Ventilation, exhaust, and air filtration systems in industry are widespread equipment in virtually all industrial segments.
They are applied in the environmental control of production processes that releases fumes, gases, or airborn dust, protecting the work environment and the external environment from the harmful effects of these pollutants.
The efficient management and maintenance of this resource in production is a very significant challenge given the harsh conditions in which this equipment operates.
1 – Bin Level Control
2 – Discharge Valve Status (Rotary, Double Pendulum, etc.)
3 – Fan Vibration
4 – Compressed Air Cleaning
5 – Air Pulse Valves
6 – Electrical Panel Safety Circuit
7 – Cleaning Controller Status
8 – Discharge Air Quality (Filter Element Breakage)
9 – Filter Element Saturation (dP)
10 – Flow Control
11 – Process Interlock
The INTELIAR software is structured into four main function blocks, namely:
It gathers information on the on/off status of critical operating functions such as bin levels, discharge valve operation, fan vibration, overheating, compressed air for cleaning, and process status. This block processes, reports, and maintains a historical record of occurrences, facilitating preventive maintenance actions.
Based on information collected by Purefeel™’s exclusive Broken Filter Element Sensor, installed in the filtered air discharge piping or stack, this unit indicates whether there are problems with the integrity of the filter elements or a fire risk, triggering configurable alarms.
Using the resources of a Frequency Inverter, the unit modulates the fan’s operating regime so that exactly the flow rate required by the process is supplied at each moment or operating cycle, including start and stop with configurable delay etc.
This module brings together sophisticated routines for controlling the degree of saturation and the lifespan of the system’s filter elements, allowing for maximum utilization and preventing performance drops associated with the use of saturated filter elements.
INTELIAR® integrates all the typical functions of a state-of-the-art Automation Software with tools for Maintenance, Configuration and Access Control, as well as historical reports, dashboards and WiFi mirroring.
Composed of specific sensors installed in the Filtration Systems, CPU and HMI, all mounted on a complete automation panel, INTELIAR® has the advantage of operating on open (market) platforms.
Block Diagram of the Inteliar System
Proper management of filter element lifespan includes not only monitoring their saturation level but also maximizing the lifespan of these expensive components without compromising the filtration efficiency of the systems.
The advanced filter element management routines in the INTELIAR software for Industrial Exhaust and Filtration Systems provide all the relevant information for optimizing the use of filter elements, and include:
• Compressed air cleaning and fault detection in the cleaning system*;
• Saturation level control;
• Indication of theoretical lifespan in hours;
• Indication of useful lifespan based on actual use;
• Prediction of next filter elements replacements;
• Broken filter element alarm.
Given the specific nature of reverse air pulse cleaning systems for filter elements in each filter type, INTELIAR does not replace the cleaning control system but monitors its integrity and provides alarms and historical records of the cleaning operation.
An industrial exhaust and filtration system typically has several exhaust points distributed throughout the factory. Since almost no industrial process is continuous, not all points of use are in operation simultaneously. This concept is known as the “Simultaneous Factor”. By introducing automatic dampers interconnected (interlocked) to the process, it is possible in many cases to achieve significant reductions in flow demand, thus reducing the size and installed power of an exhaust and filtration system. This also allows for the expansion of the system to additional points of use depending on the characteristics of these new exhaust points (especially additional duct length).
The INTELIAR Multi Points software was developed specifically for the automation of industrial exhaust and filtration systems with multiple intake points. It allows for the control and recording of usage at these points, and, along with the use of a frequency inverter, introduces flow modulation to provide only the necessary flow rate at each moment of operation.
With INTELIAR Multi Points, it is also possible to provide information directly to the points of use, enabling exhaust use without exceeding the system’s capacity (flow rate) limit.
In the medium term, maintenance and energy consumption costs are far more significant for the company than the initial investment. In other words, the cost of ownership is high in any industrial exhaust and filtration system, and reducing it is crucial for efficiency and productivity gains. Filter element replacement, along with energy consumption, is the largest contributor to the cost of ownership.
Energy waste in industrial air exhaust and filtration systems is widespread. This is due to limitations in outdated designs or even a lack of specific expertise in the process, since even the best automation and control resources are ineffective if they are not properly parameterized.
The INTELIAR® software offers several features to reduce energy consumption associated with the use of frequency inverters and automatic dampers:
• Intelligent automatic start/stop, interlocked to the process;
• Flow rate variation according to the actual process demand;
• Control of the pipeline dampers;
• Reduction of pressure drop in the filter;
Implementing these features significantly reduces the energy consumption of the electric fan motor, as well as reducing the consumption of compressed air for cleaning. These measures also reduce the frequency of maintenance and replacement of filter elements.
The main risks associated with the operation of Industrial Exhaust and Filtration Systems relate to fire, discharge of contaminated air, and explosion when operating with combustible dust (ATEX).
Proper monitoring and control of systems significantly reduces risks and serves as a source of environmental control evidence for internal and external purposes, i.e., audits.
The increased level of safety is mainly due to the following functions of the INTELIAR Software:
• Monitoring of temperature at the filter inlet and outlet;
• Monitoring of air quality at the discharge point;
• Overheating of the electric fan motor;
• Excessive fan vibration;
• Integrity of the waste discharge system;
• Integrity of explosion relief panels (ATEX);
• Status of the explosion-proof safety valve (ATEX);
The implementation of INTELIAR® basically requires the installation of sensors specific to each of the functions to be monitored and their interconnection to a Control Panel equipped with a CPU/PLC, HMI, and other electrical components of the control circuits.
The construction of the Control Panel will be the responsibility of the client, based on an Electrical Project* provided by Purefeel®. If necessary, the assembled panel itself can be supplied.
Electrical Project or Assembled Control Box
Sensor Set
Complete Power and Control Panel Design in ENPLAN
The same applies to cases where a new Power and Control Panel is needed. Similarly, Purefeel™ can provide a complete EPLAN design or, depending on the case, the panel itself assembled to meet the system’s requirements.
Complete Assembled Panel
Industrial air exhaust and filtration systems are present in virtually all segments of the manufacturing industry, such as metalworking, metallurgy, chemicals, food, pharmaceuticals, and many others. They are also widely used in heavy industries in areas such as mining, steelmaking, petrochemicals, and others. The technology of bag and cartridge air filters dates back to the 1940s, and most installed systems have few automation and control features.
INTELIAR is the most economical, tested, and guaranteed solution for modernizing (retrofitting) existing industrial air exhaust and filtration systems, especially when compared to developing your own system. Covering all the typical monitoring and control functions for this type of application, INTELIAR also offers great customization flexibility, including functions specific to each production process. With INTELIAR, it is possible to take control of the operation of industrial exhaust and filtration systems – dust collection systems – significantly reducing costs related to energy consumption, maintenance, and unexpected downtime.
The flexibility of input and output of analog or digital process signals, combined with the integration of industrial networks, makes INTELIAR® a valuable tool for modernizing industrial exhaust and filtration systems.
The INTELIAR software has a complete manual containing all the information and instructions necessary for its operation and maintenance.
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