Efficient operation of baghouses is an expected and necessary element of foundry productivity. These manufacturing facilities and systems assure clean and safe work environments, allowing people and equipment to operate without interruption. When the media, often filter bags, employed in the baghouses plugs with collected solid matter, immediate maintenance is an absolute priority. The proper function of baghouse filtration is integral to efficient foundry operations.
This was the case at a large foundry located in the United States where restricted air flow to mold cooling and sand handling equipment had reached a critical point.
The foundry employed a 450-bag Carborundum pulse-jet baghouse. The system had been designed with an air-to-cloth ratio of 9.3:1, aggressive by any standards. The processing at the foundry exposed the filter media to very fine particulate. Specifically, the particulate came from the sand handling system. This particulate, along with high moisture and hydrocarbon carryover from the mold cooling line, formed a substantial and difficult dustcake on the filter media in the baghouse. After only six months of service, blinded filter bags caused differential pressure to exceed 8” w.c., greatly reducing airflow venting of the applications. As a result, time-consuming and costly filter bag and cage change outs were required.
The foundry determined that they needed the help of experts in the area of filtration, specifically with baghouse efficiency and performance. They turned to Parker Hannifin, a leader in the design and manufacture of filtration systems. Parker recommended replacing filter bags and cages with BHA® PulsePleat® Filter Elements — a versatile and cost-effective solution. They designed the system in order to increase the total filtration area of the dust collector by over 220%. This was done with no physical modification of the dust collector.
The new system, featuring an increased filter surface area of the pleated elements, helped lower average differential pressure to 3.5” w.c. — a greater than 40% reduction from the peak of 8” w.c.
Fan amps went up by 157%, increasing air volume through the dust collection system and providing the ventilation needed by the process applications for optimum performance.
The one-piece bottom-load design of BHA® PulsePleat® filters elements reduced filter installation time by 70%.
The increased filter surface area contributed to a dramatic reduction of unplanned maintenance time and expense.
By installing BHA PulsePleat filter elements, the foundry returned to efficient production and avoided the high costs of unplanned maintenance and baghouse redesign or replacement.
To learn more about BHA PulsePleat filter elements, watch this video:
Article contributed by the Industrial Air Filtration Team.