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Home / Case Studies / Optimizing Filtration for High-Dust Sand Operations
Optimizing Filtration for High-Dust Sand Operations — A Detailed Look at Warren’s Case
Not measured, but very high.
Dust Amount
Ambient.
Temperature
Dust, sand of various fractions.
Type of Contaminants
Baghouse, fan, ductwork, and dust suction hoods.
Current System Components
Identify the cause of the problem and propose an optimal solution.
Task
The air cleaning equipment is malfunctioning. Filter bags wear out faster than expected. Consequently, after the bags wear out, the fan is subjected to abrasive sandblasting, leading to its failure as well.
Problem
Air mixed with sand is extracted from several dust generation points at transfer, drying, and crushing locations.
Production Process
Warren — One of the largest sand suppliers in Oklahoma and Texas.
Client
Initial Data
Client Communication
Client Warren:
Does the Spark Arrestor disrupt the air enough to reduce the velocity in which it enters the baghouse and passes over the filter bags?
Engineer Torch-Air:
Hello!
The Spark Arrestor has minimal aerodynamic resistance
The Spark Arrestor has minimal aerodynamic resistance
Client Warren:
We have a 48" duct going into our baghouse, and we are looking at any options that might assist in reducing some of the velocity we currently have. When you say, "minimal resistance" are there any numbers available that we can see in reference to resistance? Spark is not an issue at our facility, but we did speak with an engineer that mentioned the spark arrestor as a possibility.
Engineer Torch-Air:
Do you want to reduce the airflow velocity inside the duct? It’s unclear what you mean by «reducing some of the velocity we currently have».
Client Warren:
We are wanting to reduce the velocity of the air as it enters the baghouse. Right now, the velocity is too great as it enters the baghouse which is causing damage to the bag filters and allowing sand particles to reach the fan. The fan is being sand blasted, and this is causing significant wear on the fan and reducing the life of the fan by several months. Hopefully this helps.
Engineer Torch-Air:
Unfortunately, a spark arrestor will not reduce the airflow velocity. To address your issue, we need to identify the root cause and correct the mistake. From what you’ve mentioned, it seems the problem might be that the fan is too powerful for the baghouse filter. However, this is just an assumption. Here’s how we recommend approaching this:
- Measure the airflow: Determine the actual airflow in the system.
- Check the fan’s performance: Verify the fan's capacity and its compatibility with the system.
- Compare data: Compare the airflow and fan performance with the specifications of your baghouse.
- Replacing the fan if it is overpowered for the application.
- Upgrading the baghouse filter if the fan is properly sized but the baghouse filter is not suitable for the airflow volume.
- Installing a cyclone at the inlet to reduce dust load on the filter bags, minimizing wear and tear.
Work Performed
- On-site visit to the client and visual inspection of the system.
- Measurements of the entire system using an anemometer and calculation of the actual performance of the air cleaning equipment.
- Review of the air cleaning project and documentation for the fan and baghouse.
- Analysis of discrepancies between the air cleaning system operation and the original design.
Diagnostic Report
- The fan is operating outside its optimal mode, exceeding airflow specifications.
- The baghouse filter is incorrectly selected — its filtration area is too small even with the fan running correctly. Given the higher-powered fan, the baghouse filter is clearly underperforming. This results in an airflow velocity through the filter that is twice the intended rate.
- The baghouse filter lacks protective measures to reduce abrasive wear on the bags.
Proposed Solutions
We have several ways to solve the client’s problem: either with minimal operating costs (optimal) or with minimal initial investment (economical).
Optimal Balanced Solution
Since the client is satisfied with the system’s suction performance, the current fan can remain in place, but the baghouse should be replaced. This is the optimal solution with minimal operational costs.
Additionally, the baghouse dust collector must be protected from abrasive dust using a high-efficiency cyclone or dust chamber. Despite standard dust deflectors included in our equipment, heavy dust loads may still cause wear. We always recommend additional protection for equipment exposed to high-abrasive particles, which cause rapid wear in areas of friction. Sand, after all, is commonly used in sandblasting.
This solution ensures correct airflow velocities within the cyclone and baghouse, delivering maximally clean air to the fan. We do not recommend switching to a cartridge filter instead of a baghouse in cases of heavy dust loads, as it may lead to other complications. Using this approach, we optimize air-cleaning efficiency and extend the lifespan of filter elements and the fan — exactly what the client wanted.
Additionally, the baghouse dust collector must be protected from abrasive dust using a high-efficiency cyclone or dust chamber. Despite standard dust deflectors included in our equipment, heavy dust loads may still cause wear. We always recommend additional protection for equipment exposed to high-abrasive particles, which cause rapid wear in areas of friction. Sand, after all, is commonly used in sandblasting.
This solution ensures correct airflow velocities within the cyclone and baghouse, delivering maximally clean air to the fan. We do not recommend switching to a cartridge filter instead of a baghouse in cases of heavy dust loads, as it may lead to other complications. Using this approach, we optimize air-cleaning efficiency and extend the lifespan of filter elements and the fan — exactly what the client wanted.
Economical Solution
The budget-friendly option involves installing a cyclone (mechanical separator) or dust chamber before the baghouse. This would reduce the dust load on the baghouse and extend the lifespan of the bags. Highly efficient cyclones capable of capturing up to 99% of sand dust are available.
Drawback: The airflow velocity in the filter would still exceed the design parameters, leading to premature wear of the filter bags. The degree of improvement to the maintenance schedule is uncertain but would definitely be better than the current situation.
Drawback: The airflow velocity in the filter would still exceed the design parameters, leading to premature wear of the filter bags. The degree of improvement to the maintenance schedule is uncertain but would definitely be better than the current situation.
Client's Decision
Since the client was satisfied with the system’s suction performance and wanted to avoid high operational costs, they chose the optimal solution with minimal operational expenses — replacing the baghouse and adding a cyclone — Torch Cyclone Baghouse.
The Best Dust Collectors for Sand 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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