Andres Biancotti

Case Study – Expansion at Sunshine Minting

Background

Sunshine Minting, a global supplier and processor of precious metals, was looking to upgrade their dust collection system to support new melt lines and future expansion. Their existing small collectors were inadequate for the increased capacity and airflow requirements.

Scope of Work

Sunshine Minting needed a dust collection solution with sufficient capacity and airflow to handle their expanding operations. Additionally, they required improvements in ductwork to connect both new and existing processes to the new system. A spark trap was necessary to mitigate the fire risk from sparks traveling through the ductwork into the collector. Additionally, flame resistant filters were used for extra protection.

Solution

Baghouse.com responded to Sunshine Minting’s needs by dispatching a technician for an on-site inspection. The technician documented the facility layout, the proposed location for the new collector, and the new ductwork configuration. Following this, we installed an ACT 4-48 cartridge collector with a 20,000 CFM fan, a 50 HP motor, and a VFD control panel. A Boss Products Raptor Shield 22″ spark arrestor was also installed, along with connecting ductwork throughout the facility. The turnkey installation included programming of the VFD and airflow measurements to confirm adequate airflow and pressure at pickups and ducts.

What is a VFD?
It stands for Variable Frequency Drive, and is a type of fan controller. A VFD allows the user to run their dust collector fan at a lower or higher rate to manage performance. Rather than simply flipping a switch and running your fan at full speed (think 40kW per hour), the fan motor will run at a lower rate, saving significant energy costs in the long run.

Installation Challenges

Placing the new collector and fan without interfering with existing condensers and other equipment was a challenge. To overcome this, the inlet duct was routed up and over the area, and the fan exhaust was directed away from the facility as requested by the customer. These minor layout modifications are common and easily accomplished with a proper design and layout review.

Outcome

The installation of the modern cartridge-style collector has provided Sunshine Minting with sufficient fan and filter capacity for current processes, and extra capacity for future expansion. The VFD controller on the fan improves power efficiency and allows for easy adjustment to accommodate future changes. The MERV 15 rated nano media filters, upgraded with flame retardant treatment, ensure maximum safety from sparks or hot coals.

Sunshine Minting now enjoys enhanced dust collection efficiency and safety, with the system’s additional capacity supporting their ongoing and future operational growth. The improved power efficiency and safety features represent a significant upgrade from their previous setup.

Conclusion

Baghouse.com successfully addressed Sunshine Minting’s dust collection needs with a comprehensive solution that supports their expanded operations and future growth, enhancing both safety and efficiency in their facility.

Would you like to know how a technical inspection and a system report by Baghouse.com could improve the efficiency of your operations?

Talk now with one of our baghouse experts for more information!

July 24, 2024/by Andres Biancotti

Baghouse Accessories

What is a HEPA After-Filter and When Do I Need One?

In the search for cleaner indoor air, many industries face the challenge of maintaining optimal air quality within their facilities. One effective solution is incorporating a dust collection system equipped with a High Efficiency Particulate Air (HEPA) after-filter. Let’s review some of the most frequent questions regarding this type of filter.

Question: How Is a HEPA filter made?

Answer: HEPA filters are made from polyester, polypropylene, or fiberglass fibers that are tightly interlaced with diameters of less than one micron. The fibers are twisted, turned, scattered, and randomly placed in different directions to create a mesh maze without a straight through path. The openings between the fibers are smaller than a half micron, which is why HEPA filters can catch particles smaller than 0.3 microns.

Question: How Does a HEPA After-Filter Work?

Answer: When a dust collector draws in dirty air and dust particles, the primary filters capture larger particles while allowing cleaner air to pass through. However, ultrafine particulates may still escape through the primary filters. Here’s where the HEPA after-filter comes into play. Positioned on the clean air side of the unit, the HEPA after-filter acts as a secondary filtration stage, capturing even the tiniest microscopic particles before the air is returned to the facility.

Question: How is a HEPA filter different from regular filters?

Answer: The main difference between a HEPA filter is that it is made of thin fibers of glass and activated carbon-based materials. Regular filters are made of porous materials like cotton, paper sheets or polyester. Most importantly, HEPA filters offer much higher filtration efficiency (MERV 16 or higher) compared to a standard fabric filter.

Question: When Do I Need a HEPA After-Filter?

Answer: Consider incorporating a HEPA after-filter in the following scenarios:

— If your process generates fine particles that pose health risks or can contaminate products.
— When regulatory or industry standards demand exceptionally high air quality.
— If the collected dust contains hazardous materials, allergens, or carcinogens.
— When you aim to recirculate filtered air back into the facility, necessitating cleaner air to improve indoor air quality.

Question: Does a HEPA After-Filter Help Against COVID-19?

Answer: Yes. By incorporating a HEPA after-filter into your dust collection system, you can significantly reduce the risk of airborne transmission of the virus within your facility. While other safety measures like social distancing and mask-wearing are essential, purifying the air with a HEPA filter adds an extra layer of protection.

Question: What Does it Cost to Add a HEPA After-Filter?

Answer: First, the size and quantity of HEPA filters for your system will depend on the airflow of your system. Each HEPA filter is sized for a specific airflow, and multiple filters may be required to meet the required airflow and static pressure requirements of your system. Once the quantity, size, and type of HEPA filter is determined, a HEPA filter housing is needed to house the filters, along with ductwork to connect your HEPA filters to your existing dust collection system, and route clean air to the desired location. A Baghouse.com dust collection specialist can help you size and spec out a HEPA after-filter and provide a quote for your project.

In conclusion, a HEPA after-filter serves as a powerful ally in the ongoing battle for cleaner indoor air quality, particularly in industrial settings. Baghouse.com can provide expert guidance in selecting the right HEPA filter and offer comprehensive support from installation to maintenance.

Do you have any additional questions regarding the HEPA filters? Contact us today to discover how we can enhance your dust collection system with HEPA filtration.

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For more baghouse related training and information, be sure to check out our Baghouse Training page.

July 19, 2024/by Andres Biancotti

Dust Collector Maintenance

How to Measure Your Baghouse Filters & Cages

When ordering replacement baghouse bag filters, it is extremely important that you order the right size to ensure a proper fit in your baghouse.

Properly fitting bags and cages are integral to achieving long filter bag life and optimum baghouse performance. Filter bags come in a huge variety of sizes and types, to fit many makes and models of baghouses.

Measuring Filter Bags & Cages - Key Terms

Flat Width/Diameter

This is the most critical measurement, and the one people most often get wrong. As we need this size correct down to a ⅛”, it is not possible to measure the diameter of a loose bag accurately enough for ordering. For that reason, we instead rely on a flat width measurement, which we can then convert to an accurate diameter.

Overall Length

For top load pulse jet bags, the bag is the same length as the cage or just 1⁄2” longer. For bottom load pulse jets, where the top of the raw edge bag is folded over the top of the cage, we recommend 4” of overlap, but some OEMs recommend 2”.

Tubesheet Hole Size/Snap Band Size

Often the hardest dimension to confirm, a hole size measurement accurate down to 1/32” is required to ensure proper fit. For best results, measure the hole with calipers or check the OEM drawings for details. Alternatively, you can send a sample bag to confirm the tubesheet hole size or have us make a sample bag/cuff to test fit before releasing the entire order to production.

Size Draft/Accurate Specifications

While it is usually possible to rely on previous bag sizing when reordering, at times, there may be reason to reconfirm all bag and cage sizing choices. Over time, sloppy or copy errors can result in slight variances in sizing making their way into orders and company records. In this way, the original bag sizing can see a slight, but impactful creep over successive orders.

When we suspect this has happened, we may ask you to go back and provide us with the fundamental component sizing that dictates the overall bag and cage sizing. For top load pulse jet, reverse air, and many shaker units this is the tubesheet hole size. For bottom load pulse jets, and some reverse air/shaker units, it is the mounting hub/venturi.

Once we have this fundamental sizing information, we can then recommend the proper bag and cage sizing.

Bag/Cage Fit or “Pinch”

Filters that are too loose or too tight on the cages will severely limit collection efficiency and lead to premature failure. For most felt bag materials (polyester and aramid/nomex being the most common) we generally recommend ¼” to ½” of pinch, meaning the bag diameter is that much larger than the cage. Other specialty fabrics such fiberglass, P84, and fabrics with PTFE membrane applied to them may require tighter tolerances.

Number Cage Vertical Wires and Horizontal Ring Spacing

Proper care must be taken to ensure that the cage construction will properly support the filter bag as well as optimize cleaning and efficiencies. Most fabrics work well with using cages with 10, 12 or 14 vertical wires. However, some specialty fabrics such fiberglass, P84, and fabrics with PTFE membrane applied to them require the additional support of 20 wire cages and possibly tighter spacing on the horizontal rings.

Common Bag and Cage Size Combos

Below we have listed a few common sizes for pulse jet and reverse pulse systems in use today.

Top Load Style

—Bag: 6.25” x ¼” tubesheet hole, 5.875” diameter x 96”/120”/144” long, snap band top, disk bottom – Cage: 5.625” diameter x 96”/120/144” long, turned down flange top (with or without integral venturi), pan bottom, 12 vertical wires, horizontal rings on 8” centers
—Bag: 6.25” x ¼” tubesheet hole, 6” diameter x 96”/120”/144” long, snap band top, disk bottom – Cage: 5.75” diameter x 96”/120/144” long, turned down flange top (with or without integral venturi), pan bottom, 12 vertical wires, horizontal rings on 8” centers
—Bag: 5” x ¼” tubesheet hole, 4.625” diameter x 96”/120”/144” long, snap band top, disk bottom – Cage: 4.5” diameter x 96”/120/144” long, turned down flange top (with or without integral venturi), pan bottom, 12 vertical wires, horizontal rings on 8” centers

Bottom Load Style

—Bag: 5.865” diameter x 100”/124” long, raw top, disc bottom – Cage: 5.625” diameter x 96/120”” long, split collar top, pan bottom, 12 vertical wires, horizontal wires on 8” centers (Flex Kleen style bottom load)
—Bag: 4.625” diameter x 100”/124” long, raw top, disc bottom – Cage: 4.5” diameter x 96/120”” long, split collar top, pan bottom, 10 vertical wires, horizontal wires on 8” centers (Mikropul bottom load and “twistlok” style)

Measuring Filter Bags - Step-By-Step

Top Load, Snap Band Filter Bag

Flat width/Diameter

Lay the bag out on a table or floor, flatten it completely.
Use a tape measure or ruler and measure the width across the bag.

Length

Measure along the seam running the length of the bag. Start at the center of the snap band and end at the first stitch at the bottom of the bag.

Cage-to-Bag (Bag-to-Cage) fit

Should have ¼” to 3/8” pinch; the bottom of the bag should have about a thumbs width between the bottom of the cage and the disc bottom of the bag.

Top Load, Snap Band Filter Bag – Woven Fiberglass

Flat width: Flatten bag and measure width across.
Length: Measure along the seam running the length of the bag. Start at the center of the snap band and end at the first stitch at the bottom of the bag.
Cage-to-Bag (Bag-to-Cage) fit: Should have 1/8” or less pinch, but shouldn’t be stretched tight around the cage.

Top Load, Snap Band Filter Bag – Felt with membrane

Flat width: Flatten bag and measure width across.
Length: Measure along the seam running the length of the bag. Start at the center of the snap band and end at the first stitch at the bottom of the bag.
Cage-to-Bag (Bag-to-Cage) fit: Should have 1/8” or less pinch, but shouldn’t be stretched tight around cage.

Shaker style Filter Bag

Flat width: Flatten bag and measure width across.
Length: Measure along the seam running the length of the bag. Start at the end of the snap band to the end of the bag, not including the tail.
Length of the tail: Measure along the seam from the end of the bag to the end of the tail
Flat width of the tail: Flatten tail and measure width.
Determine if the tail is 3 ply or 4 ply by pinching the material and feeling for layers.
If there is a wear cuff at the snap band end of the bag, measure length and width.

Measuring Cages - Step-By-Step

Full length of the cage: Measure from top to bottom.

2. Diameter: Measure diameter in the middle of the cage at the widest point between wires. Ideally, using a Pi Tape to determine circumference will yield a preferred measurement.

Be aware that some OEMs make the bottom pan slightly smaller than the cage body to make it easier to insert the cage into the bag. This is why you should always measure the diameter near the middle of the cage.

3. Bottom construction: Determine if the bottom cup is crimped or if the wires are welded to the cup.

4. Number of rings: Count the number of rings.

5. Space between rings: Measure the space between the rings. Note: the space between the last ring and the bottom of the cup may be different.

6. Number of vertical wires: Count the number of vertical wires running the length of the cage.

7. Material: Plain steel, galvanized, coated, 304 stainless steel, or specify if it is some other material.

8. Determine the top construction of the cage:

- — If the top has a venturi, measure the length of the venturi.

- — If the top has a split top, measure the space between the groove in the split top and the end of the top

Another important measurement to have in mind when ordering filters or cages, is the size of the tube sheet hole where our filters will be placed. This will ensure there is a perfect seal, extending the life of the filters and not allowing dust to go through.

With a wide range of sizes and types available, it’s essential to select the right filter bags and cages to suit your specific dust collector model. Following these basic steps will help you make informed decisions when ordering replacements, ensuring smooth operation and extended filter bag life for your dust collection system.

Another option to find out the right size of your filters and cages is to send us a used filter or cage so we can measure it for you. Feel free to get in contact with us if you prefer this option and we will be happy to assist you.

If you need assistance with measuring filters or cages, please reach out to one of our experts clicking below:

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For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

May 30, 2024/by Andres Biancotti

Dust Collector Troubleshooting

The Benefits of Leak Testing for Dust Collection Systems

Even the most efficient and well-maintained dust collection systems will occasionally experience leaks, compromising their effectiveness and putting worker health at risk. A mere ⅛” hole in a single filter bag out of 1000+ bags can cause a system to fail a stack test. This is why implementing effective leak detection strategies is crucial.

A stack test, also known as a performance test or compliance test, measures the emissions from industrial stacks or ducts. While visual checks were common in the past, many facilities now use continuous monitoring systems for more reliable and less labor-intensive measurements. Visual observations still serve as a valuable backup method.

Conducting a dye test is not only for filter bags that have been in operation for an extended period of time. Newly installed ones can (and should) also undergo leak testing. It’s crucial to safeguard your investment in filter bags by performing a dye test on the dust collector after replacing filter bags.

How Leak Testing Is Done

Identify an injection port on the negative side of the gas stream closest to the baghouse inlet for injecting the fluorescent dye powder. (Note: Avoid using hopper doors for injection as it disrupts airflow and may leave some filter bag areas uncoated with dye powder.)
Ensure that the baghouse/compartment hopper is free of any accumulated material.
Deactivate the baghouse cleaning mechanism while keeping the exhaust/ID fan operational.
- —For Pulse Jet Dust Collectors, shut off and lockout the main airline feeding the cleaning system and release all air pressure from the header.
- —For Mechanical Shaker or Reverse-Air Systems, de-energize and perform a LOTO on the appropriate electrical and pneumatic devices.

Tip: Shutting down the shaking or pulse cleaning mechanism for a short period before inserting the leak testing powder will enhance detection results. This allows the dust cakes to build-up, increasing the pressure between the dirty and clean air sides of the baghouse, encouraging the leak testing powder to find the points of least resistance – the leaks.

4. Inject an appropriate amount of fluorescent dye powder into the system based on your baghouse design and application. A general rule of thumb is to use 1 lb of powder for every 1,000 sq/ft of fabric area. For smaller units, a higher ratio is needed.

Leak testing powder can be used in all baghouse types with operating temperatures up to 550°F (288°C). It is important to choose an appropriate color for your specific application, as well as keeping a contrasting color on-hand for repetitive test. The objective is to choose a color that will not blend in with process dust color.

5. Allow up to five minutes for the leak detection powder to circulate through the system after injection.
6. Shut down the exhaust/ID fan.
7. Before entering the baghouse, ensure compliance with all OSHA/MSHA and site-specific company protocols, including LOTO and Confined Space Entry.
8. Enter the clean air side of the baghouse or compartment being tested. Use a black light and UV filtering glasses to inspect the tubesheet, filter bag, snap band/seating surface, and all other areas on the clean air side of the collector that come into contact with the inlet gas stream. Any leaks will cause the fluorescent dye powder to “glow” under the black UV light, pinpointing the affected area. For optimal results, perform the dye test in darkness with minimal light. (On rare occasions, it may be necessary to also inspect the filters from the dirty side as well to locate hard-to-find leaks.)
9. Document all filter bag failures on a grid sheet and retain them for future reference. Recurring bag failures in the same area may indicate dust collector system design or operational issues.

Benefits of leak testing for dust collection systems

1. Maintaining Compliance with Environmental Regulations: Governments have stringent air quality standards in place to protect the environment and public health. In many industries, once a leak becomes large enough to create visual emissions at the stack, companies are required to document and report corrective actions and possibly face fines and sanctions. By being proactive with leak testing and promptly repairing any found, an organization can demonstrate its commitment to environmental responsibility, helping them stay within compliance and avoid fines.

2. Protecting Worker Health and Safety: This is most crucial with systems that recirculate the air after it passes through the dust collector. Dust particles generated during industrial processes often contain toxic compounds or otherwise benign materials that are harmful when inhaled. Additionally, leaks on systems handling combustible dusts can lead to accumulations in the ductwork, process equipment, and on elevated surfaces inside the plant (when recirculated), all of which form a severe fire and/or explosion hazard.

Plants that recirculate the air back into the building are often required to install triboelectric bag leak detection systems. These systems are sensitive enough to detect even minute increases in dust emissions. When installed, they can give early warning about leaks as they form, even before they reach reportable levels. For this reason, many plants find triboelectric bag leak detection systems useful even when their use is not strictly mandated by their operating permits or OSHA.

3. Enhancing Equipment Efficiency and Longevity: Leaks in dust collection systems can impact the overall efficiency and performance of many types of process equipment. By proactively identifying and repairing leaks, industries can ensure that their systems operate at optimal efficiency, reducing energy costs, extending equipment lifespan, and minimizing maintenance costs.
4. Preventing Cross-Contamination and Product Loss: In industries where contamination control is critical, leak detection becomes crucial. Leaks in dust collection systems can introduce foreign particles into the production area, compromising the quality and safety of the final product.

If you believe your dust collection system may be suffering from leaks, consider conducting a dye test or contacting professionals like Baghouse.com for assistance. Remember, the benefits of leak testing far outweigh the risks associated with system failures. Protect your workers, your environment and your investment by making leak detection a priority in your maintenance program.

Want to read more about leak testing? Read the article:

Filter Bags & Leak Testing – How Important is it?

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For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

May 29, 2024/by Andres Biancotti

Dust Collection 101

A Brief History of Dust Collectors

Dust collection began during the late 1800s Industrial Revolution in the US, spurred by the rise in manufacturing and the oil industry, which generated increased waste like sawdust, coal dust, and chemicals. This waste polluted the air near factories, leading to health concerns. To tackle this, dust collectors were invented.

The First Dust Collector

The first dust collector is subject to debate, with some attributing it to Wilhelm Beth for his filter-based design, while others credit John Finch for his Cyclone Dust Collector introduced around 1885. Cyclones became popular by 1900 for their effectiveness in collecting coarse dust, and they’re still used today. Operating on centrifugal force, cyclones create a vortex that separates dust from air, depositing it into a collector while letting filtered air out.

The Shaker Dust Collector

In the mid-1920s, a significant advancement in dust collection emerged with the invention of the Shaker Dust Collector by Wilhelm Beth in Germany. Wilhelm introduced a baghouse unit connected to machines via ductwork to collect sawdust and similar materials. The filter elements in this system are self-cleaned using a vibrating motor attached to the frame, which shakes the filter bags to dislodge accumulated dust.

Over time, the design of the Shaker Dust Collector was refined, incorporating better filters capable of capturing smaller particles while maintaining optimal airflow and efficiency. Although still in use today, Shaker Dust Collectors have declined in popularity due to their relatively low air-to-cloth ratio and large footprint, which demands considerable space.

Cartridge Dust Collector

In the early 1970s, the dust collector saw another evolution with the introduction of the cartridge collector. This innovation replaced the fabric in baghouse filters with cartridge media, offering finer filtration. Capable of efficiently filtering particles as small as 0.3 microns, cartridge collectors excel in removing fumes from the air.

New Dust Collection Options

In the mid-1900’s, environmental regulations became more common and major polluters came under pressure to clean up the massive amounts of dust they generated. Shaker bags and basic fabric filters could not handle the task.

Reverse air baghouses were invented around this time, shortly followed by pulse jet baghouses. These provided tremendous improvements in dust collection by setting up an arrangement of filtration bags that could be cleaned by fans or compressed air pulses instead of shaking. These methods kept the bags cleaner and increased the efficiency of the filters.

The invention of baghouses brought a new era in the history of dust collection. Both types of baghouses are still in use today, and they continue to work well. They are especially useful in applications with high temperatures and high humidity. Bags are now made of a wide variety of materials specialized for different needs.

The Future of Dust Collection

As technology continues to evolve, the future of dust collection holds exciting possibilities. Integration with smart devices and cloud-based platforms could enable remote monitoring and control of dust collection systems, empowering operators to manage their systems with unprecedented efficiency and flexibility. Continued research and development efforts may unveil new methods and technologies to further improve dust collection performance, ultimately fostering safer and healthier work environments across various industries.

With ongoing technological advancements, the future holds the promise of even greater strides in optimizing dust collection systems for enhanced workplace safety and environmental stewardship. Here at Baghouse.com we are always researching and implementing the latest cut edge technologies, continuing to make history in dust collection.

Would you like to know how this technology can be applied to your application?

Contact Us to Speak to One of Our Baghouse Experts

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

May 17, 2024/by Andres Biancotti

Dust Collector Troubleshooting

Troubleshooting your dust collector pulse jet cleaning system

For a dust collection system to operate efficiently, the filter cleaning system must be designed, installed and maintained properly. The following troubleshooting basics are intended to help avoid common pitfalls. (Note: Think of these tips as your dust collector’s GPS – they won’t replace the regular check-ups, but when your collector decides to throw a fit and send you through a back road, you will be better prepared to come back on track without losing lots of time or resources…)

When issues arise, it’s essential to troubleshoot effectively. Start by asking, “What has changed?” It could be a worn component or a shift in the operating environment. Even adding a single pickup point can impact the entire system.

Key Steps for Troubleshooting

Check Differential Pressure (dP): Measure with a magnehelic gauge to assess filter media condition. A correct dP reading is vital for performance tracking. The dP across the filters should slowly increase as dust builds up on the filters, then suddenly decrease when the cleaning system fires a pulse of compressed air, cleaning the filter and reducing pressure across the filter.
Troubleshoot dP Gauge: As part of your periodic inspection process, remove the air lines connected to your dP gauge and ensure there are no obstructions or leaks in the lines. Replace old lines and ensure airtight connections. Even a small amount of dust in the gauge will lead to false readings or foul the gauge.
Listen for Problems: With the cleaning system active, listen to the pulse jets fire. You should hear a tight blast of air. If it sounds “off” – you hear a squeak, a rattle, a click but no air, etc. it is a sign that something requires attention. Most common issues are worn diaphragms (rattle or puff sound), leaks in connecting hoses (hiss sound), and stuck solenoids (a click but no air noise).
Check Compressed Air Pressure: Ensure your system has a compressed air gauge nearby so you can check it as part of your daily or weekly inspection. Review your equipment manual to ensure compressed air is set to the correct pressure. Ensure that your compressed air is clean and dry.
Timer Board Settings: Less common issues arise with the timer board, most often due to a surge in electricity or an unauthorized change in the board settings. If you have a ‘clean on demand’ setup, the pulse cleaning system will only fire when the dP reaches a high limit. Equally important is the low limit, where the cleaning shuts off. There are other settings that can be programmed on your control board such as On-Time and Off-Time that control how long the valves are open for and how long it waits between firing the valves. Once set, these should only be changed by authorized personnel. Most timer boards have indicator lights that will flag errors or basic issues. Refer to your equipment manual to ensure all settings are correct.

6. Other Common Pulse-Cleaning System Issues: Less common (but still important to know) issues include damaged or out of position blowpipes, stuck solenoids, water or oil in compressed air source, and electrical wiring issues.

When to Troubleshoot

High dP without filter life exhaustion is your first indication of a cleaning system malfunction. If the dP seems off, start by listening for the pulse valves to fire, then run through the items above to identify the issue.

Adjust Timer for Medium-Pressure Systems: Lengthen pulse intervals by adjusting the timer to fill the reservoir adequately. Check for leaks and loose connections before replacing components.

Beyond Cleaning System Issues:

Filter Inspection: Assess filter condition and look for moisture or caking issues.
Environmental Conditions: Consider variations in temperature and humidity, especially in colder regions.
Wear and Corrosion: Monitor aging systems, especially if handling abrasive or corrosive materials.
Human Factors: Be aware of unintended actions like shutting off compressed air or adjusting fan dampers.
Long-Term Monitoring: It is a good practice to monitor the system (specifically the dP) over an extended period to identify patterns or external factors affecting performance.

Hopefully, these tips will be able to guide you through unexpected challenges as a GPS, navigating the potential issues and ensuring your operations stay on track without losing valuable time or resources.

You haven’t found the problem yet? Did you find the problem, but you need assistance fixing the issue?

Talk to one of our dust collection experts, and they will be able to help you troubleshoot!

January 18, 2024/by Andres Biancotti

Cement and Construction Materials

Case Study: Dust Collection Optimization in Asphalt Production

Background

Baghouse.com collaborated with an asphalt plant facing some of the following challenges:

Coarse particles cause wear and tear on dust collection equipment and filter bags.
Fine asphalt dust presenting health risks and demanding specialized filtration methods due to varying material compositions.
Elevated temperatures creating difficulties such as dust adherence, cleaning, and the risk of fire and explosion.

Scope of Work

Baghouse.com implemented a comprehensive solution featuring a large top-load pulse jet baghouse.

Key components included:

Specialized filter media designed for abrasion and temperature resistance, ensuring effective dust collection and prolonged filter life.
Equipment and filter bags designed to withstand the abrasive nature of particles, minimizing maintenance costs.
Systems equipped to handle high temperatures, preventing issues such as dust sticking, enhancing cleaning efficiency, and minimizing fire and explosion risks.

Outcome

Implementation of effective dust collection not only ensured workplace safety but also controlled emissions harmful to health and the environment, like volatile organic compounds, particulate matter, and carbon monoxide.

Additionally, closed belt systems on aggregate conveyor belts and efficient dust filtering systems contributed to reduced dust emissions.

Conclusion

By combining high-quality filter media, abrasion-resistant systems, and temperature-resilient filtration, the client’s asphalt plant achieved increased efficiency, reduced maintenance costs, and ensured compliance with environmental and safety standards. This case study demonstrates the importance of specialized dust collection strategies in the asphalt industry to mitigate health risks, environmental impact, and operational challenges.

Would you like to know how a thorough technical inspection by Baghouse.com could improve the efficiency of your operations? Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andres Biancotti

Cement and Construction Materials

Case Study: Dust Collection Optimization in Gypsum Manufacturing

Background

A major gypsum manufacturer in Houston sought the expertise of Baghouse.com to address some challenges in their processing facility. Gypsum powder, a crucial material in construction, undergoes crushing, grinding, and other processes during its production.

Scope of Work

Gypsum manufacturing, especially in drywall production, contributed to environmental concerns due to particulate emissions and energy-intensive processes.

Baghouse.com provided and installed a new baghouse system equipped with a fan and optimized ductwork. The goal was to efficiently capture and control dust emissions throughout the 5 gypsum processing stages (crushing, screening, grinding, calcination, storage and transportation).

The design incorporated a closed circulation system with negative pressure, ensuring that the air path remained enclosed. To address the increase in air volume due to water content in raw materials and evaporation during grinding, a regulated air volume system was integrated.

Outcome

The implementation of a new baghouse system reduced particulate emissions during the grinding and processing stages, and greatly reduced energy costs.

Conclusion

Baghouse.com‘s tailored solution optimized dust collection for our client in Houston. This case study showcases the effectiveness of advanced dust collection strategies in mitigating environmental impact and enhancing the sustainability of manufacturing processes in the gypsum industry.

Would you like to know how a thorough technical inspection by Baghouse.com could improve the efficiency of your operations? Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andres Biancotti

Chemical and Pharmaceutical Manufacturing

Case Study: Dust Collection Enhancement in Chemical Manufacturing at Teknor Apex

Background

Teknor Apex, a leading player in the chemical manufacturing industry, faced challenges associated with airborne dust and chemical fumes, posing risks to air quality, worker health, and plant safety. Baghouse.com collaborated with them to address these challenges through the implementation of an advanced dust collection system.

Scope of Work

Everyday processes such as mixing, conveying, and blending generated hazardous airborne dust, creating potential fire and explosion hazards. Additionally, compliance standards for worker exposure limits, environmental regulations, and combustible dust standards demanded a comprehensive solution.

Understanding the unique dust issues related to chemical processes, we designed a system with high-efficiency primary and secondary cartridge filters. To prevent the dispersion of chemical fumes and dust, hoods and extraction arms were incorporated into their machinery to capture contaminants at their origin, minimizing their spread within the plant.

Considering the combustible nature of their dusts, NFPA-compliant safety components were integrated into the system, such as an explosion isolation valve, explosion vents, and an explosion-rated rotary valve to enhance plant safety.

Outcome

The source capture strategy not only enhanced efficiency but also minimized energy consumption, resulting in operational cost savings. NFPA-compliant safety measures provided Teknor Apex with robust protection against fire and explosion hazards, ensuring a safer working environment.

Conclusion

Baghouse.com‘s expertise in dust collection systems played a pivotal role in transforming Teknor Apex’s thermoplastics manufacturing facility. By addressing airborne dust hazards at their source and incorporating advanced safety features, the implemented system not only met compliance requirements but contributed to their overall operational efficiency.

Would you like to know how a thorough technical inspection and a system report by Baghouse.com could improve the efficiency of your operations? Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andres Biancotti

Woodworking

Case Study: Dust Collection System Upgrade for Gibson Guitars

Background

Gibson Guitars, a renowned name in the music industry, faced a critical need to upgrade the dust collection systems in their Bozeman, Montana, and Nashville, Tennessee manufacturing plants. The existing systems were outdated, with operational inefficiencies and lacked compliance with combustible dust safety regulations outlined by NFPA.

Scope of Work - Nashville, TN Plant

Having recently come under new management, Gibson Guitars embarked on a multiyear project to upgrade its dust collection systems at both its Nashville, Tennessee and Bozeman, Montana plants. The goal was to increase efficiency, reduce downtime, and improve the safety and environmental aspects of their systems.

First, Baghouse.com was contacted and asked to conduct a thorough audit of the existing dust collection systems at the Gibson USA plant in Nashville TN, in particular an outdated plenum pulse envelope baghouse that was in desperate need of replacement. The unit had suffered from years of neglect and was in poor physical condition, with large holes on the roof and sides of the unit. Additionally, the system had only partial protection against combustible dust hazards, which the plant wanted to address.

Taking into account their unique needs, we designed a complete dust collection system to meet the current production needs as well as providing for future growth. This included the installation of a new pulse jet style baghouse, a larger system fan, upgraded ductwork, and the integration of NFPA-required combustible dust safety equipment. To ensure compliance with NFPA regulations, explosion vents and an explosion isolation valve were strategically installed. Additionally, explosion-rated equipment, such as rotary valves, replaced non-compliant elements in the discharge system.

Scope of Work at Bozeman, MT plant

The situation at the Bozeman, Montana plant was somewhat different. This plant, which produces all of Gibson’s acoustic guitars, had an existing system that worked well, but that was far too small to account for increased production projections. The expansion of the facility was to take place in two stages: First, a new building was to be built while the existing building and production machines were to keep running. Once the new building was up, the layout of production machines would be completely reworked between the two buildings. Additionally, Gibson asked that the new system be designed and installed in such a way so as to not disrupt existing production and that the changeover be done with little to no downtime. The new system would also need to be able to transition into its expanded role once the facility expansion project was completed in several years.

With these challenging requirements, Baghouse.com set about engineering, supplying, and installing a new dust collection system that: (1) would provide for the current production needs, (2) be capable of nearly 3x capacity when the plant expansion was completed, (3) could be installed without disrupting production, and (4) meet or exceed existing best practice for combustible dust applications.

The solution proved to be a much larger multiple compartment pulse jet baghouse capable of handling 75,000 CFM+. The module (i.e. multiple compartment) style was used to provide additional redundancy and minimize downtime when conducting maintenance. Additionally, the system was outfitted with several protection devices to resolve combustible dust hazards such as high speed abort gates, spark detection, NFPA compliant rotary airlocks and explosion venting.

Importantly, during the design stage we proposed locating the new collector and fan adjacent to the existing baghouse so that it could be installed and brought online without decommissioning the existing system. When the switchover was to take place, we were able to simply extend the existing main trunk of the ductwork over to the new collector and connect the new return air ducting into the building through an enlarged wall penetration.

Eventually, once the new plant layout has been completed, a new, larger interior ductwork system will be installed and reconnected to utilize the full capacity of the new baghouse.

Thew system provides sufficient performance for the existing plant layout and stands ready to handle the estimated 3x increase in demand that will be needed once the plant’s expansion project is completed.

Conclusion

The upgraded dust collection systems led to improved operational efficiency, reducing downtime caused by maintenance issues and gained long-term reliability, reducing the need for frequent repairs and replacements.

Baghouse.com‘s expertise in dust collection systems proved instrumental in providing Gibson Guitars with a reliable, compliant, and efficient solution. These projects not only addressed immediate challenges but also positioned these woodworking facilities to handle the demand placed on them by Gibson’s sustained growth. Additionally, Baghouse.com’s ability to offer complete turnkey solutions allowed for the development of a comprehensive plan covering the collector, system fan, ductwork, combustible dust safety and installation processes so as to minimize production downtime during the changeovers.

We feel privileged to have been able to work with such a great company and to be part of their legacy as they continue to evolve to meet the needs of the 21st century musician.

Would you like to know how a thorough technical inspection and a system report by Baghouse.com could improve the efficiency of your operations?

Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andres Biancotti

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