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A new type of filter element applied to pulse bag dust collectors significantly increases the effective filtration area through a star-shaped pleated structure (up to 1.5 to 3 times that of traditional round bags), enabling an upgrade in filtration efficiency without the need to modify the main body of the dust collector. | |||||||||
Alternative Names and Product Introduction
Alternative names: Pleated filter bags, also known as pleated cloth bags, pleated dust removal filter bags, star-shaped dust removal filter bags or pleated filter bags.
Product positioning
A new type of filter element applied to pulse bag dust collectors significantly increases the effective filtration area through a star-shaped pleated structure (up to 1.5 to 3 times that of traditional round bags), enabling an upgrade in filtration efficiency without the need to modify the main body of the dust collector.
Core structure
Filter material: Supports polyester needle felt, PPS (resistant to 190℃ high temperature), P84 polyimide (resistant to 260℃), etc. The surface can be compounded with PTFE film to improve accuracy.
Matching frame: A specially designed star-shaped cage bone without transverse support rings is required to prevent mechanical damage to the filter bags.
Product Features
High-efficiency face-enhancing design
The pleated structure increases the filtration area within the same installation space by 50% to 200%, reduces the system pressure difference to 600 to 800Pa, and significantly lowers energy consumption.
Intelligent flight clearance mechanism
Reserve vibration space between the folds. The pulse airflow needs 0.3-0.5MPa (lower than the round bag) to shake off the dust, with a stripping rate of over 95%, avoiding the problem of filter cartridge caking.
Strong environmental adaptability
High-temperature resistance: PPS/P84 materials can withstand continuous high temperatures of 190℃ and 260℃ respectively.
Corrosion resistance: PTFE-coated film resists acid and alkali corrosion (pH 2-12), suitable for acidic flue gas from waste incineration.
Explosion-proof safety: Optional anti-static treatment (surface resistance 10⁶ - 10⁹Ω) to avoid the risk of dust explosion.
Comparison of performance parameters of different materials
Material temperature resistance (℃), weight (g/㎡), tensile strength (N/5cm), applicable scenarios
Polyester ≤130 550±50, warp direction ≥800, weft direction ≥1000, normal temperature dust (grain processing)
PPS 190(instantaneous 210) 550 warp ≥1200, weft ≥1300 coal-fired power plants, chemical industry
P84 film coating 260(instantaneous 300) 500±50, warp direction ≥800, weft direction ≥1300, waste incineration, cement kiln tail
Application Scenarios
It is mainly adapted to industrial fields with high dust concentration and high emission standards. Specific scenarios include:
Core challenges in typical industry scenarios: Pleated filter bag solutions
The flue gas at the tail end of the cement production kiln, high-alkali dust from the clinker cooler, and high-temperature P84 coated filter bags with anti-hydrolysis treatment
Waste incineration fly ash captures acidic gases + dioxin adsorption PTFE substrate + acid-resistant coating
Steel and metallurgical electric arc furnace smoke dust, lead oxide recovery metal dust + high-temperature oxidation anti-static + wear-resistant base fabric
Design of PPS film coating + sealed installation for exhaust gas from chemical/pharmaceutical reaction vessels, raw material dust and organic solvent corrosion
Anti-static polyester filter bags for flammable organic dust in grain processing flour mills and feed production lines
Note: In the food/pharmaceutical field, FDA/GMP certification is required, and a silicone-free sewing process should be adopted to avoid contamination.
Product Advantages (Compared with traditional round bags)
Convenience of renovation: Directly replace the round bags and frames without modifying the main structure of the dust collector, shortening the renovation cycle by 50%.
Economy
The increase in the filtration area reduces the equipment footprint and lowers the comprehensive maintenance cost by 40%.
Energy consumption has been reduced (with a 30% decrease in fan load), and the 600MW power plant saves over 600,000 yuan in electricity annually.
Long-life design: The frequency of ash cleaning is reduced by 50%, and the service life is more than twice that of ordinary filter bags (such as in waste incineration conditions)
Ultra-low emissions: The emission concentration is stable at ≤5mg/m³, which is better than the national standard (for example, ≤10mg/m³ in the cement industry).
Customization Process
Demand confirmation (3-5 working days)
Provide working condition parameters: temperature range, dust characteristics, target emission value, installation space (diameter φ130-160mm, length 1-6m);
Scheme Design (1-2 weeks)
Material selection: Base material (PPS/P84/ polyester) + post-processing such as lamination/anti-static;
Structure: Number of pleats (8/10/12 pleats), frame material (stainless steel/galvanized)
Sample verification (2 weeks)
Make sample bags → Seal performance test (0.3MPa pressure holding for 5 minutes) → On-site bag hanging test;
Mass production (3-4 weeks)
The fully automatic production line (ultrasonic welding + laser cutting) ensures uniform wrinkle depth.
Quality Inspection Process
According to GB/T 6719-2009 and enterprise standards, it is controlled in three stages:
Raw material inspection
Fiber grammage (500±50g/m²), thickness (1.8-2.5mm), PTFE membrane pore size (bubble point method ISO 4003);
Production process monitoring
Uniformity of folds: Laser detection of fold height deviation ≤±0.5mm;
Welding strength: Ultrasonic weld point tensile strength ≥250N, torsion 10°/ m without de-welding.
Finished product testing
Physical properties: Air permeability (12-16m³/㎡·min), breaking strength (warp direction ≥800N/5cm);
Functionality
Sealing performance: No leakage at 0.3MPa negative pressure for 1 hour.
Corrosion resistance: Strength retention rate ≥85% after soaking in 10% H₂SO₄/NaOH for 72 hours;
Dust cleaning simulation: The VDI3926 dust loading curve test shows that the peel rate is over 95%.