Cement

The LCMC type low pressure long bag pulse dust collector is a new generation low pressure long bag pulse dust collector developed and designed on the basis of the design and manufacturing experience of the LCM type low pressure long bag pulse dust collector, combined with the ultra low emission requirements of the steel and machinery industries. The product retains the advantages of the original long bag pulse dust collector and gives full play to the advantages of pulse jet cleaning. It adopts filter materials with temperature resistance, corrosion resistance and high filtration precision, and is applied to the ultra clean filtration of flue gas in ironmaking yards, ore tanks, converters, electric furnaces and sintering machines in the steel industry to meet the ultra - low emission requirements. The product has been developed into an efficient bag type dust collector that meets various air volume requirements in the steel industry, and can also be used in other types of large scale dust removal projects like ball mill grinding plant.

Baghouse Dust Collectors in industrial applications can be categorized into two core types: process baghouse and nuisance baghouse. These two types play distinct roles within production systems, and their performance directly impacts production continuity and the quality of the working environment.

Process baghouse units are core supporting equipment for the production process, with their operational status deeply tied to the primary production system. A failure or downtime can directly slow or even completely halt production. These dust collectors are primarily used for process dust collection, treating dust generated at the core of the production process—such as flue gas dust from boiler combustion (typically with dust concentrations reaching 50-200 g/m³), high-temperature dust-laden gases from kiln firing (often exceeding 200°C), and ultrafine dust (as small as 1-5 μm) generated during mill grinding. Typical baghouse dust collector applications for process units include pulverized coal boilers in the power industry, rotary kilns in the cement industry, and blast furnaces in the metallurgical industry. Due to their criticality to production, process baghouse systems typically must respond to failures within 2-4 hours. Failure to do so could result in tens of thousands of yuan in production losses per hour, and could also lead to fines from environmental protection authorities for exceeding emission standards (according to China's Air Pollution Prevention and Control Law, exceeding emission standards can result in fines of up to three times the value of the goods).

Nuisance baghouse systems primarily target "auxiliary dust sources" within the production process, handling nuisance dust collection of suspended particulate matter generated during material transfer or the operation of auxiliary equipment. While this type of dust does not directly disrupt production, it can affect the work environment and personnel health. Examples include dust generated by the drop in material flow on belt conveyors (dust concentrations typically range from 1-10 g/m³), metal fume generated during welding operations (containing harmful components such as manganese and chromium), and quartz sand dust from sandblasting (which can contain over 90% free silica and can cause silicosis with long-term exposure). Typical baghouse dust collector applications for nuisance units include exhaust dust removal from storage silo ceilings, localized dust removal at welding stations within workshops, and dust collection from bagging machines. While failures in these dust collectors won't directly cause production halts, inefficient operation can cause dust concentrations in the workplace to exceed national occupational health standards (generally requiring a dust concentration below 2 mg/m³). This not only increases workers' risk of respiratory illnesses, but also accelerates mechanical wear due to dust adhesion to equipment surfaces, shortening equipment maintenance cycles by 30%-50%, indirectly increasing production costs.

The two types of dust collectors have significant design differences: process baghouse systems must withstand harsh operating conditions such as high temperatures, high concentrations, and corrosive environments. They often utilize high-temperature resistant filter media (e.g., aramid fiber can withstand temperatures of 200°C, glass fiber can withstand temperatures of 260°C) and high-strength cleaning systems. Nuisance baghouse units, on the other hand, prioritize cost-effectiveness and flexibility, often using conventional polyester filter media. The filter area can be flexibly configured to suit the workshop layout. This classification not only helps companies make accurate model selections but also guides the rational allocation of operations and maintenance resources. Process baghouse systems require backup systems and prioritized maintenance, while nuisance baghouse units can focus on routine preventative maintenance, balancing environmental compliance with production costs.

Baghouse Dust Collectors, as highly efficient dry dust removal equipment, utilize specialized fabric filters to filter and separate dust-laden gases. With exceptional dust removal efficiencies (typically exceeding 99.9%), these devices are the most widely used air pollution control (APC) devices in the industrial sector, serving a wide range of applications requiring dry dust removal, from machining to thermal power generation.

Unlike the simple filtration mechanism of conventional vacuum cleaners, the core advantage of Baghouse Dust Collectors lies in their integrated intelligent filter cleaning system. When dust accumulates on the filter bags surface to a certain level, the cleaning system automatically cleans the filter media’s through mechanical vibration, pulse jets, or backwash. This prevents sudden increases in system resistance caused by bag clogging while continuously restoring the filter media’s air permeability (typically maintaining a stable filtration velocity of 1-3 m/min). This extends the filter bags' service life to 1-3 years, significantly reducing operational and maintenance costs.

Structurally, a Baghouse Dust Collector consists of a metal shell forming the main frame. The interior is separated into a dust-laden zone and a clean zone by perforated tube sheets (also known as unit plates). The open end of the filter bags is tightly connected to the perforations of the tube sheet using clamps, springs, or sealants, forming the key channel for gas filtration. During operation, dust-laden gas first enters the dust-laden side of the shell (mostly the lower area). Driven upward by a pressure differential, it passes through the filter bags. Dust particles are trapped on the outer surface of the filter bags due to inertial collision, interception, and diffusion. The purified gas then enters the clean side (mostly the upper area) and is discharged.

The captured dust is then removed by a cleaning system and temporarily stored in a hopper at the bottom. Depending on the dust output, dust can be transported to a storage silo via regular manual removal (suitable for low-volume applications, such as laboratory dust removal) or mechanical or pneumatic conveying systems (suitable for high-volume applications, such as cement production lines) for centralized treatment or recycling.

Filter bags specifications vary to suit different operating conditions: Round filter bags with diameters of 5-6 inches (approximately 127-152mm) are the most common, with specialized sizes ranging from 2-12 inches (approximately 51-305mm) also available. Lengths range from 3 feet (approximately 0.9m) to 40 feet (approximately 12.2m). Furthermore, there are special shapes such as oval and flat rectangular envelope filters, as well as specialized types such as pleated cartridge filters and ceramic candle filters. Ceramic filter media’s can withstand temperatures exceeding 800°C, making it suitable for use in extreme environments such as waste incineration.

In equipment selection and design, the air-to-cloth ratio (also known as filtration velocity) is a key parameter. It is defined as the ratio of the processed air volume to the total filter area. Reasonable air-to-cloth ratio directly affects dust removal efficiency and system energy consumption: for example, when dealing with conventional dust, the air-to-cloth ratio is generally 1-2m/min, while when dealing with ultrafine dust, it needs to be reduced to below 0.8m/min to ensure the filtration effect and reduce filter bags' wear.

Baghouse dust collectors has spare parts like filter bags, cages, valves, covering functions from filtering dust to keeping the system sealed and cleaning the filters. Below is a clear breakdown of the most important ones, using expert terms but simple grammar.

First are the core filtration spare parts—the parts that directly catch dust, so they need regular replacement because of wear, clogging, or damage from chemicals. The most critical here is the filter bag (a key component of Baghouse Filters, Cages, and Parts), which is the "heart" of the baghouse. For some modern designs, pleated filter elements are used instead of traditional filter bags; these elements have a folded structure that boosts filter area, making them ideal for compact industrial dust collectors. Both filter bags and pleated filter elements use specialized filter media (such as polyester, aramid, glass fiber, or PTFE-coated fabric) to trap dust particles, with filtration efficiency usually over 99.9%. Spares must match the original size, media type, and surface treatment (like anti-static or oil-resistant coatings)—for example, a cement plant’s baghouse might use heat-resistant glass fiber filter bags, while a food processing plant could use food-grade polyester pleated filter elements. Another essential part in this group is the filter bag cage (also called a support cage, and part of Baghouse Filters, Cages, and Parts). This is a metal frame (often galvanized steel or stainless steel) that keeps filter bags open during operation—so air can flow through—and prevents them from collapsing when the cleaning system runs. Over time, filter bag cages can rust or bend, so spare cages are needed to avoid damaging the filter bags.

Next are filter cleaning system spare parts, which are key accessories for any type of industrial dust collector—they keep the cleaning process working to stop filter bags from clogging. For pulse jet baghouses (the most common type), the key spares are pulse valves—small valves that release bursts of compressed air to blow dust off filter bags. Spare pulse valves must match the original air pressure rating (usually 0.5–0.7 MPa) to ensure strong, consistent blasts. Also, pulse valve diaphragms (the flexible part inside the valve that controls air flow) wear out quickly, so they’re often stocked as separate accessories. For reverse air baghouses, spare damper valves are essential—these valves control the flow of reverse air that cleans the bags; if a damper valve leaks, cleaning won’t work well. For older shaker-style baghouses, vibration motors and spring assemblies are key accessories too: the motor creates vibration to shake dust off filter bags, and springs absorb shock—both parts can break from constant movement.

Then there are sealing and structural spare parts, many of which are wear components (parts that wear down over time) for industrial dust collectors. These parts keep the baghouse airtight—if air leaks, unfiltered dust can escape, and efficiency drops. The most common wear components here are gaskets (or seal strips), made of rubber, silicone, or foam. Gaskets are used between the tube sheet (the metal plate that holds filter bags) and the baghouse shell, or between door panels; they degrade over time from heat or dust, so spare gaskets are a must. Another structural spare is the access door (or inspection door)—small doors that let workers check or replace filter bags or filter bag cages. Doors can get dented or have broken hinges, so spare doors (or hinge kits, which are accessories) help avoid long downtime. For the hopper (the bottom part that collects dust), hopper liners are critical wear components—made of wear-resistant materials like polyurethane, they prevent the hopper from being worn through by abrasive dust (like coal or cement dust). Without spare hopper liners, the hopper could develop holes, leading to dust leaks.

Finally, there are auxiliary and monitoring spare parts, which are also accessories for any type of industrial dust collector. These don’t directly filter or clean, but they keep the baghouse safe and efficient. Differential pressure gauges (tools that measure pressure inside the baghouse) are critical—they tell operators when filter bags or pleated filter elements are clogged. Spare gauges ensure operators can always monitor system health. For systems that move collected dust (like pneumatic conveying systems attached to the hopper), rotary airlocks are key accessories—small devices that feed dust out of the hopper without letting air in. Their rotor vanes are wear components that wear out from dust, so spare vanes or entire airlocks are stocked. Also, dust level sensors (which track how much dust is in the hopper) can fail, so spare sensors (another type of accessory) prevent overfilling the hopper.

The LCMC - type pulse dust collector adopts a compartmentalized structure with air intake through the middle air duct. Dust - laden flue gas enters the ash hopper of each chamber through the middle inlet and the wedge - shaped air duct. In the ash hopper and before entering the filtration chamber, larger dust particles directly fall into the ash hopper due to the blocking of baffles and the action of inertial gravity. Other dust particles rise with the air flow and enter the filter bags of each filtration chamber. After being filtered by the filter bags, the dust particles are blocked outside the filter bags. The purified gas enters the clean air chamber from the inside of the filter bags, then passes through the offline valve (disc lifting valve), enters the air outlet duct, and is discharged into the atmosphere through the air outlet, fan and exhaust cylinder. The dust in the ash hopper is transported to the storage ash bin through the ash discharge valve, cutting scraper, collecting plate machine and bucket elevator, and the dust in the ash bin is discharged through the humidifier or suction device.

As the running time of the dust collector increases, the dust accumulated on the outside of the filter bags continues to increase, resulting in a gradual increase in the resistance of the filter bags themselves. When the resistance reaches a preset value, the PLC control system sends a signal. First, it commands the lifting valve of a pulse unit to close to cut off the air flow of the chamber. Then, it issues a command to open the electromagnetic pulse valve. Compressed air is injected into the filter bag at a very short time of 0.1 - 0.2s through the pulse valve and a special nozzle. Under the 诱导 of the airflow, a large amount of clean air in the clean air chamber is sucked into the filter bag. The filter bag starts to expand from top to bottom in sequence. When the expansion reaches the limit position, the filter bag undergoes high - frequency vibration and deformation under the action of the external force, causing the dust adsorbed on the outside of the filter bag to fall off. After the dust falls for a certain period of time, the lifting valve is opened, and this pulse unit enters the filtering state again, while the next pulse unit enters the dust cleaning state. In this way, dust cleaning → stopping → filtering is repeated cyclically, so that the resistance of the dust collector is always kept within a certain range, realizing long - term continuous operation.

The dust collector adopts PLC to control the dust cleaning system. According to different project requirements, it is divided into manual control and automatic control. The automatic control mode is further divided into time program control, differential pressure control and time - differential pressure composite control. The time control method is generally set, and the pulse interval and cycle interval are generally taken as the start - up basis of each dust cleaning. The pulse width is generally 0.1 - 0.15s, the pulse interval is generally 10 - 20s, and the cycle interval is generally 30 - 90min. The compressed air pressure for dust cleaning control should be determined according to the on - site specifications of the project and the above dust cleaning parameters, generally 0.25 - 0.35MPa.

The LCMC type pulse dust collector adopts a compartmentalized structure with air intake through the middle air duct. Dust laden flue gas enters the ash hopper of each chamber through the middle inlet and the wedge shaped air duct. In the ash hopper and before entering the filtration chamber, larger dust particles directly fall into the ash hopper due to the blocking of baffles and the action of inertial gravity. Other dust particles rise with the air flow and enter the filter bags of each filtration chamber. After being filtered by the filter bags, the dust particles are blocked in There is a large space at the lower part of the bag, which allows the dust laden gas to settle before reaching the filter bag, reducing the burden on the filter bag and prolonging the service life of the filter bag.

1. The world advanced low pressure large diameter pulse jet cleaning technology is adopted, which further improves the cleaning intensity and ensures that each filter bag maintains the highest working efficiency.

2. Shot blasting treatment and high quality coatings are used inside the dust collector, which greatly extends the service life of the dust collector. The service life of the main equipment is > 15 years.

3.The number of longitudinal ribs of the filter bag cage is generally selected as 12 according to the requirements of the filter material. The longitudinal ribs are made of high - quality steel wires, produced by automatic welding production lines.

4. The cage has high strength, and no burrs reduce friction with the filter bag. The surface is treated with plastic spraying for corrosion protection, resulting in a long service life.

5. A smaller pulse jet unit is adopted, which reduces the jet area and minimizes the impact of ash cleaning on the system's air handling capacity.

6. For electrical control, centralized control (DSC remote control) and local control beside the machine can be provided. An advanced PLC program control system is adopted, which can provide two ash cleaning methods: constant resistance and fixed time. Large projects are equipped with HMI upper - computer monitoring, and operating parameters are displayed and adjusted locally.

1. Selection of Filtration Air Velocity
The filtration air velocity refers to the velocity (m/min) of the gas passing through the filter material. Some also call it the air - to - cloth ratio, which is the volume of air passing through a unit area of the filter material per unit time, i.e., m³/(min·m²), or m/min. The selection of the filtration air velocity depends on the properties of dust and flue gas, temperature, dust concentration, ash cleaning method, and the performance of the selected filter material. The filtration air velocity not only determines the size of the dust collector but also has a great influence on the resistance of the dust collector, normal operation efficiency, comprehensive cost, and the determined service life of the filter material. To ensure the stable and efficient operation of the dust collector, the filtration air velocity should be determined after comprehensive consideration.

2. Selection of Filter Bags
Filter bags are the core components of bag - type dust collectors. The quality of the filter material will directly determine the specifications and size, operating resistance, emission concentration, service life, and other indicators of the dust collector.
Selection principle: According to the filter material, it is divided into conventional filter felt, antistatic, and corresponding ultra - fine needle - punched filter felt or membrane - covered filter material. The weight of the filter material can also be adjusted according to requirements, and the common one is 550g/m².

3. Pulse valve: Adopts "3" inch (submerged type), with a jet pressure of 0.25 ~ 0.35MPa, which is related to the number of filter bags blown by the pulse valve.

4. The number of longitudinal ribs of the filter bag cage is selected according to the filter material. It is usually 12, and 15 for composite filter materials, with the surface undergoing shot blasting treatment.

5. Ash cleaning control mode: High - efficiency ash cleaning method, time sequence control. The ash cleaning cycle is determined according to the change of resistance. The normal operating resistance of the dust collector is generally controlled at 1000 ~ 1500Pa, and time/pressure combination can also be used.

6. Transportation and arrangement mode: Ground layout: Star discharger → conveyor plate machine → collecting plate machine → bucket elevator → ash storage bin → dust humidifier or vacuum suction machine. For high - rack layout: Star discharger → conveyor plate machine → collecting plate machine → ash storage bin → dust humidifier or vacuum suction machine. Or directly unload into a screw conveyor.

When placing an order, please specify the product name, model, and quantity, and indicate the temperature, water content, dust properties, and concentration of the dust - laden gas, and the required filter material type.

The supply scope of the product includes the shell, air inlet, air outlet, filter bags, bag cages, porous plates, air chambers, ash hoppers, four - way rotary discharge valves, pulse valves, elevators, gas inlet pressure reducing valves, cylinders, distribution valves, pulse systems, and ash cleaning program controllers, dust collector control cabinets, belt weighing scales, and steel structures, etc.

The auxiliary conveying equipment can be supplied according to requirements, and the support height can be made according to the order requirements.

Control method: Our company generally supplies it according to electric control. If pneumatic control is required, the cost shall be calculated. The electric control system is equipped with an HMI upper - computer system and connected to the fan and other systems for interlocking control, and corresponding requirements shall be put forward.

The heat preservation and anchor bolts (foundation bolts) of the dust collector are generally not included. If needed, they should be stated separately, and the price will be negotiated separately.
Except for the main engine and supporting components, if required by the order, spare parts such as pulse valves and bag cages can be ordered, and the number of spare parts shall be determined by the order.

For various pipes, fans, air compressors, and power supply for the electric control cabinet except for the dust collector itself, such as the connecting cables inside the electric control cabinet, cable trays, power supply for the electric control cabinet, lighting of the dust collector, and foundation, etc., they shall be handled by the user.

In nearly every industrial facility, dust collection systems are a critical component for efficient operation. The operation, reliability, and efficiency of a dust collection system directly impact your facility's profitability (e.g., system downtime, high energy costs, lost production, environmental/workplace safety fines, etc.). Therefore, choosing the right industrial dust collection system can be challenging. Cementl.com can provide the industrial dust collector you need.

Unlike many competitors who offer cookie-cutter, one-size-fits-all designs, Cementl.com customizes each dust collector to our customers' specific needs without the high costs typically associated with custom designs. Our dust collectors are renowned for their high-quality construction, reliability, and ease of maintenance. With years of experience manufacturing, repairing, and optimizing industrial dust collectors, particularly those tailored for cement plants, we have a unique understanding of what works and what doesn't in cement production environments. This enables us to design and manufacture dust collectors that avoid many common issues encountered by other manufacturers. (For example, placing the pulse valve at a convenient height atop the unit platform, rather than in an inaccessible side area—a simple adjustment that can save the cement plant team countless hours of maintenance time.)

At Tongli Heavy Machinery, we understand that investing in a dust collection system is not just about buying a product – it’s about securing a long-term solution that is reliable, efficient, and cost-effective. Unlike the assumptions made by some competitors, our engineering and manufacturing capabilities allow us to design and produce precision-engineered baghouse filters and dust collection systems that are never undersized, outdated, or compromised for short-term sales tactics.

We take pride in our world-class technical team, advanced manufacturing facilities, and strict quality assurance processes. Every system is custom-designed to meet the specific requirements of our clients – ensuring optimal air-to-cloth ratio, proper filtration velocity, and maximum operational lifespan.
While others may focus on making claims, we focus on delivering measurable results:
Superior manufacturing capability with state-of-the-art production lines.

Experienced technical team with decades of practical application expertise in cement, metallurgy, power plants, and chemical industries.

Best cost efficiency through optimized design and robust fabrication, reducing both CAPEX and OPEX for our customers.

We don’t rely on marketing slogans – we rely on real engineering, proven performance, and global customer trust.

That is why Tongli Heavy Machinery stands as the preferred partner for leading cement groups and industrial enterprises worldwide.

When it comes to dust collection, one of the biggest risks for buyers is being sold the wrong system. Too many sales reps push undersized or outdated units just to win the bid with a lower price. At first, it looks like a bargain, but in the long run, the hidden costs pile up: higher maintenance, shorter filter life, higher energy bills, and constant downtime.

That’s why at Cementl.com, we don’t just sell machines—we deliver solutions. Every system we design is engineered to fit your operation’s exact requirements. We refuse to cut corners, and we’ll never push outdated technology or underpowered equipment just to close a deal.

So what makes our collectors different? Here are just a few of the value-added features that come standard with every model we build:

Larger Inlet Diffusers – These prevent hopper turbulence and dust re-entrainment, helping material settle out more effectively before it even reaches the filters.
Expanded Free-Board Zone – By creating extra clear space under the filter bags, we reduce unnecessary dust loading, minimize filter abrasion, and lower interstitial velocity. The result: cleaner operation and longer filter life.
Clean-on-Demand Controllers – Our smart control system cleans bags only when differential pressure requires it. That means lower compressed air use, less wear and tear, and reduced emissions over the lifespan of your unit.

In short: better performance, lower operating costs, and longer-lasting filters.
At Cementl.com, our promise is simple—we design and build dust collectors that work for you today and keep saving you money tomorrow.

You’ve probably met them before—the self-proclaimed “dust collection experts” who show up with a one-size-fits-all solution. They’ll tell you their undersized, outdated unit is exactly what you need. Why? Because it’s the only thing they have to sell. Or maybe they just want to throw out the lowest price on paper to win the order, hoping you won’t notice until it’s too late.

We like to joke about these “experts” as more like sales magicians—they make the problems disappear… at least until the first week of operation when filters clog, pressure spikes, and maintenance costs skyrocket.

At Tongli Heavy Machinery, we don’t play those games. Our strength is in real engineering and manufacturing. Because we design and build a full range of dust collectors—including baghouses, cartridge collectors, and customized filtration systems—we’re not limited to pushing a single model. Instead, we provide the right unit, properly sized and optimized, for your process.

The difference? Our clients get a dust collector that actually does what it’s supposed to do: longer filter life, lower energy consumption, reduced emissions, and reliable performance year after year.
In short—we don’t sell gimmicks, we deliver solutions.

Advantages of Pleated Filter Bags:
Pleated filter bags offer a much larger filtration surface area compared to traditional cylindrical bags, thanks to their pleated design. This increased surface area allows for lower air-to-cloth ratios, resulting in more efficient dust capture and reduced pressure drop. Because of this, systems equipped with pleated bags often require less energy for operation and achieve better airflow. Another major benefit is the extended filter life—since dust loading is distributed more evenly across a larger area, filters don’t clog as quickly. Maintenance costs are also reduced, as pleated filters are easier to install, remove, and replace compared to traditional bag filters. In many cases, pleated bags can even allow for retrofit upgrades in existing baghouse systems without the need for major equipment modifications.

Disadvantages of Pleated Filter Bags:
Despite their advantages, pleated filter bags also have some limitations. They tend to be more expensive upfront than standard felt bags, which can be a drawback for budget-sensitive projects. In high-temperature applications, pleated filters may not perform as well, since the pleated media can be more sensitive to heat and chemical attack depending on the material. Their rigid structure also makes them less flexible, which can sometimes lead to challenges in systems with irregular pulse cleaning or high dust loads that cause bridging and blinding between pleats. Additionally, pleated filter bags are not always the best choice for sticky, fibrous, or abrasive dusts, as buildup in the pleats can reduce effectiveness over time and make cleaning more difficult.

A baghouse operates as the “lungs” of an industrial process, removing harmful dust particles from the airstream before clean air is released back into the atmosphere or recirculated into the facility. The principle is straightforward: a fan or blower draws dust-laden air into the baghouse, where filtration takes place. As the airstream enters, the dust particles are captured on the surface of specialized filter bags, while the cleaned air passes through the filter media and exits the system. Over time, dust accumulates on the filters, creating a dust cake that actually improves filtration efficiency—until it is periodically removed through a cleaning system such as pulse-jet air, reverse air, or mechanical shaking.

Baghouses come in a wide variety of shapes, sizes, and configurations. They can be designed with just a handful of filter bags for small-scale applications or with hundreds—even thousands—of bags for large industrial plants. The choice of design depends on critical process factors such as air volume, dust load, temperature, moisture content, and the physical properties of the particulate. This flexibility allows baghouses to be tailored to industries ranging from cement and steel production to food processing, woodworking, and chemical manufacturing.

One of the most important considerations in baghouse performance is the selection of the proper filter media. Not all dust behaves the same, and different environments demand different filter characteristics. For instance, oily or sticky dust requires filters treated with oleophobic coatings that prevent blinding and ensure effective cleaning. Moisture-laden gas streams may call for hydrophobic or polypropylene filters, while highly corrosive environments often require advanced membranes such as polytetrafluoroethylene (PTFE) for maximum chemical resistance. In abrasive applications, pleated filter bags are often preferred because they provide a much larger filtration surface area, improve capture efficiency, and offer superior resistance to wear.

In short, baghouses work by combining airflow, filtration, and smart filter selection to reliably separate dust from air. With the right design and filter media, a baghouse becomes one of the most efficient and versatile dust collection technologies available—capable of handling everything from fine powders to coarse, abrasive particulates while ensuring compliance with environmental standards.

To maintain efficiency and extend filter life, baghouse dust collectors use different cleaning systems. The four main types are pulse jet, reverse air, medium-pressure, and mechanical shaker baghouses. Each method has unique advantages and limitations depending on the application, dust characteristics, and duty cycle.

Reverse Air Baghouses
In reverse air baghouses, dust-laden air collects on the outside of the filter bags suspended in the dirty air plenum. Cleaning is achieved by a fan or blower that sends a low-pressure, high-volume stream of air in the reverse direction through the filters. This backflow dislodges the dust cake, allowing it to fall into the hopper. Reverse air baghouses often clean continuously during operation, which helps maintain stable performance. They are gentle on filter bags and reduce wear, but require higher energy input and maintenance due to the large reverse-air fans. They are common in large industrial plants like cement and power generation.

Medium-Pressure Baghouses
Medium-pressure systems use timed pulses of clean air delivered through a rotating arm to dislodge dust from the filters. They rely on positive displacement pumps, which are more energy-efficient than the large blowers of reverse-air units. Cleaning intensity (pulse signature) is stronger than reverse air, making them more effective in demanding environments. These systems balance energy savings with strong cleaning capability, making them a popular option for industries requiring continuous duty operation.

Pulse Jet Baghouses
The pulse jet (or reverse pulse) baghouse is the most widely used cleaning system worldwide. It employs short, powerful bursts of compressed air directed through blowpipes above each filter row. The sudden pulse knocks the dust cake off the filters, which falls into the hopper for removal. Pulse jets provide the most effective cleaning and can handle high dust loads with compact collector designs. However, the cost of generating large volumes of clean, dry compressed air can increase operating costs, especially for large-scale facilities. Despite this, pulse jet baghouses dominate industries like cement, steel, and chemical processing due to their reliability and high cleaning efficiency.

Mechanical Shaker Baghouses
Unlike other systems, mechanical shaker baghouses do not use air for cleaning. Instead, filters are periodically cleaned by physically shaking them to release the dust cake. This requires shutting down the collector during cleaning, making them suitable for batch or intermittent processes. Shaker baghouses are simple and cost-effective, with lower capital and operating costs. However, their cleaning effectiveness is limited compared to pulse jet or reverse air systems, and they are rarely used in modern large-scale continuous operations.

1. Equipment Size: Failure to select a bag filter sized appropriately for the application and production process can exacerbate filter wear. Undersized filters or insufficient filter media will result in insufficient collection velocity and airflow, shortening filter life. This can also lead to poor ventilation, equipment damage, increased dust emissions, and even hazardous working environments.

2. Filter Media Selection: Bag filter media offer a wide variety of filter media to suit diverse industrial applications and dust characteristics. Because filter media operate differently in different environments, selecting the right filter media for the dust conditions and production process requirements is crucial. Using an inappropriate filter fabric shortens filter life and increases pressure drop, increasing energy consumption and operating costs, ultimately leading to filter failure.

3. Cleaning Type: The bag filter configuration and cleaning method significantly impact its overall performance. Common cleaning types include backflush, medium-pressure, pulse jet, and mechanical, each with its own advantages and disadvantages. Choosing the right cleaning system can improve dust collector performance, extend filter life, and reduce operating costs.

4. Dust characteristics: Dust particle size, concentration, humidity, viscosity, and other characteristics can affect dust removal effectiveness. For example, sticky dust tends to adhere to filter bags, making it difficult to remove; while fine dust can pass through the bags, leading to excessive emissions.

5. Airflow distribution: Uneven airflow distribution within the dust collector can cause localized overloading of the filter bags, leading to premature failure and reducing overall dust removal efficiency.

6. Operating temperature: Filter media has a specific operating temperature range. If the actual operating temperature exceeds the filter media's tolerance, it will deteriorate, damage, and lose its filtering performance.

7. Air leakage: When a dust collector has air leakage, it introduces outside air, reducing filtration efficiency and potentially causing captured dust to be carried away again by the airflow, affecting dust removal effectiveness.

8. Maintenance management: If daily maintenance is not in place, such as not cleaning the dust hopper in time, not checking and replacing damaged filter bags on time, etc., it will lead to increased operating resistance of the dust collector, reduced dust removal efficiency, and even cause equipment failure.

1. Pulse Jet Cleaning System
This system automatically cleans filter bags via compressed air pulses. It effectively dislodges accumulated dust, maintains consistent filtration efficiency, and extends filter bag lifespan—reducing the need for frequent replacements and downtime.

2. Modular Design
Built with pre-engineered modules, it supports easy expansion or modification as operational needs change (e.g., adding filter modules for increased capacity). It also simplifies maintenance by allowing isolated servicing of individual components.

3. Integrated Control Systems
Advanced controllers monitor real-time system performance (e.g., pressure drop, airflow) and send alerts for anomalies. Detailed diagnostics help address issues proactively, avoiding unexpected failures and maximizing uptime.

4. Wide Range of Filter Media
Offers diverse fabrics and finishes tailored to specific dust types (e.g., fine powders, corrosive particles) and operating conditions (e.g., high temperatures). Ensures optimal filtration efficiency for different industrial scenarios.

5. Wide Applications
Metals: Ideal for capturing foundry/smelter fumes, dust, and hot gases—protecting workers and complying with emissions rules while preventing dust-related machinery damage.

Woodworking: Effectively filters sawdust, sanding particles, and wood chips—improving air quality, reducing equipment wear, and minimizing downtime from dust buildup.

Pharmaceutical: Handles fine powders and active pharmaceutical ingredients (APIs) with high-precision filtration, meeting strict industry cleanliness standards and preventing product contamination.

Food Processing: Captures grain dust, sugar, flour, and other food particulates—avoiding explosive risks, cross-contamination, and ensuring compliance with food safety regulations.

Cement and Minerals: Filters limestone, clinker dust, and silica—managing high-volume abrasive particles, reducing emissions, and extending the life of processing equipment.

Chemical Processing: Safely contains hazardous dusts and chemical by-products using corrosion-resistant filter media, protecting workers, the environment, and machinery.

6. Improved Air Quality
Reduces airborne contaminants, lowering the risk of respiratory illnesses (e.g., silicosis) and creating a healthier workplace for employees.

Regulatory Compliance
Meets OSHA and EPA air emission standards, helping avoid costly fines, legal issues, and damage to brand reputation.

Increased Equipment Longevity
Prevents dust infiltration into machinery (e.g., bearings, gears), reducing wear and tear and cutting maintenance/replacement costs.

Enhanced Productivity
Minimizes downtime from dust-related issues (e.g., equipment breakdowns, contamination recalls), ensuring consistent production and better operational efficiency.

1. Gas Volume to be Processed (Air Volume)
Designers must first accurately calculate the actual gas volume under operating conditions, typically in cubic meters per hour or cubic feet per minute. This calculation should not only include the baseline air volume for normal production, but also allow for a 10% to 20% margin to account for fluctuations in process load and air volume shocks during equipment startup and shutdown. This value directly determines the dust collector housing size, number of filter bags, and fan selection. An underestimation of the air volume will result in excessive air velocity, accelerating filter bag wear; an overestimation will result in redundant equipment, increasing initial investment and operating energy consumption.

2. Dust Load and Characteristics
Designers must assess the dust concentration in the airflow and conduct a thorough analysis of the dust's physical and chemical properties. Dust concentration affects the type and number of filter cartridges, as well as the overall performance of the equipment. Regarding particle size distribution, fine dust requires high-permeability, fine-fiber filter media to prevent penetration, while coarse dust requires abrasion-resistant filter media to reduce adhesion. Highly sticky dust can easily agglomerate and clog the filter bags, necessitating increased cleaning frequency or the use of specialized cleaning mechanisms. Hygroscopic dust can adhere to filter bags in high-humidity environments, so heating or dehumidification devices should be considered during design. Corrosive dust also requires corrosion-resistant filter media and equipment components to prevent damage.

3. Filter Media and Component Material Selection
Filter media selection should be based on the operating temperature and the chemical properties of the pollutants. For example, polyester fiber is suitable for low- to medium-temperature environments and is corrosion-free, while glass fiber can withstand higher temperatures. Nomex offers both heat resistance and tensile strength, making it suitable for high-temperature applications. If the process temperature is high or there is a corrosive chemical environment, in addition to the filter media, the equipment housing, piping, and dust removal components must also be constructed of heat- and chemical-resistant materials, such as stainless steel and special alloys. This ensures long-term stable operation and prevents material damage that could affect filtration performance.

4. Air-to-cloth ratio
The air-to-cloth ratio refers to the volume of air per square foot of filter media. Designers must determine the appropriate air-to-cloth ratio, typically ranging from 2:1 to 5:1. The selection should be tailored to the dust type. When handling heavy or sticky particles, a lower air-to-cloth ratio is recommended to prevent rapid dust accumulation on the filter media surface, making it difficult to remove. When handling light and dry pollutants, a higher air-to-cloth ratio can be used to maintain filtration efficiency while effectively utilizing the filter media area, reducing equipment size and cost.

5. System pressure drop
Designers should maintain system pressure drop within a range of 2 to 6 inches of water column. Excessive pressure drop increases fan load, leading to increased energy consumption and potentially affecting airflow stability. Excessive pressure drop may indicate inadequate filter media filtration and increase the risk of dust penetration. To control pressure drop, the filter bag size, cleaning system, and airflow path must be rationally designed. For example, optimizing the cleaning frequency can timely remove dust from the filter bag surface and reduce the increased pressure drop caused by dust accumulation.

6. Ventilation and Duct Design
The ventilation design must ensure uniform airflow, and the ducting must be strategically positioned. Uniform airflow prevents turbulence within the equipment, which can lead to localized overloading of the filter bags, accelerated wear, and reduced overall filtration efficiency. During design, the shape and angle of the air inlet duct should be optimized, and air distribution plates should be installed at the air inlet to ensure smooth air flow into the dust collector. The position of the air outlet duct should also be rationally arranged to reduce airflow resistance, ensure smooth air discharge, and improve overall equipment efficiency.

7. Cleaning System Design
The type and parameters of the cleaning system are crucial. Common cleaning methods include pulse jet, backflush, and mechanical. Designers should select the appropriate cleaning method based on the dust characteristics and filter media type. For example, pulse jet cleaning is more effective and suitable for handling fine or sticky dust, due to its high cleaning power and efficiency. The frequency and pressure of cleaning must also be determined. Too frequent cleaning increases energy consumption and may damage the filter bags. Inadequate cleaning can lead to dust accumulation and increased system pressure drop. Furthermore, the cleaning system layout must be rational to ensure that each filter bag is evenly cleaned and to avoid blockage of individual bags due to incomplete cleaning.

8. Equipment Configuration and Layout
The equipment layout should be considered in conjunction with the plant space, process flow, and ongoing maintenance requirements. First, consider the dust collector's installation location, ensuring adequate operating space around it for easy inspection, bag replacement, and equipment maintenance. Secondly, ensure connections between upstream and downstream process equipment, ensuring smooth connection between the air inlet and outlet ducts and process piping to reduce airflow resistance. The ash hopper's location and ash discharge method must also be considered. The ash hopper should be located at a convenient height, and the ash discharge device should be compatible with the subsequent ash conveying system to ensure timely and smooth discharge of collected dust and avoid hopper blockage.

9. Temperature Control
Designers should consider the operating air temperature and temperature fluctuations in the equipment's operating environment. Different filter media have different temperature tolerances. Exceeding the upper temperature limit can cause the filter media to deform and damage, resulting in a loss of filtration capacity. Temperatures that are too low can cause moisture in the gas to condense, mix with dust, and adhere to the filter bags, causing clogging. If the gas temperature fluctuates significantly or exceeds the temperature tolerance of conventional filter media, a heating device (such as electric heating or steam heating) or a cooling device (such as a cooling coil) is required to control the gas temperature within the filter media's acceptable range and ensure proper operation of the equipment.

10. Compliance Requirements
Designers must be familiar with and meet local environmental regulations and industry standards, such as air emission standards set by OSHA (Occupational Safety and Health Administration) and the EPA (Environmental Protection Agency), as well as industry requirements regarding dust emission concentration, noise, and safety precautions. During design, ensure that dust collector emission concentrations remain below regulatory limits, and add auxiliary filtration devices if necessary. Equipment noise during operation must meet factory noise standards. This can be controlled through the installation of soundproof enclosures and silencers. Furthermore, the equipment must include safety features such as explosion-proof devices (for flammable and explosive dust) and emergency stop buttons to ensure compliance with safety regulations.

Round elements are cylindrical filter components for dust collectors. They use a bag cage to keep their shape. Air flows through the cylindrical filter media, trapping dust on the surface. They work well in large systems like power plants, with good airflow distribution and easy scaling.

Flat elements are flat or sheet-like filters. Their compact design fits more filter area in the same space (30-50% more than round ones). Air flows steadily through them, and dust cleans off evenly. They're ideal for tight spaces, like small industrial machines, but need good support to avoid deformation in harsh conditions.

Round elements are designed for environments with high dust loads and are suitable for very high capacities (exceeding 110,000 m³). Flat elements, on the other hand, are used in cases where compact installation design and low contamination loads are required.

No, flat elements are not fully equivalent to pleated elements—they overlap in some designs but differ in core definitions and structures.

Flat elements refer to filter components with a flat/sheet-like overall shape (their key feature is a non-circular, flat structure). They may be simple flat sheets or have basic folds, but their main goal is to save space by fitting more filter area in tight spots.

Pleated elements, by contrast, are defined by multiple intentional folds (pleats) in the filter media. These pleats greatly increase the filter area. While some pleated elements have a flat overall shape (and thus can also be called flat elements), many pleated elements have other shapes (e.g., cylindrical pleated filter cartridges).

In short: All flat pleated elements are both flat and pleated, but not all flat elements are pleated (some are simple flat sheets), and not all pleated elements are flat (some are cylindrical).

Horizontal bag arrangements in baghouse filters position filter bags parallel to the ground, often in rows. This setup offers key advantages, particularly in spaces with height restrictions, as it requires less vertical clearance-making it ideal for facilities with low ceilings. Maintenance is also simplified, as bags sit at a more accessible height, reducing the need for tall ladders or scaffolding during inspection, cleaning, or replacement. Additionally, the horizontal orientation can minimize dust re-entrainment during cleaning, as gravity helps pull dislodged dust downward into the collection hopper. However, this design has drawbacks: it demands a larger floor footprint to fit the same number of bags as vertical setups, which can be problematic in space-constrained areas. There’s also a risk of uneven dust loading, where dust may accumulate more heavily on the bottom surfaces of horizontal bags, potentially reducing filtration efficiency over time.

Vertical bag arrangements mount filter bags vertically, hanging from the top of the baghouse with their open ends connected to a clean air plenum. This design excels in space efficiency, as it requires less floor area-making it suitable for facilities where horizontal space is limited. Vertical orientation also promotes more uniform dust distribution across the bag surface, as airflow can move evenly around the cylindrical bags, reducing hotspots and extending filter life. Cleaning is often more effective too, as pulse jets or mechanical shaking can dislodge dust more consistently along the vertical length of the bags. The main disadvantages are the higher vertical space requirement, which can be challenging in low-ceiling facilities, and more difficult maintenance, as accessing upper bag sections may require ladders or elevated platforms, increasing time and labor costs.

A downflow baghouse dust collector is a type where dusty air enters from the top of the unit and flows downward through the filter bags. As the air moves down, gravity helps pull heavier dust particles directly into the bottom collection hopper before they even reach the filter sleeves. This pre-settling reduces the amount of dust that needs to be trapped by the filter media, lightening the load on the bags and extending their lifespan. Additionally, when cleaning (such as via pulse jets), the downward airflow and gravity work together to dislodge dust more effectively, improving overall cleaning efficiency and keeping filtration performance consistent.

An upflow baghouse dust collector draws dusty gas into the unit from the bottom, which then moves upward through the filter bags. As the gas rises, the filter bags trap dust particles on their surfaces, and clean air exits from the top. This design works well for certain applications—for example, handling lighter, finer dusts that are easier to trap as air moves upward. However, it has a key drawback: during cleaning, dislodged dust particles can be caught in the upward-flowing gas stream and reattach to the filter bags (called “dust re-entrainment”). This reduces cleaning effectiveness, lowers filtration efficiency over time, and may require more frequent cleaning cycles.

A crossflow baghouse dust collector features dusty air that moves horizontally across the filter bags, rather than vertically. The filter bags are typically arranged in rows, and the horizontal airflow passes through the bag surfaces to trap dust, with clean air exiting from the opposite side. This configuration is often used in compact systems because its horizontal airflow allows for a more space-saving design, fitting well in facilities where vertical or large horizontal space is limited. It’s also suited for specific industrial setups—such as handling dusts with moderate particle sizes that can be efficiently captured by horizontal airflow—though it may need careful airflow control to avoid uneven dust loading on the bags.

Baghouse dust collectors rely on filter bags (made from natural, artificial, or synthetic materials) to trap dust. They deliver high efficiency—up to 99% for fine and medium-sized dry particles-but require significant installation and maintenance costs, though their operating costs are low. Regular regeneration of the filter elements is necessary to keep performance consistent.​

Electrostatic Precipitators (ESPs) use electrostatic force to separate dust from gas. They work better for large contaminants but have low efficiency for fine particles. ESPs are more cost-effective at large scales (e.g., industrial facilities with high airflow needs) and are less demanding in terms of maintenance compared to baghouses, reducing long-term upkeep efforts.​

Cyclone Separators leverage centrifugal force to spin out dust particles. They are most suitable as a first-stage filtration system for large particles, as their efficiency drops with finer dust. They are cheaper for primary filtration, have a simple design, and require minimal maintenance-making them a budget-friendly choice for pre-filtering coarse contaminants.​

Wet Scrubbers use liquids or solutions to capture dust, vapors, or chemical contaminants. They excel at handling pollutants with chemicals, additives, or vapors (scenarios where dry collectors struggle) but come with additional costs: they require ongoing water and chemical replenishment, plus regular equipment cleaning and fluid replacement to prevent clogs or corrosion.​

Cartridge dust collectors use cartridge filters as their core media. They are highly effective for fine contaminants, with a more compact design than baghouses-this means cheaper installation and maintenance. Like baghouses, they demand periodic regeneration of their cartridge components to remove accumulated dust and maintain filtration efficiency.​

1. Filter Media: Common filter media such as polyester, fiberglass, aramid (Nomex), and polytetrafluoroethylene (PTFE) vary significantly in cost and performance. Standard polyester filter media is suitable for general operating conditions and is relatively inexpensive. However, PTFE-coated filter bags, due to their excellent corrosion resistance, high-temperature resistance, and submicron particle capture efficiency, often cost several times more than standard filter bags. In high-temperature or highly corrosive environments, companies must choose higher-grade filter media, which directly increases the overall cost of the equipment.

2. Equipment Size and Air Volume: Dust removal systems in large-scale cement plants, steel mills, or power plants often need to process hundreds of thousands to millions of cubic meters of exhaust gas per hour, which increases the number of bag chambers, the number of filter bags, and the thickness of the housing steel. For example, a medium-sized pulse bag dust collector with a processing air volume of 50,000 m³/h may cost between USD 50,000 and 80,000, while a very large unit with a processing air volume of one million m³/h often costs over USD 300,000 to 500,000. Furthermore, projects with complex spatial layouts require custom designs, and these specialized engineering requirements can also increase the price.

3. Cleaning methods: Common ones include mechanical vibration, backwash, and pulse jet. Pulse jet bag dust collectors have become a mainstream choice due to their high cleaning efficiency and low maintenance. However, their compressed air system and pulse valve assembly increase manufacturing and operating costs, resulting in a generally higher unit price compared to backwash and mechanical vibration systems. Companies requiring long-term stable operation and strict emission standards often have to choose a more advanced pulse cleaning system.

4. Performance and emission standards: It directly determine the complexity of equipment design. With increasingly stringent environmental regulations, some regions require emission concentrations below 20 mg/m³, or even below 10 mg/m³. To meet this standard, equipment not only needs to use high-efficiency filter media but may also require pre-coating, online monitoring systems, or separate chamber offline cleaning capabilities. These additional features undoubtedly increase costs. In contrast, dust removal equipment that only meets 30–50 mg/m³ requires a much lower overall investment.

5. Coating and Treatment Processes: Special coatings and treatments on the filter bag surface also incur additional costs. For example, PTFE coating can significantly reduce filter bag operating resistance and extend its lifespan, but the coating process is complex and the price of a single filter bag may be 50%–100% higher than that of ordinary filter bags. In environments with high humidity or oily dust, water- and oil-repellent treatment may also be required, further increasing the unit price of the filter bag.

6. Manufacturer's Brand: Engineering experience is also a significant factor in price fluctuations. Products from internationally renowned manufacturers such as FLSmidth, Donaldson, and Nederman tend to be more expensive, but they feature mature designs, standardized components, and excellent operational stability. Smaller and medium-sized manufacturers, on the other hand, may offer more cost-effective products. For example, Tongli, as an OEM factory for an internationally renowned brand, can offer comparable quality at more competitive prices.

7. Order Size: Order size also significantly impacts unit price. Bulk purchases can reduce unit costs by centralizing orders for components like steel, filter bags, and valves. For example, purchasing 20 or more units at once can reduce the price per unit by 5%–15%. Conversely, custom orders for individual units often incur higher costs due to the higher cost amortization.

8. Severity of Operating Conditions: When handling ambient-temperature dry dust, such as cement mill dust collection, conventional polyester filter bags are sufficient. However, for waste incineration, metallurgical flue gas, or chemical exhaust, which often contains high temperatures, acidic gases, or corrosive substances, high-temperature (>200°C) and acid- and alkali-resistant aramid or PTFE filter bags must be used, along with corrosion-resistant linings or special corrosion-resistant coatings. These specialized features can significantly increase the price of the equipment.

9. Additional Features: Modern intelligent bag filters can integrate differential pressure sensors, temperature sensors, PLC control systems, and even remote monitoring and data acquisition modules. These features can help businesses achieve refined management and reduce operating costs, but they do increase initial investment. For example, a complete automated monitoring system may add 10%–20% to the price of a single unit.

In summary, the price of a bag filter depends on multiple factors, including filter media, size, cleaning method, performance standards, suitability for specific operating conditions, manufacturer, order size, and additional features. Generally speaking, conventional equipment for small and medium-sized industrial users ranges from USD 10,000–80,000, while high-end pulse-jet bag filters used in large-scale thermal power, metallurgical, or cement industries often cost USD 100,000–500,000, or even more.