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Home / Case Studies / Metallurgical Plant Baghouse for Foundry Dust Collection and Efficient Discharge
Metallurgical Plant Baghouse for Foundry Dust Collection and Efficient Discharge
Client
Our client is a leading metallurgical enterprise. The company specializes in manufacturing various metal products and components for the aviation, automotive, and construction industries. The plant is equipped with modern machinery and technologies to ensure high product quality and efficient production processes.
One of the key manufacturing processes at the plant involves using a vibrating screen for cleaning sand molds. The sand mold is placed on a vibrating screen, which effectively removes dust and fine particles. The separated dust is then transported via a conveyor to a dedicated storage container.
The company actively invests in developing new technologies and improving production equipment. This not only enhances product quality but also optimizes production processes, reducing costs and production time.
One of the key manufacturing processes at the plant involves using a vibrating screen for cleaning sand molds. The sand mold is placed on a vibrating screen, which effectively removes dust and fine particles. The separated dust is then transported via a conveyor to a dedicated storage container.
The company actively invests in developing new technologies and improving production equipment. This not only enhances product quality but also optimizes production processes, reducing costs and production time.
Project Feature
The client requested modifications to the standard equipment to increase the dust discharge height from the baghouse, allowing it to be unloaded into big bags. After some time, the client's concept changed, and they decided to unload the dust into a truck instead.
Production Process
Manufacturing of metal products in sand molds.
Problem
High dust levels that hinder workers and negatively impact the entire production process.
Task
The task is to supply and install a baghouse for dust aspiration in the casting knockout area of a metallurgical plant. The system must handle an airflow rate of 26,000 m³/h, with provisions for unloading dust into vehicle transport. The baghouse should be equipped with a rotary valve system, vibration motors for the dust bins, and other necessary equipment to ensure efficient dust collection and discharge.
Current system component
Equipment — vibrating screen for knocking out sand molds after metal casting. There is no dust removal system.
Temperature
+35 to -20 °C
Gas/Dust
Foundry dust
Initial Data
Client Communication
Client:
Good afternoon!
Our organization is planning to purchase a baghouse for the aspiration of the casting knockout area, and the contractor has selected your Blizzard Pulse Jet Baghouse (a setup of 3 units). The requested commercial proposal is attached.
The required system capacity is 26,000 m³/h.
There is a significant amount of dust, but I am afraid there is no way to determine its exact concentration, so I will describe the technological process:
1) What is the purpose of the connecting inlet and outlet ducts? The contractor claims that this option is not necessary for us.
2) Regarding the baghouse supports – As I understand, the standard leg length of the baghouse does not allow for a dust collection container. Would it be possible to extend them by 700 mm to accommodate a big bag for dust collection?
Looking forward to your response. Thank you!
Our organization is planning to purchase a baghouse for the aspiration of the casting knockout area, and the contractor has selected your Blizzard Pulse Jet Baghouse (a setup of 3 units). The requested commercial proposal is attached.
The required system capacity is 26,000 m³/h.
There is a significant amount of dust, but I am afraid there is no way to determine its exact concentration, so I will describe the technological process:
- Vibrating screen – a sand mold is placed on the screen from the furnace, the screen vibrates, causing the dust to fall off and move along the conveyor into a container.
- Air intake points – above the vibrating screen itself, above the conveyor, and in the container where the dust is collected.
1) What is the purpose of the connecting inlet and outlet ducts? The contractor claims that this option is not necessary for us.
2) Regarding the baghouse supports – As I understand, the standard leg length of the baghouse does not allow for a dust collection container. Would it be possible to extend them by 700 mm to accommodate a big bag for dust collection?
Looking forward to your response. Thank you!
Baghouse Supports
Engineer Torch-Air:
Good afternoon,
↩ What is the purpose of the connecting inlet and outlet ducts? The contractor claims that this option is not necessary for us.
These are ducts/airways designed to connect all three baghouses into one system. If your contractor is handling the ductwork themselves, then ours are not needed.
↩ I am also interested in the baghouse supports. As I understand, the standard leg length does not allow for a dust collection container. Would it be possible to extend them by 700 mm to accommodate a big bag for dust collection?
Of course, that is not a problem.
↩ What is the purpose of the connecting inlet and outlet ducts? The contractor claims that this option is not necessary for us.
These are ducts/airways designed to connect all three baghouses into one system. If your contractor is handling the ductwork themselves, then ours are not needed.
↩ I am also interested in the baghouse supports. As I understand, the standard leg length does not allow for a dust collection container. Would it be possible to extend them by 700 mm to accommodate a big bag for dust collection?
Of course, that is not a problem.
Client:
Please kindly prepare a new proposal.
Engineer Torch-Air:
Good afternoon!
I have a question regarding the discharge process.
If we use a sealed drum for dust collection, we can simply install a basic knife gate valve, allowing the dust to fall freely into the container.
However, if a big bag is used, the discharge must be sealed properly, requiring one of the following valve options:
I have a question regarding the discharge process.
If we use a sealed drum for dust collection, we can simply install a basic knife gate valve, allowing the dust to fall freely into the container.
However, if a big bag is used, the discharge must be sealed properly, requiring one of the following valve options:
- Manual disc valve
- Double-flap valve
- Rotary automatic valve
- The manual disc valve adds approximately 200 mm.
- The double-flap valve is the longest, adding about 600–700 mm.
Diagram
Client:
The baghouse we currently have, which is due for replacement, is equipped with a standard slide gate (which I understand is the knife gate valve). This option works perfectly for us. Once the bag is filled, it is tied up and sent for disposal as is.
So, in our case, the simpler the mechanism, the better.
The 700 mm height was based on the distance from the lowest point of our existing gate valve to the floor.
So, in our case, the simpler the mechanism, the better.
The 700 mm height was based on the distance from the lowest point of our existing gate valve to the floor.
Photo of the equipment
Client:
We are making some changes to the technical specifications. Let me reiterate:
Airflow rate 26,000 m³/h, I will select the fan myself, for now, only the baghouse is needed.
Facility: Metallurgical plant.
Contaminants: Sand and soil dust (metallurgy), dust-laden air temperature up to -20°C, the baghouse will be installed in a cold room, discharge is likely to the outdoors, the ceiling height of the room where the filter is installed is 12m.
Dust discharge into vehicle transport. I am attaching the questionnaire form. The initial dust concentration is high, as can be seen in the attached video.
Airflow rate 26,000 m³/h, I will select the fan myself, for now, only the baghouse is needed.
Facility: Metallurgical plant.
Contaminants: Sand and soil dust (metallurgy), dust-laden air temperature up to -20°C, the baghouse will be installed in a cold room, discharge is likely to the outdoors, the ceiling height of the room where the filter is installed is 12m.
Dust discharge into vehicle transport. I am attaching the questionnaire form. The initial dust concentration is high, as can be seen in the attached video.
Engineer Torch-Air:
The baghouse proposal is in the attached file, along with the drawing. We recommend using the baghouse with rotary valves, as it is more convenient than manually opening and closing the gates during dust discharge. The rotary valves can be operated by a button.
Additionally, at the exit of the rotary valves, silencers will be installed to prevent the dust from scattering when unloading into the truck.
I have also included vibration motors for the dust bins in the proposal. They will help knock off the "stuck" dust from the walls of the bin during discharge into the truck.
The preliminary drawing is attached in the file.
Additionally, at the exit of the rotary valves, silencers will be installed to prevent the dust from scattering when unloading into the truck.
I have also included vibration motors for the dust bins in the proposal. They will help knock off the "stuck" dust from the walls of the bin during discharge into the truck.
The preliminary drawing is attached in the file.
Characteristics | Information |
Volume of air | 26 000 m³/h |
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 without additional equipment | 0,2 kW |
Temperature | 180 °F |
Dust concentration inlet | 3 g/m³ |
Output dust concentration (For dust from 0.5 microns) | 10 mg/m³ |
Baghouse Blizzard Drawing
Client:
Great! Everything is satisfactory, please send the invoice.
Engineer Torch-Air:
I am attaching the final drawing and visualization.
Final Drawing
Baghouse Blizzard Visualization
Proposed Solutions
To address the client's needs, we have proposed the installation of the Blizzard Pulse Jet Baghouse with the following features:
- Airflow Rate: 26,000 m³/h to handle the required dust load.
- Rotary Valves: To simplify the dust discharge process. The valves will be operated by a button and are equipped with silencers to prevent dust scattering when unloading into the truck.
- Vibration Motors: Installed on the dust bins to assist in knocking off "stuck" dust from the walls of the bins during the discharge process.
- Temperature Range: The baghouse is designed to operate in a cold environment, with the ability to handle dusty air temperatures as low as -20°C.
- Filter Material: Polyester, providing excellent filtration efficiency and durability.
- Filter Cleaning System: Pulse Jet (air) cleaning system for effective dust removal.
- Dust Concentration: The baghouse is designed to handle dust with an inlet concentration of 3 g/m³, and it will output a dust concentration of 10 mg/m³ for particles from 0.5 microns.
Summary
The baghouse has been operating in normal mode since 2022. The cleaning efficiency satisfies both the client and the inspecting organizations. Periodic replacement of filter elements (bags) occurs approximately once every 8-12 months, depending on the intensity of use and production load. The client has become our regular partner.
Best Baghouses for Foundry Dust
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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