Transport and Dust Collecting Manual

Version 1.08

Fabric Dust Collector Systems

Werner Flückiger
Leticia Nacif Flückiger

B1 (MPT 03/14902/E)

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Table of Content

1. INTRODUCTION 4

2. TECHNOLOGY OF PULSE-JET DUST COLLECTORS 4

… How the pulse-jet dust collectors work 4
… Design configurations 5
… Mechanical elements 5
… Bag Cleaning Systems 6
… Comparison between reverse air type and pulse-jet dust collector 6
… Bag fixation 7
… Filter cloth 8

3. HOLCIM-CTS DUST COLLECTOR DESIGN GUIDELINES 12

3.1 General theoretical design guidelines 12

… Filtration velocity 12
… Air-to-cloth ratio (A/C ratio) 13
… Can velocity 13

3.2 Dust collecting system design guidelines 13

… Amount of dust sources to vent 13
… Venting air volume 13
… Venting hood design 14
… Ductwork design 14

3.3 Dust collector construction design guidelines 15

… Gas flow / dust distribution 15
… Clean gas plenum / housing 17
… Dust hopper 17
… Filter bag dimension 19
… Distance between the bags 19
… Number of bags per row 19
… Venturis 19
… Bag cages 20
… Filter cloth 20
… Airlocks 21
… Fan 21

3.4 Dust collector cleaning control 21

… General 21
… Pulse sequence 21
… Pulse cycle 22
… Diaphragm and solenoid valves 23
… Purge valve 23

3.5 Problem solving guide / trouble shooting 24

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1. INTRODUCTION
The modern cement plant continually faces the challenge of keeping the process running
and producing a high quality product in a timely manner whilst remaining in compliance
with the national and local environmental regulations. The trouble-free operation of air
pollution control systems therefore has a key role to play, since there are plenty of dust
collectors in each cement plant.
The cement manufacturing is characterized by the extraction, transport, storage and
processing of very large quantities of solid material, often in a dry and powdered state.
There is an obvious potential for the generation of dust emission from the quarry to the
shipping station.
For environmental protection reasons, work safety, equipment wear rate and waste of
money, it is urgently necessary to collect the dust and bring it back to the main material
flow.
This manual is focused on nuisance dust collecting of auxiliary equipment that allows to
correctly design a pulse-jet dust collecting system and to make the right choice between
different filter types/makes on the market. We want to help keep our group plants running
and producing.

2. TECHNOLOGY OF PULSE-JET DUST COLLECTORS

… How the pulse-jet dust collectors work

The dust-tight casing has three sections (see figure 1); a clean-air plenum at the top,
a filtration housing containing a number of cylindrical or envelope type filter bags in
the middle, and a dust storage hopper at the bottom. The filter elements are
supported by a tube sheet that separates the filtration housing from the plenum.
Dust-laden air enters the collector through a diffuser, which absorbs the impact of the
high velocity dust particles, distributes the air, and reduces its velocity. The slow air
speed causes the heavier particles to drop into the hopper. The air steam then flows
through the filter units, depositing the fine dust on the outside of the cloths. The
cleaned air continues upward into the plenum and exhausts into the atmosphere.
The filter elements are cleaned by a momentary, high-pressure back-pulse of
compressed air from the clean side of the filter element. Blowpipes, arranged over
each row of filter elements, deliver the pulses. The bursts of air are optimized by
venturis located at the top of the filter elements to effectively dislodge dust along the
length of the elements.
A pulse control timer times the cleaning cycles. A differential pressure (between the
clean and dirty sides) gauge helps to determine cleaning frequency.

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… Design configurations
Dust collector supplier offers 5 basic designs to choose from:
• Bin vent collectors for mounting on silos or bins
• Small, self-contained insertables for existing enclosures
• Pre-assembled modular units for up to approximately 450 m2
• Large application sectional units for larger than 450 m2
• Cylindrical units for high pressure / high vacuum applications

… Mechanical elements

7 8 9 4
11

12

5
10
19

3
14
6

1
Raw gas
inlet
Clean gas
outlet
15
2

17

16
18
13

1 Dust loaden air 11 Diaphragm pulse valve

2 Diffuser 12 Pulse control timer
3 Bag cage 13 Rotary valve
4 Clean air outlet (Plenum) 14 Differential pressure gauge
5 Tube sheet 15 Closing valve
6 Filter bag 16 Compressed air bin
7 Venturi 17 Regulation damper valve
8 Locking ring (or snap band fixation) 18 Fan
9 Blowpipe 19 Purge unit with hand reducer
and filter set
10 Header (compressed air tank)

Fig. 1: Mechanical elements of a pulse-jet dust collector.

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… Bag Cleaning Systems

Summary of the various cleaning principles used for bag filters

(a) (b) (c) (d) (e) a, b: manual or mechanical, by

Vibrator
rapping or shaking
c: mechanical, by vibrating
d: pneumatic, by reverse air
flow (often combined with
shaking or vibrating)
e: pneumatic, by compressed
air (pulse-jet)

Since most of the mechanically cleaned filters have been replaced by compressed air
ones, mainly in the cement industry, the mechanical cleaning devices will not be
described further here.

… Comparison between reverse air type and pulse-jet dust collector

Reverse air type Pulse-jet type Pulse-jet type

with low pressure with high pressure
cleaning cleaning
Foot print of filter large due to low small due to longer bags medium due to shorter
filtration velocity bags
Number of chambers 2 extra chambers for no separate chamber no separate chamber
necessary necessary
offline cleaning
Pressure drop across 10 - 20 mbar 8 -12 mbar 8 -12 mbar
bag filter
Bag dimensions Ø300 x 10 m Ø130-150 x 7-8 m Ø120-150 x 4,5-6 m
(available)
Bag life expectances 3 - 5 years due to 3 - 5 years due to 3 years due to harder
cleaning by pressure
smooth cleaning smooth cleaning
pulses
Tank pressure (30 - 40 mbar) 0.6 - 2 bar 3 - 6 bar
Cleaning air flow 2.0 - 3.5 Nm3/m2h 0.05 -0.3 Nm3/m2h 0.02 - 0.10 Nm3/m2h
Cleaning air quality uses clean gas refrigeration dried or absorption dried
heated by roots blower
Cleaning time (open- 10 - 30 sec 600 ms 150 ms
ing time of valve)

All three bag filter types are successfully in operation. The choice has to be made by
price comparison.

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… Bag fixation

Filter bag fixation with snap-band

Snap-band

Filter bag

Fig. 2: Bag fixation by snap-band

Filter bag fixation with roll band / twist lock

Roll band

Fig. 3: Bag fixation by roll band

Filter bag fixation screwed

Fig. 4: Mechanical fixation of bag cages

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… Filter cloth
Filter media are available either in form of woven fabric or felt fabrics. The structure of
these two filter media is shown as follows:

Fig. 5: Woven fabric

and needle felt filter
cloth

The characteristics of woven fabric are its system of warp and weft threads crossing
one to another. Needle felts are "three-dimensional" filter media.
Most used filter media in the cement industry are needle felts due to a lower pressure
drop and higher dust collection efficiencies compared to the woven fabric.

Selection criteria
The filter medium is the all-important central feature of any dust collector operating on
the filtration principle. With the correct or incorrect choice of the filter material, the
whole dust collection operation will stand or fall in actual practice.
Important selection criteria are:
• filter type, particularly cleaning principle
• moisture level
• gas temperature (average and peaks)
• composition and chemical properties of the gas
• raw gas dust load, particle size
• particulate abrasiveness
• allowed dust load in the clean gas
• physical and chemical properties of the dust
Furthermore, the filter medium must satisfy the following conditions:
• high air permeability (low pressure losses)
• good mechanical strength
• good thermal stability at operational temperature
• good dimensional stability at operational temperature

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Legend:
1 exellent 2 very good 3 good 4 fair 5 poor
Properties of Various Filter Media

Fabric, Trademark Chemical DIN Tensile max. Operating Acide Alkali Resist. Abrasion Moist Heat Price Rating Density
2
Classification 60 001 strength Temperature [°C] Resist. Resist. Resist. [g/m ]
N/mm2 long time short time

Cotton Cellulose (CO) 410-670 70-90 120 5 3 2 3-4 $ 150-400

Natural
Fibers

Wool Keratin (protein) (WO) 120-230 90 120 3-4 4 3-4 3-4 $$ 400-600

Acrilan, AC/AC Polyacrylnitrile (PAN) 200-530 100-110 100-120 3 3-4 3-4 1 $$ 500-600
- copolymer

Dralon, Orlon, Zefran, Polyacrylnitrile (PAN) 200-530 110-120 120-140 2-3 3-4 3-4 1 $$ 500-600

Dolanit - homopolymer

Synthetic Polypropylene, Meraklon Polypropylene (PP) 260-640 90-100 100-120 1-2 1-2 1-2 1-2 $ 550

Organic Trevira, Dacron, Terylene, Polyester (PES) 560-820 130-150 150-160 3-4 3-4 2 5 $ 400-600
Fibers Tergal, Vestan, Kodel (dry)

Nylon, Perlon Polyamide (alipahtic) 370-850 90-110 100-120 4 2 1-2 3-4 $ 300

Nomex, Conex, Trol Polyamide (aromatic) PA 570-690 180-210 200-240 good in Excellent at 1-2 3-4 $$$$ 500-600

(Aramide) (AR) weak acids low temp.

Teflon Polytetra-Fluorethylene (PTFE) 380 260 280 1-2 1-2 3-4 1 $$$$$$$ 750-940

Ryton, PPS, Rastex, Polyphenylene- 1000-1200 180 max. 200 max. 1 1 2-3 $$$$$$ 500-800

Procon Sulfid (PPS) 5%O2 15% O2

P 84 Polyimid (PI) 850-900 240-260 280 1-2 1-2 4-5 $$$$$$ 550

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Legend:
1 excellent 2 very good 3 good 4 fair 5 poor

Fabric, Trademark Chemical DIN Tensile max. Operating Acid Alkali Resist. Abrasion Moist Heat Price Rating Density
2
Classification 60 001 strength Temperature [°C] Resist. Resist. Resist. [g/m ]
N/mm2

Glass, Fiberglass Glass 1500-2500 230-270 350 3-4 3-4 4 3 $$$ 300-400

Synthetic Stone Wool Mineral 120-260 300-350 3-4 3-4

Anorganic Various Steels Metals 500-750 up to 600 1 1 1

Fibers
Ceramic Silicium Oxyde 870 1 4 4 $$$$$$$$ > 30

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Special Treatment of the Bag Surface

• Special treatment of the fabrics and needle felts can significantly improve the
properties of the bags.

Non- Finish Purpose Available For

Fiberglass
Singe Recommended for improved cake release Polyester, Polypropylene, Acrylic, Nomex,
Ryton, P 84 (felts)

Glaze Provides short-term improvements for cake Polyester, Polypropylene (felts)

release (may impede airflow)

Silicone Aids initial cake development and provides Polyester (felt and woven)
limited water repellence

Flame Retardant Retards combustibility (not flame- proof) Polyester, Polypropylene (felt and woven)

Acrylic Coatings Improves filtration, efficiency and cake Polyester and Acrylic felts
(Latex base) release (may impede flow in certain
applications)

PTFE Surface For capture of fine particulate, improved Nomex, Polyester, Acrylic, Polypropylene
Treatments and filtration efficiency, cake release (felt) (Laminates available in Polypropylene,
Laminates Ryton and Polyester only)

PTFE Penetrating Improved water and oil repellence; limited Nomex (felt)
Finishes cake release

Acid Resistant Improved acid resistance and water Nomex (felt)

retardance

Fiberglass Finish Purpose Applications

Silicone, Graphite Protects glass yarns from abrasion, adds lubricity For non-acidic conditions, primarily for cement
Teflon and metal foundry applications

Acid Resistant Shields glass yarn from acid attach Coal-fired boilers, carbon black, incinerators,
cement, industrial and small municipal boiler
applications

Teflon B Provides enhanced abrasion resistance and Industrial and utility base load boilers under mild
limited chemical resistance pH conditions

Blue Max- CRF/70 Provides improved acid resistance and release Coal-fired boilers (high and low sulfur) for peak
properties, superior abrasion resistance, resistant load utilities, fluidized bed boilers, carbon black,
to alkaline attack, improved fiber encapsulation incinerators

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Membrane filter bag surface

• Special finishing or the application of membranes on the bag surface becomes more
and more important. The purpose of this treatment is to improve the bags' resistance
against chemical attack as well as optimum filtration efficiency and cake release,
especially for fine dust particles.

Fig. 6: Filter bag without membrane

Fig. 7: Filter bag with membrane

3. HOLCIM-CTS DUST COLLECTOR DESIGN GUIDELINES

The choice between different bag filter types/makes for the dust collection of a gas flow is
always based on the same technical questions that must be answered before deciding about
the investment. According to our experience, gained in many applications, all nuisance dust-
collecting systems should fulfill the requirements as follows:

3.1 General theoretical design guidelines

… Filtration velocity
The maximum allowed filtration velocity depends on the flow resistance of the bag pulse
filter cake and the cleaning ability of the filter bag and of course on the cleaning method.
The pressure difference (Δp) across the filter bags increases:
• the higher the filtration velocity
• the thicker the filter cake (residual dust layer after cleaning) and the quicker it builds
up (dust load time/cleaning interval)
• the higher the Blaine value of the dust (the finer the dust)
• the more compressible or sticky the dust (important for AFR usage)
• the older the bags (due to penetration of fine dust particles into the fabric)

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For sufficient cleaning of the filter bags it is necessary to reverse the gas flow through
the bags. This can be done either by having a high pressure inside (high cleaning
pressure) or by having a huge amount of gas flowing in opposite direction (low cleaning
pressure or reverse air). When the pressure drop across filter bags is too high, then the
cleaning becomes insufficient and the filter clogs up rapidly.

… Air-to-cloth ratio (A/C ratio)

The air-to-cloth ratio (A/C ratio) is simply a mathematical expression used to measure
the amount of filtering cloth area available to filter a given volume of air at a given flow
rate. There are standard air-to-cloth ratios based on cleaning mechanism styles, and
this ratio is used to determine the operating limits of the bag house. The guide ratios for
collectors with pulse-jet cleaning are as a function of the bulk material to handle for
auxiliary equipment venting as follows:
ƒ1.2 m3/m2 x min for slag, coal and clinker dust
3 2
ƒ1.5 m /m x min for limestone and cement dust

… Can velocity
The can velocity is the theoretically calculated raw gas velocity between the filter bags at
the bag bottom area. This is valid independently of raw gas inlet design. The maximum
allowed velocity depends on the gas flow direction between the bags and the terminal
velocity of particle collectives/agglomerates that have to fall into the hopper by gravity.
From experience, we know that the vertical upward vector of the gas flow velocity should
be between 1.0 and 1.3 m/s for auxiliary dust collecting systems.
The formula presented below can be used to calculate the can velocity:
Can velocity [m/s] = Total Venting Air Volume [m3/s] ÷ {Total Tubesheet Area [m2] –
(Hole Area [m2] * Number of Holes)}

3.2 Dust collecting system design guidelines

… Amount of dust sources to vent

No more than six (6) to eight (8) dust sources to vent should be connected to one dust
collector.

… Venting air volume

The true required venting air volume that the ventilation system has to handle must be
determined first. Therefore, it has to be determined how much vent air is required at
each dust point. The recommended standard volumetric requirements for the venting of
typical applications in ambient air are shown in Appendix 1. The air flow for the
remaining venting pipes before the filter should be the sum of the presented values as
shown in mentioned appendix.

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… Venting hood design

The hooding design at pickup points should provide ventilation of the dust point without
capturing product from the main material flow. If it will be done in this way, only airborne
particles will be introduced into the dust collection system. Improperly designed hoods
tend to increase the grain loading beyond of what the collector was originally designed
to handle. The recommended standard design practices for hood design are shown in
Appendix 2.

… Ductwork design
Once the volume on each individual vent point is known, the ductwork has to be
designed correctly. The proper gas velocity will depend on the dust being conveyed, but
a general rule for good ductwork design is to size the duct cross-sectional area for a
velocity of 15 to 18 m per second. For explosive dust, the pipes should be sized to an air
velocity between 18 and 24 m/s. Ducts with lower velocity will encourage material to fall
out. Ducts that have higher velocities encourage abrasion. The guide values for gas
velocity in ductwork are:
- 16 m/s for abrasive dust (clinker, slag)
- 18 m/s for non-abrasive dust (limestone, cement, raw meal)
Frequently encountered ductwork problems are poorly designed branch entries, elbows
and size variations that hamper airflow and/or cause accelerated wear. Correct and
incorrect ductworks are shown for your reference in Appendix 2.
Dust collecting systems with an excessive number of connected vent points cannot be
controlled / calibrated in a way that pollution control is effective. That is why we
recommend limiting the number of vent points connected to one filter to at maximum of 8
points.
The minimum duct diameter shall be 133 mm (5") outside, and the minimum duct and
hood wall thickness 3 mm (1/8").
Up- and downward sloping for dust-laden air shall have - to avoid dust accumulation - a
minimum slope of 60° for limestone, slag and cement and 45° for clinker, 70° for coal
measured from the horizontal.

min. 60° min. 70°

min. 45°

Limestone, Slag, Cement Clinker Coal

Fig. 8: Duct-slope for Fig. 9: Duct-slope for Fig. 10: Duct-slope
limestone, slag, cement clinker dedusting for coal dedusting
dedusting
Ductwork in horizontal should be avoided!
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For a fan discharge duct, the velocity shall be between 15 and 20 m/s. Silencer to be
provided, if required.
Orifice plates with wear protection shall be used for balancing systems, which handle
abrasive dust (e.g. clinker, slag). All other systems shall have butterfly dampers of a
minimum 6 mm thick plate construction.

Fig. 11: Typical orifice

plate design

3.3 Dust collector construction design guidelines

… Gas flow / dust distribution

A good gas flow distribution does not necessarily mean having also a good dust
distribution. But a good gas flow distribution indicates a more even dust distribution. Gas
flow jets loaded with dust do not lead to wear of bags or other internals very much.
Uneven dust distribution results in short cleaning cycles with high cleaning air
consumption and shorter bag life expectance. During the filter design the suppliers
should take care about gas and dust distribution.
The general rule is to ask the suppliers for a dust drop -out box at the gas entrance if the
raw gas dust content is above 300 g/m3.
As follows some examples of good gas distribution design at the dust collector entrance:
Typical design Recommended design

Fig. 12: Typical raw gas Fig. 13: Recommended raw gas
inlet design inlet design
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Preferred deflector plate design

6"

3" Overlap Type

Inlet

3"
m in.

6"
1"

Parting Line Wall and Hopper

3" 6" x 1/4" Flat Bar

Inlet Slide Fig. 14: Deflector plate
of Colector design

Raw gas top inlet configurations

Fig. 15: Not recommended raw gas Fig. 16: Recommended raw gas
inlet design inlet design

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Drop-out box design configurations

All dust collectors installed at the clinker transport in the section from clinker cooler to
silos must be equipped with a cyclone or drop-out box, in order to prevent damage
filter bags due to hot clinker particles.

Fig. 17: Drop out box design configurations

… Clean gas plenum / housing

Using a clean gas plenum instead of a liftable compartment cover has the advantage of
better gas tightness because it has one door per compartment only. The plenum height
has to be very high when undivided cages with long length bags are installed.
Outdoor filters larger than approximately 1.5 / 1.5 m should be equipped with weather
protection or walk-in-plenum for maintenance access i.e. sufficient height.
For small filters (< 1.5 / 1.5m) located outdoors and all filters located inside buildings,
top access (without walk-in-plenum) are also acceptable.
Bin vent type filters shall be provided with suitably reinforced bag/man catcher screen
for safety reasons.
Casing insulation shall be provided for outdoor filters, which are exposed to operation
below the dew point. The insulation wall thickness shall be minimum 50 mm.

… Dust hopper
For dust, which tends to agglomerate or leads to clogging, the corners of the hoppers
should be rounded. Anyway the valley (corner) angles of the hoppers should not be
lower then 550 in all applications, respectively 700 for coal, separator and bypass dust.
In the Appendix 3 there is a chart to find the hopper valley angle considering the
different angles of the hopper.

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A very serious problem in most group plants is the agglomeration of dust in the pyramid
hoppers due to a much too small discharge opening and a too low inclination of the
hopper walls. In such cases, which are problems of the supplier filter design, many dust
collectors have already been modified by replacing the rotary feeder with a screw
conveyor as shown below.
Fig. 18: Typical blocked
dust hopper outlet

∼ 700 ∼ 700
440

250
50

350 650 250

1250

Fig. 19: Modification of dust hopper by installing vertical side walls

∼ 750 ∼ 750
~ 450

250
50

Fig. 20: Modification of dust hopper by

1250 installing conically side walls, (for
extremely sticky material)

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… Filter bag dimension

The filter bag dimension depends on the cleaning system efficiency and the geometrical
allocation of the filter bags. The diameter of the bags is usually between 120 and
160 mm. For standardization reasons most filters should be matched in such a way that
only one size and type of bags is used. The maximum allowed bag length depends on
the cleaning system efficiency and the geometrical allocation of the bags.

The following bag lengths are recommended not to be exceeded:

new installation conversion

reverse air 11.0 m 11.0 m
low pressure pulse-jet 6.0 m 8.0 m
high pressure pulse-jet 4.5 m 6.0 m

The longer the bags, the more likely not perfectly vertical mounted, which provokes bags
touching each other at bottom area. This causes a high wear rate due to friction
between the bags. Furthermore, long bags are more difficult to clean and to remove if
filled up with dust or having a hole in the fabric.

… Distance between the bags

The minimum distance between the bags should be 50 mm. The distance between bags
and inside walls/internal stiffeners has to be 75 mm at the minimum.

… Number of bags per row

The maximum number of bags per row should not be more than 16 bags.

… Venturis
A venturi is an integral component of most pulse-jet collectors. It directs the blast of
compressed air into the center of the filter bag to prevent abrasion caused by misaligned
blowpipes and turbulent airflows. A good nozzle venturi configuration guarantees an
efficient jet gentle dust release while conserving compressed air consumption through
secondary air in draft into the venturi. If venturis become damaged or worn, compressed
air does not gain the velocity required to effectively clean the filter bags.

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… Bag cages
The bag cages have to be provided with longitudinal wires:
• 8 to 12 for filter bag diameter < 160 mm
• 16 to 20 for filter bag diameter > 200 mm
The bag cages shall be preferably of single piece design and shall be corrosion-resistant
(galvanized, stainless steel or epoxy coated) depending on their application.
Cartridge pleated filter and star bags shall not be used (except for electrical room
pressurization or special application). Envelope type dust collector should only be
applied for low venting air volume of < 5'000 m3/h.

… Filter cloth
The filter cloth specification and design data to be provided by the supplier have
carefully been checked by the consumer.
• For general application (dry gas) up to 1200 C (long time operation), needle felt
fabric made from high quality Polyester fibers are used.
• For an application in drying/grinding (humid gas) up to 1200 C (long time operation),
Polyacrylnitrile or similar fiber cloth is recommended.
• Application for temperatures above 1200 C, Polyamide (Nomex), Polyphenylene,
Glass-fiber, Teflon/graphite coated or similar.
One of the greatest enemies of the textile filter media is hydrolysis. This means the
breakdown of the molecular chain of the polymerization caused by moisture. Hydrolysis
is intensified by heat, acids and alkalis.
Polyester, for example, should not be used when moisture and elevated temperatures
occur in combination. Also aromatic polyamides (Nomex) are subject to hydrolytic
influences at temperatures above 70°C, especially if acids or alkaline agents additionally
act as a catalyzer.
Fortunately, in recent years chemical modification processes have emerged, which have
enabled these polyamides and also polyester to be substantially improved in this
respect.

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… Airlocks
• Rotary type for raw material, raw meal and cement dust.
• Double pendulum type shall be provided for all clinker dust and abrasive bulk
material applications. Motor operated units requiring power-to-open and power-to-
close are preferred. Gravity operated airlocks are also accepted.
• The minimum size for airlocks shall be 250x250 mm.

… Fan
• All fans should be selected with a 15% safety margin. As a consequence, air
quantity for fans is at least 15% higher than required.
• The fans with manually operated damper at inlet duct are preferred.
• The fan speed should preferably not exceed 1'800 rpm.
• In the absence of ducting layout and pressure drop calculations, the static pressure
for the dust collector fans should be specified as follows:
- For impact crusher and bag packing machine venting systems, the minimum fan
static pressure should be 30 mbar.
- For bin / silo vent units and electrical rooms pressurizing systems, the minimum
fan static pressure should be 23 mbar.
- For all other dust collectors, the minimum fan static pressure should be 28 mbar.

3.4 Dust collector cleaning control

… General
In pulse-jet collectors, the cleaning function not only removes the collected dust, it
rearranges the remaining dust cake structure on the bag, resulting in a change of
differential pressure. In a unit with high upward gas velocities (can velocity), mechanical
separation of the fine sub micron dust can occur, creating a dust cake structure that is
very dense. A dense dust cake creates a resistance to airflow, and higher differential
pressures.
Essential for a smooth trouble free operation of each dust collector is the availability of
sufficient dry compressed air volume in adequate quality. The usually required air
pressure to clean conventional filter bags is 6 bar and for bags with membrane layers
5 bar.

… Pulse sequence
The pulsing sequence can play an important part in lessening the re-entrainment of
material. Pulsing one row right next to another row (sequential order) can cause the fine,
sub-micron material to migrate to the cleaned row. Staggering the order of rows to be
pulsed can improve the dust cake for optimum filtration as shown in next picture.

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Typical cleaning sequence Recommended cleaning sequence

7 7

Fig. 21: Typical bag cleaning Fig. 22: Recommended bag

sequence cleaning sequence

Example
How a cleaning sequence on a dust collector with 17 respectively 12 bag rows and 10
timer positions can look like it is presented in the following tables.
Timer
1 2 3 4 5 6 7 8 9 10
Position
Valve 1 4 7 10 2 5 8 3 6 9
Numb. 11 14 17 12 15 13 16

Timer
1 2 3 4 5 6 7 8 9 10
Position
Valve 1 4 7 10 2 5 8 3 6 9
Numb. 11 12

… Pulse cycle
The cleaning cycle for pulse-jet collectors should be designed, so that the pulse duration
produces a short, crisp pulse in order to create an effective shock wave in the bag. This
duration is generally set to fire for 0.10 to 0.15 second.
The frequency of pulse-jet cleaning is also vital to proper dust cake retention. This
frequency can vary from 7 to 30 seconds or more and is adjusted by means of a
potentiometer on the timer panel. The frequency should be adjusted, so that the
differential pressure across the collector ranges from 75 - 150 mm WG.
To ensure proper cleaning frequency, an automatic "cleaning-on-demand" system
utilizing a pressure switch gauge can be installed as shown in the following picture.
Good practice is to put the low set point at about 10 mbar and the set point high at 12.5
mbar.

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Set point high

(app. 12.5 mbar)
Set point low
(app. 10 mbar)

Fig. 23: Pressure switch

gauge for bag cleaning
control

This type of system will automatically step through a cleaning cycle that starts when the
high differential pressure set point is reached and stops when it cleans down to the low
differential pressure set point it will also save on compressed air usage.
On pulse-jet collectors, the pulse frequency can of course be increased, but the next
pulse should not be programmed to fire until the compressed air pressure is regained so
the same force of pulse is obtained for each row cleaned. The regain of air pressure is
dependent on the capability of the compressed air system tied to the bag house and the
size of the compressed air piping run to the header tank.

… Diaphragm and solenoid valves

Diaphragm and solenoid valves work together for an efficient operation of the bag house
cleaning system. If either is malfunctioning, the entire system can be affected.
Good practice is to use CR (Chlorbutadien-Elastomer) diaphragm for operating
temperatures up to 800 C, Buna N (Styrol-Butadien-Elastomer) up to 900 C and Viton for
temperatures < 1800 C.
There are integral solenoid valves, which are mounted directly on the diaphragm valve
or remote solenoids mounted in a separate enclosure for special applications.

… Purge valve
Purge valves are designed to eliminate moisture build-up in the compressed air header
before entering the unit, in order to avoid corrosion and dust caking on the top of bags.
This manually operated valve is usually located in the pipeline to the air header. Today
there are automatic purge valves located at the bottom of the air header assembly and
connected to a pulse valve. When the pulse valve fires, the valve opens a discharge port
on the air header assembly, removing excessive moisture.

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3.5 Problem solving guide / trouble shooting

Jet-Pulse Dust Collector Reverse air Dust Collector

Is there Power in No Turn on Power Is there Power No Turn on power

and /or repair in and out of timer ? and / or repair timer
and out of timer ?
timer

Problem Problem Yes Yes

Check for leaking
Lake of air at Emissions from Is manifold
No solenoids and pulse No Adjust and/or
process stack pressure at Are isolation dampers
valves;check compres- repair and check
manufacturer's sealing properly ?
sed air sources and differential power
recommanded setting ? check differnetial press.
Does baghouse Yes Yes
Is System turned Yes have high Yes Check cleaning
on ? differential mechanism
pressure ? Do solenoids and No Repair solenoid or
Is reverse air fan No Turn on and check
diaphragm operate diaphragm and check differential pressure
running ?
properly ? differential pressure
No No
Visually check for Yes Yes
Start System and Are emissions Yes bag leaks; repair
check differnetial visible at the
leaks and check
pressure stack ? Is pulse duration at No Change setting and No Change motor leads
pressure Is reverse air fan
recommanded setting ? check differential and check differential
rotation correct ?
(0,1 - 0,15 sec) pressure pressure
No
Fan Ductwork Yes Yes
Is cleanig interval at Is cleaning cycle
Is fan pulling No Are belts tensioned No Retension and check the lowest setting that No Change setting and
for reverse air dwell set No Change setting and
properly ? differential pressure check differential check differential
design load amps ? will allow air manifold at manufacturer's
pressure pressure
pressure to rebuild ? specifications ?

Yes Yes Yes Yes

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From previous From previous From previous From previous

Yes Yes Yes Yes

Is the differential Change setting and
No Is fan rotation No Change motor
pressure reduced by No Is cleaning interval set No
Is fan vibrating ? leads and check check differential
correct ? stopping fan while at its shortest interval ?
differential pressure pressure
pulsing ?

Yes Yes Yes Yes

Check for damage or Does air/cloth ratio Damper fan volume Pull a bag and run
Is fan damper No Open damper and No
material buildup on exceed 6:1 if pulse-jet, down / evaluate a permeability test to
open ? check differential
fan wheel and repair or 4:1 if plenum pulse pleated media check for blinding
pressure
and clean or reverse air ? conversion

Yes Yes
Add mechanical device
Is air volume at fan No Check for
Are bags experiencing No to reduce load and
No
obstructions in Is bag blinding ?
rated capacity ? high grain loading ? check differential
ductwork and remove
pressure

Yes Yes Yes

Analyze for cause of
Check differential Remove material
No Is material stored No blinding and correct;
Is ductwork or pressure gauge for continously and
or accumulated in replace bags and
system leaking ? proper operation check differential
hopper ? check differential
pressure
pressure
Yes
Check inlet duct entry
Repair leaks and design and modify to
check differential reduce load;
pressure check differential
pressure

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APPENDIX 1

Recommended Venting Air Volume

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Dedusting Air Quantities

SIZE
MACHINE UNIT m3/h DETAILS / REMARKS
(mm)
A B C
BELT CONVEYORS
650 4250 2000
1500 1250
1750 1000 m3/h
A 850 5250 2000
2500 2250
1750 1000
1000 6500 2500
3000 2750
2250 1250
C B 1200 7750 3500
3000 2750
3250 1500
1400 8750 3500
4000 3750
3250 1500
1600 10'000 4000
4500 4250
3750 1750
APRON CONVEYORS A B C
800 6500 3500 2000 1000 m3/h
A 1000 7500 4000 2500 1000
1200 8750 4500 3000 1250
C B 1400 9750 5000 3500 1500
1600 10'000
1 5500 4000 1500
PIVOTING PAN APRON CONV. A B C
A 800 2500 9000 9000 m3/h
1000 3000 10'000 10'000
B C 1200 3500 11'000 11'000
1400 4000 12'000 12'000
BUCKET ELEVATORS CHAIN m 3/h BELT m 3/h
A A B A B
400 1250 1000 2000 1000 m3/h
500 1500 1000 2250 1000
630 2000 1250 2500 1250
800 2500 1250 3000 1250
B 1000 3000 1500 3500 1500
1250 3500 1500 4500 1500
1600 4000 1500 6000 1500
TROUGH CHAIN AND 200 500
SCREW CONVEYORS 250 500
315 500
400 750
PER 10m LENGHT
500 750
630 1000
800 1000
1000 1250
AIR SLIDES 120
150% OF THE AIR BLOWER

CALSSIFING-SCREEN 50 PER t/h (OPEN)

VIBRATORY-SCREEN 450 PER m2 (CLOSED)

SWING-SCREEN 600 PER m2 (CLOSED)

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Example Packing Plant

1 According Machine Unit m3/h

2 Bucket Elevator Food 1250 m3/h
3 Bucket Elevator Head 2500 m3/h
4 Swing Screen 1500 m3/h
5 Storage Bin 500 m3/h
6 Rotary Packer Feed 300 m3/h
7 Rotary Packer 8-Spouts 8000 m3/h
8 Takeway Belt Conveyor 2000 m3/h
9 Bag Cleaning Unit 2500 m3/h

6
9
8
2
1

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Dedusting Air Quantities

Guiding rates for plant engineering

Machine unit Size (mm) m3/h Remarks

Vibrating feeder 600 900
800 1'500
1'000 2'400
1'200 3'600
Air lift 60 Per t
Fuller pump 50 Per t 1.5-times of the expanded
Pressure vessel 40 Per t compressed air volume
Fluidstat (Bühler) 30 Per t
Bin Big 1'000 Mechanical feeding
Small 500 Mechanical feeding
Clinker storage 12 - 20’000 Cylindrical Silo
40 - 60’000 Circular Silo (clinker dome)
Roller crusher to 50 t/h 36 Per t
50 - 100 t/h 60 Per t
Jaw crusher to 100 t/h 60 Per t
100 - 400 t/h 45 Per t
400 - 700 t/h 30 Per t
Hammer crusher to 100 t/h 120 Per t
Impact crusher to 100 t/h 90 Per t
to 300 t/h 60 Per t
> 300 t/h 40 Per t
Gyratory crusher to 100 t/h 60 Per t
(cone crusher) 100 - 400 t/h 45 Per t
400 - 700 t/h 30 Per t
Packing machine 8'000 8-spouts rotary packer
6'000 6-spouts rotary packer
300 Feed
2'500 Per spout in-line packer collecting
funnel
1'500 Niagara-swing screen 1 x 2.5 m
2'000 Takeaway belt conveyor
2'500 Bag cleaning unit
Loading mobile 5'000 Air slide 400 mm
5'000 Screw 1630/1800
1'500 Hopper mobile
4'000 Double articulated (air slide or
screw)
Loading head 900 Cement 300 m3/h
1'500 Cement 600 m3/h
12'000 Clinker 300 m3/h
Tanker vehicles 540 - 660 Road 60 t/h at 2.5 bar
660 Rail 60 t/h at 2.5 bar

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APPENDIX 2

Ductwork and Venting Hood Design

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Venting Hood Design

v2
Vertical Longitudinal Transversal
E D

H ØC ØC
ØG ØG

L B L B B L

v1

Air Quantity v1 v2 L B H ØC ØG L B E D
3 3
m /h m /min ms-1 ms-1 mm mm mm mm mm mm mm mm mm

250 4.2 1.40 18.0 260 190 165 70.0 * 97 260 190 157.0 122.0
500 8.3 1.40 17.5 370 270 235 100.5 * 143 370 270 227.0 177.5
750 12.5 1.40 17.0 450 330 280 125.0 * 178 450 330 278.0 218.0
1000 16.6 1.40 17.2 520 380 325 143.5 * 207 520 380 323.5 253.5
1250 20.8 1.40 17.7 580 425 365 158.0 233 580 425 365.0 287.5
1500 25.0 1.44 17.9 630 460 400 172.0 253 630 460 396.0 311.0
1750 29.2 1.43 17.9 680 500 430 186.0 276 680 500 430.0 340.0
2000 33.3 1.39 17.9 740 540 470 198.0 299 740 540 471.0 371.0
2500 41.6 1.41 18.0 820 600 520 222.0 334 820 600 522.0 412.0
3000 50.0 1.40 17.9 900 660 570 244.0 368 900 660 574.0 454.0
3500 58.3 1.44 17.8 960 700 610 262.0 391 960 700 609.0 479.0
4000 66.6 1.40 18.0 1040 760 660 280.0 426 1040 760 666.0 526.0
4500 75.0 1.42 17.9 1100 800 700 298.0 449 1100 800 701.0 557.0
5000 83.3 1.42 17.9 1150 850 740 314.0 475 1150 850 739.0 589.0
6000 100.0 1.42 17.9 1260 930 800 344.0 524 1260 930 810.0 645.0
*Commercial Pipes and Bends
Sheet Thickness for Suction Hoods and Ducts: 3-4mm
Intake Velocity at Hoods according to Above Table: V1 = ~ 1.4m/s
Air Velocity in Dedusting Duct : V2 = > 18m/s
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Duct Elbow, Joint and Branch Design

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Hooding Design at Pickup Points

Hooding for Airslide

Typical Recommended

High velocity

Hooding for belt conveyor

Min. 2*belt width

Min. cover hood

height: 400 mm

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Hooding for steel conveyor

2 x conveyor width

1/3 belt
width

600 mm
min.

Rubber skirt

Additional venting
may be required for
dusty material

Dust curtain

50 mm clearance
for load on belt

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Hooding for Bucket elevator head

Typical Alternativ
Vent point

Relocated vent point

Impact flow meter dedusting

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Gas velocity in ductwork

For Abrasive Dust For Non-Abrasive Dust
Tube Tube Tube Gas Airflow Tube Tube Tube Gas Airflow
diameter diameter diameter speed diameter diameter diameter speed
Inch mm m m/s 3
m /h inch mm m m/s m3/h
4.5 114.30 0.114 16.00 591 4.5 114.30 0.114 18.00 665
6 152.40 0.152 16.00 1051 6 152.40 0.152 18.00 1182
7 177.80 0.178 16.00 1430 7 177.80 0.178 18.00 1609
8 203.20 0.203 16.00 1868 8 203.20 0.203 18.00 2101
9 228.60 0.229 16.00 2364 9 228.60 0.229 18.00 2660
10 254.00 0.254 16.00 2919 10 254.00 0.254 18.00 3283
11 279.40 0.279 16.00 3531 11 279.40 0.279 18.00 3973
12 304.80 0.305 16.00 4203 12 304.80 0.305 18.00 4728
13 330.20 0.330 16.00 4932 13 330.20 0.330 18.00 5549
14 355.60 0.356 16.00 5720 14 355.60 0.356 18.00 6435
15 381.00 0.381 16.00 6567 15 381.00 0.381 18.00 7388
16 406.40 0.406 16.00 7471 16 406.40 0.406 18.00 8405
17 431.80 0.432 16.00 8435 17 431.80 0.432 18.00 9489
18 457.20 0.457 16.00 9456 18 457.20 0.457 18.00 10638
19 482.60 0.483 16.00 10536 19 482.60 0.483 18.00 11853
20 508.00 0.508 16.00 11674 20 508.00 0.508 18.00 13133
21 533.40 0.533 16.00 12871 21 533.40 0.533 18.00 14480
22 558.80 0.559 16.00 14126 22 558.80 0.559 18.00 15891
23 584.20 0.584 16.00 15439 23 584.20 0.584 18.00 17369
24 609.60 0.610 16.00 16811 24 609.60 0.610 18.00 18912
25 635.00 0.635 16.00 18241 25 635.00 0.635 18.00 20521
26 660.40 0.660 16.00 19729 26 660.40 0.660 18.00 22196
27 685.80 0.686 16.00 21276 27 685.80 0.686 18.00 23936
28 711.20 0.711 16.00 22881 28 711.20 0.711 18.00 25742
29 736.60 0.737 16.00 24545 29 736.60 0.737 18.00 27613
30 762.00 0.762 16.00 26267 30 762.00 0.762 18.00 29550

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APPENDIX 3

Hopper Valley Angle

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APPENDIX 4

Dust Suppression for Feed Hoppers

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Attached bag filter to hopper enclosure

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