Wrong Filter Media or Style of Filter
The choice of baghouse filter media depends on a number of factors, such as temperature, resistance to chemicals, target dust size, physical characteristics, collection efficiency and price. If the choice of fabric is unsuitable for the application required, this can have a dramatic reduction in the lifespan of the filter.
For example, trying to use a low temperature filter fabric such as polyester (max temp 250F – 275F) in a high temperature (300F – 500F) baghouse system will quickly result in filter failure.
Often, operators must consider more than just the maximum temperature as the mix of temperature, humidity and chemical makeup in the gas stream can cause failures if not accounted for when selecting the media. For example, in many gypsum applications the temperature is not normally very high (under 200F) so polyester media might seem to be a good choice. However, the combination of elevated temperatures and high humidity can cause the gypsum to react with the polyester and cause hydrolysis, which leads to the bag becoming hard and brittle. For this reason many gypsum applications used aramid filters even though the temperature normally would allow for cheaper polyester bags.
Finally, many suffer problems due to using cartridge filters where a bag filter is more appropriate. Man applications can make good use of cartridge collectors to improve operation and reduce the overall cost of a system. However, we often see people try to use cartridges in applications ill-suited for them such those with irregular-shaped material, sticky materials, or high temps.