Category Archive: Bag House

Different Baghouse Styles: Advantages and Disadvantages

When it comes down to finding the right dust collection system, there are a few different baghouse styles to choose from. So how do you know which one is best for you?

Baghouse Styles

Before we dig into the differences between some of the baghouse styles, you need to consider your dust properties and air-to-cloth ratio.  Baghouses are ideally suited for large volume applications with airflow exceeding 1,000 CFM or when high temperature applications are above 375 degrees.  In these environments, a baghouse will handle and most efficiently filter your dust laden air. 

There are three main baghouses styles (e.g. shaker, reverse, and pulse-jet)  that are commonly used in most industrial processing and manufacturing applications.  Here’s a brief overview on the pros and cons of each to help guide you in identifying the right option for your work environment.

Pulse Jet Baghouse 

Pros:    Cons:
Constantly cleaned so there is minimal dust build up in the dust collector   Requires dry compressed air
Space Efficient   Cannot be used when there is humidity of high moisture content present
Requires fewer bags   Cannot handle high temperatures (unless you use special filter media
     

Reverse Air Baghouse 

Pros:  Cons:
Can handle high temperatures Needs to be cleaned often
Gentle cleaning which allows for longer bag life Residual dust build up is hard to remove
Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse Low air-to-cloth ratio
   

Shaker Baghouse 

Pros:     Cons:
Very simple to operate     Cannot handle high temperatures
Low initial investment cost     Not space efficient (takes up a large area)
Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse     Energy and time sensitive 

5 Ways a Dust Collection System Improves Plant Efficiency and Saves Money

Why you may need a new dust collection system for your application and how a new system can improve operations.

What is a Dust Collection System?

Dust collection systems are engineered and designed to filter airborne dust particles and debris that can cause damage to plant equipment, create a hazardous work environment, and negatively impact plant production.

Installation of a new dust collection system for your facility either by replacing an old unit or expanding your existing operation, can mean an improvement in plant maintenance, waste collection, an increase in product quality, and plant efficiency and production. A new dust collection project can be a long process. Let’s start by exploring the top 5 benefits of a dust collection system.

Baghouse

The Top 5 Benefits of a Dust Collection System

  1. Meet Compliance Regulations and Standards
  2. Boost Productivity
  3. Improve Product Quality
  4. Enhance Health and Safety Standards
  5. Preserve Quality of Equipment

Meeting Compliance Regulations and Standards

Many industrial industries in the U.S. must comply with strict air pollution control standards . These standards can be set by the Environmental Protection Agency (EPA), National Fire Protection Agency (NFPA), OSHA, or local governing entities such as the AQMD in California.

All agencies require industrial facilities to maintain and meet air quality standards to ensure a safe and clean environment for their plant, employees, and the surrounding community. To get started on what air permits may be needed for your specific application and location, check out our guide on dust collector air permits.

The risks of non-compliance are health and safety risks to employees, explosions, failed inspections, and fines from agencies such as the EPA. All companies, large or small, are susceptible to these risks. Cemex, one of the largest producers of cement in the U.S. was fined by the EPA for $1.4 million in 2011 for exposing people to sulfur dioxide and nitrogen oxide emissions. Cemex was also ordered to install pollution controls at its Ohio cement plant as part of the settlement.

Enhance Production

An accumulation of dust particles and debris on industrial equipment can interfere with overall plant performance. A dust collection system can collect these dust particles before they can interfere and compromise the health and performance of your manufacturing equipment. When your dust collection system is not performing well either due to extended wear and tear, or because your dust collector is undersized and overextended, your entire operation is at risk. Maintenance issues that go unchecked can result in an unexpected plant shut down that can close down operations for days, weeks or more. It may be difficult to know if your unit is undersized, overextended, or too old. In these cases, consult with a dust collection engineering firm and request an engineering study. By doing so you’ll get recommendations that can minimize the risk of inefficient and poorly working equipment as well as frequent and costly maintenance.

Improve Product Quality

For many manufacturing facilities, dust in the air can mean dust on their products. Dust can settle and accumulate on products during the manufacturing process. This has a negative impact on the quality and consistency of finished goods. A dust collector will reduce and effectively capture these dust particles, allowing for product quality to improve and maintain consistency.

Enhance Health and Safety Standards

Inhalation of hazardous dust affects human health and a dust collection system is vital to removing these hazards and to keep employees safe. Industries like woodworking, chemicals, iron casting, asphalt, etc. operate facilities that continuously emit hazardous contaminants, debris, gasses, and chemicals. If the hazardous dust particles and debris aren’t removed, employees inhale this polluted air and are at risk for both short-term and long-term health issues. A dust collection system can minimize this hazard. To get a better understanding of the long and short term health risks check out this guide on the health impact of dust collection systems.

Dust Collection Safety

Another serious risk for the company is the possibility of a fire or explosion due to an accumulation of combustible dust. There are only four conditions needed for an explosion to occur:

4 Conditions That Create an Explosion

  • Oxygen
  • Enclosed Space
  • Ignition Source
  • Combustible Dust at the Right Concentration Level

Do you work in an industry with combustible dust? Some of the industries that are susceptible are:

Agriculture (grain, flour, sugar, etc.)
• Wood
Metals (aluminum, zinc bronze, etc.)
• Rubber
Chemicals (coal, sulphur, etc.)
• Pharmaceuticals
• Pesticides
• Plastics
• And More

Learn how you can prevent a dust collector explosion with these resources we’ve gathered together here.

Preserve the Quality and Prolong the Life of Equipment

When dust particles and debris are created inside a manufacturing facility the contaminated dust settles onto other surfaces such as computer systems and manufacturing equipment. A buildup of dust can be harmful and result in malfunctioning equipment. This can also create unnecessary, frequent, and costly maintenance in order to keep harmful dust and debris from accumulating. With a dust collector system purifying and collecting dust particles, the chances of excessive dust build-up is minimized.

To find out if you may benefit from an engineering study at your facility, contact a US Air Filtration engineer today. If you’re looking for additional resources on dust collection systems and the buying journey, download our free Dust Collector Purchasing Guide that touches on key topics like dust properties, volume, air-to-cloth-ratio, dust collector styles, low maintenance design features, and more.

Video: How Much Does a Dust Collector Cost?

Baghouse Dust Collector FAQ

Table of Contents

Baghouse dust collectors are highly efficient systems used in industrial applications that remove dirt, dust, and debris from the air.  Baghouses improve worker health and safety, protect the mechanics of industrial equipment, and maintain compliance with environmental and workplace safety regulations.

Proper baghouse system design, installation, and maintenance are critical for minimizing plant downtime and maximizing system efficiency and longevity. Important design considerations, such as the airflow and square footage required for your system, will depend on your facility’s workspace and dust collection needs. Once a system is designed and installed, performing regular maintenance is vital for keeping it operating as efficiently as possible. Here, we address some of the most commonly asked questions about these critical systems.

Why do you need to install a baghouse dust collector system?

The primary reason for installing a baghouse dust collector system is to improve air quality by removing potentially harmful airborne particles, gas fumes, and other contaminants generated during manufacturing processes. Depending on the industry and the types of debris being produced, installing a dust collection system may be required in order to comply with air emission guidelines or workplace safety standards. OSHA, for example, requires industrial plants to meet certain indoor air quality standards to prevent dust-related health issues. Before designing a baghouse dust collector system, it is important to research what types of safety and air quality regulations might be applicable to your facility.

Baghouse dust collection systems may also be installed to upgrade, improve, or enhance a facility’s existing dust control strategies. Regardless of your specific reasons for installation, it is important to implement a preventative maintenance program in order to prevent future problems and keep the system operating at optimal efficiency. General steps may include:

  • Making sure the system operates within acceptable levels by monitoring differential pressure, timing controls for pulse valves, compressed air pressure, etc.
  • Regularly emptying drums and hoppers to prevent dust build-up
  • Frequently inspecting valves, hoses, gaskets, filters, and other components and replacing them when necessary

What type of particulate are you looking to filter?

The type of dust being generated in your facility will influence the type of dust collector that should be used. Common types of industrial dust include:

  • Wood dust. Fine wood particles generated during woodworking processes can linger in the air, causing health issues for workers.
  • Pharmaceutical dust. The manufacturing of drugs, vitamins, and minerals generates fine powders that can be highly toxic if inhaled.
  • Food particulates. High levels of dust can be created during the processing of spices, flour, sugar, cornstarch, grains, and other dry food products.
  • Metalworking dust. Metalworking processes can create a harmful mixture of fumes and fine dust ranging from 0.01 micrometer to 1 millimeter in diameter.

Particle size will help you determine the number of filters required and the best type of filter media for your system. While standard filters are usually sufficient for collecting moderate-to-large particles, pleated filters may be necessary to effectively capture very fine particles and fumes. It is also important to select a filter with the appropriate air-to-cloth ratio as this will influence the system’s ability to adequately protect workers from dust and contaminants.

Low filtration efficiency will expose workers to more particles and can increase the risk of explosions. In some cases, coating the filters with a porous particulate layer, known as a precoating, can enhance filtration and improve baghouse system performance.

 

What size of baghouse dust collector system do you need?

Baghouses tend to be larger than other dust collector systems and are typically used for high-volume and high-temperature applications. These systems employ cylindrical fabric filter bags to capture and separate dust particles from the air. The three most common baghouse designs are:

  • Pulse jet. Pulse jet baghouses are self-cleaning filtration systems that use pulses of compressed air to clean the bags.  Cleaning occurs while the system is online.
  • Reverse air. Reverse air baghouses feature a compartmentalized design that allows for the cleaning of individual sections without shutting the entire system down.
  • Shaker baghouses clean bags by mechanically shaking the dust out of them. These are simple to operate and have a low initial investment cost. However, cleaning is performed while the system is offline.

With their versatile and universal design, baghouses can meet a wide variety of industrial dust collection requirements. Common applications range from food production, pharmaceutical manufacturing, woodworking, and metalworking to energy utilities, chemicals, mining, and more. For optimal performance, your baghouse dust collector should be sized and designed to accommodate your facility’s air purification requirements as well as any spatial restrictions. Design considerations should include:

  • Anticipated cost
  • Type of dust being produced and expected dust volume
  • Size of area needing ventilation
  • Collector system size and required flow volume
  • Filter material

Baghouse Filter Bag Media

One of the most important decisions when designing a baghouse system includes selecting the right filter media.  There are a wide range of filter medias available to accommodate a variety of dust characteristics.  Temperature, dust properties such as moisture and abrasion will determine which filter media will provide the best performance and efficiency at your operation.  Here is an overview of the most common filter medias available.

  • Polyester – Polyester’s maximum continuous operating temperature is 275 degrees Fahrenheit and has good overall qualities to resist abrasion and performs well with dry temperatures.
  • PPS – PPS, also otherwise known by the proprietary name Ryton© or Procon©, is a filter bag media that is commonly used in dust collection applications where excellent resistance to acids and alkaline is required.
  • P84 – The stability of P84 filter media is a benefit to a wide variety of applications lime kilns, smelting, incinerators, coal fired boilers, and glass and ceramic industries. It can be utilized in operating conditions of a maximum 500 degrees Fahrenheit and offers a good resistance to mineral acids.
  • PTFE/Teflon – Generally used for severe environments operating at high temperatures. Industries that use PTFE filter media range from cement, steel foundries, and energy.
  • Fiberglass – Fiberglass filter media has been a leading industry standard for air filtration and applications where high temperatures are prevalent.
  • Aramid – Aramid, also known as Nomex©, is widely used in high-temperature applications because of its excellent resistance to abrasion and ability to perform at maximum continuous operating temperatures of 400 degrees Fahrenheit. 

How much do baghouse dust collector systems cost?

Baghouses are custom designed for each unique application and often require advanced engineering to integrate the baghouse system into the overall plant operation. As such, baghouse units typically start at $50,000 to $1 million or more.

To get the best value from your dust collector, it is important to size the system appropriately during the design phase. This will ensure the system captures dust efficiently while reducing energy consumption.

How do you remove dust collected by the baghouse system?

Knowing how to properly dispose of dust once it enters the baghouse system’s hopper is essential for preventing airflow blockages, fire hazards, and other issues. The most common dust removal strategies are:

  • Enclosed box. Dust is funneled into an enclosed box under the hopper that is emptied once capacity is reached.
  • Drum/bag. Dust is collected into a detachable drum or bag, allowing for convenient disposal.
  • Rotary valve. Rotary valves allow materials to be manually or automatically moved from the collector to a disposal drum or bin.
  • Screw conveyor. In large baghouse systems, screw conveyors remove dust by transporting it from the collector to a disposal area.

Most baghouse systems employ rotary valves or screw conveyers for automatic removal of dust.

Baghouses have automated cleaning options with control panels that can be programmed to clean the bags anytime the differential pressure reaches an upper threshold. This enables an ongoing cycle of cleaning that occurs automatically during dust collector operation.

Filters, filter media, and other baghouse components should also be inspected at regular intervals and replaced when necessary. Routine inspections are an essential part of preventing future problems and maintaining optimal efficiency.

How do you enter a baghouse dust collection system for further cleaning?

When entering the baghouse system for cleaning or maintenance, the following measures should be implemented to ensure employee safety:

  • Secure the system by powering down and shutting off valves, blowers, compressed air, etc.
  • Communicate the details of the operation to all employees
  • Wear the appropriate personal protective equipment (PPE)
  • Have additional crew available to assist if needed
  • Thoroughly purge the system of combustible dust before performing any hot work (welding, grinding, etc.)
  • Establish an emergency plan for escape/retrieval

Baghouse Dust Collector Systems from U.S. Air Filtration

Baghouse dust collection systems provide a versatile and efficient solution for capturing particles that are released into the air during industrial activities. At U.S. Air Filtration, we design and manufacture baghouse dust collection systems to accommodate a range of operating conditions and filtration needs. Our solutions are expertly designed and constructed to optimize your facility’s productivity while minimizing maintenance and energy costs.

For assistance with selecting or designing a baghouse dust collection system, please check out our product democontact usrequest a quote, or visit our design services page today.

Rotary Valve FAQ’s

What is a Rotary Valve?

Rotary valves (also known as airlocks, rotary feeders, or airlock feeders) are used to transition material from one pressurized point, such as a dust collector, to another unpressurized point, such as a drum or bin. Rotary valves help seal a pressurized system against loss of air and pressure. Rotary valves also help ensure loss of product during processing is minimized.

Rotary Valve Applications

Typical dust collection applications for rotary airlocks are dust collection, pneumatic conveying, pollution control, mixing, feeding, weighing, drying, and blending. Some of the relevant industries for rotary airlocks include metalworking , cement, minerals, agriculture, wood, paper, rubber, textiles, grains, paint, pharmaceutical manufacturing, and many more.
Typical Products for a Dust Collector Rotary Valve

  • Baking Soda
  • Corn or Corn Meal
  • Cloth
  • Flour
  • Grains
  • Grits (Corn)
  • Minerals
  • Oats (Rolled or Whole)
  • Peanuts (Roasted)
  • Soybean Flakes (Raw or Spent)
  • Starch (Granulated or Powdered)
  • Talcum Powder
  • Paint
  • Tobacco (Ground)
  • Wheat
  • Woodworking or paper pulp
  • Yarn
  • And more

How to prevent a dust collector explosion

Rotary Valve Construction

The main parts of a rotary valve comprise of the following:

  • Housing
  • Vanes
  • Motor (Can come in various combinations for a multitude of applications and environments. For example; speeds, explosion/spark proof, chain driven vs. direct driven, and more.
  • Drive, reducer or gear box which takes speed and converts it into power

Round rotary valve

Rotary Valve Options

Depending on your industry, application, and environment there are a few rotary valve options that could work for your facility. Here are some of those options in further detail:

  • Temperature:
    • High Temperature: Can expand when exposure to high heat. The rotary valves vanes are also shortened to leave a gap between the vanes and housing.
    • Low Temperature: Should be used or low or regular temp
  • Vanes: Standard is 6 vanes but 8 vanes can be made available, but would be more time and cost consuming.
  • Size: Sizes can vary from 6, 8, 10, 12, 14 and larger depending on application
  • Shape – Square or Round
  • Duty: Heavy duty or regular duty
  • Material:
    • Cast Iron (standard)
    • 304 Stainless Steel (resistant to most chemicals)
    • 316 Stainless Steel (resistant to chemicals 304 stainless steel can’t handle)
    • Chrome Plated Cast Iron (harder than steel, best for abrasive material)
  • Tips:
    • Beveled Steel Tips (standard – beveled spins counter clockwise so as not to compact the material and bind the vanes)
    • Replaceable Steel Edge – (good for applications that vary in their process)
    • Urethane Tips (best for large particles that may wedge between the vanes)
  •  Rotor: Open or Closed

Baghouse Cage Construction

Dust Collector filter bags are designed for use in pulse-jet style baghouses and these filter bags require internal support structures referred to as cages. The purpose of a baghouse cage is to provide the support needed for filter bags to stay open during the dust collection cycle.

The type of cage you have will depend on the design of your baghouse; top or bottom load. If you have a top load baghouse , your top construction is a rolled flange top. If you have a bottom load baghouse, your top construction is a split collar top. Besides the top configuration, there are multiple variations and options for cage construction. Below are some of the most common features and configurations for baghouse cages.

Video Option: Guide to Filter Media

Top Construction

  • Rolled Flange Top also referred to as a “Turned Down Flange”. Can come with or without a venturi – Most common for top load baghouses
  • Split Collar – Most common for bottom load baghouses
  • Split Ring
  • Rolled Flange with Handle

Venturi Option

The purpose of a venturi is to help speed up the air being pulsed through the bag. It acts like a turbo booster and ensures a proper clean with an efficient sonic ripple. The most common venturi size is a 6” depth, and will normally come welded to the cage. Typically the longer the bag, the more important it will be to have a venturi.

Bottom Construction

  • Welded Pan – Most Common. Each vertical wire is welded to the bottom of the pan.
  • Crimped – Wires are crimped over the bottom of the pan.

Material

  • Galvanized Steel – Most common
  • Mild/Carbon Steel
  • 304 Stainless Steel*
  • 316 Stainless Steel*
  • Titanium – Best for highly corrosive applications

* A good option if your application consists of moisture or chemical conditions that create an environment corrosive to metal.

Vertical Wires

The number of vertical wires on your baghouse cage will depend on the type of filter bag media you are using. For a felt bag, you will usually have a 10 or 12 vertical wire cage. For a woven bag, you will commonly see a 20 vertical wire cage. For example, fiberglass bags typically use 20 vertical wire cages since the media is flexible and requires more support.

Ring Spacing

Ring spacing is used to support the vertical wires. Ring spacing is typically 8” but can also be as small as 4”.

Coatings

Coatings such as epoxy can be applied to baghouse cages and are commonly used for corrosive environments.

Two-Piece Baghouse Cage

Two piece baghouse cages are used in dust collectors that facilitate the use of long bag technology. Two piece baghouse cages are often used when bag lengths exceed 150” and go all the way up to 300” in length. This style of cage is sectioned off in the middle creating two separate parts. They can be linked together with following connection types:

  •  Finger connection
  • Slide Lock 2 Punch
  • Slide Lock 1 Punch
  • Twist Lok ™

Baghouse Cage Resources

Do you have an upcoming baghouse cage project? Follow this link here to get access to a complete check list of the questions that are needed to find the best fit for your application and budget.

For additional resources on filter bag media, construction , and air-to-cloth ratio you can access our filter bag eBook below.

Find Your Baghouse Cage

Ready to find your cage? Get a quote within 24 hours by simply following the link below and providing your filter bag request.

Baghouse FAQ

The Most Frequently Asked Questions on a Baghouse Project

Are you looking into getting a baghouse for your next dust collector project? How do you know if it’s the right dust collector for your application? In this blog post we’ll be helping you explore the different benefits of a baghouse, which industries its commonly used in, and what type of application they are best suited for.

Baghouses are usually suited for large volume applications. They will perform best when you have a large area or high volume of dust that needs to be captured. For example, collecting more than one 55 gallon a drum per day and an airflow exceeding 1000 CFM would be considered high volume. Baghouses perform well in high temperature applications such as metalworking and castings, mining, minerals, energy and more.

Most common industries that use baghouses:

Most common benefits that should be included in your baghouse:

  • Walk-in plenums, and easy maintenance access for small or large projects.
  • Self contained
  • Weatherproof
  • Fully automated

If a baghouse seems like the right fit for your next dust collector project, then here is a check list of some frequently asked questions you’ll need to consider.

Baghouse Project Questions

  • How much CFM will be needed for the Baghouse Dust Collector?
  • What type of material will you be collecting?
  • How much dust do you usually dispose of in a day?
  • What is the bulk density of the material?
  • Approximately what air velocity (FPM) are you looking for?
  • Do you have an Air-to-Cloth Ratio in mind?
  • What is the Air Temperature projected at the inlet duct?
  • Is the material explosive? If so, do you need a spark detection system, explosion vent, or sprinkler system?
  • How many pick-up points will there be?
  • What is the static pressure you are projecting for the system?
  • Do you need us to supply the Inlet Duct, Pick-Up Hoods, Installation, or Fan?
  • Do you want a Rotary Valve or Double Dump Valve, and is a screw conveyor required?
  • What are the height and size requirements, if applicable?
  • Do you have a specific filter bag material and construction that you are looking for?

How to Get the Right Dust Collector for your Application

Your dust collector is a small but critical piece of your operation. To get the right equipment for your plant that’s going to get the performance you need at the right price point, you’ll want to consider the following.

1. What type of dust is being filtered by your dust collector?

The first step to getting the right size and type of dust collector and the right filter media is to look at the characteristics of the dust being captured and know your dust. -Size – is the dust particulate fine or large?

Density: Is the dust porous and low density like wood chips or heavy life fine steel dust?

Temperature: High heat environments require special filter media that can handle extreme temperatures without excessive filter wear and tear.

Chemistry: Is the dust abrasive or corrosive?  Is it carcinogenic? electro-static? An abrasive material may require special material for the housing unit. 

Moisture – is there any moisture or oil present in the dust/air stream? Environments with moisture/oil may require special membranes to prevent the filters from plugging prematurely.

2. What CFM or volume is needed for my application?

One of the most important considerations when selecting a new dust collector is making sure the airflow or volume of the collector is efficient at capturing dust.  Dust collector volume is measured in cubic feet per minute or CFM which measures the amount of air per minute that can be moved from a space.  Key variables for calculating dust collector CFM include the space of the area that needs ventilation, the method of ventilation, and how frequently the air needs to be turned in a given amount of time.

3. Get the Right Air to Cloth Ratio for your Dust Collector

Next you’ll want to consider your air to cloth ratio or the amount of filter media relative to the amount of air passing through the collector. The lower the air to cloth ratio in your dust collection system, the better your system is at removing dust from the environment because there is more filter media to push dust through. Getting the right air to cloth ratio will significantly impact the short and long term performance of your collector. If you have a higher air to cloth ratio than recommended, you’ll see a noticeable decrease in suction because there is too much dust being captured by not enough filter media. Generally dust that is low density, porous and permeable such as wood chips can run at a higher air to cloth ratio while greater density dust like steel would require a lower air to cloth ratio.  

Interested in learning more? Download our Dust Collector Purchasing Guide to learn other helpful tips and considerations that will help you sahttps://info.usairfiltration.com/industrial-dust-collector-purchasing-guide-us-air-filtrationve money and lower your long term maintenance costs over time.