Volume 2

A: Introduction - Baghouse Dust Collectors

A baghouse dust collector is a simple but efficient device designed to extract dust
particles from an airstream and to collect those particles in order to recycle or
discard them.

Dust
Laden Clean
Air Air
Dust
Collector

Dust
To extract the dust from the airstream, a fabric bag is used. As the dust laden air
encounters the fabric bag the dust is stopped and starts to collect. The dust free
air then continues to pass through the collector. The dust is then cleaned off the
bags in various ways to be recycled or discarded.

Dusty Clean
Gas Gas

There are 3 major types one could encounter in cement plants. They are the pulse-
jet, reverse-air and shaker. The shaker is a collector which mechanically shakes
the bags clean. These are becoming rare and therefore will not be discussed.

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A1 Description and characteristics - Pulse jet collector

A pulse jet collector (figure 1) typically consists of a one compartment bag house
with a specific number and size of bags. The number and size of bags depends
on the area to be vented. An I.D. fan provides the air flow. A tube sheet which
divides the collector into an upper and lower section, a blow pipe cleaning
mechanism and diaphragm valves that are controlled by an electronic control
module. This type uses blasts or pulses of compressed air to clean the bags.

A1.1 Tube Sheet and Bags

The upper and lower halves are divided by the tube sheet, which also
serves as the mounting plate for the collector bags. The upper half is the
clean air side and the lower half is the dirty air side. In the pulse jet collector
the bags are suspended from the tube sheet. A snap band is designed into
the bag to hold the bag in place, (different suppliers will have different
designs). A wire cage is installed inside the bag to prevent if from collapsing
inward. Especially on older models (pre 1990), the clamping method to the
tube sheet is the weakest point in the design. Many leaks occur here.
Newer designs pay a lot of attention to reinforcing this area.

Dirt laden air is drawn into the collector by the air flow created by the I.D.
fan. The dirty air enters in the lower half of the collector and is cleaned as
it is drawn up and through the bags. As the dirt is collected on the outside
of the bags it forms a dust cake. As the cake builds up on the bag it creates
an air flow resistance, and for this reason the bags need to be cleaned.

The baffle plate is important since it is there to knock down as much dust
as possible before reaching the bags. It will also help prevent the incoming
dusty air from wearing holes in the bags nearest the intake.

Close attention should be paid the assembly quality or condition of the

cages. Burrs, sharp edges, weld flashings, etc. will quickly abrade holes in
the bags.

Bags are usually made from polyester, glass or Gortex felts. Felts normally
work best in pulse-jet collectors and can be supplied with a variety of

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surface treatments (teflon, singed, etc.). The type best to used depends of
the temperature, dust type, duty and dust loading. Note it is strongly
recommended for bags used in fuel system dust collectors that they have a
grounding wire sewn into them.

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Figure 1: Pulse-Jet Dust Collector

Solenoid Valve
Compressed Air Manifold
Exhaust
Tube Sheet

Bllow Pipe

Diaphram
Valve

Venturi
Timer

Wire Cage

Filter Bag
Inlet

Discharge Hopper
Diffuser Plate

Airlock Seal

A1.2 Differential Pressure

This resistance is measured between the top and the bottom of the tube
sheet and is called Differential Pressure or D.P. There are three types of
devices used here in the plant to measure the D.P. One of the devices used
to measure D.P. is called a magnehelic. It is located on the side of the
collector near the tube sheet level. A copper tube goes from one outlet of
the magnehelic to the upper side of the tube sheet, while another goes from
the magnehelic to the lower side of the tube sheet. The difference between

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the two sides or the resistance to air flow is calculated and gives the D.P.,
or the pressure drop across the tube sheet.

The second type is called a photohelic. It is located adjacent to the

magnehelic, but is capable of controlling the D.P., by setting a high and low
point. The general range is 2" low and 6" high. What this does is keeps a
constant measure of the D.P. and starts the cleaning cycle by activating the
electronic control module. As the D.P. reaches the high set point it activates
the control module, this is turn starts the cleaning cycle. It continues to
clean until the D.P. reaches the low set point at which time it shuts off the
controller. Once it is initiated, rows of bags are sequentially pulsed until all
rows have been cleaned. This system is particularly useful in minimizing
compressed air consumption and increasing bag life. However it is not
recommended for use on units where the fan must regulate a pressure
setpoint.

The third type of is an electronic differential pressure regulator. This does

the same job as the photohelic but has no gauge or visible way to read or
change the set points. The set points are pre-set by the electronics
department in the plant.

Ideally the differential pressure across a dust collector should be about 4"
WC. However one should check with the manufacturer if a particular unit is
rated differently.

A1.3 Cleaning Process

The electronic control module activates a diaphragm valve which sends a

pulse of compressed air through the blow pipe. Between the diaphragm
valve and the control module is a copper or plastic bleed off tube, which
allows pressure to equalize between the diaphragm valve and the control
module. Once the pressure has equalized the diaphragm releases and
sends a blast of compressed air down the blow pipe.

The blow pipe is placed in line at a horizontal position typically about four
inches above the row of bags. The blow pipe has a hole about 1/4 to 3/8th's
of an inch in diameter located over the center of each bag, (this depends on

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the design). The top of the wire basket has a venturi in it. As the pulse of
air enters the venturi it draws in some surrounding air. This is referred to
as induced secondary air. The duration of the pulse is approximately 1/10th
of a second, and the effect is that of shock rather than bag inflation. One
can observe this as a bulge which travels with the shock wave. When the
shock impacts the bag, most of the dust cake is knocked loose and begins
to fall toward the bottom of the collector, but since the duration of the shock
is so short, the dust returns to the outside of the bag, only after it has fallen
just a few inches. The dust near the bottom of the bag falls into the
discharge hopper and is either returned to the system or discarded. An air
seal device is located at the discharge point to prevent outside air from
entering into the collector.

Note, it is a common but mistaken belief that pulsing the dust collector after
the system is down will purge the dust collector bags clean. If the fan is off,
some dust may fall off after the first pulse but it has been shown that very
little will come off afterwards. To purge a pulse jet dust collector the fan
must be left running while the collector pulses. The normal air flow holds
the bag against the cage which allows the shock wave to bulge the bag.
This is the most effective cleaning.

Air pressure is very important because it is the force that cleans the bags.
The amount of pressure required depends to some extent on the specific
application, fineness of dust, density, etc., but for most applications the
minimum pressure is 90 PSI. This compressed air is also dried by an air
dryer which is located between the compressor and the collector. The
compressed air used must be dry otherwise moisture can cause dust to
cling and blind the bags.

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Blowpipe

Compressed Air Blast

Induced Secondary Air Flow

Venturi

Cage
Fabric Bag
Normal gas flow
holds bag Dust Layer
against cage

Bag bulges
outward, shaking
the dust layer off
Shock Wave

Pulse or
bulge travels
downward
with the
shock wave

A1.4 Process Notes

Most early models of the Pulse-jet dust collector were not well designed.
Often they were not sized correctly and as a result many plants experience
problems with not being able to get enough gas flow through the dust
collector and the differential pressures were always high (10 to 12 inwc).
Usually the problem is that there is too much dust (per unit volume of gas)
and the collector cannot pulse the bags sufficiently clean. As mentioned
already it is important to maintain a minimum air supply pressure of at least
90 psi. Really effective cleaning comes from getting the largest possible
shock. The induced secondary air purge helps some but on early models it

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really doesn't do much, (this is reportedly much better on the latest but very
expensive models). The following graph shows a typical pulse pressure
profile as measured in the blow pipe. The best shock and hence cleaning
occurs by attaining the highest peak pressure in the shortest time. At the
very minimum this should be 40 psi although 60 to 70 is more ideal (for 100
psi air supply pressure). The rest of the pulse draws in purge air through
the venturi but as mentioned, on early models, this is wasted compressed
air. Since most units come equipped with electronic solenoid timers, it is
possible to adjust the pulse span. This should be adjusted to get the
sharpest "thud" but no more. If you have a new model check to see where
the pulse length should be set. Also the frequency of pulsing can be
adjusted to get more or less cleaning. Too high of a setting just wastes
compressed air.

Typical Blow pipe Pulse Profile

50
Pea k Sh ock Pres sure

40
Wa sted Air
Pulse Pres sure in Blowpipe, psig

30

20

10

(pu lse durations vary dep endi ng o n de sign )

0
1 2 3 4 5 6 7 8 9 10
Time m illiseconds

How to get more cleaning (and more flow through the dust collector)

a) Check that the cross sectional area of the blowpipe is greater than
or equal to the sum of the area of all holes in each blowpipe. If it is
less then the cleaning shock will be too low. You can increase this
ratio to get better cleaning but only up to a point, (which = supply
pressure - pressure losses across fittings).

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b) Check that all fittings and valves feeding compressed air into the
blowpipe are larger than the blowpipe diameter. The larger the better
since the pressure loss across these fittings can be very high. Any
restrictions will drop the shock pressure.

c) Occasionally the venturis must be replaced due to wear. Be sure

that the replacement has the largest possible throat diameter.
(different suppliers will give you venturis that fit your cages but have
different throat diameters). The smaller the throat, the smaller the
cleaning shock pressure and the higher the resistance to normal
flow.

For example at one plant the dust collector was using blowpipes made from
standard 3/4" sched. 40 pipe and each were fitted with a 1/2" shutoff valve.
Changing the valve to 3/4" improved cleaning which allowed them to
increase airflow by 8%. Then they took the step of changing the blowpipe
size to 1" dia. as well as the diaphragm valves, shutoff valves, couplings,
nipples etc. Cleaning improved again and they were able to increase airflow
by another 10%.

New designs, we have observed employ 6" diaphragm valves feeding 2"
diameter blowpipes and double venturis. The venturi fitted to the cage is
the same diameter less the thickness of the metal casting, (in other words
it has the largest possible throat). Cleaning is claimed to be so much more
effective that plants are able to reduce compressed air requirements.

A1.5 Troubleshooting - Pulse jet collector

Condition: Dirty exhaust air

1. Through compartment windows observe top of tube sheet for evidence

of dust leaking through bags or holes in tube sheet or around the venturi
where it is fastened to the tube sheet. Notify condition and location to
Mechanical Maintenance.

Condition: High D.P. noted

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1. Check main air supply and dryer for proper operation. If not O.K. refer
to equipment troubleshooting guide.

2. If O.K. check air pressure at manifold, which should be 90-100 PSI. If

the PSI is to low, check for leaks in the air lines. If leak is located
attempt to repair or notify Mechanical Maintenance.

3. If no leaks are located, check for sticking solenoid or defective

diaphragm valves. If noted, isolate defective unit and notify mechanical
maintenance of location and condition.

If no air loss noted on this collector, check remaining collector systems.

(Cleaning air comes from a common air supply). Also observe for high
D.P. on these collectors and continue to check for leaks in the system
until located. Repair if possible, if not possible notify mechanical
maintenance.

Condition: High D.P. - System air supply O.K.

1. Check to make sure collector is cleaning properly, if cycling not to

specs. Notify electrical maintenance.

2. If cycling O.K. check collector discharge and tipping valve for plugging
condition (air slide, screw or rotary feeder). If plugged refer to related
troubleshooting guide. Check collector fan dampers for proper
operation.

3. If dampers not operating properly and you are not able to repair, notify
electrical or mechanical maintenance of the problem.

Condition: Low D.P.

1. Make sure all doors are closed and there are no holes in the piping.

A1.6 Safety - Pulse jet collector

1. Never work inside a collector without another employee present.

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2. Make sure related equipment is locked out or turned off, such as fans,
collector screw if equipped, compressed air supply and rotary feeders
and dampers.

3. Use respirators and goggles when necessary.

A1.7 Walk through inspection - Pulse jet collector

1. Check collector vent stack for dust emissions; there should be none.

2. Look through the windows (where applicable), installed on the clean air
side of the collectors that have them, for dusty conditions.

3. Check the D.P. gauge; it should read between 2" and 6".

4. Listen for air leaks along the solenoid valve manifold.

5. Listen to the solenoid valve (s) go through the pulse cycle, to ensure
that all valves are working properly.

6. Check the pulsing air pressure; it should be no lower that 90 PSI.

7. Check for leaks around doors, seams and on the piping.

8. Check discharge hopper points for leaks around the air seal.

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A2 Description and characteristics - Reverse air collector

A reverse air collector (figure 1) consists of a bag house containing two or more
compartments each fitted with an equal number of bags. Size and quantity of bags
depends on the amount of venting to be done. An I.D. fan creates the air flow, and
a tube sheet which divides the collector into an upper and lower half. Dampers
are in place to direct air flow, and a timer to control the dampers operations.
Discharge hopper or hoppers with various mechanisms to take dust away, and an
air seal to prevent outside air from entering the collector through the discharge
end.

A2.1 Tube sheet and bags

The I.D. fan creates the air movement through the collector and the duct
work. The tube sheet which divides the collector in half also serves as the
mounting plate for the bags. The upper half which contains the bags is also
known as the clean air side and the lower half is know as the dirty air side.
The open end of the bag is attached to the tube sheet with metal clamps.
The opposite end is then hooked and suspended from the top of the
compartment with a chain and spring assembly. The tension is set so that
the bag will remain upright and retain its shape.

Woven bags are generally preferred in reverse air units. They come in a
variety materials depending on application such as polyester, glass and
Gortex.

A2.2 Collector Operation

Two dampers are used on each compartment to direct air flow. When the
main damper opens the reverse air damper is closed. This puts the
compartment under negative pressure. The air flow entering the collector
is dust laden and is drawn up through the tube sheet and the bags. The
dust is filtered out by the bags and the clean air exits the collector through
the main damper (figure 1). During the cleaning cycle the main damper
closes, this puts the compartment at a neutral state allowing trapped dust

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to start falling out of the bags. Then the reverse air damper opens and the
air is reversed which starts to shake the bags and dislodges the remaining
dust, (backflushes with air). This dust is drawn out of the bags with the air
flow and falls into the collector hopper. The dust in then discharged by
various ways and put back into the system (figure 2).

Since whole compartments at a time are purged clean, reverse air units will
be much larger than pulse jet units processing the same amount of gas.

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Fig. 1: Reverse air collector

Exhaust Plenum

Clean Air Main Shutoff

Flow to Fan Damper

Reverse Air
Damper

Dust collects on the

inside of each bag

Tube sheet

Hopper

Dirty Air Inlet

Dust discharges
through airlock

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Fig. 2: Reverse air collector

Left Side Cleaning

Normal Flow to Fan

Main Damper Closes

Reverse Air
Flow

This compartment
remains in normal
Reverse Air cleaning mode
back flushes
dust

Dirty Air Inlet Dust Falls into Hopper

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An air seal of various sorts is located at the discharge point to keep outside
air from flowing back into the collector. The cleaning cycle is repeated on
each compartment until the entire collector has been cleaned and then
repeats over and over. Only one compartment at a time should be cleaning.

A2.3 Compartment Isolation

Some larger units are designed with each compartment having an isolation
switch. This switch is normally located in the vicinity of the compartment
door. The switch takes the compartment out of the cycling mode. This
closes the main damper and opens the reverse air damper. It isolates the
compartment so it can be inspected and worked on.

A2.4 Trouble shooting - Reverse air collector

Condition: Not venting properly

1. Check for proper draw. If not proper, check duct work for plugging
conditions and clean obstruction.

2. If not plugged, check fan for proper operation, refer to fan

troubleshooting guide.

3. Fan's operational - check collector hopper. If full, check discharge

screw to inspect if running properly, or refer to screw troubleshooting
guide.

4. Hopper's okay, screw running, but collector still not venting; check
off/on switch for each compartment - inspect tagged compartments.

Open compartment doors for visual inspection - seam leaks in the tube
sheet; dirt build-up on the tube sheet; down, ripped or full bags. If
needed, shake bags down. If unable to clean bags or bags are down
or ripped, shut compartment off and notify mechanical maintenance.

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5. Compartments visual check is okay; check collector cycling, dampers

stuck, i.e. one or more dampers open all the time.

A. If stuck, free up.

B. Check motor (or pneumatic cylinder) and linkage on each damper

for proper operation or damper cycle.

C. If timer not working properly or a motor will not operate. Contact

electrical maintenance.

Condition: Collector exhausting dust - steps 3, 4. 5.

Condition: Collector pressurized - steps 5, 4, 3.

If all of the above check out okay, notify mechanical maintenance to

check bag permeability or process technician to check collector
pressure drop.

A2.5 Safety items - reverse air collector

1. Never work inside a collector without another employee present.

2. Make sure related equipment is locked out or turned off, such as fan,
collection screw if equipped, compressed air supply, rotary feeder and
dampers.

3. Use respirators and goggles when necessary.

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A2.7 Walk through inspection:

1. Check discharge air to make sure it is clean.

2. Check dampers to ensure proper cycling.

3. Check duct work for leaks and holes.

4. Look and listen for air leaks around the doors.

5. Check fan for vibration, unusual noise, air leaks, worn drive
components and hot or bad bearings.

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