A Short Cleaning Cycle (i.e. Frequent Cleaning) Can Have An Impact OnPulse Dust CollectorThe Performance, Lifespan, And Operating Costs Have Multiple Impacts, And The Following Is A Specific Analysis:
1、 Shortening The Lifespan Of Filter Bags
Mechanical Wear Intensifies, And The Impact Frequency Of Pulse Airflow On The Filter Bag Increases During Dust Cleaning. The Friction Between The Filter Bag And The Skeleton Also Increases, Leading To Accelerated Damage To The Fiber Structure Of The Filter Bag (such As Surface Coating Peeling And Fabric Tearing).
A Short Cleaning Cycle (i.e. Frequent Cleaning) Can Have Multiple Impacts On The Performance, Lifespan, And Operating Costs Of Pulse Dust Collectors. The Following Is A Specific Analysis:
1、 The Lifespan Of Filter Bags Is Shortened, And Mechanical Wear Is Exacerbated
The Impact Frequency Of The Pulse Airflow On The Filter Bag Increases During Dust Cleaning, And The Friction Between The Filter Bag And The Skeleton Increases, Leading To Accelerated Damage To The Fiber Structure Of The Filter Bag (such As Surface Coating Peeling And Fabric Tearing).
Frequent Expansion And Contraction Due To Fatigue Aging Of Filter Bags Cause Fatigue In The Filter Bag Material, Especially Under High Temperature Conditions (such As Coal-fired Boilers), Where The Bending Resistance Of Filter Bags Decreases Faster And Holes Or Perforations Are Prone To Occur.
2、 Rising Energy Consumption And Operating Costs
The Consumption Of Compressed Air Increases Sharply, And The Shorter The Cleaning Cycle, The More Times The Pulse Valve Is Opened. Taking A Dust Collector With A Processing Capacity Of 100000 M ³/h As An Example, Reducing The Cleaning Cycle From 10 Minutes To 5 Minutes Can Increase Compressed Air Consumption By 50%, And The Annual Energy Consumption Cost May Increase By Tens Of Thousands Of Yuan.
The Increase In Equipment Power Consumption Results In Long-term High-frequency Operation Of Components Such As Pulse Valves And Control Systems, Leading To An Increase In The Failure Rate Of Electrical Control Systems (such As PLC And Solenoid Valves). At The Same Time, The Air Compressor Needs To Operate Continuously To Maintain Air Pressure, Resulting In A Significant Increase In Power Consumption.
3、 Fluctuations In Dust Removal Efficiency
The Premature Destruction Of The Dust Layer On The Surface Of The Filter Bag ("initial Layer") Is A Key Barrier For Dust Removal. Short Cycle Dust Cleaning Will Remove The Initial Layer Too Early, Causing Fine Dust To Penetrate The Filter Bag And Increase The Outlet Emission Concentration (such As From 30mg/m ³ To 50mg/m ³ Or More), Which May Violate Environmental Standards.
Frequent Fluctuations In Instantaneous Pressure During Dust Cleaning Can Cause A Sudden Change In The Internal Air Pressure Of The Dust Collector, Which May Lead To An Increase In The Amount Of Dust Adsorbed By Some Filter Bags, Resulting In "secondary Dust" And Ultimately Reducing Dust Removal Efficiency.
4、 Wear And Failure Of Equipment Components
The Pulse Valve And Injection System Are Damaged, And The Pulse Valve Diaphragm Is Prone To Fatigue Rupture During High-frequency Opening And Closing. The Interface Of The Injection Pipe May Leak Or Loosen Due To Increased Vibration, Affecting The Injection Pressure (such As Reducing From 0.6 MPa To Below 0.4 MPa), Resulting In A Decrease In The Cleaning Effect.
Control System Overload
Frequent Execution Of Dust Cleaning Instructions By PLC Programs Can Accelerate The Wear And Tear Of Components Such As Relays And Contactors, Which May Cause Control Failures (such As Disorderly Dust Cleaning Sequence, Missed Or Erroneous Spraying).
5、 Abnormal System Pressure Loss
Under Normal Cleaning Cycles, The Resistance Of The Dust Collector Should Remain Stable At 1000-1500Pa Due To Unnecessary Resistance Fluctuations. If The Cycle Is Too Short, The Resistance May Drop Sharply To Below 800Pa After Cleaning, And Then Quickly Rise Again, Forming Severe Fluctuations That Affect The Power Matching Of The Fan (such As Frequent Load Changes And Increased Energy Consumption).
Frequent Dust Cleaning May Cause The Fiber Gaps Of The Filter Bag To Be Repeatedly Squeezed By Dust, Leading To Long-term Hardening Of The Filter Bag And A Decrease In Breathability. Even After Dust Cleaning, The Resistance Is Difficult To Recover To The Ideal Value.
6、 Increased Maintenance Workload
The Increase In Daily Maintenance Frequency Requires More Frequent Inspections Of Filter Bag Damage, Pulse Valve Sealing, Spray Pipe Tightness, Etc., Resulting In An Increase In Maintenance Hours (such As Reducing The Original Monthly Maintenance To Once A Week).
The Replacement Cost Of Spare Parts Increases, And The Replacement Cycle Of Vulnerable Parts Such As Filter Bags, Pulse Valve Membranes, And Solenoid Valves Is Shortened. According To Statistics, A Short Cleaning Cycle Can Increase The Cost Of Spare Parts By 30% -50%.
7、 Additional Risks Under Special Working Conditions
How To Avoid The Negative Impact Of Short-term Dust Cleaning?
In Short, A Short Cleaning Cycle Does Not Necessarily Mean "more Thorough Cleaning", But May Instead Trigger A Series Of Chain Problems, Requiring A Balance Between "cleaning Effectiveness" And "equipment Wear And Tear".
Frequent Dust Cleaning Can Cause A Sudden Change In The Internal Air Pressure Of The Dust Collector, Which May Lead To An Increase In The Amount Of Dust Adsorbed By Some Filter Bags Instantly, Forming "secondary Dust" And Actually Reducing The Dust Removal Efficiency.
4、 Wear And Failure Of Equipment Components
The Pulse Valve And Injection System Are Damaged, And The Pulse Valve Diaphragm Is Prone To Fatigue Rupture During High-frequency Opening And Closing. The Interface Of The Injection Pipe May Leak Or Loosen Due To Increased Vibration, Affecting The Injection Pressure (such As Reducing From 0.6 MPa To Below 0.4 MPa), Resulting In A Decrease In The Cleaning Effect.
Control System Overload
Frequent Execution Of Dust Cleaning Instructions By PLC Programs Can Accelerate The Wear And Tear Of Components Such As Relays And Contactors, Which May Cause Control Failures (such As Disorderly Dust Cleaning Sequence, Missed Or Erroneous Spraying).
5、 Abnormal System Pressure Loss
Under Normal Cleaning Cycles, The Resistance Of The Dust Collector Should Remain Stable At 1000-1500Pa Due To Unnecessary Resistance Fluctuations. If The Cycle Is Too Short, The Resistance May Drop Sharply To Below 800Pa After Cleaning, And Then Quickly Rise Again, Forming Severe Fluctuations That Affect The Power Matching Of The Fan (such As Frequent Load Changes And Increased Energy Consumption).
Frequent Dust Cleaning May Cause The Fiber Gaps Of The Filter Bag To Be Repeatedly Squeezed By Dust, Leading To Long-term Hardening Of The Filter Bag And A Decrease In Breathability. Even After Dust Cleaning, The Resistance Is Difficult To Recover To The Ideal Value.
6、 Increased Maintenance Workload
The Increase In Daily Maintenance Frequency Requires More Frequent Inspections Of Filter Bag Damage, Pulse Valve Sealing, Spray Pipe Tightness, Etc., Resulting In An Increase In Maintenance Hours (such As Reducing The Original Monthly Maintenance To Once A Week).
The Replacement Cost Of Spare Parts Increases, And The Replacement Cycle Of Vulnerable Parts Such As Filter Bags, Pulse Valve Membranes, And Solenoid Valves Is Shortened. According To Statistics, A Short Cleaning Cycle Can Increase The Cost Of Spare Parts By 30% -50%.
7、 Additional Risks Under Special Working Conditions
How To Avoid The Negative Impact Of Short-term Dust Cleaning?
In Short, A Short Cleaning Cycle Does Not Necessarily Mean "more Thorough Cleaning", But May Instead Trigger A Series Of Chain Problems, Requiring A Balance Between "cleaning Effectiveness" And "equipment Wear And Tear".
