Filter bag selection and system troubleshooting are critical to ensuring stable operation of pulse jet baghouse dust collectors. Scientific selection requires controlling three key performance indicators: filtration, physical properties, and chemical properties. Targeted troubleshooting of six major system failures—including filtration and cleaning—alongside routine maintenance of core components like pulse valves, significantly enhances industrial dust collection efficiency and reduces overall equipment operating costs.
I. Key Considerations for Filter Bag Selection and System Troubleshooting
As the core component filtration device, filter bag performance directly determines the dust collector's application scope and operational efficiency. Selection must be based on three core indicators: filtration performance, physical properties, and chemical properties.
Filtration performance encompasses pore size, air permeability, porosity, and regenerative capability.
Physical properties include electrical conductivity, thermal conductivity, strength, plasticity, and elasticity. Chemical properties refer to corrosion resistance and electrochemical characteristics, determining the equipment's adaptability to corrosive gases.
Filter bag materials are categorized into natural fibers, synthetic fibers, and inorganic fibers. Processing methods include woven fabrics, nonwoven fabrics, and composite fabrics. Common industrial types include “208” polyester pile fabric, needle-punched felt, “729” filter cloth, glass fiber filter cloth, and membrane-coated modified products. Among these, “208” polyester pile fabric exhibits outstanding filtration, abrasion resistance, and air permeability after brushing treatment. Needle-punched felt, manufactured via a non-woven needle-punching process to create a three-dimensional structure, features high porosity, excellent air permeability, low pressure drop, extended service life, and corrosion resistance, making it widely applicable.
Common failures in pulse-jet baghouse dust collectors typically occur across seven major reason, primarily manifesting as abnormal resistance, excessive dust concentration in exhaust gas, short filter bag lifespan, cleaning mechanism failure, and poor ash discharge. Key troubleshooting and handling points are as follows:
1. Filtration System Failures: Excessive emissions result from filter bag support plate deformation, welding defects, bag rupture or detachment, and cage deformation. Filter bag damage often results from scratches by metallic particles in dust or uneven airflow causing siphon effects, with damage concentrated at bag openings, bottoms, and bodies. Detachment commonly occurs due to loosening of elastic expansion rings in external-filter bags. Prompt replacement of damaged bags, repair of perforated plates, and correction of cage deformation are required.
2. Cleaning System Malfunctions: Involves components like blow pipes, air distribution chambers, and pulse valves. Pulse valve air leaks are the primary cause, leading to sudden pressure drops in the air distribution chamber. This triggers overall cleaning failure and increased equipment resistance (normally controlled below 1500Pa). Ensure blow pipes maintain proper diameter, number of orifices, and orifice size matching the blowing distance. The ratio of total nozzle cross-sectional area to net blow pipe cross-sectional area (Σf/F) should be controlled between 0.5 and 0.75 to prevent jet deviation.
3. Compressed Air System Failures: Issues with components such as air receivers, pressure-reducing filter valve assemblies, and piping directly cause insufficient cleaning capacity. Regular inspections are required for air pressure stability, pipeline sealing integrity, and filtration/drying effectiveness.
4. Flow Field System Failures: Abnormalities in air inlets, outlets, or air distribution facilities manifest as abnormal resistance and emission exceedances. Optimize airflow guidance design and repair damaged deflectors.
5. Data Monitoring System Failures: Malfunctions in sensors, transmitters, or displays may mislead operational judgments. Regularly calibrate monitoring equipment and troubleshoot signal transmission issues.
6. Control System Failures: Issues with local control panels, PLCs, remote displays, or wiring can cause cleaning or ash transport failures. Verify terminal connections and replace faulty control components.
II. Key Equipment Maintenance Points and Industry Application Outlook
Daily pulse valve maintenance requires focus on five key areas: First, maintain dry air supply by using air dryers or air receiver drain valves to prevent moisture-induced diaphragm sticking and valve body corrosion. Second, regularly clean valve body impurities with at least quarterly maintenance to prevent seal failure caused by dust or metal shavings. Third, verify the pulse sequence and cycle to prevent uneven bag cleaning caused by control irregularities. Fourth, replace diaphragm assemblies on schedule, ideally every 12-18 months, to prevent sudden failures. Fifth, ensure joint seals remain intact and promptly replace worn components to avoid air leaks and pressure fluctuations.
Currently, China's environmental strategy is advancing toward integration, with ultra-low emission requirements driving continuous innovation in baghouse dust collection technology. However, issues such as insufficient filter bag lifespan and high costs of catalytic filter bags still constrain technological adoption. Against this backdrop, strengthening core component maintenance, rapidly troubleshooting system faults, and optimizing equipment operation and maintenance management have become key pathways to enhance the operational stability of pulse jet baghouse dust collectors and reduce overall costs.
As core equipment for industrial flue gas treatment, pulse jet baghouse dust collectors will see expanding applications across metallurgy, chemical, and power industries. Looking ahead, technological upgrades to core components, optimized filter media performance, and widespread adoption of intelligent operation and maintenance systems will enable these dust collectors to play an increasingly vital role in ensuring ultra-low emissions and reducing energy costs, thereby providing robust support for industrial green transformation.
