An industrial baghouse dust collector is a filtration system used in industrial applications to remove particulates and pollutants from air or gas.
What Industries Use Baghouse Filter?
Baghouses, also known as fabric dust collectors or fabric filters, are gas pollution control devices designed to remove particulate matter from industrial exhaust gases. They function by drawing dirty stream into the device, passing it through fabric filters that capture and hold the airborne particles, and then returning the cleaned gas to the atmosphere. Some of the primary trades and applications that use devices include:
Power Generation
Especially coal-fired power plants, which produce large quantities of fly ash and other particulate emissions.
Cement Production
To capture and remove the suspended particles produced during the crushing, mixing, and burning processes.
Mining
Pollution control in extraction, crushing, and processing operations.
Agriculture
Processing facilities for grain, seed cleaning, and other operations that generate airborne contaminants.
Metal Production
Especially in foundries and steel mills, where they capture fumes and fine airborne particles from metal ore processing and smelting.
Asphalt Production
To control emissions during the heating and mixing processes.
Pharmaceuticals
Emission control in grinding, blending, and tabletting operations.
Woodworking
Sawmills, furniture manufacturing, and other woodworking operations produce significant amounts of wood dust.
Chemical Manufacturing
Control of airborne contaminants emissions during various chemical processing and manufacturing steps.
Food Processing
In tasks like milling and baking, where substantial quantities of fine suspended particles are produced.
Pulp and Paper
Particularly in areas like paper mills that generate significant amounts of pollutants.
Capturing particulates produced during the burning of waste materials.
Rock and Sand Quarries
To control pollutants from crushing and processing operations.
Textile Industry
Controlling fiber and dye aerial pollutants.
The principle is generally the same across trades: to ensure that particulate emissions are kept below regulatory limits and to maintain a safe and clean environment for both workers and the surrounding area.
Parts of a Fabric Dust Collector
• Inlet: Contaminated flow is introduced into the system.
• Filtering Chamber: A space where the pockets are located.
• Filter Pockets: Fabric bags that trap particles, allowing clean medium to pass through.
• Cages: Metal structures inside the pockets that prevent them from collapsing as stream passes through.
• Cleaning System: Mechanisms, such as reverse stream pulses or mechanical vibrators, that periodically clean the pockets.
• Outlet: Cleaned air exits the system.
• Dust Hopper: A section or container where the collected particulate is stored for subsequent disposal or removal.
• Fan: A device that creates a draft to move contaminated substance through the system and expel cleaned air out.
This basic structure may vary depending on specific requirements and application conditions.
• Filtering Chamber: A space where the pockets are located.
• Filter Pockets: Fabric bags that trap particles, allowing clean medium to pass through.
• Cages: Metal structures inside the pockets that prevent them from collapsing as stream passes through.
• Cleaning System: Mechanisms, such as reverse stream pulses or mechanical vibrators, that periodically clean the pockets.
• Outlet: Cleaned air exits the system.
• Dust Hopper: A section or container where the collected particulate is stored for subsequent disposal or removal.
• Fan: A device that creates a draft to move contaminated substance through the system and expel cleaned air out.
This basic structure may vary depending on specific requirements and application conditions.
Industrial Air Filtration System Schematic
Working Principle
The industrial baghouse dust collector operates on the principle of using fabric filters to trap pollutants from the incoming air, ensuring that only purified air is discharged from the system.
The operating principle involves 2 main stages:
An additional important stage can be identified — the regeneration of filters. During continuous stream cleaning, a layer of fine particles accumulates on the fabric, which can slow down operation. Therefore, it is essential to regularly clean the equipment. There are different cleaning methods, and baghouses are classified based on them.
The operating principle involves 2 main stages:
- Intake of dusty stream into the cleaning channel.
- The process of gas filtration. Fine particles settle on the fabric of the bags, and the clean gas is vented out through the exhaust pipe.
An additional important stage can be identified — the regeneration of filters. During continuous stream cleaning, a layer of fine particles accumulates on the fabric, which can slow down operation. Therefore, it is essential to regularly clean the equipment. There are different cleaning methods, and baghouses are classified based on them.
What are the Different Types of Baghouses?
The type of cleaning should be chosen based on production volumes, area, speed, etc.
Mechanical Shaker
Cleaning occurs through mechanical shaking of the pockets. When the ventilation stops, the pockets are shaken, leading to the detachment of fine particles.
These industrial baghouse dust collectors use bursts of compressed air to clean the pockets. The compressed air instantly "knocks out" the particulates from the bag.
Reverse-Air
In these systems, the flow is directed in the opposite direction, helping to remove fine particles from the pockets. They are typically used for processes with large volumes of contaminants.
Materials
Additionally, industrial baghouses can differ based on the materials from which the bags are made:
- Polyester: It has good resistance to acids and most organic solvents.
- Aramid (e.g., Nomex): Used in high-temperature conditions.
- PTFE (polytetrafluoroethylene or Teflon): Chemically resistant and suitable for corrosive conditions.
- Polypropylene: Resistant to many chemicals and is often used in the food industry.
- Fiberglass: Has high resistance to temperature and corrosion.
Types of Materials
How to Choose the Type of Filter
Upgrading to modern industrial baghouse filters can significantly reduce operational costs and enhance system performance.
These are general recommendations, and in practice, the choice of filtration system may depend on the specific requirements and conditions of each trade sector.
The vast range of industrial applications for baghouse dust collectors highlights their essential role in maintaining clean and safe production environments.
The vast range of industrial applications for baghouse dust collectors highlights their essential role in maintaining clean and safe production environments.
What are the Advantages of Baghouse Filters?
- Higher efficiency, i.e., the degree of gas purification.
- The ability to clean at any stream pressure, at any concentration of suspended particles, and at high temperatures.
- Chemically resistant materials are used.
- Full process automation is possible.
Cost
How to Choose a Bag Filter?
The cost of an industrial baghouse can vary widely based on several factors:
1. Size and Capacity: Small systems might cost anywhere from $10,000 to $20,000, while larger, high-capacity systems can range from $100,000 to over $1 million.
2. Type of Device: There are different designs, like pulse-jet, shaker, and reverse-air. Pulse-jet models, for instance, tend to be more costly but are also more efficient and require less maintenance.
3. Material and Construction: Units made of corrosion-resistant materials or designed for high-temperature applications will be more expensive.
4. Media: The quality and type of filters used can influence cost. Specialty devices, such as those designed for high heat or corrosive materials, will be more expensive.
5. Additional Features: Systems with advanced features like online cleaning, automated controls, and safety mechanisms can drive up the price.
6. Installation and Setup: Costs related to installation, foundation work, electrical setup, and ductwork are additional and can vary based on the site's specific requirements.
7. Operational Costs: While not part of the initial purchase price, it's essential to consider energy consumption, replacement bags, and ongoing maintenance.
Industrial baghouse manufacturers offer a range of customized solutions to meet the specific gas filtration needs of various trades. Our calculation and design of the industrial baghouse begins with a detailed assessment of the client's needs. This includes specifics of their production, work processes that generate pollution. Our extensive experience in air purification allows us to make accurate calculations.
1. Size and Capacity: Small systems might cost anywhere from $10,000 to $20,000, while larger, high-capacity systems can range from $100,000 to over $1 million.
2. Type of Device: There are different designs, like pulse-jet, shaker, and reverse-air. Pulse-jet models, for instance, tend to be more costly but are also more efficient and require less maintenance.
3. Material and Construction: Units made of corrosion-resistant materials or designed for high-temperature applications will be more expensive.
4. Media: The quality and type of filters used can influence cost. Specialty devices, such as those designed for high heat or corrosive materials, will be more expensive.
5. Additional Features: Systems with advanced features like online cleaning, automated controls, and safety mechanisms can drive up the price.
6. Installation and Setup: Costs related to installation, foundation work, electrical setup, and ductwork are additional and can vary based on the site's specific requirements.
7. Operational Costs: While not part of the initial purchase price, it's essential to consider energy consumption, replacement bags, and ongoing maintenance.
Industrial baghouse manufacturers offer a range of customized solutions to meet the specific gas filtration needs of various trades. Our calculation and design of the industrial baghouse begins with a detailed assessment of the client's needs. This includes specifics of their production, work processes that generate pollution. Our extensive experience in air purification allows us to make accurate calculations.
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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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