The air leakage problem of filter cartridges and dust collectors in overseas factories is the main cause of decreased purification efficiency and filter material loss. When the air leakage rate exceeds 5%, the purification efficiency may drop from 99.5% to below 85%, which not only violates environmental standards such as EPA and ASEAN, but also accelerates the wear and tear of production equipment. The core of governance is "precise leak detection+targeted sealing". The following is a practical operation plan.

1、 Be alert to the core hazards of air leakage

Air leakage is divided into "external leakage (infiltration of external air)" and "internal leakage (short circuit of dusty airflow)", and the hazards are concentrated in four aspects:

Purification efficiency drops sharply: unfiltered dust is directly discharged, and the emission concentration is prone to exceed the standard (far exceeding the EU 10mg/m ³ standard);
Half the lifespan of the filter cartridge: External leakage causes condensation and sticking of the filter cartridge, internal leakage exacerbates local wear, and the 12-month lifespan may be reduced to 5-6 months;
Rising costs: Fan energy consumption increases by 20% -30%, filter cartridge replacement and manual cleaning costs double;
Secondary pollution: Dust spreads to the workshop, affecting the yield of PCB boards in electronic factories and FDA compliance in food factories.

2、 Practical method for quickly locating air leakage points

By combining operational data with on-site testing, the location of air leaks can be accurately locked without the need for complex equipment.

1. Basic judgment: Identify anomalies from running parameters

Sudden drop in pressure difference (＜ 600Pa)+excessive emissions → internal leakage (at the welds between the filter cartridge, flower plate, and pipeline);
Fan current increases, air volume decreases → external leakage (sealing failure of shell and maintenance door);
Partial adhesion/no dust on the filter cartridge → internal leakage (deformation of the flower board, misalignment of the filter cartridge installation);
Frost formation/dust overflow on the outer wall of the equipment → leakage (aging of flanges and gaskets).

2. On site inspection: 3 steps to lock the specific location

Smoke test: Place the portable smoke generator inside the device, turn off the fan to check for smoke leakage on the outer wall, and turn on the fan to see if there is smoke between the filter cartridge and the flower board;
Pressure detection: The normal range inside the equipment is -500 to -1500 Pa, and the area near atmospheric pressure is the external leakage point. If the pressure difference between the filter cartridge chamber and the clean air chamber is less than 300 Pa, it is considered internal leakage;
Concentration comparison: If the dust concentration ratio at the inlet and outlet is greater than 5% (normal<1%), or if there is a suspected sudden increase in concentration, it is a leak.

3、 Segmented governance: solving problems from the root

The leakage points are concentrated in four major areas, and targeted treatment can efficiently control the leakage.

1. Equipment body: leakage core defense line

Weld seam air leakage: argon arc welding repair after grinding with a grinding wheel, coated with silicone heat-resistant sealant (-40 ℃ to 200 ℃) for secondary protection;
Check for air leakage in the maintenance door: replace the fluororubber gasket (high temperature)/FDA silicone gasket (food factory), tighten the bolts diagonally to ensure that the sealing gasket is compressed by 30% -50%;
Ash hopper connection leakage: Install a "metal skeleton+rubber" composite gasket, wrap sealing tape around the outside of the flange and apply glue.

2. Filter cartridge installation: key link for internal leakage

Gap air leakage: repair the deformed holes in the flower board, replace the nitrile/fluororubber sealing ring, and rotate the filter cartridge to a "click" sound to confirm fit;
Filter cartridge damage: Replace the dust detector after positioning, polish the flower plate burrs to prevent secondary scratches, and conduct smoke testing verification after replacement.

3. Pipeline connection: treatment of hidden air leakage points

Flange air leakage: replace graphite gasket (high temperature)/PTFE gasket (corrosion), apply glue to the flange surface, and tighten the bolts step by step to the specified torque;
Bend leakage: After repairing welding cracks, add reinforcement bars, and install wear-resistant lining plates to reduce erosion in high dust conditions.

4. Dust cleaning system: easily overlooked air leaks

Pulse valve air leakage: replace oil resistant O-ring, thread wrapped with adhesive tape;
Spray pipe leakage: Align with the center of the filter cartridge and install a high-temperature resistant pad. Tighten the nut and apply glue for sealing.

4、 Foreign trade scenario: Strengthening measures for regional adaptation

High humidity areas in Southeast Asia: use ethylene propylene rubber waterproof pads, hot-dip galvanized and spray painted shell, and add waterproof covers at sealed areas;
High temperature zone in the Middle East: choose 250 ℃ resistant sealant, fluororubber ring, airbag with insulation layer;
European and American compliance zone: CE/FDA certification documents are stored, governance records are synchronized with EHS systems, and biodegradable materials are given priority;
Africa's dusty areas: Install dust-proof retaining rings, use cloth rubber wear-resistant pads, clean dust and apply lubricating grease every 3 months.

5、 After governance: effectiveness verification and long-term maintenance

Effect verification: If the export concentration meets the standard (efficiency ≥ 99%) within 24 hours, the negative pressure is stable, and there is no overflow or adhesion within 1 week, it is considered qualified;
Daily maintenance: check bolts every week, inspect seals every month, conduct smoke tests every quarter, and establish a ledger for closed-loop management;
Preventive reserve: New equipment should have sealant grooves, and overseas factories should prepare sufficient vulnerable parts such as gaskets and adhesives.

The key to controlling air leakage in filter cartridge dust collectors is to first accurately detect and then implement targeted measures based on the specific location. Scientific leak control can not only restore purification efficiency, but also extend the life of filter cartridges by more than 30%, avoiding environmental risks and downtime losses for overseas factories.