Baghouse

In Part 2 of IAC’s “Key Parts of a Baghouse” series, IAC's Joe Haney takes a closer look at the critical components that keep your industrial dust collection system performing efficiently and in compliance. From filter bags and cages to pulse valves and differential pressure gauges, learn how each part contributes to reliable operation and optimal airflow.

Whether you’re a plant engineer, maintenance planner, or operations manager, understanding how your baghouse works helps you reduce downtime, extend filter life, and ensure emissions compliance.

What You’ll Learn:

How pulse cleaning systems maintain filter efficiency

The role of cages, bags, and venturis in dust filtration

Common signs of wear and when to replace key components

Maintenance best practices to improve uptime

Watch Part 1 here: https://www.youtube.com/watch?v=kkR2AWv-Oe4

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IAC offers complete Frac Sand Dry Plant solutions. Our expert engineers and process equipment specialists are available for everything from designing & building a complete plant, to onsite maintenance and troubleshooting services and optimization of process equipment, to engineering evaluations and inspections. IAC also supplies replacement spare parts.

IAC contracted with a Waste-to-Energy facility adjacent to a US Army Arsenal to remove and install 12 baghouse modules. The facility processes 690 tons of solid waste and sewage sludge per day, producing energy for the arsenal’s heating and air conditioning needs. The facility opened in 1990 and when it was determined that the original two baghouses needed to be replaced, IAC was awarded an EPC contract in April, 2017 to design, supply and install the new baghouses.

IAC was awarded a $50 million EPC contract to supply a variety of systems at the Drake Cement, Greenfield, Arizona Plant.

The install included silos, clinker handling, conveyors, waste product silo and additional fugitive collection systems for each.

This project required construction trades on site for over a five year period. The project incorporates $20 million EPC contract for a High Efficiency Separator.

For more information about all IAC can do, call us today at 800.334.7431 or visit us online at https://iac-intl.com

IAC, let's build something incredible.

IAC is an Engineering, Procurement, and Construction (EPC) Contractor and Original Equipment Manufacturer (OEM) of Baghouses, Dust Collectors, Pneumatic Conveying Systems, Heat Exchangers, and more for Cement Industry Plants and Terminals.. We also design and build Dry Bulk Storage Silos and Domes, and fully automated Transload and Truck Loadout Facilities.

Contact us today by calling 913-384-5511 to discuss your next greenfield build or capital improvement project.

IAC's New TIVACS Baghouse - Installation at ESM - Spring 2020

IAC Baghouse Demo and Install

3-D Animation of an IAC Steel Industry EPC Project for two OEM Reverse Air Baghouses and EAF Dust Handling System. IAC, and its subsidiary Adelphi Construction LC, handled all engineering, procurement, and construction. #IAC #EPC #dust control

Do you know the difference between a filter receiver and a baghouse? Often times, people think the two systems are one in the same, but this could not be further from the truth.

Industrial Accessories Company's Application Engineering Manager, Luis Castano, explains the importance of Air-to-Cloth ratio in Baghouse design, plus its relation to air velocity through the filters, and interstitial air velocity between the filters.

Luis Castano talks about the differences between and storage hopper and a collection hopper in a baghouse, and how to go about managing a collection hopper.

In this month's Tip of the Month Video, IAC's Luis Castano talks about how the differential pressure in a baghouse can provide insight to potential problems with the airflow.

Where are the HEPA filters in your Baghouse Industrial Ventilation system located? Before or after the fan? IAC Process Engineer Luis Castano explains how, as filtered air leaves the baghouse, proper HEPA filter placement is critical to optimal performance of downstream processing systems and prevention of possible contaminated air leaks.

Older reverse air and shaker style baghouses, some dating back to the 1950’s and 1960’s, are still in use today. However, they don’t work very well and often have restrictive access, low to no overhead space, or other issues that leave maintenance operators to struggle with the headaches servicing this equipment.

In this month’s IAC Tip of the Month Video, Process Engineer Luis Castano offers an elegant and simple solution of how to modernize older reverse air and shaker style baghouses within the housing, and convert them to more reliable and easier to service pulse jet systems. Conversion can be done at a lower cost than replacing the baghouse, and will achieve required capacity, making the investment an excellent option for many operations.

IAC Systems Engineer Luis Castano is back again with a tip about the importance of keeping your baghouse or dust collector system's discharge hopper free of grain load (fallen materials).

Proper airflow is very important to keeping your baghouse or dust collector system operating efficiently. When fallen material builds up in the hopper, air velocity is effected, and the performance of the baghouse is reduced. Using the appropriate discharge device, and placing it on a timer, will keep the hopper empty, allowing your baghouse run reliably. Learn more by watching this Tip of the Month video.

IAC and Adelphi Construction LC - Steel Industry Capabilities.
~ REVIEW VERSION~

Crane booms are in the air as the IAC and Adelphi Construction teams continue to make progress on the greenfield construction of the independent Reverse Air Baghouse Systems for two direct-current electric arc furnaces (DC-EAF), and two twin ladle furnaces (LF). IAC's project managers keep the lines of communication open with our on site personnel, our OEM fabrication facilities and outside equipment suppliers, specialized transportation fleets, and our client to ensure the project continues to run smoothly

IAC's capabilities go beyond supplying OEM dust handling & air pollution control equipment. We are a leading industrial EPC contractor. What makes working with IAC unique is our combination of OEM manufacturing capabilities, our multi-disciplined approach to engineering and design, our commitment to accurate project planning, budgeting, and safety, and our ability to execute fast track construction projects with our subsidiary company, Adelphi Construction LC.

For more information about IAC, visit https://iac-intl.com
For more information about Adelphi Construction, visit https://adelphiconstructionlc.com

IAC was awarded a turnkey EPC contract for the supply and construction of the independent Reverse Air Baghouse Systems for two direct-current electric arc furnaces (DC-EAF) having a capacity of 210 short tons (190 tons) each and two twin ladle furnaces (LF). Melt-shop Ventilation will include Canopy Exhaust above the EAF(s) and building ventilation. Total Air Volume of 3,300,000 acfm. IAC is building the EAF Dust Handling from the RAFFs to the Rail Car Load-out Silo.

IAC Steel Industry capabilities go beyond simply supplying OEM dust handling & APC equipment. We are a leading industrial EPC contractor. What makes working with IAC unique is our combination of OEM manufacturing capabilities, our multi-disciplined approach to engineering and design, our commitment to accurate project planning, budgeting, and safety, and our ability to execute fast track construction projects with our subsidiary company, Adelphi Construction LC.

#IAC #Adelphi #EPCcontractor

IAC Steel Industry EPC project construction time-lapse video with two (2) views. This video contains two (2) views of a steel industry greenfield Engineering, Procurement, and Construction (EPC) project from breaking ground at the project's start to July 2021.

Crews from IAC and our subsidiary construction company, Adelphi, have been onsite for nearly two years erecting the twin reverse air baghouses with a combined 3,000,000 CFM, along with the auxiliary equipment, and the Alloy Additives & HBI system for the company's Melt Shop Electric Arc Furnaces (EAF's).

The first half of the video shows the project in standard camera view. The second half of the video is the same time period in panoramic camera view.

Through growth of their business, a Midwestern USA handcrafter of fine custom cabinets and home fixtures needed to upgrade their woodworking dust collection system. After careful consideration of how their current dust collection system was handling the low moisture, mildly abrasive sawdust particulate, and what expectations they had for future growth, it was determined that the best course of action was to modify their baghouse dust collector with a high-pressure filter receiver.

In a process described as “pickin n’ puttin” by the foreman of the specialty welders brought in to assist IAC’s Blue Crew with the system modification, the existing ductwork and cyclone were removed and set aside for reuse, while the old dust collector, platform, safety ladder, and some structural steel pieces were removed and set aside for disposal.

IAC’s Blue Crew then installed the new top load baghouse filter receiver with hopper, rated at 4,000 AFCM @ 70 F, with a quantity of 80, 6.25” diameter x 96.50” long 16 oz singed polyester needled felt filter bags over 11-gauge, 12 wire, galvanized steel cages. The Blue Crew also installed, or reinstalled, steel bracing beams on the existing support structure, a new clean air plenum, caged access ladder, full perimeter handrail assembly around the top roof deck of the baghouse, and the existing cyclone and ductwork.

The entire project was completed in six (6) days from start to finish.

One of the biggest sources of operational problems in a ventilation system is the initial layout.

When we say the initial layout we mean the paper napkin phase of a project; the very first phase before any engineering has begun. Often, the problems in a baghouse can be traced back all the way to this beginning stage.

In this month's Tip of the Month video , Luis talks about how to properly utilize pulsing setpoints in a baghouse system.

IAC's Luis Castano describes the differences between a bottom load pulse-jet baghouse versus a top load pulse-jet baghouse.

In our October edition of the IAC Tip of the Month, Applications Engineering Manager, Luis Castano, provides tips on how to keep long filter bags from clumping together after a bag change out.

Over time we see that the systems within an industrial plant go through changes. These changes typically result in the system no longer meeting the expectations it once did. One of the more common systems that end up changing over time is a baghouse or dust collector. These systems act as the ventilation system in a plant and are a vital part of the overall process.

IAC's Eric Huggins provides information on properly installing filter bags in a baghouse dust collector.

You may be thinking to yourself that installing a snap band filter bag in your baghouse is easy; just bend the top of the bag, run the bag through the tube sheet and snap into place. If this sounds like you, then you’re going to want to keep reading!

There are some small but important details that go into snap band installation that often get overlooked and can lead to a damaged bag and poor dust collection performance.

IAC's Luis Castano joins us for another Tip of the Month where he shows how to properly install a snap band filter bag.

IAC's Luis Castano describes what the heart of every Pulse-Jet Baghouse is, and how to check if it's working properly.

In this month's Tip of the Month Video, IAC's Joe Haney discusses 5 considerations to take into account when a customer is purchasing a new dust collection system at their facility or replacing an old system.

Joe discusses the following 5 factors to consider when making this decision: Access, Clearance, Explosion Mitigation, Interstitial Velocity, & Accessories.
IAC's Engineering & Sales Teams can assist you in all of those aspects when providing a dust collection system for your unique application.

Check out our following resources on the IAC website for more information:
Baghouse Accessories: https://iac-intl.com/parts

IAC is your one stop source for all baghouse and pneumatic conveying related equipment and accessories! Call us at 800-334-7431 today for more information on how to get started.

Winterization kits for Pulse Jet Baghouses are an economical method for preventing condensation from forming in your baghouses' compressed air header.

IAC has a new Quick Ship program for replacing the Clean Air Plenum on our most popular sizes of pulse jet baghouses.

IAC's Eric Huggins joins us for this month's tip of the month where he addresses baghouse filter bag life. Short Filter Bag Life is often a complicated problem to diagnose. The following may be helpful in performing some preliminary checks.

First verify that the operating temperature is not above the recommended limit for the filter bag media. Each media type has a specific upper temperature limit in which it can operate safely.

Next check for signs of chemical attack. Bag materials can degrade due to certain chemicals present in the dust stream. A few to watch out for are: Oxygen levels above 15%, Alkaline, and Mineral Acids. High Moisture content along with relatively high temperate can also cause some medias to degrade quickly.

Next you will want to inspect the filter to see if there are any signs of localized abrasion. Abrasion of the filters at the top cuff could be due to incorrect installation or miss-aligned blowpipes. Abrasion of the filter bags at the dusty air inlet may require an inlet baffle modification. Corroded, rusted, bent, or broken support cages can also cause excessive bag wear. Available Stainless steel or coated cages can help to reduce cage related problems.

To insure your baghouse is always operating at peak efficiency, call our IAC Field Services team, The Blue Crew, and set up a routine maintenance program or inspection today.

If you’ve watched the first four parts of this Tip of the Month video series, then you’ve already sealed your doors, eliminated leaks in ductwork or welds, and even evaluated your own processes and physical plant location. Now we’re going to look at the bottom of the baghouse.

The fifth way moisture can get in your baghouse is at the airlock, located at the bottom of the baghouse dust collector. The airlock is designed to evacuate material from the baghouse, and it also designed to provide a mechanical seal. When the airlock fails to properly seal the bottom of the baghouse, it will allow moisture to enter the baghouse with outside air.

When this happens, moisture can react with the dust in the hopper, and cause bridging or material hardening issues. These issues artificially “shrink” the size of the hopper, which only compounds the maintenance problems removing dust from the hopper.

There are several reasons an airlock may not seal properly, and many times it can be simple to fix. Watch the video to learn more, and let IAC’s experienced aftermarket parts or Blue Crew maintenance & engineering experts help you troubleshoot moisture issues.

Many baghouses ventilate manufacturing process equipment designed to pull moisture out of a product, such as rotary dryers, fluid bed dryers, flash dryers, and certain types of classifiers. Naturally, some of this moisture eventually finds its way into the baghouse. While this is a normal part of many production processes, it can be worsened by two common factors.

First is that your plant is geographically located in a high humidity region, such as a coastal area. Second is that your process is batched and shut down every night or on the weekends.

Both operating conditions could pass through what’s called dew point, where water vapor in the baghouse becomes water droplets, which condense and create lots of operational issues in the baghouse.

These upset conditions are a little more complex to solve than other issues we've discussed. If you think either of these factors are contributing to moisture issues in your baghouse, please give us a call.

In this month's Tip of the Month Video, Luis talks to us about utilizing the bag pinch technique for baghouse filter bags.

How does moisture get inside a baghouse dust collector? There are five common ways as explained by Joe Haney, IAC Product Specialist. In this Tip-of-the-Month video series, we’ll take a look at the five most common ways moisture enters a baghouse and offer solutions you can implement to prevent this problem and keep your baghouse dust collector operating at peak efficiency.

Part 3 of 5: Inspect the Baghouse's Cleaning System

By now you’ve checked your door seals, housing, and ductwork, and have repaired all leaks found. If you’re still struggling with moisture in your baghouse, the next step is to check the cleaning system, which includes the air manifold, blow pipes, and pulse valves delivering compressed air into your baghouse.

The clean air plenum (or ‘top’ of the baghouse) is typically cooler than the dirty air plenum. This is, in part, caused by the compressed air used in the cleaning system. Air, when compressed, cools in temperature. If there is water vapor in the clean air plenum, the temperature changes may accelerate water droplets forming, causing corrosion or other problems, such as backside filter blinding due to agglomeration.

If your compressed air isn’t dry and clean, reactions will expedite, impinging these contaminants into your filters with each cleaning cycle. This happens when the contaminated air travels through your blowpipes and is blasted into your filter media. Baghouses don’t like moisture, It can build up and start to cause problems with function and performance of the filter elements, ultimately shortening the lifespan of the filters and causing unplanned outages.

Joe Haney offers several easy-to-implement solutions to fix moisture issues related to compressed air delivery that will save your plant time and money. Contact IAC today and let our Blue Crew Field Maintenance Team assist with your baghouse needs!

How does moisture get inside a baghouse dust collector? There are five common ways as explained by Joe Haney, IAC Product Specialist. In this Tip-of-the-Month video series, we’ll take a look at the five most common ways moisture enters a baghouse and offer solutions you can implement to prevent this problem and keep your baghouse dust collector operating at peak efficiency.

Part 2 of 5: Holes in Ductwork or Baghouse Structure:

From the inlet on your baghouse, all the way back to your process, any open areas in the ductwork, such as small holes or poorly attached expansion joints, will create easy points for your fan to pull in outside air instead of drawing it from the pick-up point. This causes two issues – it allows moisture in, and it starves your process from the air it needs to be properly ventilated.

The baghouse structure could also have open areas allowing outside air and moisture in, such as an aging flange joint, or a hopper with a welded seam that’s begun to open up. You have to inspect it and repair it!

So, what do you do? The ductwork and baghouse structure must be inspected and repaired. In this video, Joe Haney gives tips on proper ductwork and baghouse inspections. IAC offers training seminars on ventilation system maintenance for plant maintenance personnel. We also provide specially trained field engineers and maintenance professionals who can perform inspections for you. Contact us today for more information!

How does moisture get inside a baghouse? There are five common ways as explained by Joe Haney, IAC Product Specialist. In this Tip-of-the-Month video series, we’ll take a look at the five most common ways moisture enters a baghouse and offer solutions you can implement to prevent this problem and keep your baghouse dust collector operating at peak efficiency.

Part 1 of 5: Door Seals

It’s very common for seals around access doors and ports to wear out. Doors and access ports are regularly opened for inspections of the conditions inside the baghouse but inspecting the seals around them is often overlooked.

Doors and ports are also opened when unexpected downtime situations occur. Since these situations require a timely response in order to get production back up and running, door seals can get damaged incidentally, without being noticed. Environmental conditions, such being outdoors and exposed to elements, can also wear out seals over time.

When seal gasket material wears out, it fails to prevent outside air from getting in the baghouse dust collection system. More than likely, anytime outside air gets into a baghouse filtration system, moisture does too. The fan on your baghouse is always going to pull air from wherever it can get it the easiest. Therefore, if outside air is leaking into your baghouse around doors and ports, then that’s were your system is going to get airflow, as opposed to back at your process source.

Joe Haney gives tips on inspecting door seals for leaks, and recommendations on when to replace. Contact IAC for our Door Seal Guide and get a quote on the right type of seal material for your application!