Dust Removal Equipment

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What Is Bag Dust Collector?

Bag dust collectors are a fabric filter air-material separators employed for particulate removal from manufacturing and other industrial operations to keep dust and solid particulates from entering the workplace or being released into the atmosphere. In effect, bag dust collectors are industrial-scale fabric filter systems used as air pollution control devices.

Advantages of Bag Dust Collector

Durability
Bag dust collector systems tend to surpass other air purification methods by using bag filters that are more flexible and can last longer than traditional cartridge systems. Because of this benefit of durability, you may find that you have to purchase fewer amounts of filter replacements over the service life of your bag dust collector system.

Withstanding High Temperature
Working with high temperatures is a common issue found within this industry. When choosing the best system to meet this demand, bag dust collector dust collectors can frequently withstand much higher temperatures than traditional cartridge dust collectors, even temperatures above 250 degrees Fahrenheit.

Works with a Heavy Dust Load
When you experience an increase in dust, your facility may need to run through a collection system, and not all equipment will handle a heavy dust load. This is why we highly recommend utilizing a bag dust collector dust collection system, which is a perfect resolution to this issue.

Adhesive Material Processing
Traditional cartridge filtration systems are not as well equipped to handle sticky and adhesive particles as bag dust collector dust collection systems are. They are also not as efficient as having a bag filter better suited for releasing the particulates. Adhesive applications thus require a more thoughtful selection of equipment to get the job done well.

Cleaner Air
A bag dust collector improves overall air quality in facilities with woodworking, grain processing, foundries, fiberglass, and food processing. When dust particles linger in your facility’s air, this can lead to disruption of production, and can put your facility at risk for non-compliance with regulations.

Improved Product Quality
When a bag dust collector keeps the air clean in your facility, this ensures that high-quality products are being maintained, keeping them free from defects or contamination, especially in the case of food processing.

Increased Efficiency
By removing dust particles from the air, a baghouse dust collection system will also help ensure that equipment in your facility is performing efficiently, reducing potential downtime for equipment maintenance.

Types of Dust Removal Equipment

Pulse Jet Baghouse

The pulse-jet or reverse-pulse baghouse is ubiquitous in industrial dust collection. These industry workhorses boast no moving parts in their basic configurations and allow collection efficiencies greater than 99.9%. In the pulse jet dust collector, the dusty airstream usually enters from below the bags or filters. It is pulled upwards through the filters, where dust is captured on the exterior surface, and clean gas passes through to the clean air plenum side for exhaust. When fabric filters are used, the bags are supported by internal wire cages. The pulse-jet cleaning cycle is controlled by a solid-state timer which sequentially pilots “pulses” of compressed air in the reverse direction of filtering into blow pipes mounted above each row of filters. When activated, the reverse pulse air pulses travel down the length of each bag in the given row, causing a ripple effect, dislodging and releasing the caked dust into the hopper at the base.

Shaker Baghouse

A shaker baghouse, as the name suggests, mechanically disposes of collected dust by shaking it out of the bags into a collection hopper at the bottom of the baghouse. In a shaker baghouse, filter bags are hung and tensioned from the top of the filter housing and attached with the bottom open, to the tube sheet. No internal cages are used for shaker bags. The airstream enters from below the bags and is pulled upwards through the interior of the bags where the dust collects. The airstream passes through the filter bags trapping the contaminants on the dusty side. Clean gas is exhausted near the top of the collector. To clean a shaker baghouse, which normally uses woven filter bags, the airflow through the system must be periodically shut down, also referred to as being taken off-line, while mechanical shake-cleaning is employed. After the dust cake is released from the bags, it falls into a hopper at the bottom of the baghouse for removal.

Reverse Air Baghouse

There are two styles of reverse air baghouses. More common nowadays, especially with fibrous dust such as those from grain or wood processing, is around reverse air collector style, wherein dust collects on the exterior of the bags or filters. For cleaning, reverse air generated by the equipment fan or medium pressure blower is directed by a rotating arm over the bags, blowing reverse air into them to remove dust. This type of reverse air baghouse generates a lower cleaning air pressure than the compressed air pulses of a pulse jet. It is a low-pressure, high-volume cleaning system and cleans while online. This gentler cleaning method decreases wear and tear on the bags and saves on the cost of compressed air. The trade-off for the cost of compressed air, however, is the horsepower requirements and maintenance costs of the reverse air blower and moving parts.

What Materials Are Typically Filtered by Bag Dust Collectors?

Asphalt
Bag dust collector units play a crucial role in the operation of asphalt mixing plants. These systems typically feature multiple filtration bags housed in an enclosed chamber. Air from the mixing process is directed into the bag dust collector, where it is filtered through the bags, which can be made from woven or felted fabrics. The filtration process starts with a cyclone separator that captures and isolates the heavier dust particles. The remaining lighter dust is then directed to the bag dust collector system. The filtration system used in asphalt plants must be designed to endure high temperatures and corrosive gases.

Grain Production
Dust filtration is essential throughout various stages of grain production, including milling, sifting, grain elevators, and bag filling. Each stage generates dust and debris that must be managed to ensure environmental and worker safety. As grain production and processing speeds up to meet growing demand, the volume of airborne pollutants also increases. To address these higher dust control and emission requirements, more advanced dust control technologies are necessary, often involving multiple bag dust collector systems.

Cement
The cement production industry faces stringent regulations on the amount of particulate matter it can emit into the atmosphere. To meet these standards, pulse jet bag dust collectors are widely utilized. These systems are essential for containing and managing waste gases that contain high concentrations of dust during the cement production process. In cement production, bag dust collector systems serve a dual role: they filter out dust and gases, and they also recover cement materials that might otherwise be lost during production.

Silica
Filtering silica dust poses challenges due to its abrasive properties. Consequently, bag dust collector filters must be designed to resist abrasion and handle both the rapid flow rates and large volumes of dust effectively.

Aggregate
Sand and gravel extraction involves using earth-moving equipment to collect material from pits. This material is then transported to a processing plant where it undergoes crushing, screening, and sorting by size. Pulse jet bag dust collectors, specifically designed for this purpose, are employed to capture and remove the large volumes of dust, debris, and various fragments generated during the processing.

Application of Bag Dust Collector

Bag dust collectors work best for applications that deal with heavy dust, higher temperatures, require filtration for larger particles, and have more abrasive or sticky materials. An industrial bag dust collector can capture pollutants such as sawdust, fumes, powders, and more. Industrial bag dust collectors can be used widely in many industries, for a wide range of applications, including but not limited to:

Automotive manufacturing
Glass and Ceramic Manufacturing
Grain (Flour, Wheat, Filling Bins, and Silos)

Fiberglass cutting

Cement manufacturing

Food processing

Fibrous dust

Lumber milling

Lime Kilns

Mineral bulk loading

Metal Processing

Smelting

Mining applications

Steel foundries

Woodworking

How Do Bag Dust Collectors Work?

Most bag dust collectors work by having a fan or blower that pulls dust laden air into the collector. The dust laden airstream is then separated by the bag dust collector filters, which collects dust on the surface of the filter while allowing clean air to pass through and out of the collector.
bag dust collectors are available in many shapes and sizes. Depending on the process needs and filter type, bag dust collectors can use a single bag to hundreds or even thousands of felt or pleated filter bags.
A wide range of filter medias and types are available to meet the wide range of particulate and application characteristics of process owners. For example, oily dust often requires filters with an oleophobic treatment to handle the dust effectively, while the presence of moisture might require polypropylene, or Polytetrafluoroethylene (PTFE) treated filters. Pleated filters also offer higher filtration efficiencies and abrasion resistance.

Is There A Difference Between Industrial Bag Dust Collectors And Esp Electrostatic Precipitators?

Working Principle
Bag dust collectors use fabric filter bags to capture and collect dust particles. The bags act as a physical barrier, allowing air to pass through while retaining the dust. On the other hand, electrostatic precipitators use an electrostatic charge to charge the dust particles and then collect them on oppositely charged plates or electrodes.

Efficiency
Bag dust collectors are highly efficient in capturing fine dust particles, including sub-micron-sized particles. They have a high dust collection efficiency, typically above 99%. Electrostatic precipitators also have good efficiency, ranging from 98% to 99%, but may not be as effective in capturing very fine particles.

Maintenance and Operation
Bag dust collectors require regular maintenance, including bag replacement and cleaning. The collected dust needs to be periodically removed from the bags. Electrostatic precipitators are generally considered to have lower maintenance requirements, as they do not use bags that need replacement. However, the collection plates or electrodes may require cleaning from time to time.

Application
Bag dust collectors are commonly used in industries like cement, power generation, steel, and woodworking, where large volumes of dust must be captured. Electrostatic precipitators are often used in industries like thermal power plants, chemical plants, and incinerators, where they can handle high-temperature gas streams and collect dust and particulate matter.

Cost
Bag dust collectors are generally more affordable in terms of initial investment and operational costs. Electrostatic precipitators tend to have higher initial costs but may have lower operational costs due to lower maintenance requirements. Ultimately, the choice between baghouse dust collectors and electrostatic precipitators depends on the specific application, dust characteristics, space availability, and budget considerations.

What Affects Bag Dust Collector Performance?

Bag Dust Collector Size
Not using the right size dust collector for the application and process can cause increased wear on filters. bag dust collectors that are sized too small, have too little filters or filter media can lead to inadequate capture velocities and airflow, short filter life, poor venting, damaged equipment, higher emissions, and a potentially dangerous work environment.

Filter Media
A wide range of bag dust collector filter medias are available for the wide range of applications and dust characteristics that exist in industrial processes. Filter media works differently depending on the environment, so it is essential to choose the correct filter media that meets the needs of the dust and process. Using the wrong filter fabric can reduce the lifespan of the filter and lead to a higher pressure drop, which can increase energy and operational costs and cause filters to fail.

Cleaning Type
The configuration and cleaning type of a bag dust collector also has a significant influence on its performance. Each type — reverse air, medium-pressure, pulse jet and mechanical — has pros and cons and selecting the right type of cleaning system for the application can improve performance, extend filter life and reduce operations costs.

How Often Should You Change Bag Dust Collectors

With consistent inspections, you’ll be able to predict how frequently your bag dust collectors need to be changed. It’s essential to conduct regular inspections as well as be aware of the signs and factors that it’s time to replace the baghouse filter, including:
Type and amount of dust being collected – Certain types of dust particles may wear down filters faster. Also consider how much dust is being collected and frequency of bag dust collector use.
Filter bag material – The type of material used for your bag dust collector can also affect how soon it needs to be changed.
Clogged bag dust collector due to excessive dust cake buildup – If the filter cleaning system is no longer clearing out most of the dust, leading to a buildup, it may be time for a new filter.
Visible damage to bag dust collectors such as tears or holes – During regular inspections, be sure to look for any damage to filters.
Check the pressure differential gauge – If the pressure reads higher than 6”, this may indicate reduced airflow and filters should be replaced.
Dust particles can be seen in the air in your facility – If you’re able to visibly see dust particles in your facility, it’s time to replace your bag dust collector.

Bag Dust Collector Upkeep Checklist

Inspect the bags

Take a look at the bags regularly for wear and tear, holes, rips, or damage that could compromise the integrity of the filtration system. Replace any damaged bags immediately.
Clean the bags

Clean the bags regularly to prevent clogging and maintain their ability to operate at top performance.
Inspect the cages

Inspect the cages regularly for rust, corrosion, or any damage that could compromise their ability to maintain the system’s structure. Replace any damaged cages immediately.
Inspect the venturi

Check out the venturi for any developed flaws that could compromise its ability to inject air into the system.
Inspect the pulse valves

Examine at the pulse valves for damage that could compromise their ability to clean the bags.
Check the differential pressure

Monitor the differential pressure across the system to ensure that it is within the manufacturer's recommended range. A high differential pressure indicates that the bags are clogged and need to be cleaned or replaced.
Clean the hopper

Clean the hopper regularly to prevent the buildup of dust and debris. Use a vacuum, compressed air, conveyor, or the manual method to remove the debris.
Inspect the fans

Inspect the fans for any damage or wear and tear that could compromise their efficiency. Check the power level their operating at and whether air is flowing through the system at a corresponding velocity.
Lubricate moving parts

Lubricate any moving parts, such as bearings or chains regularly.
Check electrical connections

Check the electrical connections regularly to ensure that they are secure and functioning properly.
Replace filters

Replace any filters, such as pre-filters or after-filters, according to the manufacturer's recommended schedule.
Keep records

Keep a record of all maintenance activities, including inspections, cleanings, and replacements, to ensure that the system is being properly maintained on schedule and identify any trends or issues demanding attention.

Our Factory

Our guiding vision -- "A robot for every family" -- encourages customers to "Live Smart. Enjoy Life" with stylish and functional robots that are more than simple household appliances. We create home service robotics that make life easier, smarter, more efficient and connected, freeing you to spend more time doing what you love, with the people you love. At ECOVACS, we believe our smart home robotics with their unique mobility and spatial awareness capabilities will be an integral part of smart home in the future.

FAQ

Q: What are the specifications for a dust collector filter bag?

A: Material: polypropylene, polyester, acrylic, aramid, fiberglass, PPS, P84, PTFE. Maximum operating temperature: no more than 260℃(upon specific material) Micron ratings: 0.5-200 micron. Weight: 339.0 g/m2(upon size and material)

Q: What is the life expectancy of a dust collector?

A: With good maintenance, many dust collector models can function well beyond two decades, but owners need to be more vigilant as the equipment ages—especially with downtime costs that can quickly escalate.

Q: How do I make my dust collector more powerful?

A: Use a More Powerful Motor – When it comes to improving the CFM of a dust collection system, the motor's horsepower is a critical factor. A stronger motor equates to a better vacuum, which directly improves the CFM. Therefore, if your current collector lacks the necessary suction, consider upgrading to a stronger motor.

Q: Why do dust collectors have two bags?

A: On single-stage models, the top bag is usually the “breather bag”, while the bottom bag just collects the fallen dust and chips. Sometimes the bottom bag is designed to also breathe (meaning it's not sealed), but often it's a less effective plain woven bag filter.

Q: Is a dust collector better than a bag filter?

A: Baghouse dust collectors are mostly outdoor and much taller, requiring more of an installation effort. As far as maintenance goes, generally speaking cartridges need to be changed out every one to two years, while baghouse filters have a much longer life and can last for many years.

Q: What to look for when buying a dust collector?

A: Type of dust.
Determine if the type of dust in the application is combustible or explosive.
Determine toxicity.
Identify the source of dust generation.
Determine the type of exhaust hood needed to capture dust or fumes.

Q: How do I know what size dust collector I need?

A: Calculation Method: To calculate the required dust collector size (CFM – cubic feet per minute), multiply the work area's cross-sectional area (length x width) by the necessary air speed (ft/minute).

Q: What are the hazards of dust collector?

A: Accumulation can easily lead to deflagration, flash fires, or dangerous explosions. To save lives, prevent injuries, and minimize damage, dust collectors should be equipped with deflagration vents for protection from explosions.

Q: What causes dust collector fire?

A: Dust collector explosions occur due to the presence of combustible dust particles in the air, mixing with oxygen and an ignition source.

Q: How to increase dust collector efficiency?

A: Use proper line size to handle rate of flow without high pressure loss.
Integrate storage to supply air without pulling down feed to collector.
Monitor inlet pressure and drop at pulse.
Monitor flow pressure ahead of the receiver.

Q: Can I wash my dust collector bags?

A: In general, dust collector bags should NOT be washed as washing can damage the micron rating of the dust bag. The dust coating on the inside of the bag helps filter the finer dust.

Q: What is the difference between a dust collector and a baghouse?

A: Cartridge dust collectors are generally applied for fine, powdery dust and gases with efficiencies of 3 microns, whereas baghouse systems are more effective in collecting larger, sticky, or oily resin-like particulate matter with efficiencies of approximately 5 microns.

Q: Do you need a filter when using a shop vac bag?

A: If you are picking up fine debris, you need to add a high efficiency filter bag or HEPA collection bag to trap the fine dust. Without the bag the fine dust will go through the filter and blow back into your room.

Q: How strong of a dust collector do I need?

A: The amount of airflow or CFM needed will vary depending on the size and number of woodworking tools running simultaneously. Most average size table saws, planers, and jointers with 2-5 inch diameter ports need approximately 300-600 CFM to clean well.

Q: What horsepower dust collector do I need?

A: My suggestion is to start with at least a 2 HP system to draw dust through your duct work if your shop occupies a single garage stall. If your tools are spread out across the equivalent of a 2 car garage, you will want a 3 HP dust collector.

Q: What is the most common dust collector?

A: The most widely used dust collector is an industrial-scale fabric filtration system commonly referred to as a baghouse. Two popular baghouse system designs are the pulse jet dust collector and the shaker dust collector.

Q: What is the difference between a bag filter and a dust collector?

A: Each dust collector utilizes a specific filter: baghouse dust collectors contain bag filters, while cartridge dust collectors contain cartridge filters. These filters play an integral part in dust-collecting systems, as the filters capture dust particles and provide cleaner air.

Q: How long does a dust collector last?

A: A properly maintenanced dust collection system in a non-abrasive environment can typically last around 20 years.

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