Asphalt Baghouses: Cleansing Your Path to Long-Term Efficiency and Safety

Asphalt production is a crucial aspect of the construction industry. However, it is also one of the most significant sources of air pollution due to the numerous pollutants that result from its production. The air pollutants that come from asphalt production are harmful to both employees’ health and the environment. To curb the emission of these pollutants, asphalt baghouses have become an essential component in asphalt production.

Baghouse operation and maintenance at asphalt plants are comprised of a series of fabric filters which over time become clogged and require cleaning or replacement to ensure their continued effectiveness. Regular inspection of baghouses is necessary to identify signs of wear or damage that may compromise the integrity of the filters.

Air flow rates indicate the volume of air that is moving through asphalt baghouses, while pressure drops indicate the pressure differential between the inlet and outlet of the system. These metrics are essential for identifying potential problems before they become serious, and for optimizing the performance of the asphalt concrete baghouse.

After myriads of issues having been encountered for years in keeping asphalt facilities clean, it’s not an issue that should be left up to chance. Enterprises are going to need to invest only in what’s economical and what works well for them. One of the most recent innovations to address this that’s become all the rage is Torch Air’s Blizzard 50 Pulse Jet Baghouse with round bags and gas entry via shutter dampers and a performance of 26,500-295,000 cfm cleaning 99.99% of air.

This machine is reliable no matter how much dust or what kind of dust is present at the facility, as additional modules can be added with ease. The device uses shutter dampers to manage the dust load and it can withstand air temperatures of as high as 536 degrees Fahrenheit. It’s compact and its installation and transportation are quick and easy. It’s also perfect for a broad range of industries including chemical industry, asphalt plant, and concrete plants.

Despite the numerous benefits asphalt baghouses offer, there are also some common asphalt plant baghouse problems which can occur that may hinder the machine’s effectiveness. The following are some of the common problems associated with asphalt baghouses:

1. Bag Wear and Tear: Bags are prone to wear and tear due to constant exposure to dust and debris particles. The bags need to be replaced periodically to maintain the effectiveness of the baghouse.
2. Clogging: Over time, the bags can become clogged with dust and other particulate matter, reducing their ability to filter the air. This can result in decreased airflow and reduced production capacity.
3. Premature wear: Some baghouses may experience premature wear due to a range of factors, including high temperatures, humidity, and exposure to corrosive substances. This can lead to leaks, tears, and other damage that can compromise the effectiveness of the baghouse.
4. Insufficient air flow: In some cases, the baghouse may not be able to provide enough air flow to keep up with the demands of the production process. This can result in reduced efficiency and decreased production capacity.
5. Pulse Times: Asphalt plant baghouse pulse times are essential in the operation of asphalt baghouses. The bags need to be blasted in intervals to remove the accumulated dust and debris in such a way as to ensure efficient filtration and collection.
6. High Temperature: Asphalt plant baghouse temperature is quite hot, and thus has the potential to damage the bags in the baghouse. The high temperatures can cause melting, which can lead to bag failure.
7. Bag failure: Bags can fail for a variety of reasons, including tears, holes, and other damage. This can lead to the release of dust and other pollutants into the environment, posing health and safety risks to workers and the surrounding community.
8. Fire Protection: Asphalt baghouses are at risk of fires due to the high temperature and flammable nature of the materials used in production. Baghouse fire protection measures must be put in place to prevent accidents.

To prevent these issues, it's important to perform regular maintenance and inspections of asphalt plant baghouses, replace worn or damaged bags as needed, and ensure that the baghouse is properly sized and designed for the specific production process. Additionally, using high-quality bags made from durable materials can help to extend the lifespan of the baghouse and improve its overall performance.

If you're looking to enhance the efficiency of your asphalt plant, you are going to want to also periodically inspect your dust collector device. It’s essential to ensure it's running optimally as production depends on it. Here are the three most crucial items to keep in mind on your asphalt plant baghouse inspection sheet to guarantee that your baghouse is functioning efficiently:

Proper sizing: The size of your baghouse is critical. A baghouse that is too small can restrict production, while one that is too large can make it challenging to achieve desired temperatures. Aim for a correctly sized baghouse dust collector that necessitates 200 CFM per ton of material manufactured, based on 5% composite moisture in your materials. For instance, an 80,000 CFM baghouse would be required for a 400-ton-per-hour plant.

Leak detection in the system: A leak in your baghouse system can deplete the system of air and lower CFM. Ensure that there are no leaks all the way back to the drum, which includes assessing properly functioning drum seals. Look at the dust collector as a vacuum cleaner, where the ductwork and drum function as the suction hose.

Bag life: The state of your baghouse filtering media is essential. Aging or worn-out bags can cause reduced production due to high pressure drops that prevent proper pulsing. Regularly maintain your bags to lengthen their lifespan by tuning and adjusting your burner and ensuring the baghouse temperature is within recommended operating guidelines. This also will fetch a greater reward if an asphalt plant baghouse is published for sale.

Other things to check include the following:

1. Quantity of bags and individual ID
2. Bag damage/tears/holes
3. Bag thickness measurement
4. Bag installation/replacement/cleaning date record
5. Air flow rate recording (CFM) and velocity measurement (FPM)
6. Check that the air flow rates are within the specified range
7. Performance check of airlocks and dampers
8. Record pressure drops across the baghouse and individual bags
9. Check that pressure drops are within specified range
10. Investigate irregular pressure drops for potential issues
11. Exhaust gas temperature recording
12. Particle size distribution analysis of collected particulate matter
13. Baghouse humidity level check
14. Record last bag cleaning/maintenance date
15. Leak check of baghouse system

Thus, proper asphalt plant baghouse operation and maintenance are essential for ensuring the safety of workers and the surrounding community. Regular bag cleaning and replacement, monitoring of air flow rates and pressure drops, and conducting regular inspections to identify and address potential problems are all critical components of baghouse maintenance. By keeping these systems in good working order, a baghouse in an asphalt plant can help to reduce air pollution and protect the health and safety of those in the surrounding area.

Get in touch with us to order yourself your very own trusty, powerful asphalt plant baghouse today!