Fabric Dust Collector Systems Manual

Transport and Dust Collecting Manual
Version 1.08

Fabric Dust Collector Systems
Werner Flckiger
Leticia Nacif Flckiger
B1 (MPT 03/14902/E)
Holcim Group Support Ltd
CMS - Mechanical Process Technology B1/1
Version 1.08

Version 1.08

Table of Content
1. INTRODUCTION 4
2. TECHNOLOGY OF PULSE-JET DUST COLLECTORS 4
How the pulse-jet dust collectors work 4
Design configurations 5
Mechanical elements 5
Bag Cleaning Systems 6
Comparison between reverse air type and pulse-jet dust collector 6
Bag fixation 7
Filter cloth 8
3. HOLCIM-CTS DUST COLLECTOR DESIGN GUIDELINES 12
3.1 General theoretical design guidelines 12
Filtration velocity 12
Air-to-cloth ratio (A/C ratio) 13
Can velocity 13
3.2 Dust collecting system design guidelines 13
Amount of dust sources to vent 13
Venting air volume 13
Venting hood design 14
Ductwork design 14
3.3 Dust collector construction design guidelines 15
Gas flow / dust distribution 15
Clean gas plenum / housing 17
Dust hopper 17
Filter bag dimension 19
Distance between the bags 19
Number of bags per row 19
Venturis 19
Bag cages 20
Filter cloth 20
Airlocks 21
Fan 21
3.4 Dust collector cleaning control 21
General 21
Pulse sequence 21
Pulse cycle 22
Diaphragm and solenoid valves 23
Purge valve 23
3.5 Problem solving guide / trouble shooting 24
Version 1.08

1. INTRODUCTION
The modern cement plant continually faces the challenge of keeping the process running
and producing a high quality product in a timely manner whilst remaining in compliance
with the national and local environmental regulations. The trouble-free operation of air
pollution control systems therefore has a key role to play, since there are plenty of dust
collectors in each cement plant.
The cement manufacturing is characterized by the extraction, transport, storage and
processing of very large quantities of solid material, often in a dry and powdered state.
There is an obvious potential for the generation of dust emission from the quarry to the
shipping station.
For environmental protection reasons, work safety, equipment wear rate and waste of
money, it is urgently necessary to collect the dust and bring it back to the main material
flow.
This manual is focused on nuisance dust collecting of auxiliary equipment that allows to
correctly design a pulse-jet dust collecting system and to make the right choice between
different filter types/makes on the market. We want to help keep our group plants running
and producing.
2. TECHNOLOGY OF PULSE-JET DUST COLLECTORS
How the pulse-jet dust collectors work
The dust-tight casing has three sections (see figure 1); a clean-air plenum at the top,
a filtration housing containing a number of cylindrical or envelope type filter bags in
the middle, and a dust storage hopper at the bottom. The filter elements are
supported by a tube sheet that separates the filtration housing from the plenum.
Dust-laden air enters the collector through a diffuser, which absorbs the impact of the
high velocity dust particles, distributes the air, and reduces its velocity. The slow air
speed causes the heavier particles to drop into the hopper. The air steam then flows
through the filter units, depositing the fine dust on the outside of the cloths. The
cleaned air continues upward into the plenum and exhausts into the atmosphere.
The filter elements are cleaned by a momentary, high-pressure back-pulse of
compressed air from the clean side of the filter element. Blowpipes, arranged over
each row of filter elements, deliver the pulses. The bursts of air are optimized by
venturis located at the top of the filter elements to effectively dislodge dust along the
length of the elements.
A pulse control timer times the cleaning cycles. A differential pressure (between the
clean and dirty sides) gauge helps to determine cleaning frequency.
Version 1.08

Design configurations
Dust collector supplier offers 5 basic designs to choose from:
Bin vent collectors for mounting on silos or bins
Small, self-contained insertables for existing enclosures
Pre-assembled modular units for up to approximately 450 m
2

Large application sectional units for larger than 450 m
2

Cylindrical units for high pressure / high vacuum applications
Mechanical elements

1
3
4
5
6
7
8
9
10
11
1
3
4
5
6
7 8 9
10
11
12
13
14
15
16
17
18
12
13
14
15
16
17
18
Dust loaden air
Bag cage
Clean air outlet (Plenum)
Tube sheet
Filter bag
Venturi
Locking ring (or snap band fixation)
Blowpipe
Header (compressed air tank)
Diaphragm pulse valve
Pulse control timer
Rotary valve
Differential pressure gauge
Closing valve
Compressed air bin
Regulation damper valve
Fan
19 Purge unit with hand reducer
and filter set
Raw gas
inlet
Clean gas
outlet
19
2
2
Diffuser
Fig. 1: Mechanical elements of a pulse-jet dust collector.
Version 1.08

Bag Cleaning Systems
Summary of the various cleaning principles used for bag filters

Since most of the mechanically cleaned filters have been replaced by compressed air
ones, mainly in the cement industry, the mechanical cleaning devices will not be
described further here.
a, b: manual or mechanical, by
rapping or shaking
c: mechanical, by vibrating
d: pneumatic, by reverse air
flow (often combined with
shaking or vibrating)
e: pneumatic, by compressed
air (pulse-jet)
Vibrator
(a) (b) (c) (d) (e)
Comparison between reverse air type and pulse-jet dust collector

Reverse air type
Pulse-jet type
with low pressure
cleaning
Pulse-jet type
with high pressure
cleaning
Foot print of filter large due to low
filtration velocity
small due to longer bags medium due to shorter
bags
Number of chambers
2 extra chambers for
offline cleaning
no separate chamber
necessary
no separate chamber
necessary
Pressure drop across
bag filter
10 - 20 mbar 8 -12 mbar 8 -12 mbar
Bag dimensions
(available)
300 x 10 m 130-150 x 7-8 m 120-150 x 4,5-6 m
Bag life expectances
3 - 5 years due to
smooth cleaning
3 - 5 years due to
smooth cleaning
3 years due to harder
cleaning by pressure
pulses
Tank pressure (30 - 40 mbar) 0.6 - 2 bar 3 - 6 bar
Cleaning air flow 2.0 - 3.5 Nm
3
/m
2
h 0.05 -0.3 Nm
3
/m
2
h 0.02 - 0.10 Nm
3
/m
2
h
Cleaning air quality uses clean gas
refrigeration dried or
heated by roots blower
absorption dried
Cleaning time (open-
ing time of valve)
10 - 30 sec 600 ms 150 ms
All three bag filter types are successfully in operation. The choice has to be made by
price comparison.
Version 1.08

Bag fixation
Filter bag fixation with snap-band

Filter bag fixation with roll band / twist lock

Fig. 2: Bag fixation by snap-band
Filter bag
Snap-band
Roll band
Fig. 3: Bag fixation by roll band

Filter bag fixation screwed

Fig. 4: Mechanical fixation of bag cages

Transport and D
Version 1.08
Holcim Group
CMS - Me
ust Collecting Manual
Support Ltd
chanical Process Technology B1/8

Filter cloth
Filter media are available either in form of woven fabric or felt fabrics. The structure of
these two filter media is shown as follows:

The characteristics of woven fabric are its system of warp and weft threads crossing
one to another. Needle felts are "three-dimensional" filter media.
Most used filter media in the cement industry are needle felts due to a lower pressure
drop and higher dust collection efficiencies compared to the woven fabric.
Selection criteria
The filter medium is the all-important central feature of any dust collector operating on
the filtration principle. With the correct or incorrect choice of the filter material, the
whole dust collection operation will stand or fall in actual practice.
Important selection criteria are:
filter type, particularly cleaning principle
moisture level
gas temperature (average and peaks)
composition and chemical properties of the gas
raw gas dust load, particle size
particulate abrasiveness
allowed dust load in the clean gas
physical and chemical properties of the dust
Furthermore, the filter medium must satisfy the following conditions:
high air permeability (low pressure losses)
good mechanical strength
good thermal stability at operational temperature
good dimensional stability at operational temperature

Fig. 5: Woven fabric
and needle felt filter
cloth
Version 1.08

Properties of Various Filter Media
max. Operating
Temperature [C]
Fabric, Trademark Chemical
Classification
DIN
60 001
Tensile
strength
N/mm2
long time short time
Acide
Resist.
Alkali Resist. Abrasion
Resist.
Moist Heat
Resist.
Price Rating Density
[g/m
2
]
Natural
Fibers
Cotton Cellulose (CO) 410-670 70-90 120 5 3 2 3-4 $ 150-400

Wool Keratin (protein) (WO) 120-230 90 120 3-4 4 3-4 3-4 $$ 400-600

Acrilan, AC/AC Polyacrylnitrile
- copolymer
(PAN) 200-530 100-110 100-120 3 3-4 3-4 1 $$ 500-600

Dralon, Orlon, Zefran,
Dolanit
Polyacrylnitrile
- homopolymer
(PAN) 200-530 110-120 120-140 2-3 3-4 3-4 1 $$ 500-600
Polypropylene, Meraklon Polypropylene (PP) 260-640 90-100 100-120 1-2 1-2 1-2 1-2 $ 550
Trevira, Dacron, Terylene,
Tergal, Vestan, Kodel
Polyester (PES) 560-820 130-150 150-160
(dry)
3-4 3-4 2 5 $ 400-600
Synthetic
Organic
Fibers
Nylon, Perlon Polyamide (alipahtic) 370-850 90-110 100-120 4 2 1-2 3-4 $ 300

Nomex, Conex, Trol Polyamide (aromatic)
(Aramide)
PA
(AR)
570-690 180-210 200-240 good in
weak acids
Excellent at
low temp.
1-2 3-4 $$$$ 500-600

Teflon Polytetra-Fluorethylene (PTFE) 380 260 280 1-2 1-2 3-4 1 $$$$$$$ 750-940

Ryton, PPS, Rastex,
Procon
Polyphenylene-
Sulfid (PPS)
1000-1200 180 max.
5%O2
200 max.
15% O2
1 1 2-3 $$$$$$ 500-800

P 84 Polyimid (PI) 850-900 240-260 280 1-2 1-2 4-5 $$$$$$ 550
Legend:
1 exellent 2 very good 3 good 4 fair 5 poor
rt and Dust Collecting Manual
cim Group Support Ltd
chanical Process Technology

B1/10

Fabric, Trademark Chemical
Classification
DIN
60 001
Tensile
strength
N/mm2
max. Operating
Temperature [C]
Acid
Resist.
Alkali Resist. Abrasion
Resist.
Moist Heat
Resist.
Price Rating Density
[g/m
2
]

Glass, Fiberglass Glass 1500-2500 230-270 350 3-4 3-4 4 3 $$$ 300-400
Stone Wool Mineral 120-260 300-350 3-4 3-4
Various Steels Metals 500-750 up to 600 1 1 1
Synthetic
Anorganic
Fibers
Ceramic Silicium Oxyde 870 1 4 4 $$$$$$$$ >30
Legend:
1 excellent 2 very good 3 good 4 fair 5 poor
Transpo
Version 1.08
Hol
CMS - Me

Version 1.08

Special Treatment of the Bag Surface
Special treatment of the fabrics and needle felts can significantly improve the
properties of the bags.

Non-
Fiberglass
Finish Purpose Available For
Singe Recommended for improved cake release Polyester, Polypropylene, Acrylic, Nomex,
Ryton, P 84 (felts)
Glaze Provides short-term improvements for cake
release (may impede airflow)
Polyester, Polypropylene (felts)
Silicone Aids initial cake development and provides
limited water repellence
Polyester (felt and woven)
Flame Retardant Retards combustibility (not flame- proof) Polyester, Polypropylene (felt and woven)
Acrylic Coatings
(Latex base)
Improves filtration, efficiency and cake
release (may impede flow in certain
applications)
Polyester and Acrylic felts
PTFE Surface
Treatments and
Laminates
For capture of fine particulate, improved
filtration efficiency, cake release
Nomex, Polyester, Acrylic, Polypropylene
(felt) (Laminates available in Polypropylene,
Ryton and Polyester only)
PTFE Penetrating
Finishes
Improved water and oil repellence; limited
cake release
Nomex (felt)
Acid Resistant Improved acid resistance and water
retardance
Nomex (felt)

Fiberglass Finish Purpose Applications
Silicone, Graphite
Teflon
Protects glass yarns from abrasion, adds lubricity For non-acidic conditions, primarily for cement
and metal foundry applications
Acid Resistant Shields glass yarn from acid attach Coal-fired boilers, carbon black, incinerators,
cement, industrial and small municipal boiler
applications
Teflon B Provides enhanced abrasion resistance and
limited chemical resistance
Industrial and utility base load boilers under mild
pH conditions
Blue Max- CRF/70 Provides improved acid resistance and release
properties, superior abrasion resistance, resistant
to alkaline attack, improved fiber encapsulation
Coal-fired boilers (high and low sulfur) for peak
load utilities, fluidized bed boilers, carbon black,
incinerators
CMS - Mechanical Process B1/11
Version 1.08

Membrane filter bag surface
Special finishing or the application of membranes on the bag surface becomes more
and more important. The purpose of this treatment is to improve the bags' resistance
against chemical attack as well as optimum filtration efficiency and cake release,
especially for fine dust particles.

Fig. 6: Filter bag without membrane
Fig. 7: Filter bag with membrane
3. HOLCIM-CTS DUST COLLECTOR DESIGN GUIDELINES
The choice between different bag filter types/makes for the dust collection of a gas flow is
always based on the same technical questions that must be answered before deciding about
the investment. According to our experience, gained in many applications, all nuisance dust-
collecting systems should fulfill the requirements as follows:
3.1 General theoretical design guidelines
Filtration velocity
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.
The pressure difference (p) across the filter bags increases:
the higher the filtration velocity
the thicker the filter cake (residual dust layer after cleaning) and the quicker it builds
up (dust load time/cleaning interval)
the 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)
Version 1.08

For sufficient cleaning of the filter bags it is necessary to reverse the gas flow through
the bags. This can be done either by having a high pressure inside (high cleaning
pressure) or by having a huge amount of gas flowing in opposite direction (low cleaning
pressure or reverse air). When the pressure drop across filter bags is too high, then the
cleaning becomes insufficient and the filter clogs up rapidly.
Air-to-cloth ratio (A/C ratio)
The air-to-cloth ratio (A/C ratio) is simply a mathematical expression used to measure
the amount of filtering cloth area available to filter a given volume of air at a given flow
rate. There are standard air-to-cloth ratios based on cleaning mechanism styles, and
this ratio is used to determine the operating limits of the bag house. The guide ratios for
collectors with pulse-jet cleaning are as a function of the bulk material to handle for
auxiliary equipment venting as follows:

1.2 m
3
/m
2
x min for slag, coal and clinker dust
1.5 m
3
/m
2
x min for limestone and cement dust

Can velocity
The can velocity is the theoretically calculated raw gas velocity between the filter bags at
the bag bottom area. This is valid independently of raw gas inlet design. The maximum
allowed velocity depends on the gas flow direction between the bags and the terminal
velocity of particle collectives/agglomerates that have to fall into the hopper by gravity.
From experience, we know that the vertical upward vector of the gas flow velocity should
be between 1.0 and 1.3 m/s for auxiliary dust collecting systems.
The formula presented below can be used to calculate the can velocity:
Can velocity [m/s] =Total Venting Air Volume [m
3
/s] {Total Tubesheet Area [m
2
]
(Hole Area [m
2
] * Number of Holes)}
3.2 Dust collecting system design guidelines
Amount of dust sources to vent
No more than six (6) to eight (8) dust sources to vent should be connected to one dust
collector.
Venting air volume
The true required venting air volume that the ventilation system has to handle must be
determined first. Therefore, it has to be determined how much vent air is required at
each dust point. The recommended standard volumetric requirements for the venting of
typical applications in ambient air are shown in Appendix 1. The air flow for the
remaining venting pipes before the filter should be the sum of the presented values as
shown in mentioned appendix.
Version 1.08

Venting hood design
The hooding design at pickup points should provide ventilation of the dust point without
capturing product from the main material flow. If it will be done in this way, only airborne
particles will be introduced into the dust collection system. Improperly designed hoods
tend to increase the grain loading beyond of what the collector was originally designed
to handle. The recommended standard design practices for hood design are shown in
Appendix 2.
min. 60
Limestone, Slag, Cement
min. 60
Limestone, Slag, Cement
min. 45
Clinker
min. 45
Clinker
min. 70
Coal
min. 70
Coal
Ductwork design
Once the volume on each individual vent point is known, the ductwork has to be
designed correctly. The proper gas velocity will depend on the dust being conveyed, but
a general rule for good ductwork design is to size the duct cross-sectional area for a
velocity of 15 to 18 m per second. For explosive dust, the pipes should be sized to an air
velocity between 18 and 24 m/s. Ducts with lower velocity will encourage material to fall
out. Ducts that have higher velocities encourage abrasion. The guide values for gas
velocity in ductwork are:
- 16 m/s for abrasive dust (clinker, slag)
- 18 m/s for non-abrasive dust (limestone, cement, raw meal)
Frequently encountered ductwork problems are poorly designed branch entries, elbows
and size variations that hamper airflow and/or cause accelerated wear. Correct and
incorrect ductworks are shown for your reference in Appendix 2.
Dust collecting systems with an excessive number of connected vent points cannot be
controlled / calibrated in a way that pollution control is effective. That is why we
recommend limiting the number of vent points connected to one filter to at maximum of 8
points.
The minimum duct diameter shall be 133 mm (5") outside, and the minimum duct and
hood wall thickness 3 mm (1/8").
Up- and downward sloping for dust-laden air shall have - to avoid dust accumulation - a
minimum slope of 60 for limestone, slag and cement and 45 for clinker, 70 for coal
measured from the horizontal.

Ductwork in horizontal should be avoided!
Fig. 9: Duct-slope for
clinker dedusting
Fig. 10: Duct-slope
for coal dedusting
Fig. 8: Duct-slope for
limestone, slag, cement
dedusting
Version 1.08

For a fan discharge duct, the velocity shall be between 15 and 20 m/s. Silencer to be
provided, if required.
Orifice plates with wear protection shall be used for balancing systems, which handle
abrasive dust (e.g. clinker, slag). All other systems shall have butterfly dampers of a
minimum 6 mm thick plate construction.

Fig. 11: Typical orifice
plate design
3.3 Dust collector construction design guidelines
Gas flow / dust distribution
A good gas flow distribution does not necessarily mean having also a good dust
distribution. But a good gas flow distribution indicates a more even dust distribution. Gas
flow jets loaded with dust do not lead to wear of bags or other internals very much.
Uneven dust distribution results in short cleaning cycles with high cleaning air
consumption and shorter bag life expectance. During the filter design the suppliers
should take care about gas and dust distribution.
The general rule is to ask the suppliers for a dust drop -out box at the gas entrance if the
raw gas dust content is above 300 g/m
3
.
As follows some examples of good gas distribution design at the dust collector entrance:
Typical design Recommended design

Fig. 12: Typical raw gas
inlet design
Fig. 13: Recommended raw gas
inlet design
Version 1.08

Preferred deflector plate design

Raw gas top inlet configurations
3" Overlap Type
Inlet
3
"

m
i
n
.
6"
1"
6"

Inlet Slide
Colector
3"
Parting Line Wall and Hopper
6" x 1/4" Flat Bar
of
Fig. 14: Deflector plate
design
Fig. 15: Not recommended raw gas
inlet design
Fig. 16: Recommended raw gas
inlet design
Version 1.08

Drop-out box design configurations
All dust collectors installed at the clinker transport in the section from clinker cooler to
silos must be equipped with a cyclone or drop-out box, in order to prevent damage
filter bags due to hot clinker particles.

Fig. 17: Drop out box design configurations
Clean gas plenum / housing
Using a clean gas plenum instead of a liftable compartment cover has the advantage of
better gas tightness because it has one door per compartment only. The plenum height
has to be very high when undivided cages with long length bags are installed.
Outdoor filters larger than approximately 1.5 / 1.5 m should be equipped with weather
protection or walk-in-plenum for maintenance access i.e. sufficient height.
For small filters (<1.5 / 1.5m) located outdoors and all filters located inside buildings,
top access (without walk-in-plenum) are also acceptable.
Bin vent type filters shall be provided with suitably reinforced bag/man catcher screen
for safety reasons.
Casing insulation shall be provided for outdoor filters, which are exposed to operation
below the dew point. The insulation wall thickness shall be minimum 50 mm.
Dust hopper
For dust, which tends to agglomerate or leads to clogging, the corners of the hoppers
should be rounded. Anyway the valley (corner) angles of the hoppers should not be
lower then 55
0
in all applications, respectively 70
0
for coal, separator and bypass dust.
In the Appendix 3 there is a chart to find the hopper valley angle considering the
different angles of the hopper.

Version 1.08

A very serious problem in most group plants is the agglomeration of dust in the pyramid
hoppers due to a much too small discharge opening and a too low inclination of the
hopper walls. In such cases, which are problems of the supplier filter design, many dust
collectors have already been modified by replacing the rotary feeder with a screw
conveyor as shown below.

Fig. 18: Typical blocked
dust hopper outlet
700
4
4
0
5
0
250
1250
700
350 650 250
Fig. 19: Modification of dust hopper by installing vertical side walls

750
~

4
5
0
5
0
250
1250
750
Fig. 20: Modification of dust hopper by
installing conically side walls, (for
extremely sticky material)
Version 1.08

Filter bag dimension
The filter bag dimension depends on the cleaning system efficiency and the geometrical
allocation of the filter bags. The diameter of the bags is usually between 120 and
160 mm. For standardization reasons most filters should be matched in such a way that
only one size and type of bags is used. The maximum allowed bag length depends on
the cleaning system efficiency and the geometrical allocation of the bags.

The following bag lengths are recommended not to be exceeded:

new installation conversion

11.0 m
6.0 m
reverse air
low pressure pulse-jet
11.0 m
8.0 m
4.5 m
high pressure pulse-jet 6.0 m

The longer the bags, the more likely not perfectly vertical mounted, which provokes bags
touching each other at bottom area. This causes a high wear rate due to friction
between the bags. Furthermore, long bags are more difficult to clean and to remove if
filled up with dust or having a hole in the fabric.
Distance between the bags
The minimum distance between the bags should be 50 mm. The distance between bags
and inside walls/internal stiffeners has to be 75 mm at the minimum.
Number of bags per row
The maximum number of bags per row should not be more than 16 bags.
Venturis
A venturi is an integral component of most pulse-jet collectors. It directs the blast of
compressed air into the center of the filter bag to prevent abrasion caused by misaligned
blowpipes and turbulent airflows. A good nozzle venturi configuration guarantees an
efficient jet gentle dust release while conserving compressed air consumption through
secondary air in draft into the venturi. If venturis become damaged or worn, compressed
air does not gain the velocity required to effectively clean the filter bags.
Version 1.08

Bag cages
The bag cages have to be provided with longitudinal wires:
8 to 12 for filter bag diameter <160 mm
16 to 20 for filter bag diameter >200 mm
The bag cages shall be preferably of single piece design and shall be corrosion-resistant
(galvanized, stainless steel or epoxy coated) depending on their application.
Cartridge pleated filter and star bags shall not be used (except for electrical room
pressurization or special application). Envelope type dust collector should only be
applied for low venting air volume of <5'000 m
3
/h.
Filter cloth
The filter cloth specification and design data to be provided by the supplier have
carefully been checked by the consumer.
For general application (dry gas) up to 120
0
C (long time operation), needle felt
fabric made from high quality Polyester fibers are used.
For an application in drying/grinding (humid gas) up to 120
0
C (long time operation),
Polyacrylnitrile or similar fiber cloth is recommended.
Application for temperatures above 120
0
C, Polyamide (Nomex), Polyphenylene,
Glass-fiber, Teflon/graphite coated or similar.
One of the greatest enemies of the textile filter media is hydrolysis. This means the
breakdown of the molecular chain of the polymerization caused by moisture. Hydrolysis
is intensified by heat, acids and alkalis.
Polyester, for example, should not be used when moisture and elevated temperatures
occur in combination. Also aromatic polyamides (Nomex) are subject to hydrolytic
influences at temperatures above 70C, especially if acids or alkaline agents additionally
act as a catalyzer.
Fortunately, in recent years chemical modification processes have emerged, which have
enabled these polyamides and also polyester to be substantially improved in this
respect.
Version 1.08

Airlocks
Rotary type for raw material, raw meal and cement dust.
Double pendulum type shall be provided for all clinker dust and abrasive bulk
material applications. Motor operated units requiring power-to-open and power-to-
close are preferred. Gravity operated airlocks are also accepted.
The minimum size for airlocks shall be 250x250 mm.
Fan
All fans should be selected with a 15% safety margin. As a consequence, air
quantity for fans is at least 15% higher than required.
The fans with manually operated damper at inlet duct are preferred.
The fan speed should preferably not exceed 1'800 rpm.
In the absence of ducting layout and pressure drop calculations, the static pressure
for the dust collector fans should be specified as follows:
- For impact crusher and bag packing machine venting systems, the minimum fan
static pressure should be 30 mbar.
- For bin / silo vent units and electrical rooms pressurizing systems, the minimum
fan static pressure should be 23 mbar.
- For all other dust collectors, the minimum fan static pressure should be 28 mbar.
3.4 Dust collector cleaning control
General
In pulse-jet collectors, the cleaning function not only removes the collected dust, it
rearranges the remaining dust cake structure on the bag, resulting in a change of
differential pressure. In a unit with high upward gas velocities (can velocity), mechanical
separation of the fine sub micron dust can occur, creating a dust cake structure that is
very dense. A dense dust cake creates a resistance to airflow, and higher differential
pressures.
Essential for a smooth trouble free operation of each dust collector is the availability of
sufficient dry compressed air volume in adequate quality. The usually required air
pressure to clean conventional filter bags is 6 bar and for bags with membrane layers
5 bar.
Pulse sequence
The pulsing sequence can play an important part in lessening the re-entrainment of
material. Pulsing one row right next to another row (sequential order) can cause the fine,
sub-micron material to migrate to the cleaned row. Staggering the order of rows to be
pulsed can improve the dust cake for optimum filtration as shown in next picture.

Version 1.08

Typical cleaning sequence Recommended cleaning sequence

Example
How a cleaning sequence on a dust collector with 17 respectively 12 bag rows and 10
timer positions can look like it is presented in the following tables.

7

Pulse cycle
The cleaning cycle for pulse-jet collectors should be designed, so that the pulse duration
produces a short, crisp pulse in order to create an effective shock wave in the bag. This
duration is generally set to fire for 0.10 to 0.15 second.
The frequency of pulse-jet cleaning is also vital to proper dust cake retention. This
frequency can vary from 7 to 30 seconds or more and is adjusted by means of a
potentiometer on the timer panel. The frequency should be adjusted, so that the
differential pressure across the collector ranges from 75 - 150 mm WG.
To ensure proper cleaning frequency, an automatic "cleaning-on-demand" system
utilizing a pressure switch gauge can be installed as shown in the following picture.
Good practice is to put the low set point at about 10 mbar and the set point high at 12.5
mbar.
Timer
Position
1 2 3 4 5 6 7 8 9 10
1 4 7 10 2 5 8 3 6 9 Valve
Numb. 11 14 17 12 15 13 16
Timer
Position
1 2 3 4 5 6 7 8 9 10
1 4 7 10 2 5 8 3 6 9 Valve
Numb. 11 12
Fig. 21: Typical bag cleaning
sequence

7
Fig. 22: Recommended bag
cleaning sequence
Transport and D
Version 1.08
Holcim Group
CMS - Mecha

ust Collecting Manual
Support Ltd
nical Process Technology B1/23

Purge valve
Purge valves are designed to eliminate moisture build-up in the compressed air header
before entering the unit, in order to avoid corrosion and dust caking on the top of bags.
This manually operated valve is usually located in the pipeline to the air header. Today
there are automatic purge valves located at the bottom of the air header assembly and
connected to a pulse valve. When the pulse valve fires, the valve opens a discharge port
on the air header assembly, removing excessive moisture.
Diaphragm and solenoid valves

This type of system will automatically step through a cleaning cycle that starts when the
high differential pressure set point is reached and stops when it cleans down to the low
differential pressure set point it will also save on compressed air usage.
On pulse-jet collectors, the pulse frequency can of course be increased, but the next
pulse should not be programmed to fire until the compressed air pressure is regained so
the same force of pulse is obtained for each row cleaned. The regain of air pressure is
dependent on the capability of the compressed air system tied to the bag house and the
size of the compressed air piping run to the header tank.

Diaphragm and solenoid valves work together for an efficient operation of the bag house
cleaning system. If either is malfunctioning, the entire system can be affected.
Good practice is to use CR (Chlorbutadien-Elastomer) diaphragm for operating
temperatures up to 80
0
C, Buna N (Styrol-Butadien-Elastomer) up to 90
0
C and Viton for
temperatures <180
0
C.
There are integral solenoid valves, which are mounted directly on the diaphragm valve
or remote solenoids mounted in a separate enclosure for special applications.
Set point low
(app. 10 mbar)
Set point high
(app. 12.5 mbar)
Fig. 23: Pressure switch
gauge for bag cleaning
control
Version 1.08

3.5 Problem solving guide / trouble shooting

Fan Ductwork
Jet-Pulse Dust Collector Reverse air Dust Collector
Problem
Lake of air at
process
Emissions from
stack
Problem
Yes
Is System turned
on ?
Start System and
check differnetial
pressure
Yes
Check cleaning
mechanism
No No
No
Is fan pulling
design load amps ?
Check for leaking
solenoids and pulse
valves;check compres-
sed air sources and
check differnetial press.
Turn on Power
and /or repair
timer
Repair solenoid or
diaphragm and check
differential pressure
Change setting and
check differential
pressure
Change setting and
check differential
pressure
Is there Power in
and out of timer ?
Is manifold
pressure at
manufacturer's
recommanded setting ?
Do solenoids and
diaphragmoperate
properly ?
Is pulse duration at
recommanded setting ?
(0,1 - 0,15 sec)
Is cleanig interval at
the lowest setting that
will allow air manifold
pressure to rebuild ?
Are belts tensioned
properly ?
Retension and check
Is there Power
in and out of timer ?
Are isolation dampers
sealing properly ?
Is reverse air fan
running ?
Is reverse air fan
rotation correct ?
Is cleaning cycle
for reverse air dwell set
at manufacturer's
specifications ?
Turn on power
and / or repair timer
Adjust and/or
repair and check
differential power
Turn on and check
Change motor leads
and check differential
pressure
Change setting and
check differential
pressure
Does baghouse
have high
differential
pressure ?
Are emissions
visible at the
stack ?
No
No
No
No
No
No
No
No
No
No
No
No
Yes Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Visually check for
bag leaks; repair
leaks and check
pressure
Yes
Next page Next page Next page Next page
Version 1.08

Is the differential
pressure reduced by
stopping fan while
pulsing ?
Does air/cloth ratio
exceed 6:1 if pulse-jet,
or 4:1 if plenumpulse
or reverse air ?
Are bags experiencing
high grain loading ?
Is material stored
or accumulated in
hopper ?
Check inlet duct entry
design and modify to
reduce load;
check differential
pressure
Is fan vibrating ?
Check for damage or
material buildup on
an wheel and repair
and clean
Is fan rotation
correct ?
Is fan damper
open ?
Is air volume at fan
rated capacity ?
Is ductwork or
system leaking ?
Repair leaks and
check differential
pressure
Change motor
leads and check
Open damper and
check differential
pressure
Check for
obstructions in
ductwork and remove
Check differential
pressure gauge for
proper operation
Is cleaning interval set
at its shortest interval ?
Pull a bag and run
a permeability test to
check for blinding
Is bag blinding ?
f
Analyze for cause of
blinding and correct;
replace bags and
check differential
pressure
Change setting and
check differential
pressure
No
No
No
No
No
No No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Damper fan volume
down / evaluate
pleated media
conversion
No
Add mechanical device
to reduce load and
check differential
pressure
No
Remove material
continously and
check differential
pressure
No
Yes
Yes
Yes
From previous From previous From previous From previous
Version 1.08

Version 1.08

APPENDIX 1

Recommended Venting Air Volume
Version 1.08

Version 1.08

Dedusting Air Quantities
650
850
1000
1200
1400
1600
MACHINE UNIT
BELT CONVEYORS
SIZE
(mm)
m
3
/h DETAILS / REMARKS
A
B
C
4250
5250
6500
7750
8750
10'000
m
3
/h 2000
2500
3000
3500
4000
4500
m
3
/h
m
3
/h
1250
1750
2250
2750
3250
3750
1000
1000
1250
1500
1500
1750
A B C
A B C
3500
4000
4500
5000
5500
2000
2500
3000
3500
4000
1000
1000
1250
1500
1500
6500
7500
8750
9750
800
1000
1200
1400
1600 10'000
A
B
C
A
B C
A
B
800
1000
1200
1400
2500
3000
3500
4000
9000
10'000
11'000
12'000
9000
10'000
11'000
12'000
1250
1500
2000
2500
3000
3500
4000
A B C
A B A B
1000
1000
1250
1250
1500
1500
1500
2000
2250
2500
3000
3500
4500
6000
1000
1000
1250
1250
1500
1500
1500
m
3
/h
APRON CONVEYORS
PIVOTING PAN APRON CONV.
BUCKET ELEVATORS
TROUGH CHAIN AND
SCREW CONVEYORS
AIR SLIDES
CALSSIFING-SCREEN
VIBRATORY-SCREEN
SWING-SCREEN
400
500
630
800
1000
1250
1600
250
315
400
500
630
800
1000
200
500
500
750
750
1000
1000
1250
500
PER 10m LENGHT
150% OF THE AIR BLOWER
PER t/h (OPEN)
PER m
2
(CLOSED)
PER m
2
(CLOSED)
50
450
600
CHAIN m
3
/h BELT m
3
/h
1500
2000
2500
3000
3500
4000
1750
2250
2750
3250
3750
4250
120
650
850
1000
1200
1400
1600
MACHINE UNIT
BELT CONVEYORS
SIZE
(mm)
m
3
A
B
C
4250
5250
6500
7750
8750
10'000
m
3
/h 2000
2500
3000
3500
4000
4500
m
3
/h
m
3
/h
1250
1750
2250
2750
3250
3750
1000
1000
1250
1500
1500
1750
A B C
A B C
3500
4000
4500
5000
5500
2000
2500
3000
3500
4000
1000
1000
1250
1500
1500
6500
7500
8750
9750
800
1000
1200
1400
1600 10'000
A
B
C
A
B C
A
B
800
1000
1200
1400
2500
3000
3500
4000
9000
10'000
11'000
12'000
9000
10'000
11'000
12'000
1250
1500
2000
2500
3000
3500
4000
A B C
A B A B
1000
1000
1250
1250
1500
1500
1500
2000
2250
2500
3000
3500
4500
6000
1000
1000
1250
1250
1500
1500
1500
m
3
/h
APRON CONVEYORS
BUCKET ELEVATORS
TROUGH CHAIN AND
SCREW CONVEYORS
AIR SLIDES
CALSSIFING-SCREEN
VIBRATORY-SCREEN
SWING-SCREEN
400
500
630
800
1000
1250
1600
250
315
400
500
630
800
1000
200
500
500
750
750
1000
1000
1250
500
PER 10m LENGHT
PER t/h (OPEN)
PER m
2
(CLOSED)
PER m
2
(CLOSED)
50
450
600
CHAIN m
3
/h BELT m
3
/h
650
850
1000
1200
1400
1600
MACHINE UNIT
BELT CONVEYORS
SIZE
(mm)
m
3
A
B
C
4250
5250
6500
7750
8750
10'000
m
3
/h 2000
2500
3000
3500
4000
4500
m
3
/h
m
3
/h
1250
1750
2250
2750
3250
3750
1000
1000
1250
1500
1500
1750
A B C
A B C
3500
4000
4500
5000
5500
2000
2500
3000
3500
4000
1000
1000
1250
1500
1500
6500
7500
8750
9750
800
1000
1200
1400
1600 10'000
A
B
C
A
B C
A
B
800
1000
1200
650
850
1000
1200
1400
1600
MACHINE UNIT
BELT CONVEYORS
SIZE
(mm)
m
3
A
B
C
4250
5250
6500
7750
8750
10'000
m
3
/h 2000
2500
3000
3500
4000
4500
m
3
/h
m
3
/h
1250
1750
2250
2750
3250
3750
1000
1000
1250
1500
1500
1750
A B C
A B C
3500
4000
4500
5000
5500
2000
2500
3000
3500
4000
1000
1000
1250
1500
1500
6500
7500
8750
9750
800
1000
1200
1400
1600 10'000
A
B
C
A
B C
A
B
800
1000
1200
1400
2500
3000
3500
4000
9000
10'000
11'000
12'000
9000
10'000
11'000
12'000
1250
1500
2000
2500
3000
3500
4000
A B C
A B A B
1000
1000
1250
1250
1500
1500
1500
2000
2250
2500
3000
3500
4500
6000
1000
1000
1250
1250
1500
1500
1500
m
3
/h
APRON CONVEYORS
BUCKET ELEVATORS
TROUGH CHAIN AND
SCREW CONVEYORS
AIR SLIDES
CALSSIFING-SCREEN
VIBRATORY-SCREEN
SWING-SCREEN
400
500
630
800
1000
1250
1600
250
315
400
500
630
800
1000
200
500
500
750
750
1000
1000
1250
500
PER 10m LENGHT
PER t/h (OPEN)
PER m
2
(CLOSED)
PER m
2
(CLOSED)
50
450
600
CHAIN m
3
/h BELT m
3
/h
1500
2000
2500
3000
3500
4000
1750
2250
2750
3250
3750
4250
120
1
Version 1.08

Example Packing Plant

1
2
7
6
8
9
5
4
3
1
2
3
4
5
6
7
8
9
According Machine Unit
Bucket Elevator Food
Bucket Elevator Head
Swing Screen
Storage Bin
Rotary Packer Feed
Rotary Packer 8-Spouts
Takeway Belt Conveyor
Bag Cleaning Unit
m
3
/h
1250 m
3
/h
2500 m
3
/h
1500 m
3
/h
500 m
3
/h
300 m
3
/h
8000 m
3
/h
2000 m
3
/h
2500 m
3
/h
Version 1.08

Dedusting Air Quantities

Guiding rates for plant engineering

Machine unit Size (mm) m
3
/h Remarks
Vibrating feeder
600
900

800 1'500
1'000 2'400
1'200 3'600
Air lift 60
Per t
Fuller pump 50
Per t 1.5-times of the expanded
Pressure vessel 40 Per t compressed air volume
Fluidstat (Bhler) 30 Per t
Bin Big
1'000
Mechanical feeding
Small 500
Mechanical feeding
Clinker storage 12 - 20000 Cylindrical Silo
40 - 60000 Circular Silo (clinker dome)
Roller crusher to 50 t/h 36 Per t
50 - 100 t/h 60 Per t
J aw crusher to 100 t/h 60 Per t
100 - 400 t/h 45 Per t
400 - 700 t/h 30 Per t
Hammer crusher to 100 t/h 120 Per t
Impact crusher to 100 t/h 90 Per t
to 300 t/h 60 Per t
>300 t/h 40 Per t
Gyratory crusher to 100 t/h 60 Per t
(cone crusher) 100 - 400 t/h 45 Per t
400 - 700 t/h 30 Per t
Packing machine 8'000 8-spouts rotary packer
6'000 6-spouts rotary packer
300 Feed
2'500 Per spout in-line packer collecting
funnel
1'500 Niagara-swing screen 1 x 2.5 m
2'000 Takeaway belt conveyor
2'500 Bag cleaning unit
Loading mobile 5'000 Air slide 400 mm
5'000 Screw 1630/1800
1'500 Hopper mobile

4'000 Double articulated (air slide or
screw)
Loading head 900 Cement 300 m
3
/h
1'500 Cement 600 m
3
/h
12'000 Clinker 300 m
3
/h
Tanker vehicles 540 - 660
Road 60 t/h at 2.5 bar
660 Rail 60 t/h at 2.5 bar

Version 1.08

Version 1.08

APPENDIX 2

Ductwork and Venting Hood Design
Transpo
Version 1.08
Hol
CMS - Me
chanical Process Technology B1/34

Version 1.08

Venting Hood Design

L
v2
v1
H
B
C
G
L
E
B
C
G
B
D
L
Longitudinal Transversal
Air Quantity v1 v2 L B H C G L B E D
m
3
/h m
3
/min ms-1 ms-1 mm mm mm mm mm mm mm mm mm
4.2 1.40 18.0 260 190 165 70.0 * 97 260 190 157.0 122.0
500 8.3 1.40 17.5 370 270 235 100.5 * 143 370 270 227.0 177.5
750 12.5 1.40 17.0 450 330 280 125.0 * 178 450 330 278.0 218.0
1000 16.6 1.40 17.2 520 380 325 143.5 * 207 520 380 323.5 253.5
1250 20.8 1.40 17.7 580 425 365 158.0 233 580 425 365.0 287.5
1500 25.0 1.44 17.9 630 460 400 172.0 253 630 460 396.0 311.0
1750 29.2 1.43 17.9 680 500 430 186.0 276 680 500 430.0 340.0
2000 33.3 1.39 17.9 740 540 470 198.0 299 740 540 471.0 371.0
2500 41.6 1.41 18.0 820 600 520 222.0 334 820 600 522.0 412.0
3000 50.0 1.40 17.9 900 660 570 244.0 368 900 660 574.0 454.0
3500 58.3 1.44 17.8 960 700 610 262.0 391 960 700 609.0 479.0
4000 66.6 1.40 18.0 1040 760 660 280.0 426 1040 760 666.0 526.0
4500 75.0 1.42 17.9 1100 800 700 298.0 449 1100 800 701.0 557.0
5000 83.3 1.42 17.9 1150 850 740 314.0 475 1150 850 739.0 589.0
6000 100.0 1.42 17.9 1260 930 800 344.0 524 1260 930 810.0 645.0
Vertical
250
*Commercial Pipes and Bends
Sheet Thickness for Suction Hoods and Ducts: 3-4mm
Intake Velocity at Hoods according to Above Table: V
1
=~1.4m/s
Air Velocity in Dedusting Duct : V
2
=>18m/s
Version 1.08

Duct Elbow, Joint and Branch Design

B1/37
chanical Process Technology

Transpo
Version 1.08
Hol
CMS - Me

Version 1.08

Hooding Design at Pickup Points

Hooding for Airslide

High velocity
Typical
Recommended

Hooding for belt conveyor

Min. cover hood
height: 400 mm
Min. 2*belt width
Min. cover hood
height: 400 mm
Min. 2*belt width

Version 1.08

Hooding for steel conveyor

2 x conveyor width
1/3 belt
width
Rubber skirt
Additional venting
may be required for
dusty material
600 mm
min.

Dust curtain

50 mm clearance
for load on belt
Version 1.08

Hooding for Bucket elevator head

Typical Alternativ
Vent point
Relocated vent point

Impact flow meter dedusting

Version 1.08

Gas velocity in ductwork

Tube Tube Tube Gas
Airflow
Tube Tube Tube Gas
Airflow
diameter diameter diameter speed

diameter diameter diameter speed

Inch mm m m/s
m
3
/h
inch mm m m/s
m
3
/h
4.5 114.30 0.114 16.00 591 4.5 114.30 0.114 18.00 665
6 152.40 0.152 16.00 1051 6 152.40 0.152 18.00 1182
7 177.80 0.178 16.00 1430 7 177.80 0.178 18.00 1609
8 203.20 0.203 16.00 1868 8 203.20 0.203 18.00 2101
9 228.60 0.229 16.00 2364 9 228.60 0.229 18.00 2660
10 254.00 0.254 16.00 2919 10 254.00 0.254 18.00 3283
11 279.40 0.279 16.00 3531 11 279.40 0.279 18.00 3973
12 304.80 0.305 16.00 4203 12 304.80 0.305 18.00 4728
13 330.20 0.330 16.00 4932 13 330.20 0.330 18.00 5549
14 355.60 0.356 16.00 5720 14 355.60 0.356 18.00 6435
15 381.00 0.381 16.00 6567 15 381.00 0.381 18.00 7388
16 406.40 0.406 16.00 7471 16 406.40 0.406 18.00 8405
17 431.80 0.432 16.00 8435 17 431.80 0.432 18.00 9489
18 457.20 0.457 16.00 9456 18 457.20 0.457 18.00 10638
19 482.60 0.483 16.00 10536 19 482.60 0.483 18.00 11853
20 508.00 0.508 16.00 11674 20 508.00 0.508 18.00 13133
21 533.40 0.533 16.00 12871 21 533.40 0.533 18.00 14480
22 558.80 0.559 16.00 14126 22 558.80 0.559 18.00 15891
23 584.20 0.584 16.00 15439 23 584.20 0.584 18.00 17369
24 609.60 0.610 16.00 16811 24 609.60 0.610 18.00 18912
25 635.00 0.635 16.00 18241 25 635.00 0.635 18.00 20521
26 660.40 0.660 16.00 19729 26 660.40 0.660 18.00 22196
27 685.80 0.686 16.00 21276 27 685.80 0.686 18.00 23936
28 711.20 0.711 16.00 22881 28 711.20 0.711 18.00 25742
29 736.60 0.737 16.00 24545 29 736.60 0.737 18.00 27613
30 762.00 0.762 16.00 26267 30 762.00 0.762 18.00 29550
For Abrasive Dust For Non-Abrasive Dust
Version 1.08

Version 1.08

APPENDIX 3

Hopper Valley Angle
Version 1.08

Version 1.08

Version 1.08

Version 1.08

APPENDIX 4

Dust Suppression for Feed Hoppers
Version 1.08

Version 1.08

Version 1.08

Attached bag filter to hopper enclosure

Fabric Dust Collector Systems Manual

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