Optimized Baghouse Solutions for Mineral Wool Insulation Dust Control

An aspiration system is required for a new sandwich panel manufacturing plant with mineral wool insulation.

The client approached us for the manufacturing of a baghouse based on pre-prepared technical requirements. Having experience operating baghouses, the client compiled extensive specifications for the new dust collector, which is planned to be installed at a new sandwich panel manufacturing plant with mineral wool insulation.

We discussed the issues with the client, visited their existing production facilities to evaluate the current baghouses, and also suggested using more spaced-out bags, positioned further apart. Since the mineral wool insulation planned for the production process (cutting, sawing, and gluing) is fibrous, it can create so-called bridges or arches where the filter bags connect to the top plate. This issue can be addressed by spacing the bags apart, which helps to prevent the formation of such arches. The client agreed with our suggestion, and looking ahead, this is a very important advantage of our baghouses.

Issues faced by the Blizzard Baghouse during operation. It is important to note that the client already operates baghouses at their other facilities and understands their functionality and design. Additionally, the client received comprehensive training on operating our baghouse.

During commissioning and the initial partial production load, the client's employees reduced the compressed air supply from the compressor to the baghouse. Their reasoning was as follows:

1. The compressor was not selected with the correct capacity, and there was insufficient compressed air to supply both production and the baghouse separately.
2. Employees believed that since the baghouse was not operating under full planned dust load—due to ongoing production setup and testing—it could be supplied with less compressed air for self-cleaning or even temporarily turned off.

Consequences: PHOTO

Dust buildup on the sleeves increased, and dust in the hopper reached the filter bags because, for some strange reason, the client's employees did not unload the dust but instead accumulated it inside the hoppers. This should not be done, as most dust collector hoppers are not designed for permanent dust storage. Dust should be constantly or periodically unloaded (depending on the production process). After this situation, we conducted another training session for the client and emphasized the importance of keeping a service maintenance log. This is especially crucial in situations where there is a lot of dust, and the baghouse is essentially part of the production process, not just dust filtration.
It should be noted that the baghouse handled the dust well even under such conditions, as the filtration area and widely spaced sleeves provided a large margin of safety. The dust adhered to the sleeves and, due to gravity, fell into the hopper even without the cleaning system operating.

However, due to the lack of regular dust unloading, the unloading system broke down. The characteristics of mineral wool dust led to the product (dust) compacting and cementing in the hopper. This caused the auger to fail under the load and the formation of "dust clumps". All of this had to be manually cleaned from the hopper, and the auger was reinforced with additional supports to prevent such situations in the future.

Another issue during the baghouse startup was related to incorrect ductwork design. The client purchased a more powerful blower (providing higher airflow) than what the ductwork system was originally designed for in that section of the plant, which was just being commissioned.
We often encounter this mistake when clients think that a more powerful blower is better than a less powerful one, assuming it has capacity for future increases in performance if needed. This is a misconception. A blower has an aerodynamic curve that defines its characteristics, and these are heavily influenced by the resistance of the ductwork and the amount of air being moved through it. If the amount of air being moved is insufficient and the resistance is high, the blower will operate outside of its specified curve with uncertain characteristics. Well, not entirely uncertain—these characteristics will need to be measured in real-time. This happened in this case: the client hadn't yet commissioned the entire duct network and started the blower in a limited section, which led to unsatisfactory extraction from the hoods. As a result, the entire ductwork system had to be urgently completed, even though the original plan had a lead time of over six months. In this case, it might have been more reasonable to split the systems into two, commissioning one section first and later commissioning the second, so that no time was lost in completing the work and the desired effect could be achieved immediately.
All these issues were resolved within the first month of production process adjustment.

We provided a custom-designed baghouse tailored to meet the client's specific requirements, optimizing air filtration and system functionality. The key features of the system include:

• Volume of Air: 30,000 cfm
• Filtration Surface Area: 5,500 sqft
• Filter Material: Polyester
• Type of Filter Cleaning: Pulse Jet (air)
• Maximum Vacuum on the Body: 5,000 Pa
• Aerodynamic Resistance: 2,000 Pa
• Power Consumption: 0.2 kW without additional equipment
• Operating Temperature: 270°F
• Dust Concentration Inlet: 60 g/m³ (26.2 grains/ft³)
• Output Dust Concentration (for dust from 0.5 microns): 10 mg/m³

Additionally, we addressed issues such as proper dust unloading, the importance of service maintenance, and correct ductwork design to ensure efficient operation and prevent future complications. Through ongoing training and adjustments, the baghouse continues to perform effectively, meeting the client’s production needs.

The baghouse has been working for the client since 2017, and the client is satisfied with its performance, only changing the filter bags. After the commissioning of the baghouse, we only visited the client for scheduled performance measurements to gather feedback, and that’s all. Both the client and we are completely satisfied with the results of our cooperation.
We hope this information helps you choose the right dust collector for your needs. And if you need professional assistance, you know who to turn to!