A prominent and highly successful salt processing plant in the Northern Cape has chosen to partner with a widely recognised leader in the design, manufacturing and installation of industrial filtration units, Brasco Industrial Filtration. 

Brasco’s reputation for delivering cutting-edge filtration solutions made it the ideal choice for this complex project, which involved the installation of three reverse pulse bag filter units. These units were strategically placed to manage various extraction points, including the rotary dryer and the screening and bagging operations.

Given the corrosive nature of the salt being processed, Brasco showcased its industry-leading expertise by fabricating the filter units from 304-grade stainless steel, ensuring both the durability and long-term performance of the system. This decision, though requiring a significant investment, underscores Brasco’s commitment to providing high-quality, resilient solutions that stand the test of time.

The design and installation of the baghouse for the rotary dryer presented a series of technical challenges — challenges that Brasco’s design team, known for its innovative approach, expertly navigated. They addressed complex issues such as high temperatures, humidity and sensitive airflow settings, all while ensuring the dryer operated at peak efficiency, maintained the required product drying times and decreased the use of costly paraffin. Brasco’s comprehensive solution included the installation of a backward-curved centrifugal fan with an inlet regulating damper and a bleed-in damper, which introduces ambient air to reduce high temperatures when necessary. Additionally, high-temperature anti-static NOMEX filter bags and an explosion vent were incorporated, reflecting Brasco’s deep understanding of the static and combustible nature of the dust involved.

To further enhance operational efficiency, Brasco designed and installed a “trolley-bin” system on rails beneath the discharge of the filter unit hopper to capture waste salt. This innovative solution is particularly appreciated by the client, as it ensures a clean operation even under challenging conditions, such as windy weather.

When an existing cartridge filter unit proved inadequate for managing the hygroscopic dust and high dust loading in the screening and bagging system, Brasco’s engineering excellence came to the fore. The company designed a comprehensive retrofit, replacing the top section with a new cell plate, pulse valves, filter bags and wire cages. This retrofit transformed the system, allowing it to operate smoothly and efficiently, exemplifying Brasco’s ability to enhance and optimise existing systems. Replacement ducting was also installed to ensure the system met rigorous design and operational standards, while the existing fan set was successfully reused, further demonstrating Brasco’s commitment to efficient and cost-effective solutions.

The third filtration system, also supplied by Brasco, was designed to function seamlessly alongside both the rotary dryer and the screening and bagging operations. Achieving the right balance between these interconnected systems required Brasco’s unparalleled expertise in managing airflow and maintaining system integrity. The team took great care in fine-tuning the system during the commissioning phase, ensuring it performed to the highest standards.

As with previous installations, Brasco incorporated a “trolley-bin” system on rails beneath the filter unit hoppers, reinforcing the company’s reputation for delivering practical, innovative and effective solutions tailored to its clients’ needs.

This project was completed not only within budget but also on schedule, a testament to Brasco’s leadership in the industry. Its in-house design team, in collaboration with the drawing and project office, worked tirelessly to deliver a fully operational system that not only met but exceeded the client’s expectations. Brasco’s commitment to excellence in industrial filtration is evident in every aspect of this project, further solidifying its position as the go-to provider for advanced filtration solutions.