Gravity Settler

The gravity settling chamber is probably the simplest and earliest type of dust collection equipment,
consisting of a chamber in which the gas velocity is reduced to enable dust to settle out by the action of
gravity.

Its cross-sectional area is much larger than that of the duct approaching it or leading the gas away from
it, so that the gas velocity inside is much lower than in either of those 2 ducts. Baffles of some kind are
used to spread the incoming flow evenly across the settling chamber. Without the baffles most of the
flow will go through the middle and poor particle collection will result.

The basic characteristics include:

very low energy cost

low maintenance cost

low installed cost

excellent reliability

Its use, however, is limited to the removal of large particles (larger than 50 micrometers in diameter). Its
collection efficiency can be classified as low to very low. To separate smaller particles would require
excessive horizontal flow distances, which would lead to excessive chamber volumes. It is an
unsophisticated device that must be cleaned manually at regular intervals. Gravity settlers have little
practical industrial use in pollution control because they are ineffective for small particles.

Cyclones

Cyclone separators or simply cyclones are separation devices that use the principle of inertia to remove
particulate matter from flue gases. Cyclone separators are part of a group of air pollution control devices
known as precleaners as they are generally used to roughly remove larger pieces of particulate matter.
This prevents more fine filtration methods from having to deal with large, more abrasive particles later
one. As well, several cyclone separators can operate in parallel, and when this is set up the system is
known as a multicyclone.

It is important to note that cyclones can vary drastically in their size. The size of the cyclone depends
largely on how much flue gas must be filtered, and thus larger operations tend to need larger cyclones.
For example, several different models of one cyclone type can exist, and the sizes can range from a
relatively small 1.2-1.5 meters tall to around 9 meters or about 30 feet.

How it works

Cyclone separators work much like a centrifuge, but with a continuous feed of dirty air. In a cyclone
separator, dirty flue gas is fed into a chamber. Inside this chamber exists a spiral vortex, similar to a
tornado. The lighter components of this gas have less inertia, so it is easier for them to be influenced by
the vortex and travel up it. Unlike these particles, larger components of particulate matter have more
inertia and are not as easily influenced by the vortex.

Because these larger particles have difficulty following the high-speed spiral motion of the gas and the
vortex, the particles hit the inside walls of the container and drop down into a collection hopper. These
chambers are shaped like an upside-down cone to promote the collection of these particles at the
bottom of the container. The cleaned flue gas escapes out the top of the chamber.

There are several advantages and disadvantages in using cyclone separators. First, cyclone separators are
beneficial because they are not expensive to install or maintain, and they have no moving parts. This
keeps maintenance and operating costs low. As well, the removed particulate matter is collected when
dry, which makes it easier to dispose of. Finally, these units take up very little space. Although effective,
there are also disadvantages in using cyclone separators. Mainly, the standard models are not able to
collect particulate matter that is smaller than 10 micrometers effectively and the machines are unable to
handle sticky or tacky material well.

Baghouse Filter

Baghouses, also called fabric dust collectors or fabric filters, are air pollution control devices designed to
use fabric filter tubes, envelopes, or cartridges to capture or separate dust and other particulate matter
(PM). Their applications range from small household workplaces to large industrial facilities such as coal-
fired power plants and cement plants.

Compared to other types of air pollution control (APC) equipment, baghouses are incredibly versatile
and can be engineered for almost any dust producing application by varying size and bag types. They are
very efficient when properly maintained and are also rugged enough to handle rough applications.
However, they typically require a lot of maintenance and a relatively dry environment to operate
effectively. Their use is also limited to certain operating temperatures and chemical conditions.

How does it work?

Baghouses consist of filter media (bags) suspended inside a housing or casing. Fans on the outside of the
housing blow the dirty or polluted air through the filters, capturing the suspended particulate matter
and solids on the bags and pushing clean air through the outlet. While filtering, a baghouse bag allows
the formation of a layer of particulate matter on its surface, called a dust cake. This dust cake continues
to build until the thickness reaches a level where flow is sufficiently restricted; at this point, the bags are
cleaned. Cleaning can be done during operation or offline depending on the type of baghouse.
Baghouse Design

Although the design of baghouses is typically the responsibility of the manufacturer, an understanding of
the most important design criteria is helpful for making an informed selection.

The air-to-cloth ratio is the most important criteria for baghouse design. It is defined as the amount of
air entering the baghouse divided by the total surface area of the filter fabric in the baghouse. This ratio
determines the airflow capacity of the baghouse, and must be optimized to balance the size of the
baghouse (capital costs) with the pressure drop (operating costs).

Cleaning Mechanism

Baghouses are primarily classified based on the methods they use for bag cleaning.

Types

There are three different types of baghouse cleaning mechanisms; each offers its own advantages for
different applications.

Reverse Air

Reverse air (R/A) baghouses use continuous streams of low pressure air to remove collected solids. Bags
are cleaned by backwashing (reversing the air flow) within a chamber after shutting off the dirty gas flow
and isolating the compartment. The recommended air to cloth ratio for these baghouses is between
1.75:1 and 2.5:1.

Advantages

R/A baghouses are typically compartmentalized, allowing sections to be cleaned without shutting off the
whole system.

Cleaning action is very gentle, which lengthens bag life.

Preferred for high temperatures due to gentle cleaning action.

Disadvantages

Cleaning air must be filtered.

Provides no effective means for removing residual dust buildup.

Requires more maintenance than other types due to dust re-entrainment on the bags.

Shaker
Shaker baghouses use mechanical shaking or vibrating actions to dislodge the filter cake. Bag bottoms
are secured to a plate and their tops are connected to horizontal beams. These beams, driven manually
or by a motor, vibrate to produce waves in the bags which shake off particulate matter. The
recommended air to cloth ratio for these baghouses is between 2.0:1 and 2.5:1.

Advantages

Design and operation simplicity.

Can be compartmentalized to allow sections to be cleaned without shutting off the whole system.

Disadvantages

Cannot operate in high temperatures.

More energy and time intensive than other cleaning methods.

Small amounts of positive pressure inside the bag can significantly reduce collection efficiency.

Large footprint and space requirements, and requires a large number of bags.

Bag Materials

The bag material or fabric media is an important part of baghouse design and selection, as it determines
the life and effectiveness of the filter bag. Fabric filter media must be compatible both physically and
chemically with the gas stream and system conditions. Selection of the correct bag material incorporates
these factors:

Particle size

Operating temperature of the baghouse

Compatibility with gas stream chemistry, including:

Moisture levels

Acidity or alkalinity

Electrostatic nature of the particles

Abrasiveness of the particles

Air-to-cloth ratio

Fabric's resistance to cleaning energy

Fabric's permeability to allow air to pass

Fabric's flexibility to allow rippling or stretching

Fabric cost

Bags can consist of one or a number of different materials. This chart from Filter Media Services, LLC.
provides an overview of the properties of some of these materials used in bag construction.