Baghouses
Baghouses, or bag filters, iare a type of dust collection system that uses filter bags to capture and remove dust and other particulate matter from industrial processes. These systems are commonly used in a wide range of industries, including cement, mining, power generation, and metal production, to remove particulate matter from the air.
When compared to cyclone dust collectors, baghouses take less space and filter finer particles, but they require actual bags which need to be replaced, as the name indicates.
When compared to cartridge dust collectors, bahouses take more space and it’s harder to replace the filters, but they can handle more particles before needing changed.
Baghouses usually come with a jet, or reverse-air to clean out the filters, lengthening the time between when bags will need changed.
Below are the two most popular kinds of industrial baghouses, each of which come in very large and more compact models, followed with more benefits and drawbacks. To cut right to finding out which model is best for you (or if a baghouse is even what you want), or to get your system designed, integrated, or serviced, give us a call or fill out the form below.
Standard & Explosion-Proof Configurations Available
Highlights
The MCF dust collection system from Schenck offers significant energy cost savings, generating up to 50% more than conventional high-pressure air cleaning systems. The system operates with medium-pressure cleaning air at a pressure range of 7-9 psig (0.4-0.6 barg) which is more efficient and results in longer bag life. It also boasts high cleaning capacities, with the ability to handle over 250,000 CFM (425,000 m3/h).
One of the key features of the MCF is its timing mechanism, which is non-electrical and safe for use in dusty and explosive atmospheres. Additionally, the system is suitable for use in high temperatures, with the ability to handle temperatures of 240 °C and higher. This makes it ideal for use in a wide range of industrial and commercial applications.
Benefits
The MCF is a dust collection system that is built to withstand the rigors of industrial and commercial environments. It boasts a rugged steel construction with a thickness of 3mm or greater, providing durability and longevity. The system features a walk-in clean air plenum with lifting lugs for easy access, as well as a large service door measuring 1,524mm x 813mm for easy maintenance.
The MCF is powered by an explosion-proof motor that drives the direct-drive rotating surge tank and distribution arm. The cleaning mechanism is pneumatically-controlled, discharging air directly over the filter bags for optimal cleaning efficiency. The system also features topside tool-free cage and snap-band bag removal, as well as a 60-degree hopper with a 1,016mm diameter flange. Additionally, it comes with a self-contained positive displacement pump package that supplies all the required air.
Longer Bag Life
This system is designed to clean the filter bags efficiently and effectively, so that they last longer and are shielded from damage due to over-cleaning
Less Egress
The MCF’s precise application of medium-pressure air allows for a more targeted cleaning process that reduces the amount of dust and other particulate matter released.
Lower Operating Costs
This system utilizes medium-pressure, high-volume air, which is more cost-effective and efficient than high pressure systems.
Lower Maintenance Costs
Tooless bag removal saves significant installation and maintenance cost over its lifetime.
Easy Installation
When space allows, the unit’s housing, plenum, and hopper are shipped fully welded for easy installation.
Options
The MCF also offers several options to suit specific application needs, such as rotary airlocks that are sized based on the application and pollutants. Other options include a live bottom discharge for difficult materials, 304 or 316 stainless steel construction, and various accessories like sprinkler taps, broken bag detector, level probes, hopper access ports, and structural supports.
Operating Principle
The MCF PowerSaver is a dust collection system that utilizes a unique combination of components to effectively remove dust and other particulate matter from the air. The system operates with a rugged explosion-proof electric motor as the only electronic component inside the filter housing. For safety and reliability, the system is pneumatically operated except for the motor and external air blower package.
The patented Never-Miss™ Controlled-Cleaning System aligns cleaning arm and bag segments so that air nozzles fire directly into the center of the bag. This eliminates any wasted air or energy, unlike conventional random-cleaning and reverse-air systems. The diaphragm valve assemblies are located close to the air reservoir and cleaning arm to maintain cleaning pressure and minimize recovery time, doing the work of 10 to 30 diaphragm valves and solenoids on conventional pulse-jet filters.
The MCF Position-Sensing Index Assembly and Cleaning Control keep nozzles properly positioned and air pulses correctly timed for optimum media cleaning. The timing sprocket is laser-cut and self-aligning, with direct-drive, mechanically linked components that have no chains or belts to break, wear out, or go out of adjustment, and no electronic circuits to fail. These operate reliably for years in abrasive and corrosive environments, with virtually no maintenance.
The tangential inlet controls heavy dust loads by utilizing Vortex Breakers built into the MCF housing, which even out the distribution of particulate-laden air coming from the tangential inlet for improved collection. Vortex Breakers create an area at the center of the housing where the air has no upward velocity and where dust particles cleaned from the bags can flow downward. A Spiral Ridge Plate traps centrifuged particles and drives them into the hopper.
The Medium-Pressure Blower Package uses a liquid-filled pressure gauge and powers cleaning with 7-9 psig (0.4-0.6 barg) air for economical operation and longer bag life. The use of medium-pressure air virtually eliminates cold-air shocks to bags, resulting in longer bag life.
Dimensions
| Model | Cloth (Sq. M) | Dimensions (MM) | Blower (kW) | ||||||
| A | B | C | D | E | F | G | |||
| TR96MCF112 | 99.4 | 2,135 | 2,240 | 10,420 | 797 | 435 | 6,474 | 2,015 | 1.6 |
| TR96MCF153 | 135.8 | 2,440 | 2,540 | 10,875 | 925 | 470 | 6,551 | 2,320 | 1.6 |
| TR96MCF204 | 181.2 | 2,745 | 2,845 | 11,290 | 1,025 | 515 | 6,474 | 2,610 | |
| TR96MCF255 | 226.4 | 3,050 | 3,175 | 11,715 | 1,140 | 635 | 6,616 | 2,915 | 3.0 |
| TR96MCF306 | 271.6 | 3,355 | 3,455 | 12,105 | 1,255 | 6,711 | 6,711 | 3,220 | 1.6 |
| TR96MCF361 | 320.6 | 3,660 | 3,785 | 12,505 | 1,370 | 675 | 6,756 | 3,525 | 3.0 |
| TR96MCF416 | 369.4 | 3,965 | 4,090 | 13,010 | 1,495 | 725 | 6,859 | 3,830 | 3.0 |
| TR96MCF494 | 438.7 | 4,270 | 4,370 | 13,425 | 1,597 | 770 | 6,919 | 4,115 | 3.0 |
| TR120MCF112 | 124.6 | 2,135 | 2,240 | 11,175 | 772 | 470 | 7,069 | 2,015 | 1.6 |
| TR120MCF153 | 170.2 | 2,440 | 2,540 | 11,560 | 885 | 510 | 7,161 | 2,320 | 1.6 |
| TR120MCF204 | 227 | 2,745 | 2,845 | 12,005 | 987 | 570 | 7,231 | 2,610 | |
| TR120MCF255 | 283.7 | 3,050 | 3,175 | 12,430 | 1,090 | 635 | 7,286 | 2,915 | 3.0 |
| TR120MCF306 | 340.5 | 3,355 | 3,455 | 10,420 | 1,217 | 695 | 7,356 | 3,220 | 3.0 |
| TR120MCF361 | 401.7 | 3,660 | 3,785 | 13,850 | 1,317 | 750 | 7,944 | 3,525 | 3.0 |
| TR120MCF416 | 462.9 | 3,965 | 4,090 | 14,360 | 1,432 | 805 | 8,039 | 3,830 | 3.0 |
| TR120MCF494 | 549.8 | 4,270 | 4,370 | 14,785 | 1,547 | 860 | 8,114 | 4,115 | 4.1 |
| TR144MCF112 | 149.9 | 2,135 | 2,240 | 12,470 | 732 | 510 | 7,846 | 2,015 | 1.6 |
| TR144MCF153 | 204.8 | 2,440 | 2,540 | 12,875 | 860 | 560 | 7,934 | 2,320 | 1.6 |
| TR144MCF204 | 273 | 2,745 | 2,845 | 12,690 | 950 | 620 | 7,879 | 2,610 | 1.6 |
| TR144MCF255 | 341.3 | 3,050 | 3,175 | 13,765 | 1,065 | 700 | 8,201 | 2,915 | 3.0 |
| TR144MCF306 | 409.6 | 3,355 | 3,455 | 14,060 | 1,665 | 745 | 8,261 | 3,220 | 3.0 |
| TR144MCF361 | 483.3 | 3,660 | 3,785 | 14,740 | 1,280 | 815 | 8,694 | 3,525 | 3.0 |
| TR144MCF416 | 556.9 | 3,965 | 4,090 | 15,245 | 1,370 | 840 | 8,796 | 3,830 | 3.0 |
| TR144MCF494 | 661.3 | 4,270 | 4,370 | 15,755 | 1,482 | 935 | 8,906 | 4,115 | 4.1 |
Common Applications:
- Grain milling
- Cement processing
- Lime processing
- Composite board manufacturing
- Process dust collection
- Chemical processing
- Food processing
- Sugar processing
- Mining
- Aggregates production
- Metals processing
- General woodworking
- Coal transfer
The AVR Dust Collector uses a horizontal tubesheet with rows of filter bags suspended in the filter housing. Dust-laden air enters the unit near the bottom and is drawn through the filter by a remote fan, with filtered air exiting through the clean air discharge at the top. The filtered dust collects on the outside of the filter media and falls into the hopper for collection. The unit features an air pulse cleaning system, which includes a compressed air manifold, diaphragm valve, and purge tube assembly, to clean the filter bags and dislodge dust into the hopper. The cleaning system can be controlled by a solid state electronic timer or a photohelic differential pressure gauge that responds to pressure differences across the filter, increasing filter bag life by only pulsing when needed and reducing compressed air consumption.
Applications
The AVR filter is a powerful solution for heavy dust loads, ideal for vacuum, pressure, and combination vacuum/pressure bulk pneumatic receiving and dust collection systems. It can be configured with an optional receiver for added versatility. With a circular body design and pulse jet cleaning system, the AVR filter is able to handle low air volumes and high pressure applications, making it suitable for sites with limited headroom. The filter bags are conveniently loaded from the bottom, and can be easily removed through an access door on the dirty side of the filter for maintenance. Additionally, for increased filtration efficiency and more filter area, the AVR filter can also be fitted with pleated cartridges (AVRC).
Benefits of Baghouses
One of the key benefits of baghouse dust collectors is their high efficiency. Baghouses can typically achieve collection efficiencies of 99.9% or higher, making them a popular choice for many industrial applications. Additionally, baghouse dust collectors are able to handle high volumes of air flow, making them suitable for use in large industrial processes.
Another benefit of baghouse dust collectors is their ability to handle a wide range of dust types and particle sizes. These systems can be designed to capture and remove particles as small as 0.1 microns, making them suitable for use in applications where very fine dust is present. Additionally, baghouse dust collectors can handle dust with a wide range of properties, including sticky, abrasive, or high-temperature dust.
Drawbacks
Despite their many benefits, baghouse dust collectors do have some drawbacks. One of the main drawbacks is the cost of the filter bags themselves. These filter bags need to be replaced periodically, and the cost of replacement can be significant. Additionally, the filter bags can become clogged with dust over time, which can reduce the efficiency of the system and require frequent maintenance.
In terms of service and maintenance, baghouse dust collectors require regular cleaning and replacement of the filter bags. On smaller units without jets this can be done without help from us by shaking the bags to dislodge the accumulated dust, which then falls into a hopper for disposal. Additionally, the system should be inspected regularly to ensure that it is operating correctly and that there are no leaks or other issues.
When it comes to system design and installation, baghouse dust collectors can be customized to meet the specific needs of the application. This includes selecting the appropriate filter media and filter bag size, as well as designing the overall layout of the system to ensure optimal performance. Additionally, proper installation is crucial to ensure that the system is able to function properly and efficiently. This includes ensuring that the system