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Author:
Anna Frank, Equipment Selection Expert
Anna Frank, Equipment Selection Expert
A fabric dust collector is an integral part of many industrial processes associated with the release of harmful emissions into the environment. It is widely used for air filtration in ferrous and non-ferrous metallurgy, in glass-ceramics production, and for neutralizing gases from calcination furnaces, waste incineration boilers, tires, sludge, and similar sources.
Operating Principle
As an example, let’s consider the most popular type of fabric filter dust collector — baghouses, the operating principle of which is as follows:
- The contaminated gas-air mixture is collected from all pollution sources (production facilities, furnaces, etc.) and is directed through a duct to the collector’s inlet using a forced-draft fan.
- The gas then enters the dirty chamber, where secondary particulates come into contact with the external surface of the filter material and settle on it. The fabric is stretched over frames in the form of bags, and the installation may contain from several units to several hundred elements, depending on the system’s parameters.
- Due to the increased pressure in the chamber, the gas leaves the working zone, leaving the mechanical particulates on the surface of the material.
- During operation, the fabric filter of the dust collector becomes clogged with dust, which reduces the system’s efficiency. The degree of clogging of the micro-pores of the material is determined by a timer or manometer. Once the sensor is triggered, the regeneration process begins. This is carried out using air pulses or vibration.
- The mechanical particulates that fall from the bags into the collection hopper are removed via a gate or rotating screw. The gas purification process then begins anew.
Torch-Air Three-Module Pulse Jet Baghouse — Animated Operation
Baghouse Cleaning: Techniques for Filter Bag Cleaning
Fabric for Air Filters
What is a fabric collector? It is a dust extraction device whose main cleaning element is a fabric filter. The textile consists of interwoven threads or yarns, which are spun from either staple (short) fibers or filament (continuous) fibers with diameters up to 40 µm. If wool cloth is used for the filter, it is first subjected to fulling; other types of heavy textiles made from synthetic or natural fibers are napped. As a result of these processes, a layer or nap of fibers appears on the surface, with fibers entangled in various directions.
Dust collector fabric made from synthetic fibers or fiberglass has a finer structure and is not subjected to these treatments, but the degree of yarn twist and the density of its arrangement significantly exceed the corresponding characteristics of thicker textiles made from staple fibers. The cloth can be woven using plain, twill, or satin methods. Various weaving combinations are used to produce cloths with special strength.
According to research and our tests, fine textiles for air purification show a lower degree of cleaning after regeneration. For thicker materials, the difference in purification efficiency before and after regeneration is not as significant. Even with a layer of dust “cake,” the collectors demonstrate the ability to capture even submicron particles effectively.
Dust collector fabric made from synthetic fibers or fiberglass has a finer structure and is not subjected to these treatments, but the degree of yarn twist and the density of its arrangement significantly exceed the corresponding characteristics of thicker textiles made from staple fibers. The cloth can be woven using plain, twill, or satin methods. Various weaving combinations are used to produce cloths with special strength.
According to research and our tests, fine textiles for air purification show a lower degree of cleaning after regeneration. For thicker materials, the difference in purification efficiency before and after regeneration is not as significant. Even with a layer of dust “cake,” the collectors demonstrate the ability to capture even submicron particles effectively.
Types of Materials
Filter materials are characterized by high strength, wear resistance, reusability, and low cost. Natural cloths are increasingly being replaced by more advanced synthetic alternatives in aspiration processes. Polyester is most commonly used due to its affordability and abrasion resistance.
Differences Between Fabrics
Compared to natural cloths, synthetic materials for aspiration offer the following advantages:
Differences Between Fabrics
Compared to natural cloths, synthetic materials for aspiration offer the following advantages:
- High capture rate
- Improved gas purification quality
- Lower weight due to higher strength
- Wear resistance
- Better contaminant removal efficiency (washing, rinsing, drying)
- Non-biodegradable material
- Moisture resistance
- Extended service life
Types of air filter fabrics
For fine particle capture, the dust collector filter fabric is made from ultrafine yarn. This ensures a higher material density; however, such sleeves clog more quickly, leading to an increased pressure drop across the filtration element surface.
Our company offers custom industrial dust collector fabrication using the following materials:
You can order baghouse bags with anti-static effect and other properties from us, depending on the specifics of the cleaned environment.
Our company offers custom industrial dust collector fabrication using the following materials:
- Polyester, produced by thermal bonding of synthetic yarn at 100°C. Due to the unique yarn structure, the density increases and the fiber diameter decreases along the flow direction.
- Meta-aramid (Nomex) can be operated at gas flow temperatures up to 200°C, is resistant to chemical exposure, flame retardant, and has a minimal thermal shrinkage coefficient.
- PPS (polyphenylene sulfide) is characterized by enhanced heat resistance with peak temperatures up to 200°C, resistance to alkaline compounds, hydrolysis, acids, high filtration efficiency (up to 99%), and suitability for operation under high humidity.
- Lavsan (PET) is resistant to alkalis and acids, has antibacterial properties, and is durable and wear-resistant.
- Polypropylene has a low fiber density. To increase wear resistance, reinforcement is applied, and various additives are incorporated into the material composition to enhance hydrophilicity.
You can order baghouse bags with anti-static effect and other properties from us, depending on the specifics of the cleaned environment.
Characteristics, Properties, and Filtration Classes
Along with the removal efficiency, which is determined by the ratio of the concentration of secondary impurities in the flow before and after purification, important parameters include the physical and chemical resistance of the textile to the external environment.
Resistance to strong temperature fluctuations, exposure to chemically aggressive particles, the ability to maintain structure and dimensions, and resistance to regeneration — all these factors determine the effectiveness of pollutant capture and service life.
Fabric for dust collector bags is classified according to filtration performance into the following classes:
Resistance to strong temperature fluctuations, exposure to chemically aggressive particles, the ability to maintain structure and dimensions, and resistance to regeneration — all these factors determine the effectiveness of pollutant capture and service life.
Fabric for dust collector bags is classified according to filtration performance into the following classes:
- Coarse G1-G4;
- Fine F5-F9;
- High-efficiency H10-H14;
- Ultra-high efficiency U15-U17.
Filter Cloth
Fabric with class G1-G4 is designed to capture solid particulate matter with particle sizes ranging from 0.3 to 10 microns, with removal efficiency varying from 5% to 65%. The high air permeability and low resistance of this material make the coarse filtration stage effective in significantly reducing the load on the subsequent finer stage.
Membranes of classes F5 to F9 are designed to capture particulate matter mainly from 0.3 to 10 microns. This level of filtration effectively eliminates harmful impacts of polluted air on human health and creates safe conditions for occupational and other activities. In environments requiring more stringent (sterile) capture of contaminants, such as hospitals, operating rooms, electronics manufacturing, and information storage and processing facilities, higher-class filter materials are used.
Depending on the customer's requirements for dust collector fabrication and the specifics of the production process, our specialists select materials based on the following characteristics:
This emphasizes the tailored approach to material selection to optimize filtration performance and durability in industrial applications.
Membranes of classes F5 to F9 are designed to capture particulate matter mainly from 0.3 to 10 microns. This level of filtration effectively eliminates harmful impacts of polluted air on human health and creates safe conditions for occupational and other activities. In environments requiring more stringent (sterile) capture of contaminants, such as hospitals, operating rooms, electronics manufacturing, and information storage and processing facilities, higher-class filter materials are used.
Depending on the customer's requirements for dust collector fabrication and the specifics of the production process, our specialists select materials based on the following characteristics:
- air permeability;
- material density;
- operating temperature;
- chemical resistance;
- contaminants
- retention capacity;
- anti-static properties;
- cleanability or complete replaceability, among others.
This emphasizes the tailored approach to material selection to optimize filtration performance and durability in industrial applications.
Methods of Regeneration
The price of fabric for dust collectors depends not only on the material used but also on the regeneration method. There are two primary methods: discontinuous and continuous regeneration.
In the continuous method, regeneration occurs during the ongoing circulation of the gas-air mixture, for example, using pulse jet cleaning or vibrating shaking. The discontinuous method, on the other hand, involves manual servicing, whereby the bag is isolated from the contaminated flow after the treatment process is temporarily halted.
In certain cases, additional washing of the filter fabric may be required, such as in sugar production. This approach prolongs the operational lifespan of the material but does not exclude other regeneration techniques like shaking or pulse jet, which are also commonly used.
In the continuous method, regeneration occurs during the ongoing circulation of the gas-air mixture, for example, using pulse jet cleaning or vibrating shaking. The discontinuous method, on the other hand, involves manual servicing, whereby the bag is isolated from the contaminated flow after the treatment process is temporarily halted.
In certain cases, additional washing of the filter fabric may be required, such as in sugar production. This approach prolongs the operational lifespan of the material but does not exclude other regeneration techniques like shaking or pulse jet, which are also commonly used.
Pulse Jet
More effective cleaning is achieved by individually pulsing each bag with a wave of compressed air. The cleaning air flow creates an overpressure along the entire length of the sleeve, causing the fabric to deform and dislodge accumulated dust.
A crucial aspect of pulse jet is that the compressed air flows along the central axis of the element. Accordingly, each sleeve in the unit is equipped with a fixed nozzle for air supply.
This method generates a shockwave that detaches dust from the bag surface, allowing it to fall into the collection hopper. Pulse jet operation operates continuously without interrupting filtration, thereby maintaining high operational efficiency and consistent contaminant removal performance.
A crucial aspect of pulse jet is that the compressed air flows along the central axis of the element. Accordingly, each sleeve in the unit is equipped with a fixed nozzle for air supply.
This method generates a shockwave that detaches dust from the bag surface, allowing it to fall into the collection hopper. Pulse jet operation operates continuously without interrupting filtration, thereby maintaining high operational efficiency and consistent contaminant removal performance.
Baghouse Pulse Jet Filter
Vibration Shaking
Vibration is generated by an electric drive. At a pressure of approximately 0.6 MPa, dry air is directed onto the filter elements. The amount of air supplied depends on the number, size, and frequency of the shaking cycles of the air-purifying elements.
Regeneration through vibration shaking helps extend the service life of the bags. Additionally, baghouses employing this cleaning method can operate with smaller-sized sleeves. The vibration causes slight displacement of the sleeves, which reduces abrasion compared to other methods.
Regeneration through vibration shaking helps extend the service life of the bags. Additionally, baghouses employing this cleaning method can operate with smaller-sized sleeves. The vibration causes slight displacement of the sleeves, which reduces abrasion compared to other methods.
Torch-Air Vortex Vibro OP — Open-Body Shake-Cleaning Filter
Mechanical Manual Cleaning Method
The simplest method of regeneration is manual and involves:
- a complete shutdown of production processes;
- opening the chamber housing the sleeves;
- shaking.
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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
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