Asphalt production factories are one of the most important infrastructure and construction pillars in the country. The asphalt production process includes heating the aggregates, drying the materials in a dryer and mixing with hot bitumen. This process naturally produces a large amount of dust, suspended particles, hot gases and environmental pollutants. The uncontrolled release of these particles not only harms the environment and the health of the workforce, but also causes the loss of a large part of the filler and valuable materials and brings heavy crimes of the Environmental Protection Organization.
In the meantime, it becomes necessary to use an advanced industrial dust collector system, namely the bag filter system of the asphalt factory. If you are looking for the design, production and manufacture of the filter bag for the asphalt factory with the highest efficiency in Isfahan, Puya Sanat Company, as one of the pioneers of the air purification industry and the manufacture of heavy industrial equipment, offers engineering and modern solutions according to today's standards. In this specialized article, we will review all the stages, engineering requirements, advantages, components and key points of purchasing and manufacturing the asphalt factory filter bag.
What is the asphalt plant filter bag and how does it work?
Filter bag or bag dust collector is a type of industrial dry filtration that directs the polluted air full of dust particles into a large chamber with the suction of a strong suction fan. Dusty air passes through the pores of cloth bags; The particles of dust and filler are trapped on the outer surface of the bags and the purified air comes out from the top of the system.
In asphalt plants, the collected particles are transferred to the filler recycling system and return to the production cycle. The filter bag of the asphalt factory made by Puya Sanat company, using the modern pulse jet cleaning mechanism, provides a continuous and continuous filtration flow without pressure drop for the production lines.
Why is the production of bag filter of asphalt factory in Isfahan very important?
Isfahan province, as one of the biggest industrial and road building hubs of the country, is facing serious environmental challenges and continuous pollution monitoring. The establishment of asphalt factories in the outskirts and industrial areas of this province has made it mandatory to comply with the strictest chimney exit standards.
The main reasons for the need to build a filter bag for an asphalt factory in Isfahan are:
Poya Sanat Engineering Group, with full understanding of the dry climate and special operating conditions of Isfahan, designs bag filters that have a very long life against temperature changes and particle wear.
The main components of the filter bag of the asphalt plant are dynamic construction of the industry
To achieve the highest efficiency, the design of each part of the dust collector must be done with millimeter precision. Puya Sanat company uses first-class materials and strict engineering standards in the production of asphalt factory filter bags:
1. Main chamber and steel hopper
The body of the filter bag is made of strong steel sheets to resist high negative suction, high temperature of dryer exhaust gases and corrosion caused by humidity. The bottom hopper is responsible for collecting dust and is connected to the screw or star valve.
2. Heat resistant filter bags
The temperature of the incoming gases from the asphalt factory is usually between 120 and 180 degrees Celsius. Puya Sanat uses specialized fireproof bags such as Nomex, PTFE or fiberglass with engineered stitching in the filter bag of the asphalt factory to maximize the useful life of the bags.
3. Bag holder basket or cage
The cages prevent the bags from crumpling under the suction load. Industrial dynamic production cages have galvanized coating or resistant paint so that they do not have any pleats and the filter fabric does not get torn.
4. Pulse jet cleaning system
Pulse jet system includes compressed air tank, high speed solenoid valves, air distribution tubes and venturis. This system shakes the dust cake formed on the bags by throwing a momentary wind.
5. High pressure centrifugal suction fan
The powerful centrifugal suction is responsible for pulling a certain volume of air with a certain flow rate and pressure drop. The static and dynamic balance of fans in Poya Sanhat prevents the creation of vibration and additional noise on the site.
6. PLC intelligent control system
The electrical panel equipped with a PLC controller adjusts the firing timing of the air pulses according to the pressure drop and the frequency that saves the compressed air consumption and increases the life of the bags.
- Do you need to renovate, build or upgrade the filter bag of an asphalt factory in Isfahan?Engineers with dynamic industry experience are ready to provide free technical advice and estimate the exact dust collector capacity of your factory. To receive a catalog and inquire about the price of a filter bag for an asphalt factory, please contact the support numbers of dynamic industry.
Designing and manufacturing stages of the asphalt factory filter bag with the highest efficiency
Achieving an efficiency above 99% requires accurate engineering calculations before starting cutting and manufacturing. Poya Sanat company implements the production process in the following steps:
First step: calculation of aeration capacity and air-to-fabric ratio
Air to fabric ratio is one of the most vital design factors. Choosing the wrong ratio will cause the bags to clog quickly or waste energy. Puya Sanat calculates this ratio according to the production tonnage of the asphalt plant (for example, 80, 120, 160 or 240 tons per hour).
The second step: analyzing the temperature of the gases and preventing the dew point
The exhaust gases of the asphalt plant contain moisture. If the temperature inside the bag filter chamber reaches below the dew point, mud will form and the pores of the bags will be blocked. If the temperature is too high, the bags will burn. Poya Sanat keeps the operating temperature in a safe range with standard insulation of the body and precise design of the tracks.
Third step: precise mechanical construction and welding quality control
Seamless weldings and complete ventilation of the doors prevent the entry of excess air into the system and the loss of suction efficiency. All connections are tested under the supervision of the industry's dynamic quality control inspectors.
Fourth step: installation, testing, commissioning and delivery at the project site
Industry's dynamic executive team performs physical installation, cabling, compressed air piping, and hot and cold start-up of the system in the asphalt factory and provides testing of suspended particles output to the client.
Common mistakes in the construction of asphalt plant bag filter that should be avoided
Many non-specialized manufacturers produce bag filters that suffer severe problems after a few months due to lack of hydraulic and thermodynamic calculations. The most important of these mistakes are:
- Using low-quality normal bags: Normal bags against acid gases and high temperature of the asphalt plant will be destroyed in less than a few weeks.
- Miscalculation of the fan pressure drop: If the suction fan does not have the power to overcome the resistance of the bags and channels, the dust will be pushed back from the opening of the dryer and the whole plant will be covered in smoke and dust.
- Lack of proper insulation: The cold air in the environment during the autumn and winter seasons cools the internal moist gases and causes the soil on the bags to become mushy.
- Asymmetric distribution of air flow: If the air is not evenly distributed among all the bags, the incoming bags will be punctured by the impact of coarse particles.
Poya Sanat reduces all these risks to zero by installing a pre-separation chamber for coarse particles and using industrial standard materials.
Advantages of ordering bag filter asphalt factory to Poya Sanat company
Choosing a reliable manufacturer ensures uninterrupted operation of your production line. Puya Sanat is the first choice of managers of asphalt factories in Isfahan and all over Iran for the following reasons:
Comparison of dry bag filter dust collector system with wet dust collectors in asphalt factory
In the past, some factories used venturi scrubbers or water dust collectors. But wet dust collectors have big disadvantages:
- Indiscriminate consumption of water and waste of water resources in low water areas such as Isfahan
- Creation of industrial sewage sludge and the challenge of its disposal
- Loss of filler and the impossibility of reusing dust in the asphalt mixture
- Rapid decay and rusting of the metal body
On the other hand, the production of the asphalt factory filter bag by Puya Sanat does not require any water, it delivers the dust completely dry, and it is considered the most compatible system with the environment and the economy of the asphalt factory.
Maintaining and increasing the life of the filter bag of the asphalt plant
To maintain the highest dust removal efficiency, it is necessary to observe the following points:
Summarizing and registering the order for making filter bags for the asphalt factory
Building a filter bag for an asphalt factory with the highest efficiency in Isfahan is a reliable, profitable and necessary investment to maintain environmental standards and improve the quality of asphalt production. Basic filtration not only prevents crimes and air pollution, but also creates high added value through filler recycling.
Poya Sanat Company is ready to design and implement the best bag filter system for the asphalt plant according to the capacity of your plant, relying on the technical knowledge of outstanding specialists, advanced manufacturing machinery and brilliant records in numerous industrial projects.
Act today to increase the efficiency of your production line:
To receive free expert advice, price inquiry, visit the workshop and order the production of bag filter for the asphalt factory, contact the experts of Puya Sanat Company or register your request on the website so that we can contact you as soon as possible.
