About Andy Biancotti

Andy has been working in the maintenance field for over a decade, continuing to learn the secrets of preventive maintenance in the ever growing field of dust collection. Editor and marketing manager.

Entries by Andy Biancotti

Our Free Baghouse Design Calculators Are Live!

We’re excited to announce something that’s been a long time coming—a full set of free online calculators designed to make dust collection system design and troubleshooting way easier.

If you’ve ever had to stop what you’re doing to run a quick air-to-cloth calculation, estimate how much precoating powder you need, or figure out what duct diameter to order… this is for you. These calculators were built for people like you: engineers, operators, maintenance personnel, and even purchasing staff… to quickly get answers without digging through spreadsheets or flipping through manuals.

Here’s what we’ve launched:

✧ Air-to-Cloth Ratio Calculator – See if your system is sized right or running outside the ideal range. Great for both design and troubleshooting.
✧ Interstitial Velocity Calculator – Quickly check if the air between the bags is flowing fast enough to keep dust suspended and prevent dropout.
✧ Can Velocity Calculator – Measure the vertical airflow between the baghouse housing and filters.
✧ Total Filter Cloth Area Calculator – Determine how much filter media your system needs to support your airflow volume efficiently.
✧ Leak Testing Powder Calculator – Get an accurate estimate of how much fluorescent leak test powder you’ll need for a given baghouse.
✧ Precoating Powder Calculator – Find out how much precoating agent to apply before startup to protect your filter bags from blinding.
✧ Air Velocity Calculator – Helps ensure you’re maintaining the right conveying velocity in your ductwork to avoid dust dropout or wear in your ducts.
✧ Duct Sizing Calculator – The goal is to select a duct size that allows for proper dust conveyance without excessive friction loss or particle dropout.

These tools are already proving useful in day-to-day work, from initial design to routine maintenance, even quoting and system retrofits. The goal is to take the guesswork out of some of the most common calculations we all deal with in the field.

Of course, these are reference tools, not one-size-fits-all answers. Real-world systems can be messy—airflow changes, system resistance fluctuates, dust loads vary, and what looks good on paper might not work in practice. That’s why we always recommend reaching out to an expert (like us at Baghouse.com) to review your results before making big decisions.

But if you need quick numbers, you’re in the right place.

Try the calculators out today and see how much time (and stress) they can save you.

At Baghouse.com, we believe that knowledge is power, especially when it comes to investing in equipment as critical (and expensive) as a dust collection system. That’s why we’re making these calculators available for free. Our goal is to help people make informed decisions by understanding the numbers behind the quotes they receive.

Whether you’re an engineer comparing different system designs, a plant manager reviewing proposals, or a purchasing agent trying to get the best value, these tools give you the ability to ask better questions and spot red flags. In an industry where it’s all too easy to get sold a one-size-fits-all system out of a catalog, we want to empower you to choose the solution that’s right for your application—one that performs reliably for years to come.

June 19, 2025/by Andy Biancotti

Baghouse Design, Cement and Construction Materials, Dust Collector Maintenance

Asphalt Production & Dust Collectors Design and Maintenance (Part 3)

As we have seen in the previous two articles, when you’re running a hot mix asphalt plant, your dust collector isn’t just another piece of equipment—it’s the beating heart of your dust control system. But for many plant operators and maintenance teams, baghouses are still a bit of a mystery. What makes them work well? Why do they suddenly clog up or burn through filters? And how can you keep yours running for years, not just months?

Why Asphalt Plants Need Dust Control

Regulations are only getting stricter. Hot mix plants must meet tight emissions limits for dust, for sulfur dioxide, and other volatile compounds.

Hot mix asphalt plants are regulated under both federal and local environmental laws, particularly for air emissions. These plants must use effective dust collection and pollution control systems to meet standards for:

♦️ Particulate Matter (PM): Baghouses (fabric filters) or scrubbers must capture fine dust generated in drying, mixing, and conveying.
♦️ Volatile Organic Compounds (VOCs) and Hydrocarbons: Released during asphalt heating and mixing. Controlled through burner tuning, proper operating temps, and vapor capture systems.
♦️ Sulfur Dioxide (SO₂), Nitrogen Oxides (NOx), and Carbon Monoxide (CO): Emissions from combustion systems, regulated especially when using fuel oil, coal, or RAP (Reclaimed Asphalt Pavement).
♦️ Opacity Limits: Visible emissions (smoke/dust) from the stack must remain below specific opacity percentages (often 20% or lower).

Design Requirements

🔹 Design: Since many asphalt plants are portable, dust collection systems must also be rugged and easy to transport. The compactness of the design and ease of maintenance are all key considerations.

🔹 Filter Media: Asphalt production involves high temperatures. The baghouse installed on the dryer end of the system must be able to handle continuous operating temperatures up to 375°F (190°C) — and sometimes even higher during spikes.

For this reason, aramid filter media (commonly known by the trade name Nomex®) is the go-to choice. It’s a heat-resistant material that performs well under the high-temperature, high-dust conditions of asphalt operations.

To improve performance in space-constrained systems, pleated filter elements made with aramid media are gaining popularity. These offer increased surface area in the same or smaller footprint, which helps overcome the limitations of older, compact baghouse designs. However, pleated filters come with some temperature limitations and should be used where appropriate.

If you choose membrane-coated bags to cut down emissions, be warned—hydrocarbon contamination from the mix or burner can blind those bags fast.

Knockout boxes or cyclones reduce dust loading on the bags and help stabilize pressure drop, which makes the whole system easier to maintain and run.

🔹 Dust Cake and Precleaners: A good cyclone can pull out 80–90% of large aggregate dust before it ever hits the bags. This helps build a healthy dust cake and cuts wear on the filters. We also sometimes install knockout boxes or cyclones when space or volume demands. These reduce dust loading on the bags and help stabilize pressure drop, which makes the whole system easier to maintain and run.

🔹 Fan Sizing and Air-to-Cloth Ratio: Too many asphalt plants are still running baghouses with poor air-to-cloth ratios—sometimes 5:1 or more—which leads to overloaded filters and early failure. Can velocity and fan performance need to be dialed in carefully to avoid high differential pressure (DP) and re-entrainment. We recommend staying between 3.5–4.5:1 for most applications.

🔹 Cleaning System: It’s almost always pulse-jet cleaning in the asphalt world. Most systems run at 60–70 psi, which is usually enough. Cranking it up to 90–100 psi often just shreds bags faster without actually solving the problem.

Your cleaning should be on-demand with a magnehelic or photohelic set to trigger between 3–5 inches W.C. Don’t space out cleaning pulses too far apart—if you wait too long between row cleanings, air takes the easiest path and some bags end up doing all the work.

Conveyor belts are used to move a large amount of material between different parts of the asphalt plant

🔹 Discharge System: Reusing the dust you collect (as we talked about in the previous articles) makes the whole operation more profitable. To handle the bulk material collected, you need one of the following options:

✧ Rotary Airlocks, especially for coarse or abrasive dust.
✧ Slide gates are cheap and simple, but they’re prone to leaking and jamming.
✧ Conveying Systems: Screw conveyors are standard, but some plants are now implementing conveyor belts or even pneumatic systems for faster, cleaner transfers.

Asphalt-Specific Challenges

One big challenge in asphalt baghouses is hydrocarbon vapors. These can migrate into the baghouse, coat the bags, and lead to blinding—especially if you’re using membrane filters. It’s a common issue when burners aren’t tuned properly or during heavy recycling (RAP) operations. Make sure your burner system is dialed in and your bags are suited for the environment.

Condensation is also a frequent challenge in this industry.

When hot gases hit cold metal (or filter bags), moisture condenses. This turns dust into a kind of mud that eats through metal and fabric alike—especially when sulfur in the fuel creates an acid flash.

That’s why preheating the baghouse is critical. We recommend:

✧ 20+ minutes at 350°F during startup.
✧ Make sure the tubesheet, bags, and ductwork are all above the dew point—especially in cold or wet conditions.
✧ Even during midstream restarts, don’t rotate the drum until preheat is complete.

Nomex can handle up to 400°F continuously (spikes to 450°F), but you want to avoid running too cold. The sweet spot is usually around 250°F. Running cold causes condensation, but overheating can destroy the bags. Train your operators to monitor temperature and pressure closely to prevent problems before they start.

What Should An Asphalt Plant Baghouse Inspection Sheet Include?

A good inspection checklist can help you spot issues early, keep your production up, and avoid costly downtime. Here are the key things to keep on your baghouse inspection sheet:

1. Is it the right size?
A baghouse that’s too small will choke your production. One that’s too big can make it tough to hit the right temps. The sweet spot? Around 200 CFM per ton of asphalt mix, assuming about 5% moisture content. So, if you’re running a 400-ton-per-hour plant, you’ll need something around 80,000 CFM.

2. Any leaks?
Make sure everything from the drum seals to the ductwork is airtight. Think of your dust collector like a big vacuum—if there’s a hole in the hose, it won’t suck up anything properly.

3. How are your filter bags holding up?
Worn-out bags lead to high pressure drops, poor cleaning, and lower production. Keep them in good shape by checking temperatures, tuning the burner right, and making sure everything stays in the recommended range. Bags aren’t cheap, so taking care of them will save you serious money—and make your system more attractive if you ever decide to sell it.

Other things to check regularly:

🔹 Total number of bags and their individual ID numbers
🔹 Bag damage (tears, holes, or thinning material)
🔹 When bags were installed, cleaned, or replaced
🔹 Airflow readings (CFM) and velocity (FPM)
🔹 Are airflow and pressure drop within normal range?
🔹 Check airlocks and dampers for proper function
🔹 Log pressure drops across the baghouse and individual compartments
🔹 Investigate weird pressure readings
🔹 Exhaust gas temperatures
🔹 Humidity levels inside the baghouse
🔹 Size and type of dust being collected
🔹 Any signs of system leaks

Invest Some Now or Invest a Lot Later!

Smart plant managers know that a little upfront investment in dust collection pays off big down the line.

Spend on quality filter bags rated for your operating temps, install a proper precleaner like a cyclone to reduce dust loading, and make sure your cleaning system uses demand-based controls. Don’t skimp on preheat systems either—they prevent condensation and extend bag life. Even setting up a solid inspection and maintenance schedule with trained personnel can prevent costly shutdowns.

The key takeaway from this series of three articles is that having the right equipment, the right process, and the right support makes the difference in how efficient (and profitable) your plant is.

Would like to go over some of the information in the previous two articles? Here are the links!

Would like some help designing or upgrading the dust collection system of your asphalt plant?

June 10, 2025/by Andy Biancotti

Baghouse Design, Cement and Construction Materials

Asphalt Production & Baghouse Fines (Part 2)

In the first part of this series, we looked at how an asphalt plant works and why it needs a dust collection system. Now, in part two, we’ll go a step further and talk about baghouse fines (BFs)—what they are, how they’re recycled, and the role they play in asphalt quality. If you’re working at an asphalt plant or managing dust collection equipment, understanding this topic can help you get more out of your system. Also, in addition to helping the environment, you’re also saving money. Reusing fines cuts down on material costs and can actually make your asphalt stronger and more durable, which means fewer problems down the road and less money spent fixing them.

A Closer Look At Baghouse Fines

Baghouse fines are the fine particles your dust collector captures during asphalt production. They’re often seen as just a byproduct, but they can actually be a valuable resource. With sustainability becoming a bigger priority in construction, more producers are finding ways to reuse these fines in hot mix asphalt (HMA)—without sacrificing pavement performance.

Most asphalt plants today try to reuse as much of the collected dust as possible (around 80–90% of baghouse fines end up back in the mix.)

In fact, most asphalt plants today try to reuse as much of the collected dust as possible. Industry estimates say around 80–90% of baghouse fines end up back in the mix. That not only helps reduce environmental impact but also fills the mineral filler requirements for certain asphalt designs. Still, a small percentage of producers—probably under 10%—are either disposing of the extra fines in settling ponds or returning them to a quarry. And at plants that use wet scrubbers instead of baghouses, the captured material usually gets washed away and discarded.

Physical and Chemical Properties of Baghouse Fines

In batch plants, the aggregates are first dried in a rotary dryer, then screened into different sizes and stored in bins. These materials are then fed, batch by batch, into a pugmill mixer, where asphalt cement is added and mixed with the hot aggregate.

Most BFs are reused on-site, right at the plant where they’re collected. That’s partly because fines can vary a lot from one plant to another. Their characteristics—like particle size, chemical makeup, and specific gravity—depend on things like the type of aggregate being processed, moisture content, and whether it’s a batch or drum plant. The dust collection setup also plays a big role. Plants with cyclones usually collect finer particles, with up to 90–100% passing the No. 200 sieve (0.075 mm). Those without cyclones may end up with coarser material, with less than 50% passing that same sieve.

In general, baghouse fines are made up of particles smaller than 0.6 mm. Some are coarse, some are ultra-fine. Fines collected after a cyclone tend to be better suited for reuse in asphalt. Most BFs have low plasticity—usually a plasticity index (PI) under 4—and low moisture absorption (typically less than 2%). Organic impurities are rare, except sometimes in oil-fired plants.

Chemically, BFs tend to be alkaline, with pH levels ranging from 7.2 to as high as 12.4, depending on the parent aggregate. Their chemical composition basically mirrors whatever aggregate the plant is crushing—granite, limestone, traprock, or something else.

How Are BFs Recycled?

Depending on the setup, the fines can go straight back into the process or be stored in silos for later. When reused, BFs serve as mineral fillers, replacing materials like hydrated lime or stone dust. These fillers are important. If your mix has too little, it can lack cohesion. Too much, and it might get brittle.

That’s why some producers are careful about how much BF they use. Even though they’re a recycled material, BFs can meet AASHTO (American Association of State Highway and Transportation Officials) and other highway specs for mineral fillers—if the parent aggregate is high-quality and the fines are well-graded.

How Do BFs Affect Asphalt Performance?

Using BFs in the mix does affect performance. For example, bumping up the fines-to-asphalt ratio from 0.2 to 0.5 tends to stiffen the mix by decreasing binder penetration and increasing viscosity. Lab tests show that Marshall stability improves with more fines, peaking when fines make up about 55% of the binder’s volume. The resilient modulus also goes up, which means a stiffer, stronger mix. But there’s a limit—too much fine material (especially over half the binder volume) can cause moisture sensitivity and lead to durability problems in the field.

That’s why proper mix design is so important. Most mixes using BFs can be designed using standard methods like the Marshall immersion-compression test (ASTM D1075). Good designs usually keep the fines content below 50% of the binder’s bulk volume, use well-graded particles, and include plenty of very fine material (smaller than 0.010 to 0.020 mm). It’s also key to keep your fines-to-asphalt ratio consistent—any changes in BF composition can affect pavement performance.

If you’re blending cyclone dust with baghouse fines, be sure to know the proportions and mix them properly. The type of aggregate matters, too. Dust from hard, angular rocks like traprock or granite may stiffen the mix more than softer, carbonate-based materials.

In short, BFs aren’t just filler—they actually act like active components of the mix. They need to be accounted for from the start, not thrown in at the end.

Handling and Production Considerations

For structural design purposes, asphalt mixes with BFs can be modeled using standard AASHTO methods—no special tweaks needed, as long as the fines are integrated correctly.

How fines are handled depends on the type of plant. In batch plants, they can be reintroduced at several points, including the hot elevator, hot bin No. 1, or the weigh box. Introducing fines earlier in the process usually leads to better mixing and more consistent properties. In drum plants, they can be added at the cold feed conveyor, drum inlet or outlet, or—ideally—where the liquid asphalt is injected. That last option helps ensure better coating and reduces the risk of fine particles escaping with exhaust gases.

You can stick with standard mixing and compaction techniques, although mixes with a higher filler/asphalt ratio can be tougher to compact due to stiffness. Quality control doesn’t change either: use AASHTO T168 for sampling, ASTM D2726 for specific gravity, and ASTM D2950 for in-place density.

Over the years, plenty of research has been done on how BFs perform in the field. Early studies—like one by PennDOT in the late 1970s—warned of brittle pavement and compaction problems when fines were added inconsistently. But more recent evaluations are much more positive. Caltrans, for example, found that adding up to 2% BFs improved cohesion. The Asphalt Institute concluded that BFs work well as mineral fillers—as long as the aggregate is high-quality. Other studies (like those from West Virginia and NCHRP) also found that very fine fractions of BFs can boost performance, especially when particles smaller than 0.020 mm are present.

How Baghouse.com Can Help

At Baghouse.com, we’re more than just parts suppliers—we’re your partner for keeping your dust collection system running strong. Whether you need a site inspection, troubleshooting, filter replacements, or a full system rebuild, we know how much dust collector performance affects your ability to reuse baghouse fines effectively.

We can help you to:

✧ Make sure your baghouse is collecting fines that meet gradation specs
✧ Spot issues like uneven airflow or leaking bags that mess with BF quality
✧ Retrofit or upgrade your system to boost performance and cut down on downtime
✧ Train your crew on best practices for handling and recycling BFs

Your baghouse it’s part of your production line. When it’s well-maintained, it gives you a steady source of reusable material and helps you control asphalt quality from start to finish.

In the third and last article of this series, we will take a look at the best design and maintenance practices for asphalt dust collectors.

Need help with your dust collector? Let’s talk.

Image Credits

By Silverije – Own work, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=37085244

June 3, 2025/by Andy Biancotti

Baghouse Design, Cement and Construction Materials

Asphalt Production & Dust Control (Part 1)

Asphalt is everywhere. It’s under your tires on the highway, in the parking lot at the grocery store, and lining the roads in your neighborhood. Its use is so widespread that many of us take it for granted, never stopping to consider how it’s made — or the vital role dust collectors play in its production.

In the world of asphalt manufacturing, dust collection systems are essential equipment that protect workers, ensure clean operation, and help keep plants running efficiently and profitably.

Through the years, Baghouse.com has helped many asphalt plants design their systems, maintain, troubleshoot, and upgrade their systems. We have learned many good tips we would like to share with you in a series of three articles:

Asphalt Production & Dust Control (Part 1)
Asphalt Production & Baghouse Fines (Part 2)
Asphalt Production & Dust Collectors Design and Maintenance (Part 3)

Let’s first take a look at how asphalt is produced.

How Is Asphalt Made?

Asphalt is a black, sticky, and highly viscous liquid derived from crude oil.

Asphalt is a black, sticky, and highly viscous liquid derived from crude oil. It acts as a binding agent when mixed with aggregate materials like stone, gravel, or sand. When combined, they form what we commonly refer to as asphalt cement or simply asphalt.

Historically, natural deposits of asphalt were used, but today, virtually all asphalt used for commercial and industrial purposes comes from petroleum refining. The final product is a strong, durable paving material used primarily in road construction. In fact, asphalt is the most widely used material for building roads in the United States — and the country is home to around 3,600 hot mix asphalt plants, producing over 400 million metric tons of asphalt paving material annually.

These plants fall into two major categories: batch plants and drum mix plants.

The asphalt production process begins with the cold aggregate supply system (1), where different sizes of aggregates are fed into the plant. These materials are then transferred to the drum dryer (2), where they are heated by the coal burner (3). Fuel is delivered by the coal feeder (4). During the drying phase, dust generated is captured by the cyclone dust collector (5) and the finer particles are filtered out by the baghouse dust collector (6). The hot aggregates are lifted by the hot aggregate elevator (7) to the top of the tower, where they are sorted by size using the vibrating screen (8). The filler supply system (9) adds mineral fines, and everything is then weighed and blended in the weighing and mixing system (10). The final hot mix asphalt is stored in asphalt storage (11) and the bitumen supply system (12) provides the binder essential for forming the asphalt mix.

Take a look at how an Asphalt Plant works in the following video:

Where Does Dust Collection Come Into the Picture?

To understand where dust collection fits into the asphalt manufacturing process, it helps to walk through how a plant operates.

In drum mix plants, cold aggregates that have already been sized are fed into a rotating drum. Inside, the aggregates are dried, and at the end of the drum, asphalt cement is injected to coat them in a continuous process.

In batch plants, the aggregates are first dried in a rotary dryer, then screened into different sizes and stored in bins. These materials are then fed, batch by batch, into a pugmill mixer, where asphalt cement is added and mixed with the hot aggregate.

Both systems generate a considerable amount of dust during the drying and mixing phases — and that’s where dust collection systems become crucial.

A typical setup includes a drying drum connected via ductwork to a baghouse that captures airborne dust particles generated during the drying and mixing stages. Most systems also include cyclones to collect the larger, heavier particles before they reach the filters.

What Are Baghouse Fines?

Far from being useless, baghouse fines are sometimes reused in the asphalt mix itself as mineral fillers, depending on the mix design and application.

The fine particles collected by baghouses are called baghouse fines, or BFs. These are ultra-fine dust particles removed from the exhaust gas stream. Far from being useless, BFs are sometimes reused in the asphalt mix itself as mineral fillers, depending on the mix design and application.

In the United States alone, asphalt plants generate an estimated 6 to 8 million tons of baghouse fines annually. Proper handling and collection of these fines is not only critical for environmental compliance but also provides an opportunity for recycling and cost savings.

Why Are Collectors So Important?

About 40 to 50 percent of asphalt plants use baghouse systems for dust control. They are used to:

✧ Prevent fine particles from clogging downstream equipment
✧ Protect workers and the environment from harmful emissions
✧ Maintain proper airflow and temperature balance in the drying process
✧ Allow for the reuse of valuable fines in the mix

Without a reliable collector, dust can accumulate rapidly inside the plant, leading to unnecessary wear on machinery, unplanned shutdowns, and even fire hazards. And when an asphalt plant experiences downtime, every minute lost translates to significant revenue loss — especially on tightly scheduled road work projects.

A Team That Helps Asphalt Plants Stay Clean and Productive

Baghouse.com has supported many asphalt plants across North America, helping operators troubleshoot, repair, and upgrade their dust collection systems. From replacing worn-out aramid filters, upgrading to pleated elements for better airflow, to retrofitting baghouses for improved cleaning performance — we’ve seen it all.

Our team of engineers and field technicians has worked hand-in-hand with hot mix asphalt plants across the country, and we understand the challenges asphalt producers face: high temperatures, tight spaces, short timelines, and the constant need to reduce downtime and stay compliant with environmental regulations.

So whether you’re planning your next plant move or struggling with pressure drop or bag failure, we’re here to help you keep your operation clean, safe, and productive.

Stay tuned for the second and third parts of this series of articles!

Need help with your asphalt plant’s dust collection system? Contact us today at Baghouse.com — because your uptime depends on it.

Images Credit:

By Unknown author – http://www.asphaltplant.cn direct link, CC BY 1.0, https://commons.wikimedia.org/w/index.php?curid=36614371

By Trougnouf (Benoit Brummer) – Own work, CC BY 4.0, https://commons.wikimedia.org/w/index.php?curid=77336217

By Lord Mountbatten – Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=23036022

May 27, 2025/by Andy Biancotti

Dust Collector Maintenance, Operation & Optimization, Pollution/Emission Regulation

How to Balance Baghouse Performance vs Reducing Operating Costs

Let’s be honest—everyone’s trying to save money. And in the world of dust collection, that often means stretching your filter life just a little bit longer. Maybe a lot longer.

On paper, it makes sense. Filters aren’t cheap, and if you can get 18 or 24 months out of them (or in some applications even longer), instead of changing them every year, that’s real savings for the maintenance budget. But here’s the catch: filters don’t just slowly deteriorate. They clog, leak, harden, tear, and—if ignored too long—can turn your entire dust collection system into a headache.

So how do you actually strike the right balance between baghouse performance and reducing operating costs? Let’s take a walk through the plant floor and talk through what works (and what really doesn’t).

The Smart Way to Know When It’s Time to Change Your Filters

Here’s what we see a lot: some facilities change filters once a year like clockwork. Others wait until filters start leaking like a sieve. A few smart ones monitor differential pressure (DP) and start planning replacement once the readings begin to creep consistently above normal. And then… there are those who wait for disaster—a fire, visible emissions, or a complete loss of suction—before doing anything.

Monitoring differential pressure (DP) regularly and observing its trends will tell you when is best to start planning a filter changeout

If you’re only using one of those approaches, you’re probably either wasting money or risking performance. The truth is, the best results come when you combine multiple inputs to guide your decision: schedule, DP trends, emissions monitoring, and even basic visual inspections. If you can, throw in a triboelectric monitoring system to catch leaks early and keep track of overall bag performance. It doesn’t have to be expensive tech—it just has to give you enough data to make a smart call.

Read the article:

➤ How Often Should Baghouse Filters Be Changed?

What’s the Real Cost of “Saving Money”?

Yes, filters cost money. But what about:

🔴 Downtime when suction drops and production is interrupted?
🔴 Failed inspections that lead to fines or extra paperwork?
🔴 Product quality issues because dust is settling where it shouldn’t?
🔴 Worker exposure to airborne dust when the suction can’t keep up?

These are real, measurable costs—and they often don’t show up until after you’ve stretched your filter life too far. Old filters mean high DP, and high DP means fans work harder, energy bills go up, suction goes down, and eventually, you’ve got clogged machines or exposed workers.

Not worth it.

A Smart Plan: Use a Combination of Clues

Visually inspect during shutdowns—look for bag hardening, holes, or excessive dust buildup.

There’s no single answer for when to change your filters. But here’s a solid framework that’s worked well for many of our customers:

Set a baseline schedule based on your baghouse size, dust type, and usage patterns.
Track differential pressure. Don’t panic at every spike, but look at the trend.
Visually inspect during shutdowns—look for bag hardening, holes, or excessive dust buildup.
Use leak detection systems to catch issues before they lead to emissions violations, like a triboelectric broken bag detector.

Read the article:

➤ How Can I Tell When I Need to Replace My Baghouse Filters? (FAQ Series)

Use Higher-Quality Filter Media

Upgrading to premium filters might feel like an unnecessary cost at first. Why spend more when the cheap bags “get the job done,” right? But here’s the thing: better filters don’t just last longer—they perform better.

investing in PTFE-membrane bags or pleated filter elements can give you lower operating differential pressure (meaning less energy use), better filtration efficiency (which helps keep emissions low), and longer service life (sometimes 2–3 times longer than standard felt bags).

Investing in pleated filter elements can give you lower operating differential pressure, better filtration efficiency, and longer service life

For example, investing in PTFE-membrane bags or pleated filter elements can give you lower operating differential pressure (meaning less energy use), better filtration efficiency (which helps keep emissions low), and longer service life (sometimes 2–3 times longer than standard felt bags).

We’ve worked with plants that doubled their filter life by switching to a more durable media suited for their application, like a bakery using high-temp aramid bags for greasy exhaust, or a steel plant switching to PTFE for sticky fumes. Yes, the initial cost went up, but their cost-per-month of operation actually dropped, and they had fewer changeouts and shutdowns.

So the takeaway? Take a look at your process, your dust, your temperature, and your emissions goals. Sometimes spending a little more upfront saves a lot more down the line.

Train Your In-House Maintenance Staff

Another often overlooked cost-saver: invest in your team. A lot of plants rely on outside contractors for even basic baghouse maintenance—inspections, troubleshooting, filter changes. And while there’s a time and place for bringing in experts (especially for major rebuilds or testing), training your in-house maintenance team can pay off fast.

They can respond to issues faster and learn to spot small issues (like seal leaks or valve failures) before they snowball into expensive downtime. Even just one or two maintenance techs trained in baghouse basics (like checking DP trends, inspecting filters, and doing minor pulse valve repairs) can dramatically reduce long-term maintenance costs.

Training courses, like Baghouse.com training programs, adapt to the time and pace of your personnel.

Don't Let Cost Cutting Cut Into Performance

If there’s one thing we’ve learned from years in the field, it’s this: your baghouse doesn’t need to be the most expensive part of your plant, but it does need to work properly. Trying to save money by squeezing out a few more months of filter life might feel smart today, but it often backfires tomorrow.

Balance is everything. Monitor multiple indicators, make small adjustments, and plan filter changes like you would any other piece of critical equipment maintenance.

May 7, 2025/by Andy Biancotti

Industrial Health and Safety Regulations, Pollution/Emission Regulation

What Does The New NFPA 660 Standard Mean for Your Facility? —Interview with Matt Coughlin

New NFPA Combustible Dust Standards 2025

On December 6, 2024, the NFPA introduced a landmark shift in combustible dust safety standards with the release of NFPA 660: Standard for Combustible Dusts and Particulate Solids (2025). We interviewed Matt Coughlin, Owner and President of Baghouse.com, regarding how these new standards affect multiple industries.

— "What is NFPA 660, and why should we care?"

Matt: “If your facility handles anything dusty enough to be combustible, this new standard applies to you. NFPA 660 is the new consolidation of six different combustible dust standards. It replaces several older industry-specific standards, like NFPA 654, 61, 484, 655, and 664, and brings them together under one unified framework. The goal is to simplify compliance and create a consistent baseline for dust hazard analysis (DHA), explosion protection, housekeeping, ignition source control, and system design, regardless of the industry.”

— "So... what exactly does NFPA 660 cover?"

Matt: “In short: all the requirements for identifying, evaluating, and managing combustible dust hazards. It pulls together everything from hazard analysis to equipment design to training and emergency response. The first 9 chapters are based on what used to be NFPA 652, the old “Fundamentals” standard, while the remaining chapters dive into industry-specific details—like agriculture, woodworking, and metal processing. So whether you make cereal, shape aluminum, or sand furniture, there’s a chapter in the new standard that applies to your facility.”

Here’s a breakdown of the key features of NFPA 660 to help you navigate and understand this transformative standard:

Fundamental Chapters (1–10): These chapters provide core guidelines for combustible dusts and particulates, aligning with the previous NFPA 652 standard (Chapters 1–9). Chapter 10 introduces new content.
Future Topics (Chapters 11–20): These chapters are reserved for additional fundamental topics such as Fire Protection, Additive Manufacturing, and Nano Materials.
Agricultural and Food Processing (Chapter 21): This chapter replaces NFPA 61, focusing on the unique requirements for agricultural and food processing industries.
Combustible Metals (Chapter 22): Representing the previous NFPA 484, this chapter addresses risks and guidelines specific to combustible metals.
Sulfur Standards (Chapter 23): Derived from NFPA 655, this chapter provides sulfur-related guidelines, now managed by the former NFPA 654 committee.
Wood Processing (Chapter 24): This chapter supersedes NFPA 664, covering wood processing and woodworking standards.
Other Material Combustible Dusts (Chapter 25): This chapter consolidates guidelines for all other particulate materials not specified in previous chapters, replacing NFPA 654.
Committee Oversight: Committees for each specific area (e.g., Fundamentals, Agriculture) remain active to ensure accurate, industry-specific standards.
Annex Material (A–Z): Expanded annexes offer supplemental information, including explanations, diagrams, and additional guidance. These are for reference only and not mandatory.
Commodity-Specific Standards (Chapters 21–25): Include tailored requirements that address the unique risks and operational needs of specific industries, enhancing the foundational guidelines.

— "Is this standard wildly different from what we were doing before?"

Matt: “Not wildly. Most of the technical guidance is similar to existing standards, just reorganized, clarified, and modernized. The biggest updates? Clearer language, fewer contradictions, and improvements in the Hazard Management chapter—especially around process-specific equipment. Also, more detail on how to handle metallic dusts.”

— "Why did NFPA feel the need to consolidate all these standards?"

Matt: “Great question. Imagine trying to assemble IKEA furniture using six different instruction manuals written in different fonts and translated from Swedish by six different people. That’s kind of what combustible dust compliance looked like before. NFPA 660 streamlines the process. Now, you’ve got one clear document, with consistent definitions and guidance. “

— "Is NFPA 660 legally enforceable?"

Matt: “Technically, NFPA standards aren’t laws. But when OSHA or your local fire marshal adopts one by reference—or expects you to follow the “most current standard”—then yes, it effectively becomes enforceable. So, if you’ve got combustible dust anywhere in your facility, you should be planning around NFPA 660 going forward. Even if your inspector hasn’t mentioned it yet… you don’t want to be caught off guard when they do. It’s important to note however that your local regulations may differ from the NFPA standards, and you are responsible for complying with local laws regardless of whether they align with the standard.”

— "What does this mean for my Dust Hazard Analysis (DHA)?"

Matt: “If you’ve already completed a DHA under NFPA 652, good news—you’re still covered. NFPA 660 affirms that every facility handling combustible dust must complete a DHA and keep it updated. If you haven’t done a DHA yet? Well… this is your friendly reminder that now’s the time.”

— "Are there changes to dust collection system design in NFPA 660?"

Matt: “Not major ones. Most of the requirements for dust collection systems remain consistent, with some clarifications around explosion protection, fire isolation, and cleaning systems. If you were already designing to NFPA 652 or 654, you’re pretty close. Just make sure your documentation reflects the new standard and double-check anything specific to your industry. And no, NFPA 68 (deflagration venting) and NFPA 69 (explosion prevention systems) aren’t included in NFPA 660—they remain separate standards, so keep them in your compliance toolbox. And in case you are wondering, we do sell combustible dust equipment that is designed to comply with those standards as well. And if you need help understanding the standards or outfitting your facility to comply, we have a staff of experts who can help you.””

— "What industries are affected by this?"

Matt: “Pretty much any facility dealing with fine particulate matter that could become airborne—and flammable. That includes agriculture, food processing, wood, metal, plastic, rubber, pharmaceuticals, chemicals, and more.”

— "How do I start complying with NFPA 660?"

Matt: “Start by reviewing your current safety programs. Ask yourself: Have you done a DHA? Are your mitigation and suppression systems up to date? Are you training your people? Is your documentation current and aligned with NFPA 660? If you want to dig in a bit deeper on your own, you can start with some of our other posts on the basic requirements of combustible dust safety for dust collection systems. If you need help, this is where it pays to talk to experts—your equipment vendors and consultants like Baghouse.com who can guide you as well as provide the equipment”

See case study: Case Study – Combustible Dust Safety in Aerospace Manufacturing

— "Is this the final version, or should I expect more changes soon?"

Matt: “NFPA standards go through a three-year revision cycle. So yes, NFPA 660 will continue to evolve based on public input and committee feedback. The current version went into effect in December 2024, and we can expect updates in future editions—especially in the “reserved” chapters where new technologies (like additive manufacturing or nanomaterials) might be added. But for now? This is the go-to standard, and it’s worth getting familiar with.”

Final Thoughts

Standard for Combustible Dusts and Particulate Solids (2025)

NFPA 660 gives the combustible dust community a clear, consistent roadmap for staying safe and compliant. The intent is not to bury you in paperwork but to help prevent real-world tragedies from something as deceptively harmless-looking as dust.

So, grab a cup of coffee, open that PDF, and get to know NFPA 660.

You can obtain the NFPA official document following this link.

April 28, 2025/by Andy Biancotti

Baghouse Training, Dust Collection 101, Purchasing Supplies Tips

NEW FREE WEBINAR: How to Plan, Budget, and Execute Successful Projects

Whether you’re upgrading an existing system or planning a new installation, understanding the planning, budgeting, and execution processes is essential to the success of your dust collection project. That’s why we’re excited to invite you to our upcoming webinar, How to Plan, Budget, and Execute Successful Dust Collection Projects.

What to Expect from the Webinar

The webinar will provide in-depth knowledge and actionable strategies for effectively managing dust collection projects from start to finish. Our expert speakers will guide you through the essential steps of planning, designing, and executing a dust collection project. Whether you’re a plant manager, process engineer, or maintenance professional, the content is tailored to be super practical and based on real case scenarios.

Program

🔹 Welcome & Overview
🔹 How to Develop Your Dust Collection Scope and RFQ
🔹 How to Lay Out Your Ductwork, Hoods, and Fans
🔹 How to Get the Best Quotes
🔹 How to Manage Critical Spare Parts and Avoid Downtime
🔹 Conclusion & Q&A

Why Should You Attend?

Gain Practical Knowledge: The webinar is designed to provide real-world strategies for planning and executing dust collection projects. You’ll walk away with actionable insights into creating detailed RFQs, and making smarter equipment decisions.
Optimize Your Dust Collection System: Dust collection isn’t just about buying the cheapest system. It’s about understanding the needs of your facility and selecting the right components to ensure long-term performance and efficiency. This webinar will show you how to make informed decisions that can save you money, time, and headaches down the line.
Avoid Delays and Costly Mistakes: One of the key goals of the webinar is to help you develop a clear and effective RFQ that reduces the risk of miscommunication, delays, and unexpected costs. Knowing exactly what to ask for and how to compare quotes will help you avoid delays and costly mistakes.
Learn from Industry Experts: With years of experience in the field, our expert speakers have worked on numerous projects and are eager to share their knowledge. You’ll get insights from professionals who understand the challenges you face daily.

How to Connect

Attending the webinar is simple! All you need to do is register using the link provided below. Once registered, you’ll receive a confirmation email with all the details you need to log in at the scheduled time. Don’t forget to mark your calendar:

📅 Date: Wednesday, May 21st, 2025

⏰ Time: 1:00 PM (EST)

📍 Platform: Zoom

🔗 Registration Link: Click here.

The session will be interactive, with a live Q&A at the end, so be sure to come prepared with any questions you may have about dust collection systems and projects.

Questions & Answers Section

During this section, our experts answered some of the live questions our attendees sent.

✅ What are the advantages and disadvantages of using star cages for round bags?
✅ How to size a collector for a new application?
✅ What is the maximum temperature that filter bags can sustain?
✅ What are the biggest challenges you face in the process of manufacturing dust collectors and filters? Do you outsource?
✅ Why do you need continuous dust emissions monitoring?
✅ What spray coating can we apply inside the baghouse to protect it against dust and flue gas?
✅ How can we equip dust collectors that handle explosive dust?
✅ What are some baghouse maintenance schedules and techniques, along with troubleshooting methods?

You can watch our experts’ answers in the video below!

Sign up now and take the first step toward mastering dust collection planning, budgeting, and execution.

We look forward to seeing you there!

April 23, 2025/by Andy Biancotti

Cement and Construction Materials, Dust Collector Maintenance, Operation & Optimization, Mining and Quarrying

Smarter Cement Plants: The IoT Revolution You Can’t Ignore

If you are the kind of professional that is always looking into the latest cutting-edge technology and ways to implement it in your cement and mining applications, well… this article is for you.

IoT sensors are revolutionizing how maintenance is performed in cement plants. Predictive maintenance—enabled by real-time data from connected sensors—means you can fix stuff before it breaks. This transition not only saves money on repairs and energy but also increases equipment lifespan and improves overall plant efficiency.

Besides, you will get the pulse of your plant at all times. 24/7/365!

A typical cement plant goes through several important steps to make cement. First, extractors remove raw materials from the quarry. Then, crushers and mills break down large rocks into smaller pieces. These are mixed in the right amounts using blenders and mixers, and then finely ground in grinders. The mixture is heated and cooled in a large rotating kiln. Finally, the finished cement is packed and sent out using conveyor belts or trucks.

Throughout the whole process, systems like dust control, silo management, motors, fans, and conveyors play a vital role in keeping everything running smoothly.

Here’s how different IoT sensors can make your dust collection system smarter and more efficient in 2025.

Baghouse.com is teaming up with Senzary to offer advanced IoT sensors that will take your dust collection and plant maintenance to the next level.

We are excited to collaborate with this renowned company, and thrilled with the many possibilities to bring the Internet of Things to create Smart Plants, not only to the cement industry, but also all other dust collection applications.

The Power of Sensor-Driven Maintenance

In modern cement plants and other industries, sensor-based maintenance is transforming equipment upkeep:

✅ Predictive Insights: Advanced sensors continuously monitor your machinery, detecting subtle changes that indicate potential issues before they escalate into costly breakdowns.
✅ Data-Driven Decisions: Real-time data from strategically placed sensors empowers you to make informed maintenance decisions, optimizing your equipment’s performance and lifespan. By identifying maintenance needs precisely, you can schedule interventions during planned downtimes, minimizing disruptions to your operations.
✅ Cost Reduction: Sensor-based maintenance significantly reduces unnecessary repairs and replacements, lowering your overall maintenance costs.

How Does this Technology Work?

In a cement plant, IoT sensors are installed on critical equipment to monitor parameters like temperature, vibration, and pressure in real time. These low-power sensors transmit data wirelessly to gateways using robust radio technologies such as LoRaWAN. The gateways securely send the data to a cloud-based platform like IoTLogIQ, where it’s organized and processed through a network layer. The system then provides actionable insights through a user-friendly dashboard, enabling plant operators to detect issues early, plan predictive maintenance, and reduce unexpected downtime while improving overall efficiency and safety.

Essential Sensors for Your Dust Collection System

Particulate Matter Sensors (DustIQ)

Undetected leaks in a baghouse can lead to emissions violations and efficiency losses. Advanced sensors can detect leaks early, ensuring that maintenance teams address the issue promptly before it leads to significant performance declines or regulatory fines.

These sensors continuously monitor the dust concentration in exhaust air. Most leaking baghouse filters begin as small holes or rips that overtime become worse and worse. DustIQ provides real- time monitoring of dust levels and filter performance.

🔶 It’s simple to install, you just need to place it on your equipment without any wiring or configuration.
🔶 It’s autonomous, it works for several months without recharging.
🔶 It’s secure by design, its designed for harsh or even explosive environments.

The enLink Air LoRa wireless Air Quality Monitor is a high-precision device that measures up to 14 important environmental conditions.

The enLink Air LoRa wireless Air Quality Monitor is a high-precision device that measures up to 14 important environmental conditions. These include temperature, humidity, light level, volatile organic compounds (VOCs), carbon dioxide (CO₂), fine and coarse dust particles (PM2.5 and PM10), oxygen, sound level, and barometric pressure. It can also connect to 4 extra plug-in gas sensors, choosing from over 200 different gas types or sensitivity levels. The monitor sends real-time data to the cloud using long-range LoRa wireless technology, so the information can be viewed and analyzed from anywhere.

Auburn Filtersense PM series probes

Virtually any sensor with the capability to send a digital signal can be integrated with the IOT software and system. For example, the Auburn Filtersense PM series probes with 4-20mA outputs can also be integrated if you need this particular style of broken bag detection.

Differential Pressure Sensors

Monitoring the pressure difference across filter bags or cartridges is important to know how well the filters are working. If the pressure slowly goes up, it usually means the filters are getting clogged. If the pressure suddenly drops, it might mean a filter has failed. Real-time alerts help maintenance teams act quickly—cleaning or changing filters before they create bigger problems. This helps save energy and avoid unplanned shutdowns.

The EnLink Status-DP uses long-range LoRa wireless to measure and send differential pressure data, even from up to 16 km away.

The EnLink Status-DP makes this easy by using long-range LoRa wireless to measure and send differential pressure data, even from up to 16 km away. It can be used to track pressure before and after filters. It runs on a long-life battery, making installation simple and low-cost. Its special Multi-Range sensor includes up to 7 calibrated pressure ranges, so one Status-DP unit can handle a wide range of pressure monitoring needs.

Airflow Sensors

Airflow sensors help detect blockages in the ductwork or issues with the fan. If airflow drops below the ideal level, operators can respond quickly to fix the problem and keep the system running smoothly.

The enLink Status-AF focuses specifically on airflow, measuring air velocity from 0 to 40 m/s with extremely high accuracy of 0.1%.

The enLink Status-AF focuses specifically on airflow, measuring air velocity from 0 to 40 m/s with extremely high accuracy of 0.1%. Like the other enLink devices, it transmits data using LoRa wireless for easy cloud integration or connection to onsite systems via Modbus IP, enabling performance tracking and real-time alerts.

Temperature and Humidity Sensors

High humidity can cause dust to stick together and clog filters, while very high or low temperatures can shorten the life of equipment. By monitoring these conditions, plants can make adjustments to avoid damage and maintain system efficiency.

The Dragino LSN50v2-S31 is a LoRaWAN wireless sensor designed to accurately measure temperature and humidity in the surrounding environment.

The Dragino LSN50v2-S31 is a LoRaWAN wireless sensor designed to accurately measure temperature and humidity in the surrounding environment. It uses the SHT31 sensor from Sensirion, which is fully calibrated, temperature compensated, and known for its reliability and long-term stability. The sensor is housed in a waterproof, anti-condensation casing, making it suitable for long-term use. It can also send alerts if temperature or humidity goes beyond set limits. Powered by an 8500mAh Li-SOCI2 battery, it’s built to last up to 10 years depending on usage and update frequency, making it a reliable, low-maintenance monitoring solution for industrial environments.

Rotating Machine Monitoring (RotaryIQ)

RotaryIQ monitors and analyses any rotating machine and helps to automate diagnostics and predict anomalies, wirelessly and non-intrusively, with a simple installation. Sensors communicate through LoRaWan (Long range network) and data is encrypted end-to-end. Senzary’s sensors monitor not only heat and vibration, but ultrasound too, meaning customers have the earliest possible alert of drift – before any damage has occurred.

🔶 Vibrations, temperature, humidity, 3-axial accelerometer: Looseness, imbalance, misalignment, advanced degradation.
🔶 Ultrasounds: Lubrication issues, early signs of rolling degradation, gas leaks.

Monitoring Material Inside Silos (SiloIQ)

The high-frequency signals (e.g., 80 GHz) and narrow beam angles (e.g., 15°) enable accurate targeting of the material surface, even with uneven topography or buildup on walls. Radar technology allows for non-intrusive measurement without contact with the abrasive cement material. This eliminates issues like sensor wear, maintenance, and contamination associated with contact-based methods.

Real-time level data from radar sensors provides up-to-date information on material inventory in each silo. This enables better production planning, timely replenishment, and avoidance of costly run-outs or overfills. It also can optimize material usage, production scheduling, and logistics. Radar performs well in challenging silo geometries found in cement plants, including tall and narrow silos, large bunkers, and dome-shaped storage halls.

The Advantage of Smart Sensors In Your Cement Plant

Choosing an advanced IoT solution for the maintenance needs of your cement plant means benefiting from:

✅ Custom sensor networks aligned with your specific equipment, industry requirements, and operational goals.
✅ AI-powered analytics that translate complex sensor data into actionable maintenance insights.
✅ Sensors and software that integrate smoothly with existing maintenance management systems.
✅ The ability to start with critical assets and expand sensor networks as operational needs grow.
✅ Ongoing assistance from maintenance and IoT specialists to ensure maximum benefits from sensor-based maintenance programs.

Investing in IoT sensors is no longer an option—it’s a necessity for cement plants looking to remain competitive in 2025 and beyond.

If you’re a plant manager, operator, or engineer committed to pushing your facility to peak performance, now is the time to act. With each connected device, you’re not only protecting your equipment but unlocking the full potential of your plant. Don’t wait for failure—get ahead of it. Invest in intelligence, drive efficiency, and lead your plant into a new era of innovation, reliability, and profitability. The technology is here.

Let Baghouse.com help you implement this in your facility!

April 14, 2025/by Andy Biancotti

Baghouse Design

Designing High-Temperature Baghouse Systems

Powder Bulk & Solids – May 2025

This article was published in the May 2025 Edition of the Magazine Powder Bulk & Solids. You can also read it in this link:

Designing High-Temperature Baghouse Systems

It can be difficult to design a baghouse system that meets the unique challenges of operating at high temperatures. Here are some considerations to take into account when designing such a system.

High-temperature airstreams require many substantial design changes. Regardless of whether it is used to control atmospheric pollution, eliminate process contamination, or add profits by recovering product, a baghouse system without the proper filters, collector design, gaskets, etc. will suffer from premature failure, increased emissions, and loss of product control. All of these outcomes result in a higher cost for the operators and less efficiency in creating products and services.

The following are a few items to keep in mind when reviewing the performance of your baghouse system with high-temperature airstreams.

What Exactly Classifies as a “High Temperature Baghouse”?

Engineering an adequate baghouse system is often a challenge. What complicates the situation is that many processes generate dust and other fine particulates suspended in hot gases as part of a normal process flow. These applications are on dust filter media and the vessels that contain them.

For example, baghouses operating in the region between 275°F (135°C) and 1500°F (816°C) are generally considered “high temperature” baghouses. At these temperatures, filter media limitations can be classified as follows:

✦ Level I is 275°F to 400°F (135°C to 205°C)
✦ Level II is 400°F to 500°F (205°C to 260°C)
✦ Level III is 500°F to 1500°F (260°C to 816°C).

Common applications that include high-temperature airstreams such as this include cement kilns, industrial dryers, steel mills, coal-fired power plants, etc.

Some of the specific problems that can occur if a high-temperature baghouse is not designed correctly include:

Moisture in the baghouse and resultant discharge challenges filter failure if the inlet gas temp is allowed to drop below the dew point and condenses.
Early filter failure due to incorrect filter media selection.
Incorrect fits and resultant air leakage, specifically between filters and sealing components (tube sheets) due to thermal expansion at high temperatures.
Corrosion, fatigue, and other temperature-related impacts on baghouse materials.

Options For Cooling the Airstream Before The Baghouse

In many plants, a viable solution to the problems associated with a high-temperature airstream is to install cooling systems upstream from the baghouse. Such treatment options vary greatly, in both design and cost. Some treatment options include heat exchangers, coolers, and quenchers. Sometimes, introducing bleed air into the system is sufficient to cool the gas stream below the design temperatures.

Cooling the dust-laden gases before entry into the baghouse is often the only way to make it possible to use a baghouse for filtration purposes. The cost of operating additional cooling devices should be calculated based on energy usage, maintenance requirements, etc. These costs are often negated by the reduced wear and improved operation of the baghouse due to the lower temperatures (e.g. less heat attack on the filters, less thermal contraction/expansion wear on the collector itself, etc.).

However, it should be noted that over-cooling the inlet gas below the dew point may lead to condensation and moisture in the baghouse, which will cause major problems with filter life and efficiency, difficulty in getting collected dust through the hopper and discharge system, etc. For this reason, engineers should carefully review the inlet gas composition and temperature and design the system to maintain the right temperature, not just the lowest possible temperature.

Selecting The Proper High Temp Filter Media

Baghouse filters damaged by a spike in high temperatures

Choosing the right filter media for your application’s temperature will avoid premature failure from thermal degradation

Choice of media is essential in high temperature applications. High temperature filters themselves often cost as much if not more than the entire baghouse, so protecting the filter media from damage is of vital importance. High temperature operation increases the filter medium’s susceptibility to premature failure from thermal degradation, chemical attack or both, as temperature and chemistry often go hand in hand.

.
.

Aramid baghouse filters (trade name Nomex) is widely used because of its resistance to relatively high temperatures and to abrasion.

General applications for Aramid felt includes highly abrasive dust and chemical applications with high temperatures

In recently years a wide range of different fabrics have been developed to meet the needs of high temperature applications. The most popular are polyester, polypropylene, acrylic, for the lower range, aramid, P84, Ryton, fiberglass, Teflon, for the mid-range (up to 500°F), and ceramic, and sintered metal limited ultra-high range (up to 1500°F). In addition to the base fabric material, various treatments and coatings can improve the media’s performance. These include singeing or glazing the material, applying coatings such as silicone or PTFE to improve resistance to acid and alkali substances or improving fine particulate collection and dust cake release.

Filter Media Types Infographic

Would you like to know what filter and treatment would work best for your application? Download this infographic for free!

It is also necessary, depending on the kind of baghouse in use, to choose the correct media weight to withstand the baghouse cleaning cycles. A reverse-air baghouse will usually require only a 14 oz./yard fiberglass media, while in the same conditions, a pulse-jet baghouse will need a heavier 22 oz./yard fabric due to the greater strain on the filter fabric during its cleaning cycle compared to a reverse-air type.

Continuous operating temperature of 500°F (260°C) is the limit for traditional fabrics. After 500°F, the only options are to use specialty materials such as sintered metal or ceramics. These materials, while capable of handling temperatures of up to 1500°F (816°C), are much more expensive than traditional fabrics and require special design considerations to ensure they fit and function correctly in their challenging high-temp environment.

The key factors that should influence final media selection are operating temperature (both continuous and peak), abrasiveness of the particulate, chemical makeup of the gas stream, and moisture content.

Baghouse Collector Design Considerations

Even the best filters will be useless if the baghouse itself is not designed for operating in a high temperature application.

One area of concern is wear caused by regular expansion and contraction due to temperature variations. One common solution is to use a circular design. Many baghouse engineers feel this design is superior because most of the unit will expand and contract uniformly outward/inward together. This is however only partially effective since there are usually a number of “hotspots” in the collector where temperatures exceed those in other areas, thus causing uneven expansion/contraction regardless of the shape of the collector.

Insulating the ductwork coming into the baghouse will maintain the temperature above the dew point, avoiding condensation

Additional construction ideas to keep in mind include: using only heavy-duty materials and construction methods, including stiffening elements to mitigate the effects of thermal expansion/contraction, insulate to reduce heat loss and condensation (specifically the baghouse hopper, dirty side housing, and inlet ductwork), and use diaphragm and solenoid valves with copper or stainless-steel piping and Viton diaphragms rated for use in high temp applications.

Maximizing Baghouse Filter Efficiency

Once the system is up and running, maintaining best operating practices can increase your filter life substantially, while also lowering energy usage, increasing collection efficiency and reducing total emissions.

Using stainless steel cages will prevent damage from acidic or alkali gases from corroding the metal

Concern should be taken during startup/shutdown procedures to minimize the effects of crossing through the dew point, which can lead to increased condensation and cause early bag failure. Often this will include preheating the baghouse before introducing the dust-laden process gases to be filtered, and avoid unnecessary shutdowns.

Another good design practice for high temperature systems is to use stronger bag cages with more vertical wires to provide extra support for the filters. If the gas stream includes high levels of acidic or alkali gases, it is often wise to use stainless steel cages.

Concluding Thoughts

Designing a baghouse dust collection system for use in a high temperature application is no easy task. Proper care and attention must be taken to ensure the proper filter media is selected and that the system itself is engineered and constructed to withstand the effects of high temperature applications.

This guide is by no means an exhaustive list of all the things that must be considered when designing a high temp system. But this information is a good place to start when considering the design of a new system, or looking for ways to improve the operation of existing systems.

When selecting a baghouse supplier/engineering firm like Baghouse.com, work closely with them to ensure all of these considerations are taken into account. By doing so, higher efficiencies, less energy usage, and increased service life will be yours.

March 18, 2025/by Andy Biancotti

Dust Collector Maintenance, Operation & Optimization, Dust Collector Troubleshooting

3 Baghouse Maintenance Tasks for Your Next Shutdown/Outage

When management hear of the plan to shut down the Baghouse system for routine maintenance, they begin to ask questions and usually get a little nervous. After all, when a Baghouse system is not operating, more than likely the plant is not either. No Baghouse, No Plant, No Production, No Income.

However, planned shutdowns of Baghouse systems are a necessary part of routine maintenance, therefore it is essential to plan well in advance in order to minimize downtime and maximize efficiency.

What tasks should be completed during your next planned shutdown? Usually the main task of a shutdown is to replace the baghouse filters, which have deteriorated over the course of normal operation. However, there are other items that should be inspected and tasks that need to be addressed in order to prevent future unplanned outages and issues.

Let’s examine some of these tasks in further detail.

Inspect and Review The Condition Of The Entire System

Exposure to rain, snow and sun can result in a breakdown of exterior components, water ingress and corrosion of the system.

Rain, snow, and sun can cause corrosion of the baghouse and its components

Normal operation and constant exposure to the weather can result in various parts of a Baghouse system deteriorating and or being damaged. For example, exposure to rain, snow and sun can result in a breakdown of exterior components, water leakage and corrosion of the system. Thus, a planned outage is the perfect time to inspect and review the condition of the entire system and to replace or repair any necessary items.

Check for rust and other corrosion, especially near doors, hatches, and other ports. Insulate against cold or heat where necessary to prevent hot/cold spots that can cause condensation issues. Ensure all door and hatch gaskets are in good condition, and replace worn out ones immediately.

Holes in the ductwork lead to loss of vacuum (i.e. loss of suction). Additionally, holes allow for outside air to enter into the baghouse. Hot, cold or moist air can cause problems inside the unit such as corrosion, acid flashes or sticky dusts. Finally, holes in the structure allow dust to escape, where it can accumulate nearby, disperse to nearby working areas, or into the filtered gas steam and show up as increased emissions.

Inspect All Movable Parts

Diaphragms should be given regular maintenance and repair if needed

All movable parts should be fully inspected during a shutdown. These include fans, bearings, brushes, belts, gears, etc, to mention just a few. Constant operation can lead to these items being worn or damaged. Therefore, during the shutdown, these items should be repaired or replaced.

Poorly maintained diaphragm pulse valves have a dramatic effect on the efficiency and effectiveness of a pulse jet baghouse. Leaking diaphragms waste huge amounts of (often very expensive) compressed air. More seriously, worn out diaphragms decrease the effectiveness of the cleaning pulses, which results in poor bag cleaning. Inadequately cleaned bags create higher operating differential pressure, increasing operating costs and lowering suction throughout the system (product dropout and damage to vented equipment).

Keeping the diaphragm valves in good working condition is fairly simple and relatively inexpensive. Extra diaphragm repair kits should be kept on hand so malfunctioning valves can be repaired without delay.

Conduct A Leak Test

Even the most efficient and well-maintained dust collection systems will occasionally experience leaks, compromising their effectiveness and putting worker health at risk.This is why implementing effective leak detection strategies is crucial.

A planned shutdown is also a perfect opportunity to conduct a leak test of the entire system. This is to ensure the Baghouse system is operating to its optimum performance.

Conducting a dye test is not only for filter bags that have been in operation for an extended period of time. Newly installed ones can (and should) also undergo leak testing.

It is also a great time to test the system to see if it will continue to meet environmental standards as well as meet any future requirements.

All the stress and anxiety of a planned outage can be alleviated by contacting a professional before your next planned shutdown. Baghouse.com can provide expert advice, advance planning, review system and provide any necessary suggestions.

March 3, 2025/by Andy Biancotti

About Andy Biancotti

Entries by Andy Biancotti

Asphalt Production & Dust Control (Part 1)

Contact Us

Explore Our Filtration Solutions

About Baghouse.com