BAGHOUSE 101 TRAINING

Presented by:

March 10, 2005

Baghouse 101 Outline

 Overview
 Design
 Fabric Types
 Shaker Baghouse
 Reverse Air Baghouse
 Pulse Jet Baghouse
 R&D
OVERVIEW
 Why Do We Need A
Baghouse

 Recover useable product

 Keep plant clean and

workers safe

 Comply with state and

federal regulations
Typical System Components
 Emission Source
 Pickup Points

 Ductwork

 Collection Equipment
 Baghouse

 Air Mover
 Fan
 Types of Dust Collection
 SETTLING: dust settles on surfaces.

 CYCLONE: cyclone is utilized to capture larger particles

 ELECTROSTATIC PRECIPITATORS: positively charged particles become

negatively charged for release.

 WET SCRUBBERS: mix water with dust, dust settles in a pond and is drawn back
into the system.

 BAGHOUSES: dust collection method gathers dust on a piece of filter media and
then it is removed from the material by air, or mechanical shaker.
 Components of a
Baghouse

 Hopper

 Housing

 Tubesheet

 Plenum
 3 Types of Baghouses

 Shaker Baghouse

 Reverse Air Baghouse

 Pulse Jet Baghouse

 Shaker Baghouse

 The first and oldest cleaning style

 Utilizes mechanically driven devices to
“shake” the filter bag
 Particulate collects on the inside surface
of the filter bag
 Reverse Air Baghouse

 The second and next oldest cleaning style

 Utilizes a system of reversing air flow
through the filter bag to create a “back
washing” effect on the particulate,
changing the filter bag surface contour,
and releasing the collected particulate.
 Particulate collects on the inside surface
of the filter bag
 Pulse Jet Baghouse

 The third and newest cleaning style

 Differs drastically from both the shaker
and reverse air baghouse
 Utilizes a powerful, short blast of
compressed air in a reverse direction
 Particulate collects on the outside surface
of the filter bag
BAGHOUSE
DESIGN
 Baghouse Design

 Inlet Grain Loading  Inlet Velocity

 Air-to-cloth Ratio  Can Velocity
 Differential Pressure (P)  Inlet Temperature
 Fabric Selection and Efficiency  Outlet Emissions
 Inlet Grain Load

 0.1 to 5.0 grains/ft3 = Light

 6.0 to 15.0 grains/ft3 = Medium
 16.0 to 30.0 grains/ft3 = Heavy

 1.0 Grain = 1/7000 LB

 Air-to-Cloth Ratio

 Shaker: 1.5:1 to 3.0:1

 Reverse Air: 1.5:1 to 2.5:1

 Pulsejet: 4.0:1 to 8.0:1

 Differential Pressure

 Differential pressure (P) not to

exceed 6” static pressure water
gauge (S.P.W.G).

 Magnehelic gauge/manometer
used for monitoring differential
pressure

Magnehelic gauge
 Fabric Selection
 Operating temperature
 Abrasion resistance
 Collection efficiency
 Chemical make-up of gas stream
 Dust loading
 Air-to-cloth ratio
 Cleaning method
 Air Flow

 Volume (CFM)

 Temperature

 Inlet velocity (3000 FPM or less)

 Can velocity (300 FPM or less)

 Outlet Emissions
 Location dependent

 Application dependent

 Media dependent

 Regulatory impact
MEDIA TYPES
 Media Types

 Natural Fibers
 Cotton
 Wool
 Paper
 Synthetic Fibers – Most Widely Used
 Woven
 Felts
Fabric Selection Chart
 Fabric Finishes
Non-Fiberglass Finish Purpose Available For
Polyester, Polypropylene, Acrylic, Aramid, PPS, P-84®
Singe Recommended for improved cake release (felts)
Provides short-term improvements for cake release (may
Glaze impede airflow) Polyester, Polypropylene (felts)
Aids initial cake development and provides limited water
Silicone repellency Polyester (felts and wovens)
Flame Retardant Retards combustibility (not flame-proof) Polyester, Polypropylene (felts and woven)
Acrylic Coatings Improves filtration, effeciency and cake release (may
(latex base) impede flow in certain applications) Polyester and Acrylic (felts)
PTFE Surface Aramid, Polyester, Acrylic, Polypropylene (felt) -
Treatments and For capture of fine particulate, improving filtration Laminates available in Polypropylene, PPS and
Laminates efficiency, cake release Polyester only
PTFE Penetrating
Finishes Improved water and oil repellency; limited cake release Aramid (felt)
Acid Resistant Improved acid resistance and water retardance Aramid (felt)

Fiberglass Finish Purpose Applications

For capture of fine particulate, improved filtration Cement/lime kilns, incinerators, coal-fired boilers,
PTFE Membrane efficiency, cake release and airflow capacity cupola, ferro/silica alloy furnace
Silicone, Graphite For non-acidic conditions, primarily for cement and
Teflon® Protects glass yarns from abrasion, adds lubricity metal foundry applications

Coal-fired boilers, carbon black, incinerators, cement,

Acid Resisant Shields glass from acid attack
Provides enhanced abrasion resistance and limited
Teflon B® chemical resistance
Provides improved acid resistance and release properties,
superior abrasion resistance, resistance to alkaline
Chemical Resistant attack, improved fiber encapsulation
industrial and small municipal boiler applications
Industrial and utility base load boilers under mild pH
conditions
Coal-fired boilers (high and low sulfur) for peak load
utilities, fluidized bed boilers, carbon black,
incinerators
 SHAKER
BAGHOUSE
 3 Basic Styles of
Shaking Action

 Horizontal Shake

 Tube Shake

 Cradle Shake
Shaker Cleaning
Side View Front View

Clean Air
Outlet

Dirty Gas
Dirty Gas
Inlet Open
Inlet Closed

Slidegate closed Slidegate Open

Filtering mode Cleaning Mode

REVERSE AIR
BAGHOUSE
 Components of a
Reverse Baghouse
Reverse Air Cleaning Cycle

 Close the outlet or poppet damper

 Provide a period of “null” period to provide for
settling of particulate
 Open reverse air poppet valve to allow reversed
air flow to “backwash” through the fabric filters
 Close reverse air poppet valve, allowing a “null”
period to all for settling of particulate
 Open outlet or poppet damper
 Compartment is brought back “on-line”
Reverse Air Cleaning

Filtering Collapsing Cleaning

 Points of Inspection

 Hanging structure
 Tensioning hardware
 Failure due to weight and elevated temperatures
 Chemical reaction will also deteriorate hanging
hardware
 Filter caps may contain corrosion
 Clamps and fasteners usually cannot be used
safely more than once
 Points of Inspection

 Condition of thimbles
 Corrosion
 Particulate build-up
 Broken welds
 Cell plate for broken welds, corroded leakage
 Exterior door seals
 Biggest cause of compartment corrosion and
collection efficiency
 Points of Inspection

 Hopper evacuation equipment

 Hopper screws, rotary airlock valves, dump
valves
 Magnehelic gauges. All lines should be
cleared and cleaned before gauges are
inspected
 Particulate removed from the hopper
 Filter Bag Installation

 Cell plates should be carefully cleaned

 Thimbles should be brushed to remove
particulate build-up
 Cell plates without thimbles should be
carefully swept and holes brushed clean
of particulate build-up
 Filter Bag Installation
(cont)

 Filter bags should be located in boxes, nearest

the locations that they are to be installed.
Beginning should be furthest from the
compartment entry and furthest from any
provided walkways
 Install hanging hardware prior to installing filters
 Attach filter bags at the top first, leaving the
bottom of the filters to remain loose.
 Filter Bag Installation
(cont)

 Install bottom of filter bags

 Seams of each filter bag should face the
walkway that serves that row of filters
 Check that seams are not twisted
 Tension filter bag
 Installing Bag On Thimble
STEP 1 STEP 2 STEP 3

INSTALL ONE SIDE OF BEADED INSTALL OTHER SIDE OF BEADED INSTALL CLAMP ABOVE BEADED
CUFF OF BAG OVER THIMBLE BEAD CUFF OF BAG OVER THIMBLE BEAD CUFF OF BAG JUST UNDER THIMBLE BEAD

IMPROPER IMPROPER IMPROPER

 Proper Tensioning
Typical Filter Bag Tension

 5” diameter 35 lbs.
 8” diameter 50 lbs.
 11.5” diameter 50 lbs. (Polyester)
 11.5” diameter 75 lbs. (Fiberglass)
 Tension Guidelines
Excessive Tension:
 Results in high stress around ring covers and cuffs.
 Prevents the proper flexing needed to release the dust cake.
Insufficient Tension:
 Results in bag to bag abrasion.
 Results in bag to structure abrasion.
 Inhibits flow of dust out of bag.

 Accelerates fatigue failures.

Operating Instructions
for M-C Tensioning Tool

SHEET
Instruction
 Daily
Preventive Maintenance

 Walk through the baghouse area to check for

normal or abnormal visual and audible
conditions
 Check Differential Pressure
 Check the proper operation of the cleaning cycle
 Monitor the evacuation system
 Observe the stack for clean air particulate
(opacity)
 Weekly
Preventive Maintenance

 Check poppet valves for proper operation

 Inspect fans/blowers for corrosion and
vibration
 Monthly
Preventive Maintenance

 Clean the monitoring equipment lines

 Check the filter cleaning sequence to see
that all poppit valves are seating properly
 Check all moving parts on the evacuation
system
 Inspect inlet and outlet ducts for
corrosion, leaks, and particulate build-up
 Quarterly
Preventative Maintenance

 Calibrate all monitors, particularly the

outlet (opacity) monitors
 Yearly
Preventative Maintenance

 Inspect filter bags for leaks and holes

 Inspect compartments for particulate
build-up
 Inspect hoppers for abrasion and
corrosion
 Inspect door and port gasketing
 Inspect baghouse structural for corrosion
 Start-Up Procedure

 Process air should be brought up

gradually
 Pre-coating fabric filters can reduce initial
particulate impact and help to prevent
blinding during initial process air
introduction
 Monitoring systems should be observed
and noted
PULSE JET
BAGHOUSE
 Components of a
Pulse Jet Baghouse
 Pulse Jet Cleaning Cycle

 Uses compressed air from air compressors

 Cleaning pressures of 80 – 110 PSI
 Components
 Sequential timer
 Solenoid valve
 Diaphragm valve
 Air header
 Blowpipes
 Cleaning Mechanism
 Air compressors are used to develop higher pressure
air
 Air is distributed from the compressor storage tank to
the baghouse “header” assembly via pipe plumbing
 Pulse valve is attached to each of the pulse tubes and
connected to the compressed air source
 On command, pulse valves momentarily open and
close, allowing a short blast of compressed air to
enter the pulse tubes and be distributed to each filter
served in that row by that pulse tube
Pulse Jet Cleaning
Clean
Air Outlet

Fabric
Filter
Bags

Dirty
Air
Inlet Hopper
 Clean on Demand vs.
Continuous Cleaning

 Clean on Demand
 Cleaning system is activated when differential
pressure reaches high limit set point and
deactivated when differential pressure
reaches low limit set point. Always keeping a
consistent dustcake
 Continuous Cleaning
 Cleans on a specific on-time and off-time
 Points of Inspection

 Inspect cages for corrosion, damage, broken

wires and areas that might abrade or cut filter
surfaces
 Pulse tubes and nozzle openings for blockage
and corrosion
 Venturis should be observed for uneven
abrasion wear
 Flexible tube connectors inspected for cracks,
holes and leaks
 Points of Inspection

 Diaphragm valves and solenoid valves for proper

operation
 Timer board inspected and tested for firing
sequence and pulse duration
 Hopper door and plenum doors should be
inspected for seal damage, wear and leaks
 Points of Inspection

 Evacuation equipment inspected to be sure

hopper is continually emptied as needed
 Tubesheet should be cleaned and inspected for
corrosion and physical stress leaks
 Inspect manometer and clean lines
 Hoppers should be emptied completely and
swept clean
 Installation Procedure for
Snapband Bag
 Step 1: Bend the snapband into a kidney
shape. Place the grooved gasket into
the tubesheet hole.

 Step 2: Move the snapband into place. A

sharp popping noise should be noticed as
the band is properly seated around the
circumference of the tubesheet hole.

 Step 3: Check to make sure you cannot

twist the snapband and that band is
securely seated with the metal tubesheet
fitted into the center of the band
groove.
Installation Procedure for
Bag and Cage Assembly
Installation of Top Removal
Blowtubes
 Daily
Preventive Maintenance

 Walk through the baghouse area to check for

normal or abnormal visual and audible condition
 Check Differential Pressure
 Check the proper operation of the cleaning cycle
for both time between cycles and duration of
cleaning cycle
 Check compressed air and water traps on clean,
pulse air system- #1 reason for cleaning
problem
 Daily
Preventive Maintenance

 Monitor the evacuation system

 Observe the stack for clean air particulate
(opacity)
 Weekly
Preventive Maintenance

 Spot check for fabric filter leaks and holes

 Monthly
Preventive Maintenance

 Clean the monitoring equipment lines

 Check temperature indicating equipment
 Check the compressed air lines and
operation of “dryer” if available
 Quarterly
Preventative Maintenance

 Perform a leak detection test

 Calibrate all monitors, particularly the
outlet (opacity) monitors
 Yearly
Preventative Maintenance

 Inspect hopper and interior of

compartments for corrosion and leaks
 Inspect all control valves and plumbing
 Inspect entire cleaning air system for
moisture and corrosion contamination
 What Not To Do When
Installing Bags
 Do not open carton or remove bags until they are ready to install.
 Do not sit on, stand on, or walk on bags. Damage will occur that is not
visible to the naked eye.
 Do not drag bags over catwalks, guard rails, thimbles, or any rough
surface.
 Do not have hand tools or sharp instruments in pockets or pouches near
bags.
 Do not pull on any loose threads.
 Do not stack cartons higher than five
 Do not install bags you have reason to believe will fail prematurely.
 RESEARCH &
DEVELOPMENT
 Typical Fabric Tests
 Tensile Test
Pounds/1” of width to pull apart.

 Air Permeability Test

 First Bubble Point

Inches w.g. with Isopropyl alcohol  2.5 mean for paper

 Mullen Burst Test

Approximately 90 (wet) psi for strong paper.

 MIT Flex Test