How to reduce the energy consumption of bag filters?
Feb 27,2026
Bag filter is the core equipment for industrial dust control, widely used in mining, chemical and other fields. Its operating energy consumption (mainly from fans, pulse valves, etc.) accounts for a significant proportion of the total life cycle cost of the equipment. For overseas enterprises, reducing their energy consumption can not only control costs, but also align with the global trend of green and low-carbon.
1、 Scientific selection: Controlling energy consumption from the source
The selection directly determines the energy consumption foundation, and improper selection can lead to limited energy-saving optimization effects in the future. Considering the characteristics of overseas working conditions, three key points should be focused on:
One is to accurately match and process air volume. Avoid excessive selection, accurately calculate the required air volume based on parameters such as dust emissions and intake concentration of the production process, and eliminate redundancy. For example, small and medium-sized workshops can be equipped with local dust removal systems to reduce fan load.
The second is to choose energy-saving core components. Fans account for more than 70% of the total energy consumption, and variable frequency centrifugal fans are preferred. The speed can be flexibly adjusted according to the working conditions to avoid full load operation; The pulse valve adopts low consumption products to reduce compressed air consumption and indirectly reduce the energy consumption of the air compressor.
The third is to choose filter bags reasonably. The resistance of the filter bag directly affects the energy consumption of the fan. It is necessary to select materials with low resistance and good breathability according to the characteristics of the dust, temperature and humidity (such as Flumets for high temperature and waterproof and oil proof filter bags for high viscosity dust), while ensuring that the specifications of the filter bag match the equipment to avoid airflow disorder.
2、 Optimize operating parameters: improve efficiency and reduce energy consumption
Optimizing parameters in daily operation can significantly save energy without affecting the dust removal effect. The core focus is on the operation of the dust cleaning system and fan, which is an easy link for overseas enterprises to implement.
（1） Optimize the parameters of the ash cleaning system
The energy consumption for dust cleaning mainly comes from compressed air, and optimizing injection parameters can reduce ineffective consumption:
1. Set a reasonable blowing pressure: control it at 0.3-0.6MPa, adjust it according to the working conditions during trial operation, balance the cleaning effect and energy consumption, and avoid damaging the filter bag too high and accumulating dust too low.
2. Optimize the spraying cycle and time: based on the pressure difference between the inlet and outlet (start cleaning at 1500-2000Pa, stop below 1000Pa), to avoid frequent cleaning; The spraying time is controlled at 0.1-0.3 seconds per time to prevent waste.
3. Adopt zone cleaning: Large equipment will clean the filter bags in different zones alternately to avoid sudden changes in system resistance, and adjust the spraying frequency accurately according to the accumulation of dust.
（2） Optimize the operating parameters of the fan
Variable frequency fans can adjust their speed as needed: reduce speed and air volume when the production load is low, and increase speed and maintain efficiency when the load is high; Regularly adjust the opening of the fan valve and clean the heat sink to reduce airflow resistance and efficiency decline caused by high temperature.
3、 Strengthen daily maintenance: stabilize energy consumption levels
Equipment failure and lack of maintenance can easily lead to a surge in energy consumption, and four key areas of maintenance should be emphasized:
1. Regularly clean/replace filter bags: promptly address blockages and bag sticking issues, check installation sealing to avoid increased resistance and disrupted airflow.
2. Ensure equipment sealing: Check the sealing parts of the shell, maintenance door, etc., replace aging gaskets, control the air leakage rate below 5%, and reduce the additional load on the fan.
3. Maintain the unloading device: Ensure smooth operation of star shaped unloaders, clean up stuck materials, and avoid ash accumulation in the ash hopper blocking the airflow channel.
4. Maintenance of auxiliary equipment: Regularly clean the air compressor filter, inspect the variable frequency control cabinet, ensure efficient operation of auxiliary equipment, and reduce comprehensive energy consumption.
4、 Detail optimization: Exploring potential energy-saving space
Add three practical details to further enhance the energy-saving effect:
1. Optimize intake design: reduce pipeline bends and sudden changes in diameter, install deflectors to evenly distribute airflow and reduce resistance.
2. Utilize production waste heat: Use waste heat to cool down in high temperature conditions, and use waste heat to heat the ash hopper in low temperature conditions to avoid additional energy consumption and filter bag blockage.
3. Establish energy consumption monitoring: Install instruments on major energy consuming equipment, analyze energy consumption data, and accurately adjust optimization plans.
Reducing the energy consumption of bag filters requires systematic promotion, which can be achieved through scientific selection, parameter optimization, and daily maintenance without requiring significant additional investment. Overseas enterprises can combine their own working conditions, balance dust removal standards with energy conservation, control costs while practicing green production, and achieve long-term benefits.
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