Filter cartridges are used in many applications in dust collectors, so many people call them dust collector cartridges. The industrial environment’s pollutants, temperature, and humidity are relatively complex, so that the filter cartridge will encounter many problems during use. In this article, I have compiled 9 problems and solutions.
1. The filter material is stuck, hardened, and corroded
It is common for the filter material of the filter cartridge to become stuck and hardened in an industrial environment.
In the desulfurization industry, sulfur in coal is burned to form sulfur dioxide, which would be more expensive to capture directly.
Sulfur dioxide is attached to the dust particles. If a certain amount of calcium hydroxide lime powder is added. Calcium sulfate will be generated through the reaction and attached to the filter material during filtration to achieve collection.
However, water and tar are generated during the reaction, which can easily cause clogging and hardening, reducing the filter cartridge’s dust removal efficiency. At the same time, sulfur dioxide dissolves in water to form sulfuric acid, which is corrosive and damages the filter material.
To blow down the clogged dust during cleaning, greater injection pressure and frequency are required. Greater injection pressure and frequency will intensify the wear of the filter material and significantly reduce the life of the filter cartridge. Tar and other sticky substances adhering to the surface of the filter material are difficult to remove, so filter materials that have been used for a long time should be cleaned regularly.
Solution
Therefore, in the desulfurization industry, it is necessary to use filter materials that are acid-resistant, high-temperature resistant, strong, wear-resistant, and easy to clean.
2. Filter cartridge size restrictions
Cartridge dust collectors are suitable for many industries and have high filtration efficiency. The filtration efficiency for sub-micron particles is as high as 99.99%. It has low filtration resistance, energy consumption, and operating costs. Due to surface filtration, dust particles are easily discharged during cleaning, and compared with bag dust collectors, it is easier to replace the air filter.
Due to the limitations of filtration wind speed and filter cartridge height, the air volume handled by the dust collector cannot meet the requirements.
Solution
To meet the needs of the dust removal process, we increased the filter cartridge’s height to 1400mm in the design, and its filtration area was significantly increased. After the height is increased to adapt to high-concentration dust conditions, the creases of the filter cartridge are widened to 2~12mm during production so that the dust entering during dust removal and filtration can be easily removed, thereby preventing dust from accumulating and remaining in the creases.
3. The placement of the filter cartridge is inappropriate
The most common types of filter cartridge placement are vertical and horizontal. The vertical dust cleaning effect is better, but it takes up a larger space, and the finer dust particles are easily blown up again after cleaning, causing primary dust. The horizontal type is generally downstream and has a better filtration effect, but the dust in the upper filter cartridge will affect the lower filter cartridge during dust cleaning, causing uneven dust cleaning.
Solution
Choose the appropriate placement method according to the working conditions, determine the frequency of dust cleaning, and increase the air blowing appropriately.
4. High-temperature environmental impact
Purifying dust-containing gases emitted by industrial furnaces is essential in current environmental protection and governance. Due to the relatively low temperature of the filter material used in filter dust removal devices, dust collectors often use ordinary cartridge filters in high-temperature environments. The material cannot meet the requirements and is often burned out.
Solution
We have developed a high-temperature-resistant filter cartridge with high strength, porosity, and air permeability, and it is not easily deformed during sintering.
Our high-temperature-resistant nonwoven filter cartridge is made of high-temperature-resistant and high-strength glass fiber and is formed through stiffening. It has the characteristics of dense fibers, small surface micropores, and firm texture. It has the characteristics of good stiffness, good wear resistance, and good chemical resistance and is suitable for occasions with high-temperature requirements.
5. The filter cartridge is not cleaned thoroughly
The operating status of the filter cartridge and the speed of resistance rise are closely related to the dust cleaning system.
In the desulfurization dust collector, dust is easy to harden on the surface of the filter cartridge, and sticky substances adhere to the surface of the filter material. A more considerable injection pressure and frequency are required to achieve an ideal effect, which generates additional energy costs.
The choice of filter material will also have a certain impact on the injection system.
I found that many projects have the problem of incomplete backflushing of the filter cartridge.
Project case: During the trial operation of a boiler dust removal project, we found that the early dust cleaning effect was better than expected, but after running for some time, it did not meet the design requirements.
Solution
By adjusting the blowing interval of the electromagnetic pulse valve, the nozzle was improved, and the compressed air pressure was increased, successfully solving the problem of incomplete backflushing.
6. Improper use of compressed air volume and pressure
For some relatively long filter cartridges, due to insufficient compressed air volume or pressure, the lower part of the filter cartridge is not thoroughly cleaned, and the dust layer at the lower part of the filter cartridge is thicker, which reduces the dust removal efficiency of the entire filter cartridge.
Because the filter cartridge is long, a nozzle is installed at the bottom of the filter cartridge to induce a certain amount of air to achieve a better dust-cleaning effect.
However, due to the nozzle installation, the upper part of the filter cartridge is basically in the air induction stage, and the compressed airflow does not have time to spread, resulting in poor dust cleaning in the upper part.
solution
A circle of baffles is set up in the upper part of the filter cartridge, which changes the flow field of the airflow in the upper part of the filter cartridge during filtration and cleaning, thereby improving the upper dust cleaning effect.
7. Effect of filter cartridge angle
I conducted an experimental study on the backflush cleaning performance of four different specifications of filter cartridges. The test results show that the filter cartridge’s angle greatly influences the filter cartridge’s dust-cleaning performance. When the angle of the filter cartridge is small to a certain extent, online backflush cleaning is ineffective, and offline cleaning must be used.
solution
Reasonable selection of the angle of the filter cartridge based on factors such as filtration area, filtration wind speed, filter cartridge size, space, etc., will significantly improve dust removal efficiency and reduce resistance.
8. Improper installation position of electromagnetic pulse valve
If the installation position of the electromagnetic pulse valve is slightly deviated, the dust-cleaning effect of the filter cartridge will be poor. The side facing the airflow will have a better dust-cleaning effect, while the other side will have a poor one.
At the same time, the side facing the airflow is more seriously worn due to the long-term direct injection.
solution
The general requirement for installing the electromagnetic pulse valve is that the injection port faces the center of the filter cartridge to ensure that the injection airflow can enter along the center line of the filter cartridge.
9. Airflow distribution problem
Airflow distribution is also critical to improve the efficiency of filter cartridge dust removal. If the airflow distribution plate is too close to the filter cartridge, the high wind speed will cause high wear areas on the filter material. The filter cartridge cannot fully utilize the airflow if the distance is further away.
solution
Use a porous airflow distribution plate in the dust collector. This airflow distribution method is widely used in electrostatic precipitators and is rarely used in other dust collectors. However, it has unique requirements when used in cartridge dust collectors. The airflow distribution must be very stable and uniform. , which is conducive to the rise of airflow and the fall of dust.
Uniform filtration wind speed on the surface of the filter cartridge is also an essential symbol of airflow distribution. In application, it is necessary to ensure that as many filter cartridges as possible of the dust collector can work within a reasonable filtration wind speed range.
Last summary
As a top filter cartridge manufacturer, we have encountered and helped customers solve many problems. At the same time, the design of our filter cartridges is scientific and combined with practice so that our filter cartridges can help you complete various filtration tasks.
