and predictive maintenance capabilities can improve system reliability and efficiency while reducing maintenance costs and unplanned downtime. Its superior linear output can help users track real-time particle emissions levels and meet emissions regulations.

In addition to monitoring, the DPT Control System optimises the performance and uptime of dust collector systems of all sizes through efficient and reliable pulse-jet filter cleaning control. For facilities that use large baghouses, application-specific control algorithms can reduce pulsing frequency, which can extend filter life and reduce the amount of compressed air consumed. The control logic can maintain quite low and stable differential pressure during operation and automatically maintains differential pressure within ±25 Pa (±0.1 inch) of water column of set point while minimising pulsing. This ensures consistent cleaning performance, maintains a proper filter cake and can reduce compressed air use by 15% to 40% over standard, on-demand cleaning and up to 90% over continuous. It also helps ensure consistent airflow to maintain production, ventilation and dust recovery.

The system provides extensive general filter pulse jet cleaning control modes, such as easily selectable pulsing patterns and a full range of basic timing modes. Modes include continuous, high/low, single cycle and cycle down.

The complete DPT Control System solution includes the DPT P150 Particle Monitor, DPT P151 Controller and P152 DPT Particle Sensor. Watch this video to learn more about the Dust Pulse Technology Control System.