ITDEFRES
Waveline

Waveline

Introduction and Purpose

The new Waveline filter represents a patented and revolutionary customized solution capable of enhancing the technology of dust collectors from the perspectives of energy efficiency, emission control, and space conservation in plants operated with pulse-jet cleaning technology using compressed air. Based on a simple and clear principle, the Waveline filter increases, with the same structural framework, the filtration surface of the filter media, promoting a decrease in the average pressure of the collector's cleaning system.

Key Features

Flanged Collar

The flanged collar provides a more stable configuration and offers better protection for the elastic band of the sleeve. Additionally, it serves as the ideal support base for mounting Venturi and digital control devices.

Optimized CAD Design

Each filter is custom-designed to fit the hole of the tubular plate and optimized with a star-shaped profile created via CAD to precisely match the contour of the sleeve during operation.

Filter with Snap Band Elastic Band

The upper part of the sleeve features a double-ring elastic configuration, Snap Band type, to ensure excellent adherence to the tubular plate and prevent accidental dust leaks.

Increased Filtration Surface

The special shape of the basket fully utilizes the extended surface of the sleeve, resulting in savings on surface load and reduced energy impact.

Available in almost all Materials

To ensure filtration in different environments with varying temperature and humidity conditions, Waveline can be crafted from different materials, ranging from Polyester to PTFE.

16-Wire Profile

The 16-wire star-shaped profile is specifically designed to provide adequate contact points between the sleeve and cage, ensuring fatigue resistance during operation and cleaning cycles.

Key Features
The Advantages

The Advantages

The main advantages of Waveline can be summarized as follows:

  • Increased air output
  • Reduced energy consumption
  • Reduced use of compressed air for cleaning

The Technology

In Cleaning with Compressor
In Cleaning with Compressor
In Operation
In Operation

The components are as follows:

The Sleeve

Made from different materials according to various operational applications, it has a patented classic milk bottle shape.

The Cage

The correct design of the filtration support is crucial for Waveline filter usage. It is necessary for the profile of the sleeve during suction to exactly match the star-shaped profile of the basket. Each ring is therefore customized for this requirement.

EcoTurbo

The flanged collar serves as the ideal support base for the EcoTurbo Venturi device, which enhances the shock wave during cleaning, achieving better dust discharge with significant additional energy savings for the fan and compressor.

Return on Investment

Differential pressure

The advantage of having an increased filtration area allows for a choice between having a larger quantity of air introduced or reducing energy and air consumption. In fact, by using the same traditional filter surface, it is possible to treat more air. Alternatively, by reducing the dust load for each filter, the average differential pressure of the system is lowered, thus reducing energy consumption. This enables the realization of longer working cycles under the same previous conditions. Energy will be saved both during the cleaning phase (compressor and valves) and during operation (fan).

Comparison

In circumstances where the cost of energy constitutes a substantial part of the operational management expenses of the facility, the use of the patented Waveline filter, in comparison to a traditional filter, has a payback time ranging between 12 and 24 months depending on various usage conditions.

Applications

Steel and Metals
Steel and Metals
Cement
Cement
Chemical Industry
Chemical Industry
Waste-to-Energy Plants
Waste-to-Energy Plants
Food Industry
Food Industry
Waste Treatment
Waste Treatment
Agricultural Industry
Agricultural Industry
Oil and Gas
Oil and Gas

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FAQ – Frequently Asked Questions Waveline features

How can I calculate the energy savings for my facility?

Through a questionnaire that will be filled out together, it is possible to highlight the potentially achievable energy savings and calculate the return on investment.

Can I use the Waveline filter in my current collector?

Yes, the Waveline filter is adaptable to all existing tubular plate sizes. Depending on the cleaning system setup, the most economically sustainable solution can be chosen. However, the Waveline filter cannot be used for flat cages.

How long does the Waveline filter last compared to a traditional filter?

The Waveline filter is made of the same material as the traditional filter, but by allowing less frequent cleanings, it can last longer than a traditional filter. Generally, experiences conducted so far confirm the possibility of using Waveline for the same period as a traditional filter, although this strongly depends on operating conditions and cleaning parameters used.

In what materials is the Waveline filter available?

In general, it is available in all materials currently used for traditional sleeve filters.

To what extent does Waveline increase the filtration surface compared to a traditional filter?

The filtration surface is increased by approximately 25%, depending on the customization for the customer.

Is the Waveline filter more expensive than a traditional sleeve filter of the same size and length?

Only seemingly, as the filter has more fabric, and the support is specially designed for the Waveline filter, the investment costs are higher than those of a standard sleeve. However, thanks to savings on energy costs and overall operational costs, the ROI is typically less than two years, depending on local energy prices. Additionally, the system provides the most cost-effective capacity increase, as no structural modifications are needed. The ROI less than two years refers to the initial installation where supports must also be changed. In subsequent modifications, where only the sleeves need to be replaced, the ROI will be much lower.

Has the Waveline filter been installed in the market?

Yes, the filter, despite being of a new design, has been installed and tested in many industries, including metal processing, where it has demonstrated superior performance. Some tests have shown a lifespan of over eight years.

Are there videos of the operation and laboratory tests?

Yes, available upon request. The videos clearly show that Waveline, in addition to having a larger filtration surface, has better cleaning efficiency. Furthermore, Waveline has been tested by a German university, ILK Dresden, regarding energy savings.

In what materials is the support of the Waveline filter available?

In traditionally used materials: raw and pre-galvanized carbon steel, EcoAtex cataphoresis treated, or low-carbon austenitic steels.

What length and diameter can I have for the Waveline filter?

There are no limitations in terms of length and diameter. The same diameters and lengths used in the current sleeve system will be used for Waveline filter elements. Depending on the length and cages currently used, the number of joints is adapted to customer preferences.

Do Waveline filter elements collide during the cleaning cycle?

No, they do not. A video of the operation clearly shows that the cleaning cycle works perfectly without Waveline elements colliding with each other.

Are there any plant requirements for using the Waveline filter element?

For general use of Kappa Waveline filter elements, there are no prerequisites. However, to achieve energy savings, the fans should be equipped with a frequency converter. To achieve an increase in capacity, a frequency converter is not necessary but helps further increase capacity.

Do I need to modify cleaning parameters?

The Waveline filter works even without modifying cleaning parameters. However, to fully exploit the energy-saving potential and protect filter elements from increased wear, you will receive suggestions on how to adjust cleaning parameters at the time of installation.

How can I save up to 50% of compressed air using Kappa Waveline filter elements?

Thanks to higher cleaning efficiency, fewer cleaning cycles are needed. Also, experience shows that a cleaning pressure of 3 bar is sufficient for Kappa Waveline; especially using the EcoTurbo Venturi, results can be further increased. The currently used cleaning pressure can be adjusted and decreased.

Is it possible to reduce CO2 emissions with Kappa Waveline?

Yes, as the system's energy consumption is reduced, CO2 emissions are also reduced. Regarding greenhouse gas emissions and objectives set by the Greenhouse Gas Protocol, Kappa Waveline filter elements can be an integral part of reducing CO2 emissions and achieving goals.

Where does the reduction of CO2 emissions fit in?

In general, the reduction of CO2 emissions should be seen as scope 2, as the definition of scope 2 is: Scope 2 - Indirect emissions from purchased electricity: Scope 2 refers to indirect emissions resulting from the purchase and use of electricity, steam, heat, and cooling. These emissions occur during the production of energy that takes place outside the company but is used by the company for its activities. The exception is when the energy used in the company is produced directly on-site; in this case, it could be seen as Scope 1 - Direct Emissions: includes all direct greenhouse gas emissions from sources that a company controls or owns. Examples include emissions from the combustion of fuels in owned or controlled vehicles and structures (e.g., company vehicles, generators).

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