Andy Biancotti – Page 3

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

A New Tool Empowering Your Personnel: An Online Dust Collection Course

JANUARY 30, 2025 – After more than two years of writing, designing and field testing, we are excited to announce our new, first-of-its-kind online training course on dust collection systems. This is the online version of the in-person training our experts have provided for more than 40 years throughout Mexico, United States and Canada. However, much of its content is updated and revised with the latest best practices in dust collection. This course is meticulously designed for Plant & Maintenance Managers, Engineers, Project Managers, Environmental, Health and Safety Managers, and Purchasing Managers.

Would you like to see a sneak peak of our training courses?

Watch the video below!

A Dynamic Learning Experience

The course is designed to be engaging and dynamic, ensuring that learning is not only informative but also enjoyable

Our programs are structured into eight lessons, each featuring easy-to-understand diagrams and graphics, videos, downloadable materials, links to related articles, and interactive quizzes. The first lessons lay the groundwork with the simplest concepts, and the following lessons continue to build with the more deep and complex dust collection parameters. The first lesson of this Dust Collection Training Course is available free of charge, giving you a preview of the valuable knowledge and insights you’ll gain throughout the program. Check it out now!

Our Four Training Programs

At Baghouse.com, we understand that every business has unique needs when it comes to dust collection training.

That’s why we offer four flexible training programs to fit your team’s schedule and learning style:

► In-Person Training

✧ This option combines a hands-on inspection of your dust collection system with an engaging class led by our experts. It’s perfect for teams that want personalized guidance right at their facility.

► Virtual Training

✧ Join a live instructor on Zoom for interactive sessions designed to address your specific concerns. It’s as close to in-person as you can get, without leaving your office.

► Self-guided Online Training

✧ Learn at your own pace with their self-guided courses. This option allows you to access expert knowledge anytime, anywhere, making it ideal for busy schedules.

► Combined Training

✧ This unique program blends self-guided online learning with live Q&A sessions at the end of each lesson. It’s the best of both worlds—flexibility with expert support.

Our training provides insights into the principles of dust collection systems, equipping you and your personnel with the knowledge and skills necessary to optimize your facility’s operations. Here’s a snapshot of what you and your team will gain:

✦ Recognize Each Baghouse Type and Describe Its Basic Function
✦ Describe Different Styles of Baghouses and Their Suitable Applications
✦ Understand Filter Options
✦ Identify Key Design Parameters
✦ Troubleshoot Common Operational Issues
✦ Conduct System Inspections and Audits

Does It Have Group Discounts?

Yes! To make it even more accessible, Baghouse.com offers discounted pricing for group enrollments, making it an ideal opportunity for facilities looking to train multiple employees. If you enroll 5 or more employees, you’ll receive a 10% discount. For groups of 10 or more, they have a 20% discount. And for facilities with 20 or more participants, we offer a substantial 30% discount. This package pricing ensures that your entire team can benefit from their expert training while optimizing your investment. Ask about a discount for your company.

Why Enroll in This Course?

By the end of this course, you’ll be armed with practical knowledge and skills that can be immediately applied to your facility’s dust collection system. Whether you’re looking to optimize performance, reduce maintenance costs, or ensure regulatory compliance, this course is tailored to meet your needs. It’s an investment in your professional development and your facility’s future.

Enroll today and take the first step towards mastering dust collection systems with Baghouse.com’s expert training course!

January 31, 2025/by Andy Biancotti

Baghouse Design, Woodworking

Case Study – Turning Challenges into Solutions at a Woodshop

Do you have a woodshop and you are having dust collection problems?

■ Not enough suction at the pickup points?
■ Contaminated recycled air into the facility?
■ Danger of combustible dust in ducts/baghouse?

You will find this article super interesting!

Background

Poor suction, inefficient dust collection, and loads of resources spent on maintenance were some of the problems this plant was experiencing

The US Army’s Aberdeen Proving Ground woodshop was working with an aging dust collection system that could no longer meet their needs. Their existing cyclone and baghouse setup suffered from poor suction, inefficient dust collection, and loads of resources spent on maintenance.

To make matters worse, the return air system consisted of a makeshift, home-built plenum that was not functioning effectively. These issues created a challenging work environment and prompted the woodshop to seek a reliable, long-term solution.

Scope Of Work

The goal was to replace the outdated system with a modern, efficient solution while addressing the following challenges:

● Poor suction and collection performance.
● Difficulty with the maintenance of the equipment
● Inefficient and noisy return air management.

Baghouse.com was tasked with designing and installing a new dust collection system that integrated seamlessly with the existing ductwork.

Solution

Baghouse.com dispatched a technician to assess the woodshop’s existing setup and understand its operational needs. A thorough inspection was conducted on-site, and standard sizing factors were used to engineer a tailored solution.

Baghouse.com personnel installing a new cyclone and a cartridge collector

Baghouse.com installed a new cyclone and a cartridge collector

The proposed system included:

● A new cyclone separator for pre-separation.
● A 3-12 cartridge collector for fine dust collection.
● High-performance rotary airlocks to eliminate dust discharge issues.
● An engineered return air plenum to replace the makeshift one, reducing noise and improving airflow efficiency.

The new system was carefully integrated into the existing ductwork while addressing spatial constraints during installation. The project was completed within three months of the proposal’s approval.

Conclusion

Some of the immediate improvements the new dust collection system delivered were better suction and airflow performance

The new dust collection system delivered immediate improvements. The woodshop experienced significantly better suction and airflow performance. The engineered return air plenum also reduced noise levels.

From initial evaluation to final installation, Baghouse.com provided high quality customer service, proving they are a trusted partner for even the most demanding projects.

December 30, 2024/by Andy Biancotti

Dust Collector Maintenance, Dust Collector Troubleshooting, Purchasing Supplies Tips

Top Load Snap Band Baghouse Filter & Cage Measuring Guide

Purchasing and maintenance people commonly call Baghouse.com requesting assistance to figure out what kind of filter bags they need for their top load baghouse. Often, they do not know which measurements they need to identify the filter size and configuration required to quote replacement filters for their baghouse.

This short article will explain the key features of the most common baghouse filter style: the top load, snap band style baghouse filter.

Description of a Top Load Baghouse

Airflow in a baghouse from the dirty air plenum to the clean air plenum passing through the filters

Top load baghouses are known for their efficiency, reliability and ease of maintenance, making them a popular choice for many industrial applications.

A top load baghouse has a housing with the filter bags arranged so that they hang vertically. The dirty air ductwork usually connects to the baghouse hopper, allowing the dirty air to enter from the bottom of the filters.

The dust particles are captured on the outer surface of the filter bags (falling to the hopper), while the clean air passes through the filters and then travels up through the bag and out the top of the housing.

In top load pulse jet baghouses, the filters are installed into the tubesheet from above. The tubesheet is a metal plate in the baghouse where the filters are installed, separating the clean air from the dirty air. On a pulse jet baghouse, the tubesheet is near the top ¼ of the baghouse and it is a smooth steel sheet with uniform holes into which each filter is installed.

To allow access to the filters, smaller units will generally have removable doors or hatches on the top of the unit surrounded by railings while larger units will have a walk-in clean air plenum which allows entry to the baghouse through a door in the side.

Snap Band Filters for Top Load Baghouses

View of a snap band before its covered with material and attached to the filter bag

Cut view of the ring (snap band) and the layer of sown fabric around it that allows for a tight fit against the tube sheet

The snap band is a metal ring sewn into the top of the bag and covered with fabric. The snap band is used to secure and seal the filter bags to the tube sheet.

The pressure from the band pushing against the sides of the hole (when aligned correctly) forms an airtight seal.

To install a snap band bag, the bag is inserted into the round tube sheet hole. The snap band is deformable, allowing the user to manipulate its shape and insert the band into the tubesheet hole. When released, the snap band “snaps” into place, tightly locking the filter into the hole.

Once installed, a metal wire cage is inserted into the cage to hold it open during operation. Then the blowpipes are installed above the filters.

Why Are Snap Band Filters So Popular?

Snap bands ensure a tight fit at the connection points between the filter bag and the tubesheet, preventing air or dust from bypassing the filter bag. Additionally, they are easy to install and more reliable than older methods that require the use of hold down hardware or clamps to secure the bags into the tubesheet.

Snap Band Filter Bag & Cage Terminology

The relationship between snap band size, bag diameter, and cage diameter has to be carefully calculated, since each component plays a crucial role in ensuring the effective installation, sealing, and performance of filter bags.

Here is a brief explanation of each one of these dimensions:

● Tubesheet Hole size/Snap Band Size

An accurate measurement of the tubesheet hole will ensure that the snap band of the filter will have a tight fit

The tube sheet hole size refers to the diameter of the opening in the tubesheet where the filter bag’s snap band is inserted. This size must match the snap band diameter to ensure a tight fit and prevent leakage or bypass of dust-laden air. Snap bands are sized down to 1/32” so this measurement should be taken with calipers if possible. Always measure across the center of the hole in a straight line from one edge to the opposite edge.

● Bag Diameter

The bag diameter refers to the width of the filter bag when laying flat

The bag diameter refers to the width of the filter bag body (NOT the snap band at the top of the bag, which is considered a separate piece). Since we cannot accurately measure the true diameter of the bag outside of a proper jig in the factory, we usually ask customers to measure the flat width instead, which is the width of the bag when laid flat. The bag diameter is almost always slightly smaller than the snap band/tubesheet hole size.

● Cage Diameter

The cage diameter is the outside diameter (OD) of the cage body measured at the center of the cage

The cage diameter is the outside diameter (OD) of the cage body that goes inside the filter bag. The cage diameter will always be slightly smaller than the bag diameter, usually ¼” smaller. If the bags fit too tightly to the cage, the cages will be very difficult to install and remove, and the bags will not flex properly when pulsed and the cleaning power will be reduced, thus contributing to poor operation of the system.

So, when looking to get replacement filters and/or cages for your pulse jet baghouse, you need to gather the following information: (1) tubesheet hole diameter, (2) the bag flat width and length and (3) the cage body outside diameter (OD) and length.

If you are unable to shut the unit down to take the hole measurement, we can still quote you the bags with only the bag flat width and length. Then, once you place an order, we can confirm the exact tube sheet hole size by having you send us a used bag to test fit at our facility. Alternatively, we can send you a pre production sample bag to test fit before we release your order to production.

Instructions to Measure Snap Band Filter Bag & Cage Size Step by Step

Common Sizes of Top Load Bags and Cages

With so many different baghouse manufacturers, there is no “standard” size for top load bags. However, there are some common sizes/configurations that are used by multiple OEMs. Common size combinations include:

Small diameter bags: 4” and 5”

● 5” tubesheet hole, 4.5” bag diameter, 4.25” cage diameter
● 5” tubesheet hole, 4.625” bag diameter, 4.5” cage diameter
● 5” tubesheet hole, 4.875” bag diameter, 4.5” cage diameter

Large diameter bags: 6”

● 6” tubesheet hole, 5.875” bag diameter, 5.5” cage diameter
● 6” tubesheet hole, 5.875” bag diameter, 5.625” cage diameter
● 6.2” tubesheet hole, 5.875” bag diameter, 5.5” cage diameter
● 6.25” tubesheet hole, 5.875” bag diameter, 5.5” cage diameter (Most common)
● 6.25” tubesheet hole, 6” bag diameter, 5.875” cage diameter

Measuring Pleated Filters For Top Load Baghouses

Pleated filters can be used in top load baghouses, often as retrofits for units originally designed to take traditional bags and cages. Some units are designed from the factory to use pleated filters. This is most common with small bin vent style units. Would you like to know if pleated filters would be a good option for your baghouse? Contact us to review your application.

Similar to bags and cages, when looking for replacement pleated filters, we will need to know the tube sheet hole size along with the filter diameter and length.

The Dangers of Size Drift

Size drift in top load baghouses can be quite risky to the efficiency of your dust collector. This happens when measurements are taken inaccurately, and over time, the bags end up being a bit too big or too small for the system.

This can lead to various issues, like:

● Reduced filtration efficiency
● Compromised dust capture
● Increased emissions
● Potential damage to equipment components

To prevent these problems, it’s important to measure accurately and keep an eye on things to catch any drift early.

Additional Tips When Changing the Filters

Any cages that are bent, rusty, or have shape edges should be discarded and replaced. Filters that are installed onto damaged cages will suffer early filter failure.

● Before removing the filters, the blow pipes must be removed to allow access to the tube sheet.
● If reusing cages, these must be carefully removed and set aside so as not to damage them before putting new filters on them and inserting them back into the tube sheet.
● When reusing existing cages it’s usually best to remove only a section of filters at once, since there is only limited space to stack the cages at the top of the baghouse.
● Any cages that are bent, rusty, or have shape edges should be discarded and replaced. Filters that are installed onto damaged cages will suffer early filter failure.

Understanding the dimensions and components of a top load baghouse will help us order the exact replacement pieces, proper installation, sealing, and long filter life.

Do you have any questions or need the advice of an expert in dust collection?

Are you ready for your next filter changeout?

December 11, 2024/by Andy Biancotti

Industrial Health and Safety, Industrial Health and Safety Regulations, Safety

Combustible Dust Hazards: Prevention & Protection Technologies

Combustible dusts present both fire and explosion risks. What technologies can help you prevent them?

What is Combustible Dust?

Many manufacturing processes create very small particles of dust that settle on surfaces throughout the plant. Eventually these particles not only create a housekeeping issue, but if the particles are combustible, they can represent a potential fire or explosion hazard. Combustible dusts generally present both fire and explosion risks so it may help to consider the management of these risks separately.

Fire triangle

Fire management strategies traditionally focus on the control or elimination of one of the three key elements necessary for a fire — often represented by the “fire triangle.”

Explosion Pentagon

The explosion pentagon includes two additional elements necessary for an explosion: dispersion of a “Dust Cloud” and “Confinement” of dust. The management or removal of one or more of the elements in the explosion pentagon can reduce the explosion risk.

What is a Dust Explosion and How Does It Begin?

A dust explosion can be defined as: Any solid material that can burn in air will do so with a violence and speed that increases, with increasing degree of subdivision of the material. In other words, when a combustible material is in dust form it has the potential to not only burn but also under the right conditions explode with great force. This is true even of some materials that may not normally be thought of as combustible when in solid form such as food products like wheat flour or metals like iron.

An explosion typically begins when an ignition source enters the dust collector

An explosion typically begins when an ignition source enters the dust collector. This ignition source can come from many things and in most cases is never identified. When a pulse cleaning event occurs, a suspended cloud of combustible dust is present in high concentration within the collector. This completes the five elements of a dust explosion and initiates the explosion.

Many dust explosions that occur in process plants are relatively small, leading to limited damage. However, under the right circumstances, even small explosions can escalate into major incidents. This is most commonly the case when secondary dust explosions happen. The typical scenario is that a small “primary explosion” raises a dust cloud, often from dust deposited over time on plant surfaces, and ignites the resulting dust cloud. This “secondary explosion” takes place where often people are present, placing them in immediate danger. Secondary dust explosions can form a chain reaction that can run through a facility as long as fuel is present, leading to injuries and damage to property.

Mechanism of dust explosions

dust stream with particles of different sizes

Even materials that are traditionally thought of as non-flammable, such as aluminum, or slow burning, such as wood, can produce a powerful explosion when finely divided, and can be ignited by even a small spark

Dusts have a very large surface area compared to their mass. Since burning can only occur at the surface of a solid or liquid, where it can react with oxygen, this causes dusts to be much more flammable than bulk materials. For example, a 1 kg sphere of a material with a density of 1g/cm3 would be about 27 cm across and have a surface area of 0.3 m2. However, if it was broken up into spherical dust particles 50µm in diameter (about the size of flour particles) it would have a surface area of 60 m². This greatly increased surface area allows the material to burn much faster, and the extremely small mass of each particle allows it to catch on fire with much less energy than the bulk material, as there is no heat loss to conduction within the material. When this mixture of fuel and air is ignited, especially in a confined space such as a warehouse or silo, a significant increase in pressure is created, often more than sufficient to demolish the structure.

Explosive Materials & Equipment

The following materials are prone to dust explosions:

Materials that are prone to dust explosions

• — Coal

• — Fertilizer
• — Cosmetics
• — Pesticides
• — Plastic & plastic resins
• — Wood
• — Charcoal
• — Detergents
• — Foodstuffs (sugar, flour, milk powder, etc.)
• — Ore dusts
• — Metal dusts
• — Graphite
• — Dry industrial chemicals
• — Pigments
• — Cellulose

Typical industrial equipment that requires explosion protection.
• — Dust Collectors
• — Dryers
• — Cyclones
• — Crushers
• — Grinders
• — Silos
• — Pulverisers
• — Conveyors
• — Conveyor ducts
• — Screw conveyors
• — Bucket Elevators
• — Furnaces
• — Hoppers
• — Bins

Dust Collection Systems to Control Combustible Dust Hazards

A properly designed, operated and maintained dust collection system is the great defense against combustible dust hazards in your facility

Many process requirements may make elimination of combustible dust, mist, or fume impractical. However, it may still be very possible to manage the dispersion of dust within your plant by using an appropriate and effective industrial ventilation system including dust collection. A well designed, maintained, and operated industrial ventilation system including good hoods, proper duct sizes, and properly selected collection equipment can provide effective dust control and can therefore help manage the presence of dispersed dust. This not only reduces housekeeping frequency and expense, but could also help you reduce the risk of dust explosions in your facility, particularly the destructive secondary explosions, by helping reduce the presence of dispersed fuel in your facility. A properly designed, operated and maintained dust collection system is the great defense against combustible dust hazards in your facility.

Who Sets Standards for Combustible Dust Safety?

The three key entities involved in combustible dust issues: OSHA, NFPA and AHJ

The three key entities involved in combustible dust issues are OSHA, NFPA and AHJ

In general there are three key entities involved in combustible dust issues, each with its own particular area of responsibility: (1) The National Fire Protection Agency (NFPA), (2) OSHA and your (3) local Authority Having Jurisdiction (AHJ). In addition to these agencies, others such as the US Chemical Safety Board (CSB) may assist with investigation of combustible dust accidents and advise on the setting of standards for specific industries.

Combustible Dust Control Strategies

Combating combustible dust hazards effectively in your facility requires dedication and a comprehensive approach. In the following section we will discuss several common combustible dust explosion prevention and protection strategies and technologies as they relate to dust collection systems.

Dust Hazard Analysis Required

NFPA regulations require that a Dust Hazard Analysis (DHA) be performed for all operations that generate, process, handle or store combustible dusts or particulate solids. The standard specifies that the facility owner or operator is responsible for determining if the handled materials are combustible or explosive, and if so, characterizing their properties for the DHA.

NFPA regulations require that a Dust Hazard Analysis (DHA) be performed for all operations that generate, process, handle or store combustible dusts or particulate solids

Hazards associated with combustible dusts and dust collection systems include the following:

● Explosion hazards in the right concentrations and conditions.
● Ignition sources such as open flames, electrostatic discharge, lift truck activity, moving chains, hot surfaces, and rotating equipment with bearings can ignite accumulated or airborne dust, causing a deflagration.
● Downstream through a dust collector’s ducting if not isolated, posing fire, pressure-wave, and noxious-gas hazards.
● Dust buildup on floors, elevated surfaces, and in hidden areas can be disturbed by a primary explosion, become airborne, and contribute to a secondary explosion.
● Dust buildup inside ducting due to deficient filter performance or poor design can contribute to flame or pressure propagation through the duct and into the workspace.
● Metal dusts can have high rates of pressure rise and pressure maximums during a deflagration, causing an improperly designed dust collector to explode and produce shrapnel. • Metal dusts can be reactive with other dust oxides and liquids such as water and produce explosive gases that are highly ignitable.
● Metal dust fires are more difficult to extinguish and can be worsened with the use of improper extinguishing agents.

Explosion Protection and Prevention Technologies

There are many types of devices and systems used to comply with NFPA standards for the explosion protection of dust collection systems, but they fall into two general categories: Passive systems react to the event, while active systems detect and react prior to or during the event.

The goal of a passive system (also called protection) is to control a fire or an explosion so as to keep employees safe and minimize equipment damage in the plant. An active system (also called prevention), by contrast, can prevent an explosion from occurring. An active system involves much more costly technology and may require periodic recertification.

Passive Devices (Protection)

● Explosion venting: Designed to be the “weak” link of the dust collector vessel, an explosion vent opens when predetermined pressures are reached inside the collector, allowing the excess pressure and flame front to exit to a safe area. It is designed to minimize damage to the collector and prevent it from blowing up in the event of a deflagration, thereby reducing the safety hazard. In addition, a flameless vent extinguishes the flame front exiting the vented area, not allowing it to exit the device. This allows conventional venting to be accomplished indoors where it could otherwise endanger personnel and/ or ignite secondary explosions.
● Passive float valve: Designed to be installed in the outlet ducting of a dust collection system, this valve utilizes a mechanical barrier to isolate pressure and flame fronts caused by the explosion from propagating further through the ducting. The mechanical barrier reacts within milliseconds and is closed by the pressure of the explosion.
● Back draft damper: A mechanical back draft damper is positioned in the inlet ducting. It utilizes a mechanical barrier that is held open by the process air and is slammed shut by the pressure forces of the explosion. When closed, this barrier isolates pressure and flame fronts from being able to propagate further up the process stream.
● Flame front diverters: These devices divert the flame front to the atmosphere and away from the downstream piping. Typically, these devices are used between two different vessels equipped with their own explosion protection systems. The flame front diverter is used to eliminate “flame jet ignition” between the two vessels that could overpower the protection systems installed.

Active Devices (Prevention)

● Chemical isolation: Designed to react within milliseconds of detecting an explosion, a chemical suppression system can be installed in either inlet and/or outlet ducting. Typical components include explosion pressure detector(s), flame detector, and a control panel. This system creates a chemical barrier that suppresses the explosion within the ducting and reduces the propagation of flame through the ducting and minimizes pressure increase within connected process equipment.
● Chemical suppression: Whereas chemical isolation is used to detect and suppress explosions within the ducting, chemical suppression protects the dust collector itself. It is often used, together with isolation, when it is not possible to safely vent an explosion or where the dust is harmful or toxic. The system detects an explosion hazard within milliseconds and releases a chemical agent to extinguish the flame before an explosion can occur.
● Fast acting valve: Designed to close within milliseconds of detecting an explosion, the valve installs in either inlet and/or outlet ducting. It creates a mechanical barrier within the ducting that effectively isolates pressure and flame fronts from either direction, preventing them from propagating further through the process.
● High-speed abort gate: The gate is installed in the inlet and /or outlet ducting of a dust collection system and is used to divert possible ignition hazards from entering the collector, preventing a possible explosion from occurring and preventing flame and burning debris from entering the facility through the return air system. A mechanical barrier diverts process air to a safe location. Abort gates are activated by a spark detection system located far enough upstream to allow time for the gate to activate.

Additional Prevention Devices and Strategies

● Maintain air velocity safety above the minimum conveying velocity: One of the most common sources of potential fuel for combustible dusts is found in the dust collector ductwork. Accumulated dust in ductwork often provides the fuel for devastating secondary explosions or fires. Maintaining the air speed inside the duct safety above the minimum conveying velocity will prevent material buildup.
● Spark arrestor: A mechanical device designed to extinguish spark and embers. They are installed in the ductwork on the inlet side of the dust collector (the dirty air line coming into the unit) upstream from the last pickup but downstream of the collector.
A few variations exist, but the device causes the embers to burn out by a combination of the following: Turning vanes that cause the dust-laden air to change direction rapidly and forcing it to take a tortuous path that allows more time for the spark to burn out; screens that break up the ember into smaller pieces that then burn out; a housing larger than the ductwork to reduce the air velocity causing particles large enough to burn to fall out of the airstream; forcing the dust-laden air to impact a flat surface, causing the larger particles to fall out. For proper functioning of the spark trap, the length of duct between the spark source and the spark trap should be at least one duct diameter, and between the spark trap and the dust collector should be at least ten times the duct diameter. A shorter distance will prevent the spark trap from working correctly and is not recommended. Finally, be careful not to confuse a knockout box like device or a cyclone dust collector with a spark arrestor. These devices cannot guarantee 100% spark removal.
● Special Filter Media: While there is no such thing as a “Fire proof filter” certain filter medias provide a level of added resistance to sparks and embers such as flame retardant coatings. Others use conductive materials within the fabric and can assist with static dissipation.
● Sprinklers: Per local building codes you may be required to install traditional water sprinklers inside certain parts of the process, including inside the dust collector incase of fire.
● Choice of filter style: For applications with high dust loading, heavy dusts or “sticky” dusts the use of cartridges may create an additional hazard. With horizontally-mounted cartridges, dust becomes trapped in the pleats in the upper third of the filters This trapped dust can burn even if the filter media is fire retardant.
● Hopper discharge devices: Normally the choice of a discharge varies depending on the process needs and budgetary concerns. With combustible dust applications however the choice of a discharge device can have a major impact on safe operation. Rotary airlocks rated for combustible dust applications work best. Rotary valves enable quick and continuous emptying of the hopper, eliminating the potential for material in the hopper to serve as fuel for a potential explosion or fire. Discharge to a seal drum or hopper can also work well if they are rated to withstand potential explosion pressures. But these must be constantly replaced in order to prevent material backing up into the hopper. Finally, double dump valves rated for combustible dust applications can prove useful in applications with combustible dust but also larger pieces that could potentially jam rotary valves.

So, now that we have seen more clearly what are the hazards you might face and the pasive and active approaches to make your facility safer… its time to make an honest review of what needs to be adjusted in order to minimize risks.

November 25, 2024/by Andy Biancotti

Dust Collection Blog, Dust Collector Maintenance

Dust? What Dust? P84 Filters Made It Disappear!

Known for their exceptional durability and high-performance filtration properties, P84 filters are designed to work on extreme conditions across industries like cement, incineration, power generation, and more. Let’s understand why P84 filters are a preferred option for many industrial processes and how they deliver consistent, cost-effective results.

Unique Characteristics of P84 Filters

P84 fibers are needled into high-quality felts, suitable for pulse jet baghouses, and can also be blended with other fibers like PTFE, PPS, PAN, and PES to meet specific operational requirements. P84 filters are engineered with tri-lobal fibers that offer:

— High surface area: The irregular shape creates 30–90% more surface area compared to round or oval fibers, enhancing dust collection and cake release.
— Temperature resilience: Continuous operation up to 500°F, with short-term peaks of 500°F without fabric degradation.
— Chemical resistance: Effective against acids, alkalines, and hydrolysis, making them suitable for aggressive environments.
— Non-flammability

Applications Across Industries

P84 filters have become a go-to choice for numerous industries, thanks to their versatility and reliability in extreme conditions:

⦿ Cement Plants: Ideal for kilns with fluctuating temperatures and dust loads. Withstands alkaline dust and high humidity in alumina calciners. Provides high filtration efficiency even under heavy dust loads (>500 g/Nm³). Compatible with varying pH levels (2–12), ensuring performance with secondary fuels. (Read here our most recent case studies in the Cement and Aggregates application)

⦿ Waste Incineration Facilities: Handles aggressive chemical environments during scrubber or cooling system downtimes.Supports dust cake formation, capturing fine particles and dioxins, neutralizing acidic flue gases using lime powder and retaining heavy metals with activated carbon. Enables cost-effective bag disposal through incineration, avoiding hazardous waste treatment fees.

⦿ Power Generation: Performs well in coal-fired boilers, resistant to SO₂ and oxygen. Suitable for biomass-fired plants with varying operating loads and flue gas compositions. Operates efficiently in wet scrubbing systems and semi-dry absorption setups.

⦿ Metallurgical and Processing Industries: Resilient against sparks, abrasive dust, and extreme temperatures in lime kilns and electric arc furnaces. Prevents dust penetration during fluctuating airflow rates or A/C ratios. (Read here our most recent case studies in the Metalworking and Foudries application)

⦿ Asphalt Production: Delivers reliable filtration in asphalt and hot mix plants. (Read here our most recent case studies in the Asphalt application)

Advantages of P84 Filters

Low Maintenance Costs: Long service life minimizes bag replacements. Durable needle felts withstand cleaning pressures up to 6 bar without delamination.
Cost-Effective Design: Standard cages are sufficient; no need for costly double-wire cages. Lower energy consumption due to reduced pressure drops and efficient cleaning cycles.
Environmental Safety: Minimal toxic emissions during incineration of used bags. Meets stringent emission standards, ensuring regulatory compliance.
High Flexibility: Performs across a wide range of flue gas compositions, temperatures, and dust loads. Adapts to varying operating conditions in industries using secondary fuels.

Operational Guidelines for Filters P84

Temperature Management

In general, the life cycle of any synthetic material is reduced with rising temperatures. Every 50° F the speed of the chemical reaction doubles! This increase is lower for P84 but in principle also valid for P84. Therefore the continuous operating temperature in conjunction with the flue gas parameters has a decisive influence on the lifetime of filter bags. Special attention has to be taken into consideration in case of the occurrence of high operating temperatures together with oxidizing agents like O2 and NO2. Most of all NO2 is very aggressive for any kind of synthetic fiber, while NO has no influence on the life cycle at all.

Continuous operation should stay within the recommended temperature range to maximize lifespan:

235°–320°F: 60–72 months
320°–355°F: 24–48 months
355°–392°F: 12–36 months

Short term peaks of 500° F do not cause problems for P84, however longer periods around 500 °F may lead to fabric shrinkage in case the heat treatment of the needle felt in production has not been made in a proper way. Short-term peaks are defined with duration of the app. from 5 to 10 minutes. Depending on the continuous operation temperature and other flue gas components, the total peak temperature duration can be limited from 100 to app. 400 hours per year for achieving the requested bag life.

Moisture and Dew Point

Operation at or below the acid –and water– dew point should be avoided at any time. Heating baghouses during shutdowns can mitigate moisture-related risks.

Condensation as well as operation close to the dew point may result in problems in case the pH of the dust is extremely acidic (pH < 3) or alkaline (pH > 11). In that case, heating of the bag house during shutdowns is recommended. As long as moisture is excluded, dry acidic or dry alkaline dust does not attack the fiber. High moisture contents (> 35 % vol) have to be taken into consideration as well.

Bag Disposal at the End of Filter Life

In comparison with PTFE materials or glass products, P84 shows very low toxic gas generation when being burnt. Instead of expensive bag disposal at hazardous waste treatment plants, P84 bags can be burnt in the incinerators of end users.

Final Thoughts

P84, PPS and other similar fabrics are used in high temp applications to replace aramid or fiberglass when certain chemical or extra high moisture contents make aramid ineffective.

P84 filters are designed to work on extreme conditions across industries

If you’re considering upgrading your dust collection system or need help selecting the right filter for your specific application, reach out to us. It is always better to double check with a dust collection expert before making the change to a different filter fabric.

November 19, 2024/by Andy Biancotti

Chemical and Pharmaceutical Manufacturing, Dust Collection Blog

Case Study – Innovative Solutions for Cosmetics Manufacturing

A Dust Collection Success Story at Cosmetics Group USA

Background

Cosmetic Group USA is an ever growing developer and manufacturer of cosmetics and skin care for national and international brands.

Cosmetics Group USA is a California-based maker of a range of beauty products, partnering with the world’s most well-known cosmetics brands. The process of cosmetics manufacturing begins with the careful blending of raw materials to create the desired formulations. These powders are then finely milled and sifted to achieve the right texture and consistency.

Scope of Work

As part of their plans to expand and upgrade their Los Angeles factory, Cosmetics Group leadership recognized two main issues with dust collection that needed to be addressed:

An efficient, central dust collection system with capacity to support planned operations and expansion in the factory.
The air pressure in the building required balancing, as the dust collection system generated significant negative pressure, resulting in slamming doors, potential dust and particulates being pulled into the building through windows and doors, and inefficient heating and cooling of the facility.

Solution

To resolve these challenges, the company partnered with Baghouse.com to design and install a dust collection system that would satisfy their unique challenges.

“Our team worked efficiently to ensure the new dust collection system was up and running ahead of schedule, minimizing any disruptions to the Cosmetics Group’s operations” —said David Dal Santo, Systems Engineer for this project.

Baghouse.com developed a dust collection system using two 4-32 cartridge dust collectors with high-efficiency nano-media cartridge filters and twin 75 HP ground-mount fans. The various process dust pickup points in the lab and production areas were connected to the dust collectors via galvanized steel, clamp-together duct, an economical duct configuration that is perfect for lighter duty applications like cosmetic powder and dust.

“With high-efficiency nano-media cartridge filters and a robust ductwork design, we’re confident that this setup will exceed expectations for years to come” —said David Dal Santo.

Positioned on the clean air side of the unit, the HEPA after-filter acts as a secondary filtration stage, capturing even the tiniest microscopic particles before the air is returned to the facility.

To address the pressure balancing challenge, Baghouse.com designed the dust collection system exhaust to return to the building. Dual HEPA after-filter units were installed on the return air ductwork to meet compliance requirements and ensure the highest filtration efficiency for the filtered air that would be returned to the building. Baghouse.com also supplied and installed a central vacuum system with 30+ vacuum ports with flap valves for easy plug in of hoses where necessary.

In addition to the dust collection system sizing design, and delivery of the equipment, a Baghouse.com team installed the dust collection system and commissioned the units, successfully completing the project.

Conclusion

Baghouse.com developed a dust collection system using two 4-32 cartridge dust collectors with high-efficiency nano-media cartridge filters and twin 75 HP ground-mount fans. The various process dust pickup points in the lab and production areas were connected to the dust collectors via galvanized steel, clamp-together duct, an economical duct configuration that is perfect for lighter duty applications like cosmetic powder and dust.

Newly installed cartridge collectors, ductwork and HEPA After-Filters

“We were excited to take on this challenge and are thrilled with the outcome. Helping Cosmetics Group USA expand their operations while solving their dust collection issues was truly a rewarding experience” —said Matthew Coughlin, Engineer and Owner of Baghouse.com.

Happy with the results of their new dust collection system, Cosmetics Group USA continues to work with Baghouse.com to support additional future expansion plans for their factory.

November 12, 2024/by Andy Biancotti

Dust Collection 101, Dust Collector Maintenance, Purchasing Supplies Tips

Pleated Baghouse Filters: A Smarter, More Cost-Effective Solution!

Traditional Filters vs. Pleated Filters

Made from a variety of materials, filter bags can be used in high temp, high dust loading, abrasive, corrosive and high humidity applications

Traditional baghouse filter bags have been the standard in dust collector for nearly 100 years and they continue to be the most common type of filter used across nearly all industries and applications. Their wide use, and simple construction means they present the lowest cost per filter option.

However, when the time for your next filter replacement comes, are traditional baghouse filters always the most cost effective option when all cost factors are considered? In many applications this is not the case. One choice that should be given more consideration is to replace your existing traditional filter bags and cages with pleated filters.

This article will examine exactly what are pleated baghouse filters and what are their advantages over traditional bags and cages.

What are Pleated Baghouse Filters

Pleated filter elements have many folds of the fabric that provide a greater surface area of filter cloth in a shorter length, allowing for improved air-to-cloth ratios in the same space

As one of the latest technologies in industrial dust collection, pleated filters improve on the design of traditional bags by packing more filter fabric into a smaller space.

Additionally, the shorter overall filter length also creates additional space underneath the bottom of the filters, keeping the filters above the dirty inlet gas stream.

traditional filter bags versus pleated filters

Shorter filter length reduces abrasion problems caused by incoming dust particles striking the filters and further slows the incoming air, which improves filter dust cake release when the filters are pulsed

Another advantage over traditional filters is that they do not require separate cages, as the bag and cage are combined into a one-piece construction. This means no more separate cage purchases and easier storage of filters. Due to these reasons, they are more efficient at removing particulate than traditional bags and last longer, sometimes up to 2 times as long. Pleated filters are designed to operate with today’s high demand production demands and can replace existing bags and cages in most standard pulse jet baghouses without any modifications required.

Why use Pleated Filters Over Traditional Bags and Cages

As noted, there are compelling operational and performance benefits to switch from traditional filters to pleated filter elements. But there are also significant financial advantages. The use of pleated filters in today’s high production demands can reduce costs by up to 60%. How is this the case? Let’s examine some of the benefits of switching to pleated filters.

— Reduction in Total Number of Filters:

The total number of filters required is reduced due to the overall filter cloth area being increased when using pleated filters. Less filters are required for the same filtering efficiency.

Installation can take 50% less time than it takes to replace traditional filters

— Easier Installation:

The reduction in the number of filters being installed results in faster changeouts, less downtime and lower installation costs. Also the one-piece unitary design means there is no cumbersome operation to remove and reinstall the cage and bag together, therefore installation can take 50% less time than it takes to replace traditional filters.

— Reduction in Compressed Air:

With less physical filters and an improved filter area, pleated filters load dust better and are easier to clean. This leads to a significant reduction in the use of compressed air during the cleaning cycle.

— Increased Lifespan:

Shorter length of filters and a reduction in cleaning, results in pleated filters experiencing less wear and tear during operation. This means pleated elements commonly last from 25 to 75% longer than filter bags. Sometimes as much as 2 to 3 times longer. Longer lifespan means replacing filters less often.

— Improved Operation and Greater Capacity Through Increased Filter Area:

Pleated Filter elements can dramatically improve operation costs by increasing capacity, by decreasing emissions, reducing electricity usage. Pleated elements can effectively increase the amount of filter media inside a collector by as much as 700%.

With the greater amount of filter media, operators can either:

Keep the airflow the same and thus increase the air-to-cloth ratio for improved performance and filter life
Increase airflow to have a greater baghouse capacity of a baghouse, possibly allowing for the combination of several dust collection systems into one larger unit and in turn reducing operation costs.

Conclusion - Pleated Filters Provide Significant Advantages In The Right Application

what is cheaper: a filter bag or a pleated filter?

Traditional filters usually mean lowest cost per filter, but with pleated elements the overall short term and long term cost of replacing and maintaining your baghouse can be dramatically reduced

There are many advantages to switching from traditional to pleated filters.

In certain cases however, switching to pleated filters will not be a viable option. For example, pleated filters are not advisable for high temperatures or when the airstream contains highly corrosive gases. Higher temp versions do exist, but they have significantly higher costs per filter and may only be viable in applications where improving dust collector performance will provide significant financial upside and with few to no other options available to do so.

In summary, from cost savings to improved efficiency and longer lifespan, pleated filters can be a game-changer for your dust collection system.

To find out more information on the pleated filters and to discuss the option of converting your baghouse to pleated filters, please contact us at Baghouse.com

October 24, 2024/by Andy Biancotti

Industrial Health and Safety, Industrial Health and Safety Regulations, Safety

Hazardous Dust: Key Risks and Practical Management Solutions

How Harmful is Exposure to Dust in the Workplace?

In many industries, workers can be exposed to high levels of dust, causing breathing problems that could lead to life-threatening respiratory diseases. Most occupational lung diseases are caused by repeated, long-term exposure, but even a severe, single exposure to a hazardous agent can damage the lungs.

In What Industries is Dust a Hazard?

Manufacturing factories, processing facilities, and industrial sites all have the potential to emit dangerous dust.

Dust is a prevalent exposure at workplaces in various industries such as:

— Mining
— Foundries
— Chemical
— Food industries
— Stone working
— Woodwork

While many industries expose workers to dust, not all dust is equally harmful. Excessive exposure to some types of dust has been linked to the development of particular health problems, such as lung cancer or asthma. Different forms of the same substance may present different hazards. For example, a large piece of wood may be safe, but when ground into dust, it can become hazardous.

What Problems Can Exposure to Dust Lead To?

Exposure to any dust in excessive amounts can create respiratory problems. The harmful effects of dust can vary, from skin irritation to lung cancer, depending on the composition of the dust and the type and degree of exposure. Dust is not always an obvious hazard because the particles which cause the most damage are often invisible to the naked eye, and the health effects of exposure can take years to develop.

Safe Materials When Solid, Hazardous in Dust Form

As we mentioned, some materials that are generally safe in their solid form can become hazardous when they are ground into dust and inhaled over long periods. For example, Silica is found in materials like sand, stone, and concrete, silica is harmless in its solid state. However, when these materials are cut, ground, or drilled, they produce respirable crystalline silica dust. Prolonged exposure to this dust can lead to silicosis, a serious lung disease, as well as lung cancer and other respiratory issues.

Inherently Toxic Dusts

Other dusts are inherently toxic and should be avoided as much as possible due to their severe health risks:

— Heavy Metals: Dust from metals like lead, cadmium, and arsenic can be extremely toxic. Inhalation of these dusts can lead to serious health issues, including damage to the nervous system, kidneys, and other organs.
— Asbestos: Asbestos fibers, when inhaled, can cause severe lung diseases, including asbestosis, lung cancer, and mesothelioma. Even small amounts of asbestos dust can be dangerous.
— Mineral Acids: Dusts from mineral acids, such as sulfuric acid, can cause severe respiratory and skin irritation.

How Can We Prevent Dust-Related Diseases?

PTFE filters from Baghouse.com can easily reach sub-micron filtration ranges. In some applications efficiencies are high enough to allow for the recirculation of treated air back into the facility.

In some applications, PTFE membrane filtration efficiencies are high enough to allow for the recirculation of treated air back into the facility.

In normal situations with non-hazardous materials, a simple dust collector with basic filters is often sufficient to meet regulatory requirements. However, when handling hazardous dust, additional steps are necessary to comply with local regulations. For example, hazardous dust might require dust collectors fitted with high-efficiency filters, such as bags or cartridges with nanofiber or PTFE membranes. These filters capture a higher percentage of the smallest particles.

Using HEPA Filters for Extra Safety

HEPA after-filter serves as a powerful ally when searching for cleaner indoor air quality, particularly in industrial settings

If the dust is particularly hazardous, local authorities or safety regulators may require an extra set of filters known as after-filters or HEPA (High-Efficiency Particulate Air) filters. These are usually placed after the primary filters, either before or after the fan. HEPA filters act as a fallback safety measure. In normal operation, the primary filters capture all the dust. However, if there’s a hole or damage to the primary filters, the HEPA filters will capture any escaping dust, preventing it from being released into the environment or recirculated back into the building.

Conclusion

This guide aims to promote safety by educating company owners, managers, environmental personnel and workers about the dangers of hazardous dust and advocating for effective prevention strategies. Remember, a little awareness and action can go a long way in keeping your team safe and healthy.

Would you like to talk to a dust collection expert to determine if you are working with hazardous dust?

Are you wondering what measures should you take to keep your facilities safe?

October 14, 2024/by Andy Biancotti

Baghouse Accessories, Dust Collection News, Dust Collector Maintenance, Operation & Optimization

Introducing the Vacu-Valve: The Economical Dust Discharge Solution

If you’re in industries like foundry, mining, cement, or pharmaceuticals, think of dust management like that one chore you can’t skip—because nobody wants their facilities and equipment to look like it’s been hit by a sandstorm!

That’s where the Vacu-Valve comes in—an economic and reliable solution for continuous dust discharge in systems operating under negative pressure.

How the Vacu-Valve Works

The Vacu-Valve operates without any electrical power, lubrication, or complicated mechanisms. Instead, it uses a simple yet effective method of airlock and vacuum management. Here’s how it works:

— The sleeve inside the valve forms an airtight seal due to the vacuum present in the system.
— As dust particles accumulate above the valve, their weight and the force of gravity eventually force the sleeve to open, allowing particulate to trickle out while maintaining the vacuum.
— The valve then closes automatically, sealing the system again without any external input.

Fine spherical particles, such as sand, pass through most effectively, but the Vacu-Valve can handle a wide variety of particulate sizes and shapes depending on the application.

Industries that Benefit from the Vacu-Valve

The Vacu-Valve is perfect for a wide range of industries, including:

— Foundry
— Mining
— Cement
— Pharmaceutical
— Plastics
— Chemicals
— Manufacturing

Frequently Asked Questions about the Vacu-Valve

— What makes the Vacu-Valve different from a rotary valve?

The Vacu-Valve operates without power or controls, relying on the balance between the vacuum pressure and the weight of particulate matter. Rotary valves require power and regular maintenance, making the Vacu-Valve a more economic and simpler alternative.

— Can the Vacu-Valve handle high temperatures?

Yes! The high-temperature silicone sleeve option can handle temperatures up to 500°F, while the VHT chemical-resistant sleeve is suitable for temperatures up to 400°F.

— What types of dust materials can the Vacu-Valve handle?

The Vacu-Valve works best with free-flowing, dense materials such as sand, industrial powders, coffee, and other small particulates.

— How durable is the Vacu-Valve?

The Vacu-Valve is highly durable and resistant to wear and tear. Its sleeves are available in different materials such as neoprene, nitrile, and silicone, allowing it to be used in abrasive or chemically aggressive environments.

— Does the Vacu-Valve require a lot of maintenance?

No, the Vacu-Valve requires minimal maintenance. Since it doesn’t need lubrication or electrical power, the valve can run continuously with little oversight.

— How quickly can I get a Vacu-Valve after ordering?

Most Vacu-Valves are stocked and can ship within 2-3 business days after placing an order.

Why Choose the Vacu-Valve?

If you’re looking for an efficient, worry-free, and low-cost method of dust discharge, the Vacu-Valve is a very smart investment.

Ready to simplify your dust management system? Contact us today to learn more about how the Vacu-Valve can meet your specific industrial needs.

September 13, 2024/by Andy Biancotti

Baghouse.com News, Dust Collection News, News

New Partnership: Baghouse.com Becomes Authorized Partner for DustVent Equipment

Baghouse.com personnel working on a DustVent equipment.

Baghouse.com personnel servicing a DustVent dust collector.

We are thrilled to announce a new partnership between Baghouse.com and DustVent (Mid-Air Consulting), marking a significant milestone for both companies. Baghouse.com is now the exclusive service partner for all DustVent equipment including their Cyclone Collector, Fabric Collector, and Downdraft Bench. This partnership means that customers who own DustVent equipment can now rely on us for expert on-site service and support, maintenance and repairs for their equipment.

DustVent has a rich history, dating back to the 1970s when it was founded by an innovative engineer whose passion for dust collection systems laid the foundation for what the company is today. William Fitzpatrick (Fitz), the current owner, began his journey with DustVent in 1989, working closely with the company’s founder to redesign and enhance their product offerings. In 2008, the company rebranded as Mid-Air Consulting, and Fitz, along with his dedicated team, has continued to deliver high quality products.

Our team has the capability to service any DustVent collector or downdraft table.

By complementing DustVent’s products with our extensive expertise and on-site service capabilities, we can now ensure that your DustVent equipment continues to meet your production requirements. This collaboration not only enhances our service portfolio but also underscores our commitment to delivering the highest quality support and solutions to our clients.

We are excited about the possibilities this partnership brings and look forward to servicing more DustVent equipment.

Do you have DustVent equipment that needs service?

Are you ready for your next filter changeout?

Give us a call at (702) 848-3990!

September 2, 2024/by Andy Biancotti

About Andy Biancotti

Entries by Andy Biancotti

■ Not enough suction at the pickup points?

■ Contaminated recycled air into the facility?

■ Danger of combustible dust in ducts/baghouse?

● 5” tubesheet hole, 4.5” bag diameter, 4.25” cage diameter

● 5” tubesheet hole, 4.625” bag diameter, 4.5” cage diameter

● 5” tubesheet hole, 4.875” bag diameter, 4.5” cage diameter

● 6” tubesheet hole, 5.875” bag diameter, 5.5” cage diameter

● 6” tubesheet hole, 5.875” bag diameter, 5.625” cage diameter

● 6.2” tubesheet hole, 5.875” bag diameter, 5.5” cage diameter

● 6.25” tubesheet hole, 5.875” bag diameter, 5.5” cage diameter (Most common)

● 6.25” tubesheet hole, 6” bag diameter, 5.875” cage diameter

— Reduction in Total Number of Filters:

— Easier Installation:

— Reduction in Compressed Air:

— Increased Lifespan:

— Improved Operation and Greater Capacity Through Increased Filter Area:

Contact Us

Explore Our Filtration Solutions

About Baghouse.com