Author: Anna Frank, Equipment Selection Expert
A baghouse dust collector is an air pollution control device engineered to filter and capture particles, and other contaminants from industrial exhaust streams. It uses fabric bags or cartridges to trap particulates while allowing purified flow to pass through.
Baghouse dust collectors are used in various industries such as metallurgy, chemical industry, woodworking, concrete production sector, food processing, and mining. These devices are also used in the energy sector, for example, in coal-fired power plants.
Baghouse dust collectors are used in various industries such as metallurgy, chemical industry, woodworking, concrete production sector, food processing, and mining. These devices are also used in the energy sector, for example, in coal-fired power plants.
Working Principle
The baghouse dust collector design includes several key components: carbon steel casing, supports and hopper, sleeves, valves, regeneration unit.
How does a baghouse dust collector work? Dust-laden flow is drawn into the equipment through ducts. The gas passes through the bags, typically made from materials like polyester, fiberglass, or PTFE. Particles are captured on the surface of the bags while clean air exits. Over time, a layer of pollution forms on the bag surface, enhancing filtration efficiency but requiring periodic cleaning.
How does a baghouse dust collector work? Dust-laden flow is drawn into the equipment through ducts. The gas passes through the bags, typically made from materials like polyester, fiberglass, or PTFE. Particles are captured on the surface of the bags while clean air exits. Over time, a layer of pollution forms on the bag surface, enhancing filtration efficiency but requiring periodic cleaning.
Blizzard BIG with round bags and gas entry through a damper plate
Design
When designing a baghouse dust collector system, it is essential to consider several key factors to ensure efficient operation and compliance with gas filtration standards:
1. Gas Volume
Calculate the volume of gas to be processed, measured in cubic feet per minute (CFM). This value determines the size of the equipment and the required filter surface area.
2. Dust Load
Assess the concentration of contaminants in the gas stream, as it directly influences the type and quantity of sleeves needed, as well as the overall performance of the setup.
3. Material Selection
Select materials like polyester, fiberglass, or Nomex depending on the operating temperature and the chemical properties of the contaminants.
For high-temperature processes or aggressive chemical environments, use heat-resistant or chemically resistant components.
4. Air-to-Cloth Ratio
Determine the optimal air-to-cloth ratio, typically ranging from 2:1 to 5:1 (cubic feet of air per square foot of material).
Use lower ratios for heavy or sticky particles and higher ratios for light and dry contaminants.
5. Pressure Drop
Maintain the system's pressure drop within the range of 2 to 6 inches of water column (inWC) to optimize energy efficiency and reduce the workload on the fans.
6. Ventilation Design
Ensure proper ventilation design and appropriate positioning of ducts to maintain an even flow and minimize turbulence inside the setup.
1. Gas Volume
Calculate the volume of gas to be processed, measured in cubic feet per minute (CFM). This value determines the size of the equipment and the required filter surface area.
2. Dust Load
Assess the concentration of contaminants in the gas stream, as it directly influences the type and quantity of sleeves needed, as well as the overall performance of the setup.
3. Material Selection
Select materials like polyester, fiberglass, or Nomex depending on the operating temperature and the chemical properties of the contaminants.
For high-temperature processes or aggressive chemical environments, use heat-resistant or chemically resistant components.
4. Air-to-Cloth Ratio
Determine the optimal air-to-cloth ratio, typically ranging from 2:1 to 5:1 (cubic feet of air per square foot of material).
Use lower ratios for heavy or sticky particles and higher ratios for light and dry contaminants.
5. Pressure Drop
Maintain the system's pressure drop within the range of 2 to 6 inches of water column (inWC) to optimize energy efficiency and reduce the workload on the fans.
6. Ventilation Design
Ensure proper ventilation design and appropriate positioning of ducts to maintain an even flow and minimize turbulence inside the setup.
Configuration Layout
This approach ensures the efficiency of a baghouse dust collector while meeting industrial and environmental standards. Baghouse dust collector suppliers offer various configurations and solutions, but first, it is essential to understand the key performance indicators. Their performance and application depend on several key technical characteristics, which should be carefully considered when selecting the right model for your needs.
Equipment Overview and Categorization
Classification of baghouse dust collectors based on their regeneration mechanism, design type, and specific applications or operational features. Here's a detailed classification:
1. By Regeneration
Shaker
The operation of a baghouse dust collector employs mechanical shaking to dislodge particulate matter. Common in small-scale or batch operations with low emissions volumes.
We are proud to introduce our range of installations — Vortex Vibro. These units feature round-type bags and handle dust loads of up to 50 g/m³. Automatic regeneration is achieved through a vibrating plate equipped with a vibrator located at the center of the housing. The duration and interval of vibration shaking can be set independently via the controller mounted on the unit.
The vibration motor shakes the rack to which the filter elements are attached, causing contaminants to fall into the hopper or any other discharge system integrated into the equipment.
Our device design helps you save money on filter bag replacements. A dust chamber is installed before the filters to ensure solid particles settle directly into the hopper, reducing wear and tear. Additionally, a damper plate guarantees a more even distribution of the gas flow across all elements. This extends the lifespan of the Vortex Vibro, improves gas purification by ensuring balanced loads, and reduces operating costs.
1. By Regeneration
Shaker
The operation of a baghouse dust collector employs mechanical shaking to dislodge particulate matter. Common in small-scale or batch operations with low emissions volumes.
We are proud to introduce our range of installations — Vortex Vibro. These units feature round-type bags and handle dust loads of up to 50 g/m³. Automatic regeneration is achieved through a vibrating plate equipped with a vibrator located at the center of the housing. The duration and interval of vibration shaking can be set independently via the controller mounted on the unit.
The vibration motor shakes the rack to which the filter elements are attached, causing contaminants to fall into the hopper or any other discharge system integrated into the equipment.
Our device design helps you save money on filter bag replacements. A dust chamber is installed before the filters to ensure solid particles settle directly into the hopper, reducing wear and tear. Additionally, a damper plate guarantees a more even distribution of the gas flow across all elements. This extends the lifespan of the Vortex Vibro, improves gas purification by ensuring balanced loads, and reduces operating costs.
Pulse-Jet
The working principle of a baghouse dust collector involves using high-pressure air pulses to clean the sleeves, effectively removing accumulated pollution and maintaining optimal performance. Continuous operation, as cleaning happens in small sections without stopping airflow. Ideal for high-volume applications with fine particulate matter.
In our company, this category includes the Blizzard series installations. They are reliable, efficient, and highly productive. We use two types of bags—flat and round.
Round elements are designed for environments with high dust loads and are suitable for very high capacities (exceeding 100,000 m³). Flat elements, on the other hand, are used in cases where compact installation design and low contamination loads are required.
The pulse regeneration mechanism operates as follows: in the clean chamber at the top, pneumatic tubes are connected to diaphragm valves of the pneumatic system. These valves are mounted on air receivers containing compressed air supplied by a compressor. Periodically, the valve activates, and air is delivered through the valve into the pneumatic tube. From there, it is distributed into the bag through nozzles. The bags are shaken and blown clean, and the contaminants fall into the collection hopper below.
To extend the lifespan of the filter elements, the Blizzard design includes an optional louver damper or baffle plate at the inlet. These components ensure that incoming airflow first strikes them, leading to an even distribution of the flow. This enhances performance and reduces wear on the filters.
The working principle of a baghouse dust collector involves using high-pressure air pulses to clean the sleeves, effectively removing accumulated pollution and maintaining optimal performance. Continuous operation, as cleaning happens in small sections without stopping airflow. Ideal for high-volume applications with fine particulate matter.
In our company, this category includes the Blizzard series installations. They are reliable, efficient, and highly productive. We use two types of bags—flat and round.
Round elements are designed for environments with high dust loads and are suitable for very high capacities (exceeding 100,000 m³). Flat elements, on the other hand, are used in cases where compact installation design and low contamination loads are required.
The pulse regeneration mechanism operates as follows: in the clean chamber at the top, pneumatic tubes are connected to diaphragm valves of the pneumatic system. These valves are mounted on air receivers containing compressed air supplied by a compressor. Periodically, the valve activates, and air is delivered through the valve into the pneumatic tube. From there, it is distributed into the bag through nozzles. The bags are shaken and blown clean, and the contaminants fall into the collection hopper below.
To extend the lifespan of the filter elements, the Blizzard design includes an optional louver damper or baffle plate at the inlet. These components ensure that incoming airflow first strikes them, leading to an even distribution of the flow. This enhances performance and reduces wear on the filters.
Reverse Air
Airflow is reversed to remove pollution from the bags, and the system operates in cycles, often requiring one compartment to be offline for regeneration. It is particularly suitable for applications with low-to-moderate volumes of gas and those involving fragile or sensitive filter media.
2. By Orientation
Vertical arrangement — bags hang vertically, allowing dust to fall directly into the hopper. This option is more common due to its efficient pollution discharge and reduced clogging.
Horizontal arrangement — mounted horizontally, which makes them compact for certain installations. Requires more frequent cleaning.
Airflow is reversed to remove pollution from the bags, and the system operates in cycles, often requiring one compartment to be offline for regeneration. It is particularly suitable for applications with low-to-moderate volumes of gas and those involving fragile or sensitive filter media.
2. By Orientation
Vertical arrangement — bags hang vertically, allowing dust to fall directly into the hopper. This option is more common due to its efficient pollution discharge and reduced clogging.
Horizontal arrangement — mounted horizontally, which makes them compact for certain installations. Requires more frequent cleaning.
3. By Airflow Configuration
4. By Application and Features
Modular baghouse dust collectors are engineered with multiple compartments or modules for large-scale operations.
The majority of the devices in our catalog are modular units. They offer a key advantage over conventional ones—rapid performance upgrades. You can enhance performance by adding an extra module.
Easy and quick installation—no welding or complex operations required. Simple and fast transportation. High-Temperature equipment built with materials like fiberglass or ceramic for use in processes with extreme heat (e.g., cement kilns or metal smelting).
- Downflow — What is a baghouse dust collector with downflow air? The stream enters from the top, and contaminants settle downward due to gravity. Reduces the load on the sleeves and improves cleaning efficiency.
- Upflow — Gas enters from the bottom, moving upward through the bags. This method is effective for certain applications but can cause particles to re-entrain.
- Crossflow — The stream moves horizontally across the bags, a configuration often used in compact systems or specific industrial setups. A small baghouse dust collector is suitable for use in areas with limited space and low gas volume. It is ideal for small-scale manufacturing, laboratories, workshops, or small shops where the particulate matter may be dry or of medium size.
4. By Application and Features
Modular baghouse dust collectors are engineered with multiple compartments or modules for large-scale operations.
The majority of the devices in our catalog are modular units. They offer a key advantage over conventional ones—rapid performance upgrades. You can enhance performance by adding an extra module.
Easy and quick installation—no welding or complex operations required. Simple and fast transportation. High-Temperature equipment built with materials like fiberglass or ceramic for use in processes with extreme heat (e.g., cement kilns or metal smelting).
Comparison of baghouse vs. dust collector
Main Issues in the Reconstruction of Gas Cleaning Systems at Operating Enterprises
The experience of our specialists shows that several serious problems arise during reconstruction, which pose obstacles when replacing outdated equipment or installing new systems in existing production facilities.
Firstly, since new devices are mostly installed in the places of old equipment, a major issue is the delivery and installation of the new device in its designated location. Often, the size of existing installation openings is insufficient, or the opening is located far from the installation site, with the route blocked by existing technological equipment. Sometimes, baghouses are located at the upper levels of the premises. In all these cases, a large volume of design and construction works is required just to ensure the delivery of the device to the installation site. Sometimes it is necessary to dismantle part of the roof, widen existing openings, or create new openings in the walls and ceilings. These works not only cause significant inconvenience and interfere with the technological processes at operating enterprises but are also costly, significantly increasing the cost of implementing the gas cleaning system reconstruction project.
Firstly, since new devices are mostly installed in the places of old equipment, a major issue is the delivery and installation of the new device in its designated location. Often, the size of existing installation openings is insufficient, or the opening is located far from the installation site, with the route blocked by existing technological equipment. Sometimes, baghouses are located at the upper levels of the premises. In all these cases, a large volume of design and construction works is required just to ensure the delivery of the device to the installation site. Sometimes it is necessary to dismantle part of the roof, widen existing openings, or create new openings in the walls and ceilings. These works not only cause significant inconvenience and interfere with the technological processes at operating enterprises but are also costly, significantly increasing the cost of implementing the gas cleaning system reconstruction project.
VORTEX Vibro CP
Our company manufactures baghouse dust collector filters that can be supplied either assembled as modules with transportable dimensions for road transportation, or disassembled, which helps to significantly reduce transportation costs and enables container shipping to remote regions.
When supplied disassembled, the equipment of virtually any capacity can be delivered through a standard door opening of 900x2000 mm. The body parts consist of precisely manufactured panels with holes and reinforcing ribs. Since the devices have a modular design, performance can be increased by adding the required number of modules. Clean chambers for each module are supplied assembled, and their dimensions also allow them to be delivered through a standard opening.
The assembly of our equipment is carried out directly at the installation site. The body, hopper, and clean chamber parts are fastened using bolted connections. For example, assembling a six-section baghouse with a capacity of up to 80,000 m³/h takes about five working days.
Secondly, there is the issue of ensuring sufficient space for service maintenance. It is often the case that there is a lack of space above or beside the equipment. A distinctive feature of our equipment is the ability to choose the side for service access in the standard configuration of the filter. Access to the filter elements can be arranged either from above or from the side, depending on the client's needs. The body, in its standard configuration, is equipped with service doors both on top and on the side. The frame of the air purifying elements has a special fastening design that allows the sleeve with the frame to be removed or installed either from the clean chamber side from above or from the dirty chamber side from the side.
This feature of our baghouse dust collector allows easy adaptation of service access based on available space, either above or on the side.
When supplied disassembled, the equipment of virtually any capacity can be delivered through a standard door opening of 900x2000 mm. The body parts consist of precisely manufactured panels with holes and reinforcing ribs. Since the devices have a modular design, performance can be increased by adding the required number of modules. Clean chambers for each module are supplied assembled, and their dimensions also allow them to be delivered through a standard opening.
The assembly of our equipment is carried out directly at the installation site. The body, hopper, and clean chamber parts are fastened using bolted connections. For example, assembling a six-section baghouse with a capacity of up to 80,000 m³/h takes about five working days.
Secondly, there is the issue of ensuring sufficient space for service maintenance. It is often the case that there is a lack of space above or beside the equipment. A distinctive feature of our equipment is the ability to choose the side for service access in the standard configuration of the filter. Access to the filter elements can be arranged either from above or from the side, depending on the client's needs. The body, in its standard configuration, is equipped with service doors both on top and on the side. The frame of the air purifying elements has a special fastening design that allows the sleeve with the frame to be removed or installed either from the clean chamber side from above or from the dirty chamber side from the side.
This feature of our baghouse dust collector allows easy adaptation of service access based on available space, either above or on the side.
Key Contributors to Cost
7 Key Steps for Baghouse Calculation
The baghouse dust collector price can depend on several factors. Here are the main ones:
- Filter material — different materials (polyester, fiberglass, aramid, PTFE, and others) have different costs, and their choice affects the price.
- Size — larger or specialized devices for complex operating conditions are generally more expensive.
- Type — dust collector with baghouse with different cleaning methods can vary in price.
- Performance and efficiency — devices capable of capturing finer contaminants or working at high temperatures tend to be more expensive.
- Coating or additional treatment — components with extra coatings (for example, to improve water-repellent properties) may be more expensive.
- Manufacturer — the brand and reputation of baghouse dust collector manufacturers can influence the price.
- Quantity and order volume — larger orders may result in lower prices due to bulk discounts.
- Operating conditions — devices engineered for aggressive or extreme environments (high temperatures, chemical exposure) are typically more expensive.
- Additional features — the presence of built-in sensors, monitoring mechanisms, and automatic regulation may increase the price.
Additional Package: Custom Features
Our company, a baghouse dust collector producer, offers to enhance the equipment with customized options. Key options include explosion-resistant membranes, anti-static fibers, fire extinguishing systems, and protective coatings for harsh environments. These features ensure reliable operation in high-risk conditions.
For easy maintenance, our systems include top-removable filters, accessible floors, and stairs. Thermal protection and heating options are available for cold or humid environments, preventing freezing and condensation. Advanced control features allow real-time monitoring, automatic shutdowns, and performance optimization to ensure efficient operation and reduce downtime.
The specialists at Torch-Air baghouse dust collector factory always conduct an in-depth analysis of the client’s needs and are ready to offer the best solutions to their problems.
Looking for a reliable and efficient solution? Contact us today to learn more about our baghouse dust collectors for sale. With our products, you benefit from:
For easy maintenance, our systems include top-removable filters, accessible floors, and stairs. Thermal protection and heating options are available for cold or humid environments, preventing freezing and condensation. Advanced control features allow real-time monitoring, automatic shutdowns, and performance optimization to ensure efficient operation and reduce downtime.
The specialists at Torch-Air baghouse dust collector factory always conduct an in-depth analysis of the client’s needs and are ready to offer the best solutions to their problems.
Looking for a reliable and efficient solution? Contact us today to learn more about our baghouse dust collectors for sale. With our products, you benefit from:
- Durable materials ensuring long service life.
- Customizable options tailored to your specific needs.
- Energy-efficient designs that reduce operational costs.
- Expert support at every stage—from design to installation and maintenance.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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