When should you actually consider putting a cyclone dust collector ahead of your baghouse?

Making the decision to implement a cyclone dust collector in your existing dust collection setup is a big one.

We don’t need to remind you that because dust collection is inherently tied to EPA regulations and workplace safety compliance, baghouses and other fabric filters are an excellent way to capture material cycling through your process.

Baghouse 101: What to Watch for

As dust-laden air travels through a collection system, it passes through the system of fine filter media that baghouses utilize to intercept and collect particulate. That dust collects on the filter until it is either cleaned or replaced, so that only clean air is vented out of the collection system.

Baghouses perform best when they are not subject to high particle loading or exposed to excess heat and moisture. These conditions can present challenges that force the filters to work harder, requiring frequent cleanings, maintenance, and replacement. Depending on the material(s) they’re filtering and the process conditions, baghouses can oftentimes benefit from some extra upstream filtration via a cyclone dust collector.

So—how do you know when it’s time to think about adding a buffer between your baghouse and the rest of the collection system? Hint- we’ve already touched on it.

First, ask:

1. Does the process create situations where heavy dust loading is possible?
2. Does the process involve airstreams with high temperatures?
3. Are airstreams traveling throughout the dust collection system exposed to moisture?
4. Does the process contain dust that is fibrous, sticky, or hygroscopic?
5. Does the material in your process need to be captured for reuse or resale?

If you answered yes to any of those questions, then, ask:

1. Are you noticing baghouse filters frequently become clogged or blinded?
2. Are filters subject to unsafe fire risk? If yes, is an adequate spark arrestor in place?
3. Is frequent downtime for maintenance and replacements causing issues? If yes, is this creating budget or profit concerns as a result of decreased production time?
4. Are you experiencing issues with product reclamation as a result of filter complications? Is the volume of material reclaimed worth the cost and effort of reclaiming it?

If you answered yes to one or more of the problem questions on the second list, your process may benefit from the implementation of a cyclone dust collector upstream of your fabric filters.

When placed ahead (or upstream) of fabric filters like baghouses, cyclone dust collectors have a big impact. They act as a pre-filter, collecting the majority of particulate before it comes in contact with downstream filters. By removing large, coarse dust before it reaches the baghouse, the loading the filter(s) have to handle is reduced; less dust in the airstream also equals greater removal efficiency.

In applications where dust is hygroscopic or sticky, a cyclone will remove the majority of particulate before it reaches the baghouse. When baghouses handle less dust, their bags last longer and they are less prone to needing frequent compressed air cleaning or replacements; the more dust the filter has to handle, the more it has to be cleaned. Baghouses can unfortunately be high maintenance because of their bag changing requirements, plus the associated costs and downtime—particularly if an outside contractor is hired in to change or clean the bags. Those costs add up, and can eat into any business’ bottom line. Cyclones, however, require little maintenance: observe the pressure drop and inspect the cyclone on a routine basis, (notice we used the word routine rather than frequent) watching for any signs of wear and tear, and you’re well on your way. Depending on the application, cyclone dust collectors acting as baghouse pre-filters can extend bag life by a year or more.

MORE ON CYCLONE DUST COLLECTORS

In terms of product reclamation, baghouses aren’t always ideal for valuable materials, because dust has a propensity to get lost either in the filters or during the cleaning process. Cyclones, however, do not require any filtration, and all recovered material can be reclaimed through the attached discharge valve.

For processes with high-temperature exhaust gas streams, filters are subject to the possibility of burn damage and fire risk. While high-temperature filter bags are available, they can be an expensive addition and are still not completely immune to process temperatures. In these situations, the right cyclone collector acts as both a pre-filter and a spark arrestor, reducing the temperature of the air stream, increasing the time and space any sparks have to travel (giving them more time to burn out), and reducing the particulate loading before it comes in contact with downstream filtration media.

Cyclone pre-filters can have a big impact on your process.

In the right situation, cyclone pre-filters can extend filter life, decrease the frequency and cost of maintenance demands, and increase your process’ removal efficiency—all of which help make your workplace safer. With all this information in mind, it’s important to mention that you should still be weighing factors like materials, labor, and downtime against the cost of implementing a cyclone dust collector into your process.

To address questions about whether a cyclone dust collector could be the right pre-filter for your application, we always recommend speaking with a member of our experienced engineering team.

—

Try our new cyclone configurator below, a tool designed to help you research cyclone options for your application.

We always recommend running your results by a member of our engineering team for sizing and other specifications.