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Pulse dust collectors are a necessity for maintaining clean, safe, and efficient operations in feed mills, fertilizer plants, and new energy material processing facilities. However, any well-constructed systems can have issues with their functionality that can render them less efficient, higher consuming of energy, or lead to early failure. At Shanghai Yuanyuda International Trade Co., Ltd., as a qualified global turnkey supplier with over 30 years of experience, we understand that timely troubleshooting is a key factor in minimizing downtime.This document provides an overview of a troubleshooting guide for common issues and their solutions for pulse dust collectors.
Excessive Pressure Drop (High Differential Pressure)
Problem: The system shows the systematically raised pressure difference in the filter bags. This means that the air flow is minimal and the fan must work harder and this increases the price of energy, and reduces efficiency of collection.
Causes & Fixes:
Overloaded Dust: An undersized system may exist with regard to the actual process volume.
Fix: Review process data. Increasing the filter area, raising the cleaning frequency, or installing a pre-separator for coarse particles can all be effective solutions.
Absence of Sufficient Pulsing: The loosening pulses of the dust cake are inadequate or non-existent by the weak or broken cleaning pulses.
Fix: Ensure the compressed air supply pressure is maintained within the normal range (85-100 psi). Inspect solenoid diaphragms and pulse jets for blockages or malfunctions. Test the functionality of the timer controller.
System Humidity: Dust cannot be removed effectively when it becomes sticky due to moisture absorption, or when the filter media is blinded by condensation.
Fix: Insulate the collector and ducts adequately in low temperature conditions. Check for and fix air leaks. Install aftercoolers or air dryer in compressed air. Hydrophobically coated or PTFE-coated filter media should be used for wet operating conditions.
Low Pressure Drop (No Pressure Differential)
Problem: Little to no pressure differential is recorded across the filters. This typically means gas is bypassing the filter media entirely, resulting in the direct emission of unfiltered gas, which can cause environmental pollution and product loss.
Causes & Fixes:
Filter Bag Failure: Bags are torn, frayed or lost out of their cages.
Remedy: Isolate and inspect each compartment. Replace damaged bags promptly. Identify the root cause of failure, which may include abrasion from high inlet velocity, chemical degradation, or improper installation.
Leaking Diplegs/Tube Sheets: Bag cage/Tube sheet seals have been ruined.
Resolution: Shut down the system and inspect all gaskets and sealing areas. Check the filter bags and ensure all bag cages are correctly fitted and all hold-down devices are properly installed and secured.
Visible Emissions (Dust Discharge from Stack)
Problem: Unfiltered dust is escaping through the clean air outlet/stack, which is referred to as a filtration failure.
Causes & Fixes:
Failed Filter Bags: In this case, as in the one above, the tears or holes permit the dust to pass through.
Fix: Replace damaged filter bags. Always inspect all adjacent bags, as even a small defect can result in the release of hazardous particulates into the environment.
Poor Sealing: Access door leak, inspection panel leak or duct connection leak.
Fix: Perform a powder leak test (e.g., using fluorescent tracer powder). Check and tighten all bolts, and replace any worn or damaged seals and gaskets.
Wrong Filter Media: The media is not the right cloth or felt to the size of the particle.
Fix: Consult a technical expert (e.g., Yuanyuda) to select the appropriate media weight, finish (e.g., calendered finishes), or membrane laminate suited for sub-micron particle filtration.
Compressed Air Issues
Fix: Consult a technical expert (e.g., Yuanyuda) to select the appropriate media weight, finish (e.g., calendered finishes), or membrane laminate suited for sub-micron particle filtration.
Causes & Fixes:
Low Air Pressure/Volume Cause: The air compressor is undersized, or air lines are excessively long, undersized, or leaking.
Fix: Audit air compressor system. The diameter of the airlines should be sufficient. Fix all leaks. Position the collector near a dedicated air receiver tank.
Frozen or Clogged Lines: Lines are frozen or are sludged with moisture.
Fix: Install appropriate air drying and filtration equipment (e.g., a coalescing filter) ahead of the pulse valves. Drain the air receiver tank regularly.
Malfunctioning Solenoid Valves or Diaphragms: The solenoid valves or diaphragms rip open or rip close or stick.
Remedy: Perform regular preventive maintenance on the system. Maintain a stock of spare solenoid valves and diaphragms to enable immediate replacement when needed.
Abnormal Noises
Symptom: Rattling, banging or high pitched whistling.
Causes & Fixes:
Rattling/Banging: This noise is typically associated with the cleaning system, caused by loose or damaged diaphragms or other loose components.
Fix: Secure all pulse valve fittings and inspect all internal components for damage or looseness.
Whistling/High Velocity: It is an indication that there is a leakage of air, and the leakage can be dislodged gasket or puncture in the duct work.
Fix: Do a comprehensive air leak inspection as follows.
Mechanical Noise from the Fan: Caused by fan blade imbalance, material buildup, or excessive wear.
Fix: Schedule and perform fan cleaning and inspection. Check the fan blades for wear and verify proper lubrication levels.
Proactive Prevention with Yuanyuda's Expertise
While troubleshooting is sometimes necessary, prevention through proper design, correct equipment selection, and regular maintenance is the most effective strategy. At Shanghai Yuanyuda International Trade Co., Ltd., we ensure our pulse dust collectors are customized to match the processed material (e.g., feed dust, fertilizer fines, or new energy powders), process air volume, and on-site environmental conditions via our tailored turnkey solutions.Our ISO-certified, CE-certified and SGS-certified machines are planned to be efficient and durable.
Do not let dust collector issues affect your productivity. Contact our global support team to obtain professional troubleshooting advice, source genuine spare parts, or request a full system audit. We have served clients in over 50 countries, and we will ensure your operations remain clean and efficient for years to come.
