The MULCERAFIL ceramic fibre filter element is a low-density, porous, tube-shaped filter formed from bonded inorganic fibre granules. Lightweight yet rigid, it needs no supporting cage and withstands 900 °C continuously and at peak, allowing hot flue gas to be filtered directly without cooling while capturing dust below 1 micron. It is used in waste incineration, metallurgy, glass, cement and chemical plants.
The MULCERAFIL ceramic fibre filter element is an ultra-high-temperature filtration element made by AIFILTECH (Guangzhou Tuokai Environmental Technology Co., Ltd.). Produced from bonded inorganic fibre granules, it is a low-density, porous, tube-shaped filter. Lightweight yet rigid, it requires no supporting cage and operates continuously — and at peak — at up to 900 °C. It filters hot flue gas directly, without pre-cooling, and captures dust below one micron. Typical applications include waste incineration, metallurgy, glass, cement and chemical processing.
A ceramic fibre filter element is a rigid inorganic filter made from inorganic fibres and binder granules that are blended, formed and fired into a test-tube-shaped cartridge. Unlike a flexible fabric bag, it does not rely on a textile structure to hold its shape, so it withstands both the filtration pressure drop and the mechanical shock of pulse-jet cleaning without a support cage.
The MULCERAFIL element has a porous, open structure with high porosity and good gas permeability, so gas passes through the filter wall at low resistance. Dust is retained on the outer surface, forming a dust cake that the pulse-cleaning system removes at set intervals. The element resists strong acids and alkalis, will not burn, and can be used on gas streams containing flammable or explosive components.
Elements are fixed to the tubesheet in the upper part of the housing. Dust-laden hot gas enters the dirty-air plenum and is drawn from outside to inside through the filter wall. Dust is retained on the outer surface while clean gas passes through the wall into the clean-air plenum above the flange, from where it goes to downstream equipment or to the stack.
As the dust cake thickens, the differential pressure across the element rises. When it reaches the set point, cleaning starts automatically: a pressure sensor or timer triggers the pilot valve, which opens the diaphragm valve and releases a short pulse of compressed air into the element inlet. The instantaneous reverse flow dislodges the dust cake, which falls into the hopper, and the element returns to filtration.
Figures above are drawn from product documentation and measurements on operating installations. Actual performance varies with gas composition, temperature, dust loading and other site conditions, so each selection should be engineered against the specific duty.
| Filter media | Continuous (°C) | Peak (°C) |
|---|---|---|
| Polyester | 140 | 160 |
| Nomex | 200 | 240 |
| P84 | 240 | 260 |
| PTFE (Teflon) | 260 | 280 |
| Glass fibre | 260 | 300 |
| MULCERAFIL ceramic fibre element | 900 | 900 |
The values above are the nominal ranges normally quoted for each media type. Because the ceramic fibre element works directly in gas above 500 °C, systems built around it generally do not need a gas-cooling stage.
Basis: 10,000 Am³/h of raw gas at 500 °C. A fabric filter would first require cooling to around 200 °C, using either a heat-exchange system or dilution air.
| Configuration | Cooling method | Cooler power (kW) | Added gas volume (m³/h) | Filtration velocity (m/min) | Filter area (m²) | Collector size (relative) | Installed power (kW) |
|---|---|---|---|---|---|---|---|
| MULCERAFIL high-temperature system | Not required | None | None | 3 | 56 | 1 | 15 |
| Conventional baghouse | Water cooling (heat exchanger, cooling tower, pumps) | 6.5 | None | 1 | 84 | 1.5 | 14 |
| Conventional baghouse | Air cooling (heat exchanger, fan) | 5.5 | None | 1 | 84 | 1.5 | 13 |
| Conventional baghouse | Dilution air | None | 17,000 | 1 | 450 | 8 | 55 |
What the comparison shows: on this duty, a system built on MULCERAFIL elements needs no cooler, cooling tower, pumps, heat exchanger or dilution-air fan. Filter area and collector size are smaller than in the fabric-filter options, and both capital cost and operating energy fall accordingly. The dilution-air route increases gas volume substantially, which pushes up both plant size and installed power.
| Industry | Notes |
|---|---|
| Waste incineration | Flue gas from industrial, chemical, municipal, hazardous and medical waste incinerators |
| Metallurgy | Ferrous and non-ferrous processing: calcium carbide, ferroalloy, primary and secondary aluminium, alumina calcining, sintering machines, copper smelting, blast furnace, converter |
| Glass | High-temperature dedusting of glass furnace flue gas |
| Ceramics | Flue gas treatment for ceramic kilns |
| Cement | High-temperature gas cleaning for cement kilns and sintering machines |
| Power generation | High-temperature dedusting of boiler flue gas |
| Chemical processing | Coal gasification and high-temperature precision filtration of process gas |
| Precious metal recovery | High-temperature gas cleaning in precious metal smelting and recovery |
The MULCERAFIL ceramic fibre element and the all-in-one catalytic element install the same way, in four steps:
The element is rigid enough to serve without a cage. Removal follows the same steps in reverse and can be handled by one person.
| Overall length (mm) | Outside diameter (mm) | Flange height (mm) | Flange diameter (mm) | Filter area (m²) |
|---|---|---|---|---|
| 1000 | 60 | 20 | 80 | 0.19 |
| 1250 | 60 | 20 | 80 | 0.23 |
| 1500 | 60 | 20 | 80 | 0.28 |
| 1800 | 150 | 30 | 195 | 0.83 |
| 2000 | 123 | 15 | 159 | 0.77 |
| 2045 | 130 | 30 | 160 | 0.82 |
| 2250 | 150 | 30 | 195 | 1.05 |
| 3000 | 125 | 30 | 160 | 1.17 |
| 3000 | 150 | 30 | 195 | 1.40 |
Sizes above are standard. Flange type and dimensions can be made to suit an existing tubesheet. Ceramic fibre and catalytic elements share the same dimensions and are directly interchangeable.
All data above are obtained under specific test conditions; the actual solution must be engineered to site conditions. AIFILTECH provides custom design and sizing based on actual gas volume, temperature, dust characteristics and emission limits.
