PCME - Passionate about Particulate

PCME’s involvement with the Tobacco industry over many years has lead to the development of several novel and unique solutions for in-stack particulate monitoring. Working worldwide in conjunction with the industry’s leading manufacturers, PCME provides an unparalleled range of instrumentation to monitor the extremely low levels of dust normally associated with the filtration systems used in the manufacture of Tobacco based products. These systems help protect our environment by aiding legislative compliance, assist manufacturing operations, support ISO 14000 objectives and also save operator costs by reducing filter maintenance and process downtime. Additionally, due to the value of the raw product, filter performance monitoring can provide valuable process data to improve product recovery efficiency. PCME are familiar with potential issues surrounding particulate emissions monitoring for Tobacco plant, including:

• Awareness of the constraints on materials and substances exposed to tobacco product, for example PMCE provide instruments to the Tobacco industry which are free from certain polymers, which are known to cause polymer fume fever and are therefore forbidden
• Monitoring of cartridge filters in tobacco feed fan/filter systems allows planned maintenance before entrained particulate matter (‘caking’) adversely effects tobacco feed system performance
• Moist particulate matter as found in drying plant emissions can foul traditional particulate monitoring instruments, PCME offer solutions demonstrated to be highly tolerant to contamination whilst maintaining accuracy, and therefore require significantly less maintenance

PCME offer approved (TUV & MCERTS) systems for particulate measurement, filter leak monitoring and filter performance monitoring, depending on the plant specific requirements which are specified in close consultation between plant operators and PCME. Tobacco plant often requires monitoring on multiple emission points across primary and secondary processing operations, which can be addressed with a networked multichannel system. By offering a range of measurement technologies in reliable, rugged instruments, PCME are able to provide a full range of solutions to meet and often exceed legislative compliance, significantly improve the operation of filter plant including a reduction in filter maintenance requirements, and improve the efficiency of product recovery.
 

Primary Processing

The principal sources of contained particulate emissions during primary tobacco processing include blending, milling, threshing, cutting, drying and mixing operations, and fugitive emissions can occur during materials transfer, for example during discharge into hoppers and onto conveyors, and delivery to silos and equipment. In most cases contained particulate emissions are abated using fabric or cartridge filters, or in some cases cyclones. Particulate concentrations are typically very low after abatement, and emission limit values (ELV) reflect this. For example, in the UK the Process Guidance Note (PG6/36) for tobacco processing specifies ELV of 50mg/m³ from drying and conditioning processes, and 20mg/m³ from contained processes. Tobacco plant operators therefore require particulate monitoring systems with robust and proven performance at very low concentration levels, and confidence in signal and measurement integrity in conditions which can foul less suitable instruments.

Secondary Processing

Secondary tobacco processing, which consists mainly of the cigarette or cigar making process, often includes in-line tobacco recycling from waste during process operations including that collected via dust abatement systems. Maximising the collection efficiency and operation of filter plant therefore allows a greater proportion of waste tobacco to be recycled into the process. Particulate emissions from packing and filling operations are often abated with fabric bagfilters, and fugitive emissions from secondary process lines are also present, although less frequently controlled.



 

Tobacco Process Materials:

Tobacco product cannot be exposed to certain polymers which are known to cause polymer fume fever and are therefore forbidden in tobacco plant. Standard probe electrification type instruments typically include these materials in their key components, and therefore are not suitable for tobacco plant application. However PCME’s extensive experience in the tobacco industry has led to the development and deployment of alternatives with no compromise in instrument performance, providing plant operators with confidence in the suitability of their particulate emissions monitoring system.

Contamination Detection and Tolerance:

Short Circuit and Contamination Detection
With traditional Probe Electrification type instruments, performance can be compromised by contamination of the sensor probe insulator by damp or conductive particulate matter. Over time, this build up can lead to short circuit of the sensor probe via ‘bridging’ of the insulator, which is of particular concern in Tobacco plant applications where damp particulate matter is prevalent in certain processes. PCME’s ElectroDynamic™ range of instruments includes a patented probe rod contamination check feature, which provides operators with a pre-warning check of possible probe rod short circuit, enabling predictive sensor maintenance scheduling, lower down times and confidence in signal quality (for example see PCME STACK 990).

Tolerance to Contamination
PCME’s unique and patented ElectroDynamic™ Probe Electrification technology allows sensors to operate normally with significant contamination build-up on the sensor rod, avoiding the signal drift issues associated with traditional probe electrification type instruments and offering greatly reduced maintenance requirements. Additionally, PCME’s patented insulated sensor rod option offers unrivalled performance in high humidity (non-condensing) applications.

Humid Process Application:

PCME’s ElectroDynamic™ range includes a patented insulated sensing probe option for use in high humidity and condensing gas applications, providing unrivalled performance in humid processes such as tobacco conditioning plant. The insulated probe has been demonstrated to operate with minimum maintenance for extended periods with ‘sticky’ particulate matter caking the sensing probe, due to the unique ElectroDynamic™ measurement technique.

Network Integration:

Tobacco plant typically requires instrumentation across several emissions sources. PCME sensors can be networked into one central control unit, integrated with existing plant DCS/SCADA systems, and provide Ethernet connectivity for plant-wide LAN integration.