Air Pollution Control Equipments Manual

1.0 BAG FILTER

1.1 Definition
A Bag Filter (BF), Baghouse (BH, B/H)or fabric filter (FF) is an air pollution control device that
removes particulates out of air or gas released form industrial combustion process .Baghouse
come into widespread use in the late 1970s after the invention of high-temperature fabrics (for
used in the filter media) capable of withstand temperatures over 2000C.

1.2 Scope
PP-1 & PP-2

1.3 Principle
Bag filter is the filtering apparatus with porous cloth or felt bags through which dust- laden gases
are sent, leaving the dust on the inner-surfaces of the bags.
Filtration is basically the separation of the solids from the gas by mean of a filter media through
which only gas can pass, while dust particles in the gas are retained on the filter media.
In jet-pulse bag filters the dusty gas comes to the filter inlet, it is distributed uniformly through
filter cross section via buffle plates. Ones the gas reaches the bags in the dirty gas chamber, the
dust retained on the outer surface of the filter media while it allows gas pass from the outer
surface to the inner surface of the bags. Clean gas leaves the filter from clean gas chamber. Dust
collected on the bag surfaces builds up a dust cake which decreases the air permeability of the
filter media. After a while, bags are cleaned by compressed air injected with diaphragm valve
and controlled by an electronic sequencer. The jet-pulse system is the most efficient way for bag
cleaning and lead to low pressure loss across the filter. The dust removed from the bag surfaces
falls down to the hopper where it is discharged out of the filter.

1.4 Design Criteria

The design bag filter is a relatively sample operation, thats why you should pay attention to
observe few important design steps to obtain an effective and reliable filter. The key design
parameter, designing a bag filter, is the filtration velocity, also known as air to cloth ratio To
obtain the total filtering area required to perform the duty, divide the actual gas flow rate of the
filtration velocity suggested for the application. The most common value used which covers a
wide range of application is:

1m/min = 3.3 ft/min

Once obtained the total filtration area it is possible to configure your bag filter. In bag filters, the
filtering medium is represented, of course, by bags. Bags can have a different size that means the
number of bags required for a total filtering area can vary. Now you have calculated your total
number of required bags.

Typical values are:

Dbag: 150mm= 6
L bag: 6m = 20 ft
To calculate your tube sheet surface required for your filtering area calculate at least 200mm of
bag to wall clearance (referred to bag centreline) and at least 220 mm of bag to bag
clearance.

1.5 Operation Criteria

To prevent equipment from generating the dust and to achieve trouble free operation of
dedusting plant certain conditions must be met. Some of these conditions are described in the
following points
Max.6 dedusting points should be connected to one common filter

Calculate the dedusting airflow for each dedusting point and duct
Calculate the air flow for the complete dedustiong pipe system
Determine the pipe sizes from the air flows
Choose the auxiliary equipment- throttle valves,ventilation flaps, filter, fan and
insulation-,based on the dedusting air volumes and other data such as Barometric
pressure , temperature and humidity

The maximum allowed filtration velocity depends on the flow resistance of the bag pulse
filter cake and the cleaning ability of the filter bag and of course on the cleaning method.

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The pressure difference (p) across the filter bags increases: if higher the filtration velocity,
thicker the filter cake (residual dust layer after cleaning) and the quicker it builds up (dust
load time/cleaning interval) , higher the Blaine value of the dust (the finer the dust) the more
compressible or sticky the dust (important for AFR usage) the older the bags (due to
penetration of fine dust particles into the fabric) false air ingress via the worn out rotary air
lock , worn out filter body ( this causes dust entrainment also)

Table: 1.1: Baghouse Inspection and startup checklist

1. Visually inspect:
Structural connections for tightness
Duct flanges for proper seal
Filter bags for proper seating in tube sheet
Dampers for operation and sequence
System fan, reverse-air fan, and conveyors - check for proper rotation
Electrical controls for proper operation
Rotary valves or slide gates for operation
2. Remove inspection door and check conveyor for loose items or obstructions.
3. Adjust ductwork dampers - open or at proper setting.
4. Remove any temporary baffles.
5. Test horn alarm system, if included, by jumping connected sensors.
6. Start screw conveyors and check for proper operation.
7. Start reverse-air fan, if included.
8. Start system fan.
9. Log manometer and temperature (if appropriate) readings at 15-minute intervals; log
readings.
10. Check to see that reverse-air dampers are cycling.
11. Adjust pressure drop cleaning initiation switch, if included.
12. Determine system air volume and adjust dampers, as required.
13. Check cell plates for dust leaks.
14. Check to see that dust is being discharged from hopper.

Table: 1.2: Baghouse Monitoring Devices

Parameter
Pilot lights

Method of Measurement
Electronic on/off signals

Temperature indicators

Thermocouple

Pressure drop

Manometer, magnehelic
photohelic gauges

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Function
Show
motors
operating,
compartments on- or off-line,
number of bags being pulsed,
etc
Alert operators of high or low
temperature conditions.
or Determine pressure drop of
various points in the baghouse
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Opacity

Transmissometer or visual
observation

Gas flow

Calibrated orifice (pitot tube)

or an installed flow monitor
using an ultrasonic, thermal,
or pressure differential
measurement technique
Ammeter

Fan motor current

(amps)

- across each component or

the entire baghouse
Indicator of potential
problems. Also,
broken bags can be located by
isolating each compartment to
determine which one causes
the high opacity
Indication of process change

Indication of gas flow and

early warning signs of
potential fan failure if fan is
not operating at design levels.

Daily Maintenance
1. Check pressure drop.
2. Monitor gas flow rate.
3. Observe stack outlet visually or with a continuous monitor.
4. Monitor cleaning cycle, pilot lights, or meters on control panel.
5. Check compressed air on pulse-jet baghouses.
6. Monitor discharge system; make sure dust is removed as needed.
7. Walk through baghouse to check for normal or abnormal visual and audible conditions.

Weekly Maintenance
1. Check all moving parts on the discharge system including screw-conveyor bearings.
2. Check damper operation; bypass, isolation, etc.
3. Spot check bag tensioning for reverse-air and shaker bags.
4. Check compressed air lines including line oilers and filters.
5. Blow out any dust from manometer lines.
6. Verify temperature-indicating equipment.
7. Check bag-cleaning sequence to see that all valves are seating properly.
8. Check drive components on fan.

Monthly Maintenance
1. Spot check bag-seating condition.
2. Check all moving parts on shaker baghouses.
3. Check fan for corrosion and blade wear.
4. Check all hoses and clamps.
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5. Spot check for bag leaks and holes.

6. Inspect baghouse housing for corrosion.
Quarterly Maintenance
1. Thoroughly inspect bags.
2. Check duct for dust buildup.
3. Observe damper valves for proper seating.
4. Check gaskets on all doors.
5. Inspect paint on baghouse.
6. Calibrate opacity monitor.
7. Inspect baffle plate for wear.
Annual Maintenance
1. Check all welds and bolts.
2. Check hopper for wear.
3. Replace high-wear parts on cleaning system.
Baghouse Performance monitoring: If a baghouse is operating properly and to aid in
troubleshooting when failures occur, the operator must monitor certain operating parameters.
Routine monitoring of key parameters, either on a continuous or periodic basis, is imperative for
performance evaluation and problem diagnosis. An adequate baseline must be developed to
determine when future changes in performance occur. Some typical parameters that are
monitored are: inlet and outlet gas temperature (only on units operated above ambient
temperature), pressure drop, opacity, and gas velocity. In addition to these parameters that can be
routinely measured, it can be important to periodically evaluate the chemical composition of the
gas stream, including moisture, acid dew point, and particle loading and size distribution. The
following describes how the above parameters affect performance and the techniques used to
measure each. In addition, there is also some common auxiliary equipment that should be
monitored or periodically checked. These include receiver air pressure, bag tension, fan
amperage, and high hopper level.

1.6 Trouble Shooting

Excessive pressure drop across filter bag: The differential pressure gauge or manometer on
your dust collector should read 6 w.g. or less. Higher readings and /or steadily increasing
readings will result in the reduction of the main air flow through the dust collector which may
produce a potential process problem such as poor suction through the evacuation control system.
In extreme cases (over 10 w.g.) filter elements will be damaged. Check the following:
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1.0 Differential Pressure Gauge Operating - check the differential pressure gauge and the
tubing leading to the dust collector. Disconnect the lines at the gauge and clear with
compressed air. Look for loose fittings, cracked, broken or pinched tubing. Make sure that
gauge is zeroed.
2.0 Pulsing System- inspect the compressed air cleaning system as follows, to make sure that
the entire filter bags are being pulsed clean.
(i)
If none of the solenoid valves are operating, check the timer.
(ii)
Check the air the air pressure at the header; it should recover to 90-100 psig before
each pulse. If not, check to make sure that the compressed air supply system is in
good operating condition, correctly sized, and supply lines are not too small or
restricted. Listen for the sound of compressed air flowing continuously through one
or more rows of bags; an indication of a valve or valves stuck in the pulsing
position. The usual causes for this condition are leaks in tubing to solenoid pilot
valves, and dirt in the solenoid or diaphragm valves.
(iii) Check that all solenoid pilot valves are firing in sequence by holding a finger over
each solenoid exhaust port as described earlier.
1.0 Water or Oil in Compressed Air - inspect upper portions of the filter bags for dust caking,
dampness, or oil. Any or all of these symptoms are indications of moisture or oil in the
compressed air supply. Install equipment that will ensure a continuous supply of clean, dry,
oil-free compressed air. See your compressor supplier for recommendations.
2.0 Bags Loaded with Dust- a condition known as blinding. If the dust is dry, see Paragraphs A
thru D; if the dust is wet, see Paragraphs E and F.
A. Dust Not Discharging from the Hopper - check hopper for overloading or bridging
across the dust discharge. Correct by repairing dust discharge equipment, replacing with
higher capacity equipment, or installing hopper vibrators, etc., as required to keep the
hopper clear. Never store material in the hopper.
B. Air Flow Too high if the main air flow is too high to allow dust to drop off of the
filter bags, an excessive pressure drop across the dust collector will result and dust will
build up in the system. In many cases, this high pressure drop in turn leads to a reduction
in the main air flow, so that it is necessary to remove the dust accumulation from the
bags (and the rest of the system) before measuring the main air flow volume.
Visually inspect the bags for heavy caking. If caking is evident, see the note below and
take the necessary action to clean the bags. Next, measure the main air flow with a pitot
tube or equivalent device and compare with the original volume for which the unit was
designed. If the flow is too high, cut back the main fan to prevent a recurrence of the
problem.
C. Particle Size and Dust Load - if possible, compare the dust particle size and loading
with the original design specifications. Finer dust may cause a higher pressure drop. Do
not hesitate to call us if you need to discuss further this potential problem.
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D. Filter Bag Dimensions Changed Chemical cleaning or washing the filter bags may
alter the dimensions which could cause the bags to not properly fit on the support cages.
If the bags are not correct dimensionally, insufficient flexure, during the cleaning cycle,
can result, which will reduce the force required to loosen the caked dust.
E. Water Leaks - inspect the dust collector housing and ductwork for holes, cracks, or
loose gasketing where water could enter the collector.
F. Condensation if moisture has been condensing inside the collector, check the dew
point temperature of the incoming air stream. It may be necessary to insulate the
collector and/or the ductwork leading to the collector to keep surface temperatures above
the dew point and prevent condensation on the filter bags.
Note:- Collectors that have had blinded or caked bags can possibly be put back into service
by first running the pulsing air system for 15 to 30 minutes with a 3 second off time
setting and without the main fan or blower operating. If the pressure drop is not lower when
the main fan is started again, the bags must be changed.
Extremely low pressure drop: In addition to inspecting the filter bags for proper installation or
holes or tears, the following items should also be considered:
1.0 Pressure Gauge working - check the differential pressure gauge and the tubing leading to
the dust collector.
2.0 Ductwork, Dampers inspect the ductwork to and from the dust collector for air leaks or
blockage. Make sure that any dampers in the system are correctly positioned to allow air to
flow through the dust collector.
3.0 Leaks in the Housing check the tubesheet and the dust collector housing for holes, cracks
or loose gasketing that would permit air to bypass the dust collector or filter bags.
Primary (Continuous) dusting: A continuous flow of dust out of the exhaust of the clean air
plenum is considered a primary dusting problem. Other causes of this condition are as follows.
1.0 Holes in the Filter Bags or Bags incorrectly installed - inspect the filter bag assemblies for
holes, rips, tears, or excessive wear. Make sure that the filter bags were installed correctly
and that no bag/cage assembly has dropped off.
2.0 Check the tubesheet for holes, cracks or loose bolts that would permit dusty air to bypass the
filter bags.
3.0 If primary dusting is noted, the problem should be investigated immediately. Dust in the
clean air plenum can be blown back into the bags during the pulse cleaning. The dust can be
extremely abrasive and could seriously abrade holes in an entire set of bags in a very short
time.
SECONDARY (INTERMITTENT) DUSTING
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Puffs of dust that are noted in the exhaust of the clean air plenum after each cleaning pulse is a
secondary dusting problem. This condition is normal with new filter bags, and should stop after
the first several hours of operation. Other causes of this condition are as follows:
1.0 Air Header Pressure Too High - check the air header pressure gauge. If the pulsing air
pressure is over 100 psig, filter bags may be flexing excessively and allowing fine dust to
pass through the bag material.
2.0 Worn Filter Bags inspect the filter bags for wear. Thin bags may not stop fine dust when
flexed by a compressed air pulse.
3.0 Residual Dust - if dust has gotten into the clean air plenum because of a dropped or torn
bag, hole in tubesheet, etc., the pulsing air may stir up the dust and allow it to escape into the
clean air exhaust after each pulse. Residual dust may also be driven down inside the filter
bags by the pulsing air. If the filter bags are filled with several inches of dust, clean both the
clean air plenum and the bag/cage assemblies to avoid further problems.
SHORT LIFE OF FILTER BAG
This is often a complicated problem to diagnose, and we recommend that you call the supplier
for advice. The following list may be helpful in performing some preliminary checks:
1.0 Temperature operating the gas temperature above the recommended limit of the filter bag
material.
2.0 Chemical Attack the filter media can degrade due to attack from certain chemicals in the
dust or gases in the air stream.
3.0 High Moisture - high moisture content in the collector may cause certain filter bag materials
to shrink or degrade. The process will be accelerated at elevated temperatures.
4.0 Localized Abrasion premature bag wear can occur near the tops of the filter bags if the
bag and cage assemblies have been installed improperly or if an accumulation of dust on the
clean side of the tubesheet has developed which may abrade the elements during the pulsing
cycle. Localized abrasion can also occur near the bottom of the filter bags in the vicinity of
the dust gas inlet. If this situation exists, an inlet baffle may be required to deflect the
incoming gas stream if one does not already exist.
5.0 Cage Deterioration corroded, rusted or broken filter bag cage assemblies can cause
excessive bag wear. Stainless steel or coated cages are available.
6.0 Filter Bags Rubbing premature wear can occur if the bags are found rubbing against each
other or against one of the interior walls of the unit.

1.7 Types of Bag Filter

Baghouse classification depends on the cleaning method used of the bagfilter cleaning. The three
most common types of baghouse are:
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1.0 Machanical shakers,

2.0 Reverse gas &
3.0 Pulse jet
*In pellet plant 1 & 2 all installed bagfilter is pulse jet type.
Baghouse Filter Media selection: Filter media selection is the important steps of design
criteria for increase the life span of the Bag filters media & Performance. The following
parameters are considered for baghouse filter media selection.
Temperature of the gas /air, material- filter beings used for, Chemistry- filter withstands the
chemical makeup of the dust particles.
Resistance- Is the filter media able to resist the abrasion of the dust particles
Choosing the correct filter media is an important and sometimes difficult process. To assist you
in the identification of the right media for, keep the following in the mind: Filter bag
performance is directly related to how well it can tolerate the environment in which it is being
used. How efficiently it can remove the dust particles from its fabric and its ability to be cleaned
by the dust collector is also important. You must first learn to identify the type of filter media
currently used your application. Below you will find a list of typical construction methods.
Dedusting plants may be divided into the following components.
A. Equipments to be dedusted
B. Dedusting pipes and valves
C. Filter
D. Fan and motor
E. Insulation

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