Control dust emissions and keep efficient the upstream equipment

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Indepth analysis

Restore and improve performance of the baghouse

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Control emission and keep efficent the upstream equipment

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Experts engineers

Get minor changes and lower total cost of ownership

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Get full compliance with local environmental regulations

Baghouse is a critical equipment for industrial plants

Baghouse is a critical equipment because it ensures compliance with increasing emission regulations in terms of outlet dust and pollutants, and the maximum efficiency of a plant’s upstream equipment. However, consider a baghouse that was designed several years ago without the latest available technologies for optimal gas distribution or for less strict emissions regulations, and most likely, for different plant production requirements and fuel use.

How can the industrials ensure that the existing air pollution control (APC) system still performs within the threshold inlet parameters and this does not lead to premature wear of its internal components and uncontrolled energy consumption?

It is not unusual to observe in existing baghouses that over the years and with the same components installed, dedusting performance is reduced, bag or cage change-outs are required with an increased frequency, and there is an increase in differential pressure and dust emission levels.

Identifying the reasons behind this issue

Useful factors to consider include:

  • different inlet conditions, leading to a gas distribution review
  • quality and process compliance of newly-purchased filter elements
  • compliance with the proper bag to cage fitment guidelines
  • incorrect or improper installation methods

All the above conditions will inevitably lead to the following:

  • a great deal of time spent by the procurement, technical and maintenance team to
    resolve the issue
  • coordination of many different suppliers, such as bag manufacturers, cage manufacturers, external manpower and original equipment manufacturer (OEM)
  • unplanned shutdowns
  • higher costs in terms of maintenance manpower, spare parts, compressed air
    and energy consumption

Figure 1: Detailed inspections and tests on used bags are provided to identify the causes of early-deterioration of the filter media.

In-depth technical analysis and service-oriented approach

CTP Team, with its leading position as an experienced OEM combined with its service-oriented approach, is able to carry out comprehensive and in-depth technical analysis of the areas discussed below for any brand or design of baghouse.

Figure 2: Cleaning efficiency is a key parameter strictly connected to the level of emissions requested by CTP clients. This parameter optimises the bags arrangement together with the type of filter media and the choice between high or low compressed air pressure for the cleaning system.

Analysis of inlet parameters

To ensure smooth and cost-effective operation each process baghouse is designed taking into account several factors, such as the gas chemical composition, and carefully-sized, allocating the proper cloth area for the required inlet gas flow volume. If this balance changes over the years, several key design factors can affect the smooth operation of the system, leading to several critical conditions, such as a higher air-to-cloth higher differential pressure, increased cleaning frequency to the filter bags, corrosion issues and modified gas distribution. All these evaluations can be undertaken quickly and easily by CTP Team experts.

The role of existing components

Sometimes all the attention is given to new parts and their technical specification
to comply with the existing ones. However, a key role is played by existing components. Therefore, damage to any new replacement parts can be avoided by analysing existing conditions.

Filter cages are a good example.

The cage quality, shape and design play a key role when new filter bags are being installed. The number of vertical wires should be correct depending on the process and the kind of bags they will have to host. A proper coating should be ensured to avoid rust, oxidation and smooth operation in high-temperature environments. A poor supporting cage quality or design will lead to poor filter bag operating performance and lifetime.

The same is true of the cleaning valves. The efficiency of the cleaning system must always be ensured to avoid bags being cleaned differently or not properly. A routine check of the membrane or piston valves should be carried out. Any unusual noises coming from the filter during the cleaning process should  immediately be investigated further.

Enhanced system performance

Thanks to a constant R&D work together with years of experience across
several applications, CTP Team can integrate its latest dedusting technologies and baghouse control system on any existing equipment to restore performance with minor changes and lower the total cost of ownership. Examples include compressed air consumption, fan energy consumption, key component replacement frequency/lifetime, etc. Therefore, if a plant need an immediate and long-term solution instead of just replacing components that result in a non-optimised system, CTP Team can step in and take care of equipment with its highly-skilled technical experts.