Entries by dominickdalsanto

Why You Need to Properly Size Your Baghouse System (Part 1 of Design Guide)

Dust collection systems play a vital role in many commercial and industrial facilities. Whether part of a system process, used to capture harmful pollutants from furnaces/boilers, to convey dry bulk product or to maintain a clean and safe work environment, dust collection systems need to function at near constant peak efficiency for facilities to operate safely and productively. While maintenance and proper operation play a large role in keeping these systems running properly, many facilities face challenges due to improper system design and engineering.

Many users rely on outside vendors or so-called “experts” with little to no actual dust collection experience to design and engineer a system for them. Other times vendors may purposefully undersize a system in order to undercut other potential suppliers regardless of how it actually performs in the end for their customer. Still others design their own system in-house thinking it an easy process that just any engineer can accomplish with little to no outside guidance. These cases frequently end with an inadequate dust collection system that cannot meet the needs of the process, resulting in high emissions, lowered productivity, hazardous work environments or all three! So what can facilities do to ensure they do not encounter these same issues?

 

In our experience, an educated user benefits the most and becomes best customer. With that in mind, we have prepared this guide (broken into 4 major sections) to assist users in designing and properly sizing a dust collection system. By following the direction in this guide closely, you can effectively estimate what kind of system you require and then use this information as a basis for gathering quotes and additional assistance.

This guide is NOT an exhaustive course on dust collector design. Each system presents unique circumstances that affect the general operation of a baghouse system. As such, the guidelines present in this guide should be used only to estimate the sizing of your system. A qualified, and experienced dust collection system OEM should be consulted before purchasing any equipment or making design changes.

Now let’s get right into it! First we start with the four key dust collector design variables.

Next Section – Part 2 – The Four Key Baghouse System Design Variables

 Baghouse Design Guide Overview

Key Points to This Guide

  • Many So-called “Baghouse Experts” know little about proper dust collection design and operation OEMs and sales reps frequently undersize systems to win contracts leaving customers with a system that does not work
  • Educated clients can determine the general size they need and use it as a basis to compare quotes from multiple sources
  • Understanding principles of dust collection system design enables facilities to make better decisions regarding baghouse maintenance, operation and safety

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How To Correctly Size a Baghouse Dust Collector (Article Series)

How large of a baghouse do you need? How do you determine how many filters you need? What air to cloth ratio meets your needs? How much vacuum pressure (static pressure) do you need in the system fan? How much CFM do you need?

 

Calculating the size of a dust collection system

Calculating the size of a dust collection system

These are just some of the questions that may arise when working with dust collection systems are your facility. When designing a new system plant engineers need to decide how large of a system they require before they begin getting quotes from vendors.

A danger exists when facilities ask outside vendors to design a system for them. Many so-called “dust collection experts” are really just sales rep organizations that have little technical background or engineering experience with these systems. As such, they will often sell whatever product lines they have with little regard for making sure it is the best fit for your specific application. Others vendors purposefully recommend undersized systems in order to undercut other vendors on pricing, regardless of how the end system performs for the customer.

Plant personnel can easily avoid being sold an undersized dust collection system by conducting research in advance to get a general idea of what size system they need. Then they can use this estimated sizing information as a basis for getting quotes from multiple vendors.
For this reason, Baghouse.com has prepared a detailed series of articles to help educate users on how to properly size their baghouse system. Each article in this series will cover a different step in the process of determining your dust collection needs for your system. This article series will primarily be of use to plant personnel looking to install new baghouses and ductwork systems. However, the information can also be used when troubleshooting existing systems (where capacity may not be sufficient) or when looking to expand capacity on existing systems.

Complete guide to sizing your baghouse

Click here to download the complete eBook: How To Size a Baghouse Dust Collection System.

Next Section – Part 1 – Why You Need to Properly Size Your Baghouse System

 Baghouse Design Guide Overview



Download our FREE Filter & Cage Baghouse Step-by-Step Measurement Guide

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Find Leaking Baghouse Filters Faster with a Triboelectric Broken Bag Detector

By Dominick DalSanto
Baghouse.com

Quickly finding and replacing leaking filters is crucial for keeping a baghouse operating at peak efficiency. The longer you take to replace the leaking filter the more likely you will have to report the event to your air quality control regulatory agency (reportable event) and the more abatement costs you will incur.

How Broken Bag Detectors Work

How Triboelectric Dust Detection Systems Work

How triboelectric bag leak detection systems work – Courtesy of http://auburnsys.com/

Triboelectric broken bag detectors measure the amount of static electricity generated by dust particles in an airstream. Dust particles generate an electrical current when they encounter the insulated metal probe in the ductwork. A dust particle directly impacting the probe creates a DC signal while a particle passing near to the probe generates an AC signal. The latest generation of triboelectric detectors (such as the Auburn Systems’ TRIBO series) unify both signals and then output a measurement of particle concentration to a nearby control panel or transmit it to a PLC.

Using a Triboelectric Broken Bag Detector as Early Warning

Most leaking baghouse filters begin as small holes or rips that overtime become worse and worse. Catching a leak quickly is crucial. The longer a leak persists the worse it becomes, often quickly causing a plant to exceed its maximum PM 2.5 emissions limits set out in its air permit. Additionally, abatement requirements quickly increase as a leak continues over time.

Older optical emissions monitors (i.e. opacity meters) and optical bag leak detectors can only detect a filter leaking so badly damaged that the increase in emissions exceeds 10% opacity (often greater than the maximum permissible levels for many air permits).

Triboelectric systems are sensitive enough to detect even the smallest of increases in dust emissions such as when a bag first begins leaking. Operators can then examine the realtime trending emissions data to see whether it was a sudden spike indicates a damaged bag (such as from quickly worn hole) or slow rise indicating wearing filters.

 

Using Broken Bag Detector to Pinpoint Which Filters Are Leaking

An added advantage of triboelectric bag leak detectors is they can enable operators and maintenance technicians to pinpoint exactly which bags are leaking and need to be replaced.

Personnel should carefully monitoring emissions while cleaning system runs. When emissions spike during one cleaning cycle it means that leaking filters are present. Using this method, maintenance personnel can trace the leaking filters down to a specific baghouse, compartment and even row (pulse jet only) of bags. This saves time and money over traditional dye leak testing.

However, on older units, or when first beginning to troubleshoot a unit dye leak testing should still form part of your maintenance schedule. Dye leak testing can pinpoint multiple leaks at once, and in structural components as well as filters.

By quickly pinpointing leaking filters maintenance staff also reduce the amount of abatement required after the leak is fixed.

Below is the sample data from a test conducted to determine the differences in performance between a triboelectric leak detection system and a typical optical system (opacity meter). Notice the huge difference in response time and abatement required.

Leak Test Results Triboelectric Bag Leak Detector Optical System
Estimated Time to:
Detect Leak Less than 1 Hour 2-3 days
Locate Leaking Filter(s) Less than 1 Minute 2-3 Man Hours (dye leak test)
Clean Up Leak Less than 1 Man-Hour 8-10 Man Hours
Estimated Size of:
Hole Detected 1/4” 8”
Dust Accumulation 2.6 cubic feet 60 cubic feet
Dust Clean Up Tool Shopvac Shovels

Source: https://cdn2.hubspot.net/hubfs/354686/BrandBuilder%20Solutions/Case%20Studies/Aluminum_Case_Study.pdf

Reduce Baghouse System Downtime

When a baghouse goes down it often brings much down with it, from specific equipment to entire production lines to even entire plants due to emissions or health and safety issues. Preventing unscheduled baghouse shutdowns directly impacts the bottom line. In some facilities, losses from just one down day can add up to tens of thousands of dollars in lost production, fines and other costs. Therefore, investing in the maintenance and upkeep of these baghouse systems is well worth the initial capital costs.

Triboelectric dust monitoring system often prove one of the most cost-effect ways to improve dust collector maintenance and operation. With the ability to monitor emissions in realtime and trends over time, operators can better assess the condition and operation of their baghouses than those who rely solely on differential pressure.

For example, by carefully analyzing the triboelectric data trends maintenance planners can accurately predict when filters will no longer achieve their require collection efficiency and need a changeout. Further, they can begin preparations for the changeout in advance, sourcing filters and cages, obtaining contract labor for the changeout and scheduling the changeout for the next most convenient time (e.g. yearly maintenance shutdown). Compare this with the added costs and stress involved when a changeout is done at the last minute!

Additionally, as mentioned above, triboelectric bag leak detectors also prevent downtime by quickly alerting plant personnel to any leaks as soon as they begin to form. By catching leaks before they become serious plants can avoid stoppages for abatement, repair and any possible fines or sanctions from air quality regulators.

Recap of the Key Points

  • Triboelectric bag leak detectors directly impact the bottom line of your baghouse by improving maintenance efficiency, reducing downtime
  • Increased detection range means finding leaks quicker, before they become reportable events
  • See when filters first begin to fail allows predictive maintenance planning to reduce inconvenient shutdowns
  • Find leaking filter bags quicker, pinpoint down to specific unit, compartment and row without a dye leak test
  • Comply with MACT standards that require triboelectric broken bag detectors over opacity meters

Interested in a Triboelectric Broken Bag Detection System?

If you would like to know more about our line of triboelectric broken bag detectors and how they can benefit your facility contact us today for a free consultation and quote!



Call us now!

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FAQs – Dust Collection System Design and Operation

Question: What is “normal” differential pressure in a baghouse? Answer: In most applications a baghouse dust collector should run between between 3″ to 6″ w.g. under normal use. Once levels rise above 6″ (roughly) and the cleaning system cannot return it any lower (even when turned to continuous cleaning or “Test” mode) it is a sign […]

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FAQs – Dust Collector Filters

Question: Why are my baghouse filters so expensive to replace?

Answer: Many simply buy their replacement filters from the OEM or sales rep that supplied their baghouse. Often times, manufacturers and sales rep organizations deliberately sell their units cheaper and then make convince their customers that they are locked into using a proprietary filter design that only they can supply and thus they charge outrageously high prices for them. Other times, they convince their customers to use an outdated or rarely-used technology so hard to find form other manufacturers that it nearly guarantees them your repeat business for replacement parts. This is common with many cartridge collector OEMs, whereby they win the initial unit sale by undercutting other manufacturers (often by recommending a undersized dust collection system) and then plan on making their profit on the expensive replacement filters later on. This marketing technique is commonly called the “razor blade” system, for its well-known use by makers of disposable razors and cartridges.

Need New Filters?

We offer replacement baghouse filters, cartridges, and pleated filters for all makes and models of dust collectors, including the most popular brands Farr, Donaldson / Torrit, Wheelabrator, and more. Often we can offer significantly better prices than buying from the original dust collector manufacture, sometimes as much as 50% less! If you do not believe us, give us a try and let us give you a quote for your next set of replacement baghouse filters.



Get Your Quote For New Filters Now!

Question: How long will my baghouse filters last?

Answer: Baghouse filters have an average service life of 1-3 years in most applications. Some can go beyond that without major increases emissions, while others may last less than a year in more difficult applications. The main reason to replace baghouse filters is because when old they begin to leak and thus the system is no longer collecting particulates as its designed to do. Filters can also be damaged prematurely by sparks/embers that can cause fires or even explosions. Upset conditions in the process may cause a spike in temperature (beyond the maximum for the filter fabric) or may create an acid flash or similar chemical attack on the bags. Finally, bags may be damaged during maintenance or by other external forces.

The main signs that your filters need to be replaced are that they are can no longer be cleaned effectively by the baghouse and/or they start leaking.

Baghouse filters that are blinded

Blinded filters must be replaced.

Question: What does it mean when my baghouse filters are “blinded”?

Answer: Blinded filters means the filters are so loaded with dust that they can no longer be cleaned by the baghouse cleaning system and must be replaced.

During normal operation dust particles accumulate on the surface of the filters and form a dust cake, which is then cleaned by the pulses of compressed air during the cleaning cycle. Overtime, some dust particles pass through the surface layer and become embedded deep within the fibers of the filter fabric where it cannot be removed by the cleaning pulses. Eventually, the fabric becomes so filled with dust particles that it severely restricts the movement of air through the filter. When this occurs the filter is said to be “blinded”.

When a baghouse can no longer clean itself down to a lower DP range (e.g. below 6” of DP) even with constant cleaning (i.e. continuous cleaning mode or test mode) it is likely that the filters are blinded and must be replaced.

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FAQs – Baghouse Controls and Cleaning Settings

Question: What does the “On-Time” setting on my baghouse control board do? Answer: On-Time determines how long the pulse valve is open for during a cleaning cycle. This setting is VERY important for proper cleaning of the baghouse filters on a pulse jet dust collector. If set too long then the air pulses will be weak and […]

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How to Avoid Undersizing a Baghouse Dust Collection System

Dust collector OEMs constantly try to come in with bids lower than competitors. In an attempt to do so, some baghouse manufacturers offer undersized systems. This article discusses what customers can do to avoid accepting a bid for an inadequately-sized baghouse dust collection system. By Dominick DalSanto Dust Collection Expert & Sales Director Baghouse.com ”I’m […]

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