BAG FILTERS

A BAG FILTER is a system used to enhance the quality of air released from industrial and
commercial processes by collecting dust and other impurities from air or gas. Designed to handle
high-volume dust loads, a BAG FILTER system consists of a blower, dust filter, a filter-cleaning
system, and a dust receptacle or dust removal system. It is distinguished from air purifiers, which
use disposable filters to remove dust. Unlike electrostatic precipitators, where performance may
vary significantly depending on process and electrical conditions, functioning bag filters typically
have a particulate collection efficiency of 99% or better, even when particle size is very small.

Where are these BAG FILTERs are employed?

• Bag Filters are employed in cement industry as a process bag filter either in raw mills, kiln
or cement mills.

• Bag filters are also installed in places, which cleans the dust laden air from the suction
points specially in transfer points and leaves out clean air into the atmosphere.

Operation
Bag filters use long, cylindrical bags (or tubes) made of woven or felted fabric as a filter medium.
For applications where there is relatively low dust loading and gas temperatures, pleated, nonwoven cartridges
are sometimes used as filtering media instead of bags.
Dust-laden gas or air enters the bag filters through hoppers and is directed into the bag filters compartment. The
gas is drawn through the bags, either on the inside or the outside depending on cleaning method, and a layer of
dust accumulates on the filter media surface until air can no longer move through it. When a sufficient pressure
drop (ΔP) occurs, the cleaning process begins. Cleaning can take place while the bag filters is online (filtering) or
is offline (in isolation). When the compartment is clean, normal filtering resumes.
Bag filters are very efficient particulate collectors because of the dust cake formed on the surface of the bags.
The fabric provides a surface on which dust collects through the following four mechanisms:

• Inertial collection – Dust particles strike the fibers placed perpendicular to the gas-flow direction instead of
changing direction with the gas stream.
• Interception – Particles that do not cross the fluid streamlines come in contact with fibers because of the
fiber size.
• Brownian movement – Submicrometre particles are diffused, increasing the probability of contact between
the particles and collecting surfaces.
• Electrostatic forces – The presence of an electrostatic charge on the particles and the filter can increase dust
capture.
A combination of these mechanisms results in formation of the dust cake on the filter, which eventually increases
the resistance to gas flow. The filter must be cleaned periodically.
TYPES OF BAG FILTERS
Bag filters are classified by the cleaning method used. The three most common types of bag filters are
mechanical shakers, reverse gas, and pulse jet.

Mechanical shaker Bag filters

In mechanical-shaker bag filters, tubular filter bags are fastened
onto a cell plate at the bottom of the bag filters and suspended
from horizontal beams at the top. Dirty gas enters the bottom of
the bag filter and passes through the filter, and the dust collects on
the inside surface of the bags.
Cleaning a mechanical-shaker bag filter is accomplished by shaking
the top horizontal bar from which the bags are
suspended. Vibration produced by a motor-driven shaft
and cam creates waves in the bags to shake off the dust cake.
Mechanical-shaker bag filter range in size from small, handshaker
devices to large, compartmentalized units. They can operate
intermittently or continuously. Intermittent units can be used
when processes operate on a batch basis; when a batch is
completed, the bag filters can be cleaned. Continuous processes
use compartmentalized bag filters; when one compartment is
being cleaned, the airflow can be diverted to other compartments.

In mechanical-shaker bag filters, there must be no positive pressure inside the bags during the shake cycle.
Pressures as low as 5 pascals (0.00073 psi) can interfere with cleaning.
The air-to-cloth ratio for mechanical-shaker bag filters is relatively low, hence the space requirements are quite
high. However, because of the simplicity of design, they are popular in the minerals processing industry.

Reverse air bag filters

In reverse-air bag filters, the bags are fastened onto a cell plate
at the bottom of the bag filters and suspended from an
adjustable hanger frame at the top. Dirty gas flow normally
enters the bag filters and passes through the bag from the
inside, and the dust collects on the inside of the bags.
Reverse-air bag filters are compartmentalized to allow
continuous operation. Before a cleaning cycle begins, filtration
is stopped in the compartment to be cleaned. Bags are cleaned
by injecting clean air into the BAG FILTER in a reverse direction,
which pressurizes the compartment. The pressure makes the
bags collapse partially, causing the dust cake to crack and fall
into the hopper below. At the end of the cleaning cycle, reverse
airflow is discontinued, and the compartment is returned to the
main stream.
The flow of the dirty gas helps maintain the shape of the bag.
However, to prevent total collapse and fabric chafing during the
cleaning cycle, rigid rings are sewn into the bags at intervals.

Space requirements for a reverse-air bag filters are comparable to those of a shaker bag filters; however,
maintenance needs are somewhat greater.
Pulse jet Bag Filters
In reverse pulse-jet bag filters, individual bags are
supported by a metal cage (filter cage), which is
fastened onto a cell plate at the top of the bag filters.
Dirty gas enters from the bottom of the bag filters and
flows from outside to inside the bags. The metal cage
prevents collapse of the bag.
Bags are cleaned by a short burst of compressed
air injected through a common manifold over a row of
bags. The compressed air is accelerated by
a venturi nozzle mounted at the reverse-jet bag filters
top of the bag. Since the duration of the compressed-
air burst is short (about 0.1 seconds), it acts as a rapidly
moving air bubble, traveling through the entire length
of the bag and causing the bag surfaces to flex. This
flexing of the bags breaks the dust cake, and the
dislodged dust falls into a storage hopper below.
Reverse pulse-jet bag filters can be operated
continuously and cleaned without interruption of flow
because the burst of compressed air is very small
compared with the total volume of dusty air through
the collector. On account of this continuous-cleaning

feature, reverse-jet BAG FILTERs are usually not compartmentalized.

The short cleaning cycle of reverse-jet collectors reduces recirculation and redeposit of dust. These collectors
provide more complete cleaning and reconditioning of bags than shaker or reverse-air cleaning methods. Also,
the continuous-cleaning feature allows them to operate at higher air-to-cloth ratios, so the space requirements
are lower.
A digital sequential timer turns on the solenoid valve at set intervals to inject air into the blow pipe and clean the
filters.

More about PULSE JET BAG FILTER BAG FILTERS

HOW THE PULSE-JET BAG FILTER WORK?

As the dust laden air enters the BAG FILTER housing through the inlet duct, the baffle plate located
inside of the inlet act as a pre-filter and prevents re-entrainment by guiding the gas stream
downward uniformly. The baffle plate deflector directs the heavier dust particles into the hopper.
The remaining lighter dust particles are drawn against the outer surface of the filter bags where
they are retained.

Clean air passes through the filter bags and leaves the clean air chamber through an outlet duct.

As dust accumulate on the filter bags, periodic cleaning of the bags are important in order to
maintain continuous operation. This periodic cleaning of bags is achieved by introduction of timed,
momentary pulse of compress air through a specially designed blow pipe with nozzles mounted
above each filter bag. Only a portion of the filter bags are cleaned at one time, allowing the
remaining filter bags to continue their filtering action.

PROCESS
Pulse Jet Bag Filter is cleaned by a blast of compressed air. The filter bags are arranged in rows and
the number of rows depends on the filter size. A blowpipe is mounted above each row of bags and
fed by a compressed air manifold (or tank) mounted on the outside of the filter. The blowpipe
contains nozzles to coincide with the centre line of each bag. When each pipe receives a signal to
blow, the appropriate diaphragm valve is opened by means of a solenoid valve allowing
compressed air into the blowpipe.

The above figure shows the filter during normal operation

An equal amount of compressed air is blown vertically

downwards into each bag. Each row of bags therefore receives
a short pulse of compressed air of approximately 100 ~ 200m
sec duration. The high pressure compressed air creates a
shockwave down each bag causing it to release the majority of
dust formed around the outside. This falls into the hopper
below.
The above figure shows the filter during cleaning mode

HOW THE FILTER BAGS ARE FIXED

Bags are held firmly in place at the top by clasps and usually have an enclosed bottom (the bag is
sewn closed at the bottom). In another design, a snap ring is sewn into the top of the bag which
fits into the tube sheet opening. The cage slides inside the bag and the top of the cage sits on the
tube sheet (see Figure below). Dust-laden gas is filtered through the bag, depositing dust on the
outside surface of the bag. Pulse-jet cleaning is used for cleaning bags in an exterior filtration
system (See Figure below).
The pulse-jet bag filter BAG FILTER has been designed to achieve maximum operating efficiency
whilst reducing maintenance cost and time.

Bag filters are generally used in application requiring high yield recoveries from pneumatic
transport systems, or for the removal of hazardous materials from the working environment.

Such systems may incorporate the use of a cyclone as the primary means of recovery followed by
a bag filter unit for final separation of particles from the air stream. Alternatively, the bag filter may
be used as the only means of separation.

The total recovery of conveyed product is the prime objective in each instance and this criterion
can only be reached by balanced designed of the total system. Often the costs of installing such a
system can be justified from increased yields.

The pulse-jet bag filter BAG FILTER is constructed from a series of modular components which
allows for standardization yet retains the ability to be completely flexible with selection, sizing,
materials of construction, filter media and equipment arrangement.

It is believed that each application requires further careful evaluation and that the filter unit
recommended should be on the basis of product characteristics, product to air loading and air to
filter cloth ratios, with consideration of product heat stability and other physical and chemical
properties. By selection of the correct filter sock material and consideration of the above factors
optimum performance is assured.
ADVANTAGES OF THE PULSE-JET BAG FILTER

1. Automated self-cleaning of filter bags

2. Continuous operation
3. High filter rates
4. No internal moving parts
5. Low maintenance costs
6. Fast top removal of bags – working at the clean air side
7. Dependable solid state timer controls
8. Weather proof – all welded construction
9. Dust pre-separator – baffle plate deflector

PULSE-JET OFF-LINE PULSING SYSTEM

(COMPARTMENT CLEANING BY ISOLATION)
Pulse-jet bag filters can also be compartmentalized. In this case, pneumatic controlled dampers
located both at the dust laden inlet and clean air outlet are used to stop the flow of dirty air into
the compartment.

Each compartment is equipped with pulse valves that supplies compressed air that direct pulsing
air into the blowpipes above the bag rows in the compartment. During the cleaning cycle the inlet
and outlet pneumatic damper closes, stopping the air flow through the compartment. The pulse
valve opens for about 0.1 second, supplying a burst of air into the bags for cleaning. The
compartment remains off-line for approximately 30 seconds, although this time period can be
longer or shorter if desired. The inlet & outlet pneumatic damper then automatically reopens,
bringing the compartment back on stream (or known as “on-line”).

Alternate compartments are cleaned successively until all the bags in the bag filters have been
cleaned. The cleaning cycle in each compartment lasts about 40 to 120 seconds. This cleaning is
called off-line cleaning.

It is frequently used on fabric filters installed on coal-fired boilers and municipal waste
incinerators, allowing very thorough bag cleaning while the bag filters continuously achieve very
low emission levels (less than 50 mg/m3).

Video Link: https://www.youtube.com/watch?v=bbXZCzgZh4w

Inspection of Bag Filters before start up

▪ Check that the Compressed air is of the required working pressure. It should be between
3.5 bar and 5.5 bar
▪ Check that the discharge hopper is free from any accumulations.
▪ Check the suction damper/delivery damper of the fan.
▪ Check the operating cycle of the timer.
 ▪ Check that the gases at the outlet of the filter is not colored or dusty. This indicates incorrect
assembly of the bags on the base plate or damaged bags.
▪ Check for damaged membranes inside the valves. An easier way to check for the damaged
membranes is to observe the pressure at the inlet of the bag filter. If the bag filter has
defective membranes, there will be drop of the pressure coming into the filter and at the
outlet of the membranes we can hear the sound as well as the temperature of that
particular pipe will be colder as compared with that of the other ones.
▪ Check the pressure drop. If it increases it is an indication that the filter bags are clogged or
the adjustment of the louvres has been changed. Normal value is between 10 mbar to 12
mbar.
▪ If the fan is driven by driving belt check that the belt tension is sufficient.
▪ Check the discharge hopper for any possible accumulations. Any accumulations indicate a
failure in the discharge system.
▪ Check the temperature of the fan bearings and rotary air lock using a temperature scanner.
▪ Check that the safety valve (drainage) on the tank works correctly by raising briefly the
pressure to 4.5 bars.
▪ Check that between two cleaning cycles, the compressed air tank pressure raises correctly
up to 4.5 bars.
▪ For each air ejection, the pressure falls by any value between 0.25 bar and 1 bar.
Inspection of the bag filters while in operation.
▪ Compressor air pressure
▪ Pressure drop across the filter
▪ Discharge hopper conditions
▪ Clean gases at the outlet of the BAG FILTER
▪ Timer panel and its subsequent solenoid valve operation
Electronic timer panel details
▪ General supply switch
▪ Reset key
▪ LED indicators
▪ Selector switch
▪ RED LEDs states the outputs.
▪ “+” and “-” buttons.
▪ Display panel. Adjustments of parameters.
▪ Press the Select key until the led comes ON in front of the wanted parameter.
▪ Change the value of the parameter you want to change by pressing the “+” or “-” button.
▪ Come back to the pressure display mode by ‘select’.
▪ The following parameters are displayed in sequence.
▪
Adjustments of parameters.
▪ Press the Select key until the led comes ON in front of the wanted parameter.
▪ Change the value of the parameter you want to change by pressing the “+” or “-” button.
▪ Come back to the pressure display mode by ‘select’.
▪ The following parameters are displayed in sequence.
Automatic mode operation
▪ The electronic panels can accommodate all the Bag cleaning Solenoid Valves.
▪ In automatic mode, the solenoid valves are operated in a cycle, according to the
following sequence: first solenoid valve of each group (in sequence), then second
solenoid valve of each group (in sequence) and so on up to the last solenoid valve of the
last group, then the cycle restarts from the beginning. The number of cleaning cycles
per hour can be set in the range 10 to 14 by a potentiometer.
▪ A LED lights up whenever a solenoid valve is energized and a three-digit display indicates
the energized one – the first digit indicates the group number the second and third digit
indicates the solenoid valve number.
▪ L3 green LED allows to check the Operating impulse
▪ “OFF LINE TIME” potentiometer controls the regulation of the occurring time between
the operation of one solenoid valve and the next one {from 2” to 35”}
▪ Operating time can be adjusted from 40 msec to 70 msec
Manual mode operation
▪ When the auto/manual switch is changed to manual mode, it stops the sequential cycle
and activates two push buttons.
▪ 1st Manual: STEP BY STEP push button permits the operation to search the desired
solenoid valve.
▪ 2nd Manual: HIT ALARM RESET push button permits the excitation of the displayed
solenoid valve each time when pushed, or alarms “reset”
Filter pressure drop
▪ If the DP across the filter is increased, the bag cleaning equipment may operate with
the CLEANING ON led on.
▪ When the set min. DP is reached, the cleaning cycle is stopped and the CLEANING ON
led is off.
▪ With a depression of 12 mBar is reached, MAX DP alarm is triggered.
▪ With a depression of 10 mBar is reached the above mentioned alarm will get
automatically reset.
Machine components of the Lid lifting system
▪ Trailer mounted frame
▪ Oleo dynamic pump
▪ Oil distribution system
▪ Single acting cylinder
Important safety aspects
▪ For 220 Volt pilot solenoid valves, it is necessary to insulate electrically the
compartment.
▪ Before carrying out any inspection, insulate the air receiver by means of the shut off
valve, then drain the compressed air fully.
▪ Filter inspection is conditional upon supervision by an entrusted process operator.
▪ Follow general safety and specific safety before the inspection of the bag filter.
▪ Access to hoppers is not advisable. To proceed with the inspection of the hopper, it is
necessary to stop the filter, run the dust disposal system until the system is clean and
then stop for inspection.

Performance
Baghouse performance is dependent upon inlet and outlet gas temperature, pressure
drop, opacity, and gas velocity. The chemical composition, moisture, acid dew point, and particle
loading and size distribution of the gas stream are essential factors as well.

• Gas temperature – Fabrics are designed to operate within a certain temperature range.
Fluctuation outside of these limits, even for a small period of time, can weaken, damage, or
ruin the bags.
• Pressure drop – Baghouses operate most effectively within a certain pressure drop range. This
spectrum is based on a specific gas volumetric flow rate.
• Opacity – Opacity measures the quantity of light scattering that occurs as a result of the
particles in a gas stream. Opacity is not an exact measurement of the concentration of particles;
however, it is a good indicator of the amount of dust leaving the baghouse.
• Gas volumetric flow rate – Baghouses are created to accommodate a range of gas flows. An
increase in gas flow rates causes an increase in operating pressure drop and air-to-cloth ratio.
These increases put more mechanical strain on the baghouses, resulting in more frequent
cleanings and high particle velocity, two factors that shorten bag life.

Design variables
Pressure drop, filter drag, air-to-cloth ratio, and collection efficiency are essential factors in the
design of a baghouse.

• Pressure drop (ΔP) is the resistance to air flow across the baghouse. A high pressure drop
corresponds with a higher resistance to airflow. Pressure drop is calculated by determining the
difference in total pressure at two points, typically the inlet and outlet.
• Filter drag is the resistance across the fabric-dust layer.
• The air-to-cloth ratio (ft/min or cm/s) is defined as the amount of gas entering the baghouse
divided by the surface area of the filter cloth.

Filter media
Fabric filter bags are oval or round tubes, typically 15–30 feet (4.6–9.1 m) long and 5 to 12 inches
(130 to 300 mm) in diameter, made of woven or felted material. Depending on chemical and/or
moisture content of the gas stream, its temperature, and other conditions, bags may be
constructed out of cotton, nylon, polyester, fiberglass or other materials.
Nonwoven materials are either felted or membrane. Nonwoven materials are attached to a woven
backing (scrim). Felted filters contain randomly placed fibers supported by a woven backing
material (scrim). In a membrane filter, a thin, porous membrane is bound to the scrim. High energy
cleaning techniques such as pulse jet require felted fabrics.
Woven filters have a definite repeated pattern. Low energy cleaning methods such as shaking or
reverse air allow for woven filters. Various weaving patterns such as plain weave, twill weave, or
sateen weave, increase or decrease the amount of space between individual fibers. The size of the
space affects the strength and permeability of the fabric. A tighter weave corresponds with low
permeability and, therefore, more efficient capture of fine particles.
Reverse air bags have anti-collapse rings sewn into them to prevent pancaking when cleaning
energy is applied. Pulse jet filter bags are supported by a metal cage, which keeps the fabric taut.
To lengthen the life of filter bags, a thin layer of PTFE (teflon) membrane may be adhered to the
filtering side of the fabric, keeping dust particles from becoming embedded in the filter media
fibers.
Some baghouses use pleated cartridge filters, similar to what is found in home air filtration systems
Fabric quality – Table of typical characteristics

Flex.
Fabric Max. Temp Moisture Acid Base Organic
Abrasion
Polypropylene 90oC Good Excel. Excel. Excel. Excel.
Acrylic 120oC Good Good Good Good Good
Polyester 130oC Excel. Fair Fair Poor Good
Nomex 190oC Good Poor Poor Fair Good
Fibreglass 260oC Poor Excel. Excel Excel Excel
PPS 180oC Good Good Good Excel Good

Bag / Cage / Venturi Arrangement

Cages are wire frames placed inside pulse jet filter elements to provide support to the fabric as flexing occurs
during filtration and cleaning cycles. Configuration of a frame generally follows the shape of the filter elements, i.e.,
circular, oval, flat or star- shaped. Cages for long filter elements are made in sections which snap together for easier
handling. Wearpoints on filter bags may develop at the horizontal supports.
Cage designs to reduce these points increase the number of vertical wires and reduce the horizontal supports.
Protective coatings on cages can extend the life of the cage and the bag. Coatings such as vinyl, epoxy, zinc, and

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Teflon® may be used.