R&D Project: EPC Solutions for 50,000 CFM OEM Baghouse in Specialty Chemicals & Polymer Production
Initial Data
Development and Implementation of a High-Performance Baghouse System within an EPC Project
We managed all stages of the Baghouse system integration into the client's new production facility, covering technological and construction aspects, as well as its integration with production control systems.
A key feature of this project was the application of the Research and Development (R&D) methodology. Given the client's unique requirements and the specifics of their production process, we conducted a comprehensive engineering analysis that enabled us to develop a new, high-performance Baghouse modification. The process included the following stages:
- Analysis and modeling of operational parameters to optimize filtration efficiency;
- Development and testing of innovative design solutions to enhance system reliability and durability;
- Seamless integration of the newly developed solution into the existing technological workflow and production control systems.
Commentary by Michael Klepik, CEO of Torch-Air
I started my career in our company as an EPC project engineer specializing in gas cleaning systems within OEM Baghouse equipment construction. EPC (Engineering, Procurement, and Construction) projects cover the entire construction cycle—from design and material procurement to construction and commissioning. In the context of gas cleaning systems such as OEM Baghouse, this means that we take full responsibility for system development, component selection, procurement, installation, and integration into both existing production lines and new facilities.
OEM (Original Equipment Manufacturer) Baghouse refers to a type of dust collection equipment manufactured according to customer specifications. These systems are designed to remove solid particles, such as dust, from industrial gases—an essential process for meeting environmental standards and safety regulations. Within EPC projects, we not only design and install the equipment but also ensure its seamless integration into the overall production system, guaranteeing its efficiency and reliability.
Client Communication
Our company requests that you consider the possibility of manufacturing and delivering two units of bag filters to our address.
Attached are the questionnaire and an additional appendix in the form of a system diagram.
Parameter | Value/Details |
Process Description | Appendices to the Questionnaire |
Principal schematic (description) of the production process | Appendix |
Volumetric flow rate and temperature of the gas-dust stream | 50,000 CFM |
Dust concentration at the inlet to the air cleaning system | 0,011 gr/ft³ |
Particle size and distribution by fractions (granulometry) | Not specified |
Name and concentration of harmful gases at the inlet | Not specified |
Required cleaning efficiency at the outlet | 0,002 gr/ft³ |
Bulk density | 0.032-0.056 lb/ft³ |
Gas and dust temperature | 210-230°F, maximum 2200°F |
Physical properties | Hygroscopicity, Caking |
Required material for equipment manufacture | Carbon steel |
Operation mode (continuous/intermittent) | Continuous |
Characteristics of the existing dust and gas cleaning system | Newly installed |
Proposed location of the newly developed dust and gas cleaning system | Outside production area |
Filter regeneration preferences (reverse air cleaning, compressed air cleaning, vibration, no cleaning) | Reverse cleaning or vibration |
Compressed air parameters | Working pressure: 870 psi, Dew point temperature: -31°F |
Air discharge system | |
Discharge method (manual, automatic) | Automatic |
Discharge system operation mode | Continuous |
Required bottom mark of discharge flanges | Determined by the project |
Special requirements for discharge | |
Need for transporting cleaning products | Pneumatic transport |
Specific type of discharge device | Sluice conveyor |
Explosion and fire safety requirements | None |
Need for recirculation of cleaned air | No |
ADDITIONAL REQUIREMENTS | Please mark with a + where applicable |
Filter housing with filling | + |
Explosion-proof execution | |
Firefighting system | + |
Heat insulation of the housing | + |
Service room made of corrugated steel | |
Service room made of sandwich panels | + |
Filter material Nomex (400°F) | |
Filter material with water and oil-repellent properties | + |
Filter material with special properties | |
Air intake valve before the filter | |
Hopper without screw conveyor | |
Double hopper without screw conveyors | |
Large volume storage hopper | |
Hopper with screw conveyor | |
Hopper vibrator | + |
Dust level sensor | |
Heat insulation of the hopper with sandwich panels | + |
Additional screw conveyor (connection screw), length 4-26 feet | |
Local control panel for screw conveyor and/or sluice valve | |
Dust discharge valve "Double flashing" type | |
Sluice rotary valve with drive, no speed control | + |
Sluice rotary valve with drive and speed control | |
Dust slide valve with manual drive | |
Shelter for the hopper room made of corrugated steel | |
Heat-insulated shelter for dust discharge room made of sandwich panels | |
Shelter for dust discharge room in transport made of corrugated steel, height = 13 feet | |
Heat-insulated shelter for dust discharge room in transport made of sandwich panels, height = 13 feet | |
Compressed air dryer | |
Regeneration system heating (operational down to -40°F) | + |
Compressor unit | |
Support platform with standard dust discharge height from the ground – 60 inches | |
Ladder | + |
Guardrails | + |
One such filter is available, made for a client, you can come and see it in person at our warehouse. Please feel free to ask any questions.
Option for arrangement in a row:
Also, regarding your previous proposals, the baghouse in two rows is more suitable for us as it is much more compact.
Name | Baghouse |
Quantity | 2 |
Dimensions (L x W x H), max. | 310 x 236 x no restrictions |
Operating Parameters | |
Airflow capacity | 40 000-60 000 cfm |
Filtration surface area | Determined by the developer |
Number of filter bags | Determined by the developer |
Filtration speed per minute | Determined by the developer |
Material of the bags | Determined by the developer |
Number of modules | Determined by the developer |
Max pressure (vacuum) inside the apparatus | Determined by the developer |
Temperature | 300°F |
Aerodynamic resistance | 0.3 psi |
Medium | Complex additives: |
- Superplasticizer | |
- Technical lignosulfonates | |
Composition | Powder from light yellow to brown color (H2O content not more than 10% by weight) |
Bulk density of the medium | 22 ÷ 44 lb/ft³ |
Toxicity | No |
Explosion hazard | No |
Fire hazard | |
Dust mass concentration at the filter inlet (max.) | 26 grains/ft³ |
Dust mass concentration at the filter outlet (max.) | 0.0022 - 0.0044 grains/ft³ |
Operating conditions | |
Location | Outdoor installation |
Need for insulation | Yes |
Need for installation of welded parts for insulation | Yes |
Apparatus Service Life | At least 20 years |
Climatic Conditions | |
Ambient air temperature, °F: | |
– absolute maximum | 105 |
– absolute minimum | -15 |
– lowest 5-day average with a 0.92 reliability | 10 |
Average relative humidity, % | |
– coldest month | 83% |
– warmest month | 72% |
– barometric pressure, Pa | 994 |
Delivery Package |
Fully factory-ready apparatus with a full set of required equipment. |
Include in the delivery: |
– Control panel |
– Screws, conveyors, sluice feeders |
– Shut-off valves with electric drive |
– Vibrating shakers with electric drive |
– Electric heating for pneumatic system, filter hopper cone, product discharge system |
– Clean air outlet collector |
– Heat insulation for modules, inlet/outlet ducts, valves, product discharge system |
Electric Heating Requirements |
1. Electric heating should be factory-ready |
2. The electric heating system is to maintain the required temperature (no less than +41 °F) |
3. Provide electric heating and control heating for each module separately |
4. The electric heating system must contain: |
– Heating part, consisting of heating cables, the heating cables should be self-regulating |
– Materials and equipment for securing heating cables and control systems |
– Control system, consisting of thermostats for controlling heating sections and sensors with their fastenings |
5. The location of thermostats and power input boxes for heating sections should be near the heated areas, power input boxes at the filter block boundary, to be coordinated with the Design Organization |
6. The supplier must provide the calculated power consumption for each circuit, reflecting power consumption at both start-up and during normal operation under normal conditions, and the starting currents at temperatures of: +50°F, +40°F, 32°F, 14°F, and -20°F |
7. The electric heating system for the filters should be alternating current with a supply voltage of 220V, 50Hz, neutral grounding system TN-S |
8. Heating cables placed on heated surfaces should have proper protection from mechanical damage and appropriate labels warning personnel about the prohibition of mechanical impacts |
9. The lengths of the supplied cables and the equipment set should have a 10% technological reserve |
10. Cable materials must be resistant to the surrounding environment |
11. Operating mode of the electric heating system – continuous |
12. The electric heating system must comply with environmental protection and ecological safety requirements |
13. Electrical equipment must have external grounding terminals, marked with the appropriate symbol |
14. Junction boxes and equipment must have corrosion-resistant cable entries for connecting power cables with copper conductors |
15. Power cables must be rated for 0.6/1.0 kV |
16. The electric heating system should be controlled by an electronic thermostat located in its own enclosure |
17. The electronic thermostat should ensure: |
– Turning on and off the heating section power based on temperature sensor |
– Alarm for low temperature |
18. Provide visual indication of the electric heating system operation on-site |
19. Electrical equipment should have an IP rating of at least IP 65 |
20. Electrical equipment should operate at ambient temperatures from -45 to +110°F |
21. Detailed list of spare parts for two years of operation, including catalog numbers |
22. The supplier must: |
– Calculate the electric heating system for the heated equipment using heating cables, indicating the installation method (linear, two-row, spiral, etc.) |
– Calculate heat losses and justify the chosen type of heating cables and equipment |
Documentation Package |
Equipment Drawings |
Installation Instructions |
Operating Manual |
Electrical Schematics |
Electrical Connection Schematics |
Values of Power Consumption for the Electric Heating System |
Technical documentation will be provided in electronic PDF format |
Additional Instructions |
1. The material construction of the equipment should ensure its resistance to minimum temperatures during transportation, storage, installation, and operation |
2. The dimensions and weight of the delivered equipment should comply with the requirements for transportation by rail and road according to the "Rules for Cargo Transportation by Road" |
Other |
Technical documentation for equipment manufacturing should be agreed with the design organization |
I am also attaching the drawing of the Baghouse that was at the beginning of the project. Please check if you can offer a similar option?
Photo
Proposed Solutions
Blizzard Bag Filter – a base model upgraded for the client.
Baghouse Specifications for the Client:
- Gas temperature: 210-230°F, maximum 2200°F
- Filtration efficiency: up to 0,002 gr/ft³
- Dust concentration at the inlet: up to 0,0264 0,0264
- Aerodynamic resistance: 0.3 psi
- Material: carbon steel
- Operating mode: continuous
- Dust discharge system: rotary airlock valve with automatic control
- Thermal insulation: filter, air ducts, dust discharge system
- Climatic conditions: from -15°F to +105°F
Technologies, Speed, Results: Baghouse in Action
As of now, our BagHouse has been operating in standard mode since 2022. This client has become a long-term partner, with whom we have already completed a dozen new projects.
Client's Conclusion
I want to highlight the approaches we implement in our production to reduce environmental impact.
— All modernization efforts for our existing facilities, as well as the construction of new production capacities, are designed and executed with environmental safety as the top priority. We select modern equipment tailored to specific technologies and emissions, ensuring maximum efficiency in addressing environmental concerns.
It is important to understand that these initiatives are capital-intensive, systematic, and long-term. They typically take between three months and three years to implement. In some cases, our environmental measures may even contradict economic feasibility. However, we recognize that they are fully justified.
Investing in expensive equipment alone is not enough. It is equally essential to cultivate a production culture that prioritizes compliance with technological processes, proper equipment usage, responsible resource management, and employee education. Ensuring that staff strictly adhere to environmental safety measures is a key component of our approach.
In my opinion, all modern enterprises must make a fundamental decision: environmental responsibility should always come first. At our company’s plants, this principle was adopted long ago.
Our environmental program accounts for regional climate conditions and peak loads. This commitment is recognized and appreciated not only by our employees and local residents but also by industry experts. We have developed an advanced environmental monitoring system, including accredited mobile laboratories that conduct continuous air quality assessments. Additionally, our stationary laboratories are regularly upgraded with cutting-edge equipment to enable real-time monitoring across multiple parameters. These assessments, sometimes conducted unexpectedly, provide us with confidence in our compliance—something validated by the fact that we have never received any violations.
Beyond reducing negative environmental impact, we also strive to make a positive difference. Our company actively supports various green initiatives, participates in environmental awareness campaigns, contributes to regional greening projects, and organizes eco-events for young people.
All industrial equipment inevitably impacts the environment in some way and generates waste. The key question is the level of responsibility with which management approaches this challenge.
Best Baghouses for Polymer Production Site
Vladimir Nikulin
