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Author:
Anna Frank, Equipment Selection Expert
Anna Frank, Equipment Selection Expert
A dust collector is an industrial gas-cleaning device designed to remove dispersed solid particles from gas streams by passing them through a system of filter elements. Gas purification is achieved by mechanically trapping particles on the surface or within the porous structure of the media, providing a high collection efficiency (up to 99%) even for fine particulate contaminants.
During operation, a layer of contaminants accumulates on the surface of the filter media, leading to an increase in hydraulic resistance; therefore, cleaning is required using a pulse-jet method.
During operation, a layer of contaminants accumulates on the surface of the filter media, leading to an increase in hydraulic resistance; therefore, cleaning is required using a pulse-jet method.
Equipment Layout
The pulse-jet dust collector design consists of the following elements and their functions:
• Compressor – supplies air to the solenoid valve and provides the pressure needed for the pulses. Without it, the system cannot operate.
• Housing cover – the upper part of the device where the particle-laden gas stream enters.
• Solenoid valve – controls the supply of compressed air to the pulse-cleaning system.
• Compressed air inlet pipe – transports air to the nozzles of the media.
• Nozzle – directs a pulse of air into the filter, generating a shock wave for cleaning.
• Automatic regeneration control unit – manages the sequence and duration of pulses, ensuring optimal cleaning without stopping the equipment.
• Bag or cartridge – the filter element on which particles are deposited.
• Frame – supporting structure for the filters, ensuring proper positioning and tension.
• Hopper – compartment for collecting discharged debris, which is then removed from the system.
• Compressor – supplies air to the solenoid valve and provides the pressure needed for the pulses. Without it, the system cannot operate.
• Housing cover – the upper part of the device where the particle-laden gas stream enters.
• Solenoid valve – controls the supply of compressed air to the pulse-cleaning system.
• Compressed air inlet pipe – transports air to the nozzles of the media.
• Nozzle – directs a pulse of air into the filter, generating a shock wave for cleaning.
• Automatic regeneration control unit – manages the sequence and duration of pulses, ensuring optimal cleaning without stopping the equipment.
• Bag or cartridge – the filter element on which particles are deposited.
• Frame – supporting structure for the filters, ensuring proper positioning and tension.
• Hopper – compartment for collecting discharged debris, which is then removed from the system.
Pulse Jet Dust Collector Demonstration
Pulse jet dust collectors efficiently capture dry contaminants of different origins — mineral (cement, limestone, quartz), organic (wood, food, textile), and metallic produced during grinding, cutting, or welding processes.
Working Principle
How a pulse-jet dust collector works? Pulse-jet regeneration is used in configurations where the particle-laden gas stream flows from the outside to the inside of the filter, and pollutants are deposited on its outer surface.
The working principle of a pulse-jet dust collector is that a jet of compressed air, emitted from the nozzle of the distribution pipe, draws in the cleaned gas and enters the bag or cartridge. Under the action of the overpressure, the filter expands, the dust layer is dislodged, and the particles fall into the hopper.
The working principle of a pulse-jet dust collector is that a jet of compressed air, emitted from the nozzle of the distribution pipe, draws in the cleaned gas and enters the bag or cartridge. Under the action of the overpressure, the filter expands, the dust layer is dislodged, and the particles fall into the hopper.
Baghouse Pulse Jet Filter
In addition to conventional pulse-jet baghouse dust collectors, this regeneration method is also applied in cartridge units, where the filter media has a pleated cylindrical shape. The principle remains the same: a short pulse dislodges contaminants from the cartridge surface, restoring its filtration efficiency.
Besides the purging effect, the pulsating air flow also provides a mechanical shaking action. Pulse-jet regeneration is performed without shutting down filter sections. To prevent excessively intensive regeneration, which could remove the residual equilibrium dust (leading to a high initial breakthrough after regeneration), the compressed air pressure, pulse duration, and pulse frequency are varied.
Typical operating parameters are: pulse duration of 0.1–0.2 seconds, pulse frequency of 10 pulses per minute, and compressed air pressure of 500–600 kPa. Compressed air consumption is 0.1–0.2% of the cleaned gas volume.
According to our tests at Torch-Air, the optimal interval between pulses is 10 seconds.
Besides the purging effect, the pulsating air flow also provides a mechanical shaking action. Pulse-jet regeneration is performed without shutting down filter sections. To prevent excessively intensive regeneration, which could remove the residual equilibrium dust (leading to a high initial breakthrough after regeneration), the compressed air pressure, pulse duration, and pulse frequency are varied.
Typical operating parameters are: pulse duration of 0.1–0.2 seconds, pulse frequency of 10 pulses per minute, and compressed air pressure of 500–600 kPa. Compressed air consumption is 0.1–0.2% of the cleaned gas volume.
According to our tests at Torch-Air, the optimal interval between pulses is 10 seconds.
Device Models
This pulse jet type dust collector is designed for both cartridge and baghouse configurations. We manufacture modular units, which allows the system capacity to be quickly and easily increased if needed.
Thanks to their well-thought-out design, our units:
Thanks to their well-thought-out design, our units:
- can be cleaned without shutting down the system;
- maintain optimal performance and low pressure drop;
- extend the service life of both the filter media and the entire unit;
- ensure stable operation even with different types of contaminants;
- can be easily integrated into existing production lines;
- are adaptable to specific customer requirements, including temperature, chemically aggressive media, and solids density;
- minimize operating costs due to the efficient pulse-jet cleaning system;
- provide safe working conditions by reducing the concentration of harmful airborne particles.
Main Stages of Calculation
Pulse jet dust collector design calculation involves hydraulic, aerodynamic, and mechanical considerations to ensure optimal performance and longevity of the system. Properly designed equipment requires not only accurate calculations but also practical experience of the engineer.
Step 1: Determination of the flow parameters for purification
Step 1: Determination of the flow parameters for purification
- Volumetric flow rate (Q) – determined by the technological process, e.g., in m³/h.
- Temperature and composition – affect the selection of filter materials and their resistance to aggressive environments.
- Density and viscosity (ρ, μ) – necessary for calculating filter resistance and gas velocity through bags or cartridges.
- Diameter and length of bags or cartridges – calculated based on the required filtration area Af to ensure permissible filtration velocity (vf=Q/ Af).
- Filtration velocity – practical experience and reference manuals are used for accurate determination.
- Number of filters – determined by the required filtration area and structural limitations of the housing.
- Initial filter resistance (ΔP₀) – pressure drop through a clean filter.
- Resistance under dust load – accounts for pressure increase as contaminants accumulate.
- Gas velocity in the collector and between bags or cartridges – should be optimized for uniform deposition without turbulent zones.
- Compressed air volume and pressure – determined for complete cleaning of each element; pressure is typically 5–7 bar.
- Pulse duration (tₚ) – 0.1–0.3 seconds for most installations.
- Interval between pulses – selected to prevent excessive accumulation of contaminants and to avoid overloading the blowback system.
- Nozzles and pipelines – selected by diameter and length to create a sufficient shock wave inside the element.
- Mechanical strength of filters and frame – considers the weight of elements, gas pressure, and compressed air pulse.
- Tensioning – necessary to prevent sagging and damage during cleaning.
- Hopper volume – must ensure storage of discharged solids between emptying cycles.
- Discharge velocity and hopper shape – important to prevent sticking and “dead zones” where particles can accumulate.
Maintenance
To maintain the high efficiency and longevity of a pulse jet dust collector, regular maintenance is recommended at established intervals. The frequency of inspections depends on operating intensity and the type of dust being collected, but basic procedures should generally be performed monthly, and some weekly. Specific intervals are provided in the equipment’s operation manual. Pulse jet dust collector manufacturers always provide such documentation with their equipment.
- Filter inspection – monitor the condition of cartridges or bags; clean or replace them as needed.
- Hopper cleaning – regularly remove accumulated debris to prevent blockages and system overload.
- Pulse-jet cleaning system check – ensure solenoid valves and nozzles operate correctly, and that compressed air pressure is within normal range.
- Air pressure and flow monitoring – monitor pressure drop to maintain optimal performance.
- Visual inspection of the structure – check the frame, supports, and connections for damage or sagging.
- Regular automation diagnostics – inspect the automatic regeneration control unit, adjusting pulse intervals and duration as necessary.
Baghouse Service: Overview, Required Maintenance Tasks, Possible Breakdowns and Their Remedies
Contact us for a consultation. We manufacture custom systems, and wholesale pulse jet dust collectors are also available. Our specialists have experience across a wide range of industries. Our production facilities allow us to supply both a small, cheap pulse jet dust collector and large-scale air cleaning systems. We are always open to discussing pricing, as we are a direct manufacturer.
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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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