Theoretical Reliability Analysis of a Segmented 2-out-of-3 Particulate Filter System for Industrial Chimneys

Abstract

Industrial chimney particulate filters may experience clogging, leakage, structural damage, and other failure modes that interrupt their intended operation. This study proposes a theoretical segmented-filter configuration comprising three parallel modules with a 2-out-of-3 system-success criterion. The configuration is analysed using the standard -out-of-  reliability model under assumptions of identical modules, statistically independent failures, equal airflow distribution, and successful isolation of a failed module. For an illustrative module reliability of , the predicted segmented-system reliability is 0.896, compared with 0.800 for a conventional single-filter configuration, representing a 12% relative increase. A sensitivity analysis across different assumed module reliabilities demonstrates the mathematical behaviour of the proposed configuration. A Monte Carlo simulation using 100,000 trials for each module-reliability value agreed closely with the analytical model, with a maximum absolute error of 0.00057 and a maximum percentage error of 0.0636%. These results describe theoretical system reliability and do not represent experimentally measured filtration efficiency. Common-cause failures, airflow redistribution, pressure drop, particle-removal efficiency, dust loading and clogging behaviour require experimental or computational investigation. The framework provides a basis for evaluating modular segmentation as a potential reliability-enhancement strategy for industrial particulate-filtration systems.