The pulse valve of the bag filter plays a crucial role in the dust removal system. Its performance directly affects the operational efficiency of the dust collector, the lifespan of the filter bags and the maintenance cost.
Optimize the selection and design of pulse valves
Selecting the appropriate pulse valve is the key to reducing dust removal costs. For instance, the use of pulse valves with low resistance and high injection volume can reduce the overall cost of the injection system, as each valve can clean a larger area of filter material, thereby reducing the number of valves and lowering equipment and maintenance costs. In addition, compared with the right-angle pulse valve, the straight-through pulse valve significantly reduces resistance, and the injection pressure can be lowered by approximately 50kPa, providing a better injection effect. At the same time, it extends the diaphragm's lifespan and reduces maintenance workload.
2. Enhance the reliability and service life of the pulse valve
By adding a fixed device with a buffering function, the problem of the pressure drop of the air source for the dust collector's injection can be solved, the reliability of the pulse valve operation can be enhanced, the service life of the filter bags can be prolonged, and thus the maintenance cost can be reduced. Meanwhile, the use of an adjustable DC regulated power supply can solve the problem of power voltage drop in the pulse valve power supply line, increase the operation rate, and further enhance the dust removal effect.
3. Reduce the number of pulse valves and optimize the design of the ash cleaning system
By optimizing the design of the dust cleaning system, such as using long-bag low-pressure pulse bag filters, the number of pulse valves can be reduced, thereby lowering the overall manufacturing cost. For instance, directly blowing a 7500 mm long cloth bag without installing Venturi can reduce the system pressure difference loss by up to 400 Pa, and at the same time, reduce the total number of pulse valves to 120, lowering the total equipment cost by more than 33%. In addition, the adoption of low-pressure long-bag tube-type pulse bag dust removal technology further reduces the number of pulse valves, lowers the cost of construction and operation.
4. Strengthen equipment maintenance and management
Regular maintenance and inspection are important means to reduce the cost of dust removal. Regular inspection and maintenance can ensure the stability and operational efficiency of the equipment, and reduce faults and maintenance costs. At the same time, the replacement time of the filter bags should be reasonably arranged to avoid waste caused by premature replacement. Meanwhile, the replaced filter bags should be properly managed to prevent damage and waste.
5. Recycle and reuse dust to reduce raw material costs
The dust collected by bag filters can be recycled and reused, thereby reducing the cost of raw materials. For instance, a foundry with an annual output of 100,000 tons adopted a pulse bag filter with a processing air volume of 20,000 m³/h. The collected metal dust can be recycled into valuable metals such as zinc and lead worth 150,000 yuan per month, achieving a win-win situation for both environmental protection and the economy. In addition, by improving the production process and reducing the generation and emission of waste gas, the burden and operating costs of the dust collector can also be lowered.
6. Adopt intelligent control technology
The application of intelligent control technology can enhance the operational efficiency and intelligence level of the dust removal system. For instance, the pulse jet control system of bag-type dust collectors based on the equipment combination control mode can save equipment investment and engineering construction costs. Meanwhile, the pressure waveform, acceleration waveform and key data of the pulse valve can be directly printed out through the computer, allowing for pulse valve optimization tests, injection volume tests, etc., to further optimize the ash cleaning effect.
7. Reduce energy consumption and operating costs
Energy consumption can be reduced by optimizing the pulse injection system. For instance, the adoption of a low-pressure injection system can effectively reduce energy consumption, with low operating energy consumption and remarkable energy-saving effects. In addition, by reasonably arranging the on and off times of the equipment and avoiding unnecessary energy waste, the operating costs can also be reduced.
8. Optimize the design of filter bags and the selection of materials
The material and design of the filter bags directly affect the dust removal effect and operating costs. Choosing the appropriate filter bag material can enhance the dust removal efficiency, extend the service life of the filter bags, thereby reducing the frequency of replacement and maintenance costs. Meanwhile, by optimizing the distribution and structure of the filter bags, the dust cleaning effect can be enhanced, and the wear and damage of the filter bags can be reduced.
9. Enhance the sealing performance and structural optimization of the equipment
By enhancing the tightness of the equipment, the air leakage rate can be reduced to less than 10%, further raising the quality requirements of the products while reducing energy consumption and maintenance costs. In addition, by optimizing the airflow distribution of the dust collector, the service life of the filter bags can be prolonged, the operating resistance can be reduced, and thus the dust removal cost can be lowered.
10. Adopt advanced dust cleaning technology
By adopting advanced dust cleaning technologies, such as the spray pulse bag filter, the dust cleaning efficiency can be enhanced, the injection frequency can be reduced, and thus energy consumption and maintenance costs can be lowered. Meanwhile, by optimizing the injection device, the dust cleaning effect can be improved, and the wear and damage of the filter bags can be reduced.
Summary
The key to reducing the dust removal costs of enterprises lies in optimizing the selection and design of pulse valves, strengthening equipment maintenance and management, recycling and reusing dust, adopting intelligent control technology, reducing energy consumption and operating costs, optimizing the design and material selection of filter bags, enhancing equipment sealing performance and structural optimization, as well as adopting advanced dust cleaning technologies. Through these measures, not only can the operational efficiency and environmental performance of the dust removal system be enhanced, but also the dust removal costs of enterprises can be significantly reduced.
