R&D Project: Custom OEM Baghouse Solution for Polymer Modified Asphalt & Warm Mix Production

Question 1

Client:

Good afternoon,
We require a Blizzard baghouse filter with a capacity of approximately 24,000-30,000 CFM. Please send us a technical and commercial proposal (TCP) indicating the delivery time and cost for two units.

Technical Requirements:

Product:

Polymer Modified Asphalt Cement
Warm Mix Asphalt

1. System Performance

Air Volume: 24,000-30,000 CFM (cubic feet per minute)
Pressure: Medium negative pressure at the inlet, compatibility with the ventilation system needs to be confirmed.

2. Dust Characteristics
Dust Type: Dust generated during the production of asphalt additives and modifiers includes:

Polymer dust (polyethylene, polypropylene) – 60%
Mineral fillers (chalk, limestone, ash) – 30%
Asphalt particles – 10%

Dust Particle Size:

Average particle size: 5–10 µm
Ultrafine particle fraction (<2 µm): 20%
Coarse particle fraction (>20 µm): 10%

Dust Concentration at Inlet:

Average concentration: 13 grains/ft³
Maximum concentration: 26 grains/ft³

Required Dust Concentration at Outlet:

Must comply with EPA and OSHA regulations.

3. Temperature Conditions

Inlet Temperature: 250–350°F (121–177°C)
Temperature Peaks: up to 400°F (204°C)
Filters must be heat-resistant to withstand peak temperatures.

4. Filtration System Characteristics
Filtration Type:

Pulse Jet System (compressed air pulse cleaning for effective filter maintenance).

Filter Material:

Aramid (Nomex) with PTFE membrane for high-temperature resistance, chemical inertness, and reduced dust adhesion.

5. Filter Housing

Material: Carbon steel.
Insulated housing to prevent condensation in low temperatures.
Designed considering the climatic conditions of the operation region.

6. Dust Emission & Disposal System
Dust Collection System:

Hoppers (cone or flat-bottom design, depending on layout) with rotary airlock feeders.
Sealed system to prevent secondary emissions.

Additional Components:

Manometers for monitoring pressure differential.
Automated control and alarm system for operational deviations.

7. Environmental Conditions

Operating Climate: North Carolina, USA (resistant to humidity, temperature fluctuations, snow).

8. Additional Parameters
Compliance Standards:

OSHA – Workplace safety regulations.
EPA – Emissions and environmental regulations.
NFPA – Explosion risk assessment (spark suppression, grounding).

Other Requirements:

Noise Level: <85 dB at 3 feet distance.
Power Consumption: To be determined based on selected equipment.

9. Operation & Maintenance Conditions

Filter lifespan: 14–24 months under normal operating conditions.
Regular maintenance for filter cleaning system performance monitoring.

Best regards,
Head of Capital Construction Department

Answer

Good afternoon,
I am attaching two options: one for 24,000 CFM and the other for 30,000 CFM.

Question 2

Client:

Good afternoon,
We would like to invite a specialist from your organization to visit our facility to determine the most suitable filter for our needs on-site.
Best regards,
Head of Capital Construction Department

Answer

Good afternoon,
Sure, our design engineer, who specializes in baghouse filters, will visit you. You can discuss the technical details with him. His name is Alexander, and he will call you tomorrow.
During the discussion, our Technical Director will also be in contact for any technical questions. For commercial matters, feel free to discuss them with me.

Question 3

Engineer Torch-Air:

Good afternoon,
The proposal in the attached file is based on the analysis of the data received during the trip. Here are the comments regarding the technical proposal:

The gas flow velocity through the bags has been reduced to 3.28 feet per minute, which is why the filtration area is 8,100 square feet. This has resulted in the need for a larger filter housing.
The bags inside the housings are spaced further apart, which will positively affect the reduction of "bag sticking" and decrease the formation of a "dust arch" at the top of the bags. This, too, has led to an increase in the filter size (I am attaching a visualization).
We are installing reinforced electromagnetic valves for a stronger pneumatic pulse.

Comments on the commercial side and filter dimensions:

If the dimensions do not fit, we can develop a different filter housing. Initially, we will provide an approximate design based on the required number of bags, and then refine the details after the agreement.
If the cost is too high, we can reduce the distance between the bags, which will allow us to fit them into a more compact housing. However, this may increase the "sticking" of the bags.
If this turns out to be too expensive, we can reduce the number of filters inside the housing. Instead of 8,100 square feet, the filtration area will be 5,400–6,500 square feet. This will make the filter smaller, but the gas flow speed will increase, and, accordingly, the sticking effect will become more intense.
If you have any specific requirements, we are, as always, ready to accommodate them.

Question 4

Client:

Please send options for 8,100 square feet and 7,500 square feet.

Best regards,
Head of Capital Construction Department

Answer

Good afternoon,
Please take a look at the layout options:

Option 8100 – This is a filter with 8,100 square feet of filtration, BUT the bags are placed closer together (not spaced out). The risk of "arch" formation increases. The drawing is attached.
Option 7500 – This is TWO filters with 7,500 square feet of filtration, BUT the bags are spaced farther apart. This reduces the possibility of arch formation. The drawing is attached.

You can review the dimensions on the diagrams.
Which option would be more suitable for you?

Question 5

Client:

Good afternoon,
I’m having trouble arranging the baghouses on our new planned site. We’ve decided to place the equipment there after all. I’m attaching the proposed layout, with the area for the baghouse highlighted in the center. Could you please help, as I’m not very proficient with CAD programs?

Best regards,
Head of Capital Construction Department

Question 6

Engineer Torch-Air:

This is how the baghouses are arranged, but we don't have enough space for connecting the flues, and it will be inconvenient for dust removal and maintenance. Are there any other layout options?

Question 7

Client:

Hello,
Attached is the filter layout with reference to our new site (third one). Please send a proposal for this location, as we discussed during the Zoom meeting, and provide the dimensions of the filter supports for foundation planning.

Best regards,
Head of Capital Construction Department

Question 8

Engineer Torch-Air:

Good afternoon,

I am sending you the proposal for the baghouses along with the drawings containing all dimensions. This baghouse has been specifically designed for your requirements.
If you have any questions, feel free to call or write.

R&D Project: Custom OEM Baghouse Solution for Polymer Modified Asphalt & Warm Mix Production

Initial Data

Commentary by Michael Klepik, CEO of Torch-Air

Client Communication

After the trip and the analysis of the received data

Proposed Solutions

Summary

Best Baghouse Solutions for Polymer Modified Asphalt Cement & Warm Mix