Filter Bags for the Metals Industry

GORE® Filter Bags are highly efficient filter media that improve the overall operation of air pollution control systems (baghouses) in metallurgical processing operations.  These improvements, such as increased airflow, efficient energy utilization and better temperature capabilities, allow for maximum compliant flexibility in operations such as smelting, refining, recycling and recovery. 

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Resource Library

Case Study: Lead Oxide (PbO) Barton Process Filtering in Pulse-Jet Dust Collectors

Particle and Gas Filtration for Industrial Processes & Bag Houses

Original set of GORE® membrane filter bags were in service for more than three years and were removed during a planned maintenance shutdown. Emission levels measured less than required by standards/regulations during this operational period.

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All Resources For Filter Bags for the Metals Industry

Overview

The wide-ranging metals industry is united by a need for efficient, reliable and cost-effective filtration solutions that can be counted on from day to day.

By example, across the steel, secondary lead, ferroalloy and other non-ferrous metals industries, GORE® Filter Bags are proven to provide greater reliably and a lower total cost of ownership than other filters by delivering:

  • greater efficiency
  • lower resistance
  • greater airflow
  • higher durability
The three key filtration factors

Baghouse operators purchase filter bags primarily for particulate collection. This is a primary filtration factor. As the particulate is collected, the resistance to flow, differential pressure, increases, causing higher fan energy costs.  This is a secondary filtration factor.  When the filters have holes so they are no longer as efficient at particulate capture as they need to be or when the differential pressure of the filter bags is too high, the filter bag life is over.  Although life is a primary thing considered during a filter selection, it is defined by the primary and secondary factors.  Gore provides the optimal balance of

  • extremely high filtration efficiency
  • very low resistance to flow
  • and extremely long filter life.

These qualities make our filter bags extremely durable and reliable through each cleaning cycle, resulting in a long product life overall. Because our bags stay running longer, they don’t need to be replaced as often — equaling lowered maintenance costs, increased yield and greater productivity. What this amounts to is a lowered overall cost of ownership.

Why Gore?

As the leading developer of high-quality, reliable filtration products for baghouses in the metals processing industries, we've listened to our customers and taken industry needs into account when developing solutions that truly address what metals manufacturers face each day.

Gore was the first to develop PTFE-based membrane filters. With their PTFE membrane and robust construction, our filter bags deliver high performance — and value — while ensuring your plant meets all environmental regulations. Across all of our filter products, reliability is the Gore standard.

Our recent, innovative solutions include GORE® Low Drag Filter Bags, which are proven to reduce operating costs by promoting improved airflow and energy utilization, and GORE® Low Emission Filter Bags, whose seam-taped design reliably prevents emission leaks through stitch holes.

When analyzing Gore’s filtration products for use in your filtration system, we encourage you to consider 3 important factors:

  • our truly innovative products which offer filtration performance that you will not find elsewhere
  • our proven product reliability and
  • our unique system approach to filtration process optimization, which includes our technical support for the lifetime of the filter bags

These three attributes enable Gore’s solutions to deliver the lowest total cost of ownership available in a filtration system.

Steel

In steel production, flue gas streams flow through baghouse filters to extract any particulates generated during the smelting process. This process, while simple, must reliably meet all regulatory requirements while being operated and maintained at the lowest total cost.  This reliability, capability and cost can be drastically different depending on the specific filters used.

For one, filters must help plants comply with regionally specific EPA regulations and the National Ambient Air Quality Standards (NAAQS). Total particulate emissions, both from the baghouse as well as from the meltshop, are closely monitored; non-compliance results in significant additional costs and attention for the plant. Another concern is worker safety; plants must create a comfortable and safe working environment inside the meltshop, or risk non-compliance with the Occupational Safety and Health Administration (OSHA) regulations and poor labor relations.

 

In the extreme, poor APC operations can force steel plants to curtail operations and production rates to maintain compliance

Innovative Products for steel producers

GORE Filter Bags are superior in steel baghouses because they reliably capture more of the finest particulates while providing better airflow. This results in increased fugitive capture efficiencies and lower overall particulate emissions. Because of the high-performing, PTFE-based membranes in our filters, binding of the filtration media is prevented and a consistent airflow is maintained in the process. Due to increased cleaning efficiency, the overall baghouse pressure drop is reduced, and a 10–15% increase in airflow can be typically achieved

GORE® Low Drag Filter Bags: Lower Resistance to Flow has many possible benefits!

Though each of our filters provides these benefits to the steel industry, the GORE® Low Drag Filter Bag is especially effective. The lower the filter drag, the less energy is needed to move air through a steel plant baghouse. Through the use of a new proprietary membrane, Gore is able to achieve a filtration surface that’s left almost perfectly “clean” and unclogged after each cycle of a cleaning system, allowing for lower pressure drops and more air to flow.

Membrane comparison
Compare Low Drag Membrane with Standard Membrane

The results include:

  • Increased fan energy efficiency
  • Increased flow capacity
  • Increased bag life due to reduced cleaning
  • The potential to decreased number of filter bags installed
  • Greater steel operations flexibility
  • Reduced emissions

Our filter bags reliably deliver the emissions control that keeps steel manufacturers in good standing with the EPA and other environmental organizations around the world. The Gore difference is that while our customers remain compliant, they can also explore options to reduce that cost of compliance, through energy savings and/or improved fugitive capture at the furnace and meltshop due to the increased capacity of their off-gas system. Such improved performance can allow for more flexibility to optimize their meltshop operations.

Secondary Lead

So prevalent in consumer electronics and automobiles, lead is one of the world’s most versatile and recycled metals. Unfortunately, use of this metal presents some risks, and the EPA and other international environmental organizations have set extremely tight regulations for lead dust emissions by the lead refining and recycling industries. In the U.S., for instance, the combined stack limit is 0.2 milligrams/normal cubic meter of lead particulate.

Equally regulated are the limits for plant workers’ exposure to lead. Due to fumes potentially escaping smelting furnaces and refining kettles, workers are at risk of lead exposure by breathing air that could be contaminated. This has led the industry to adopt a rigorous blood-level monitoring program with current targeted blood-lead concentrations of less than 20 ug PB/dl.

With costly impacts to operations if workers were to exceed these limits, the goal for lead recycling plants is to absolutely minimize worker exposure, which includes improving the fugitive capture of lead emissions at their source.

Innovative Products for secondary lead producers

While many ePTFE membrane filter bags can meet low emissions requirements only through the filter media itself, the new GORE Low Emission Filter Bags take emissions capture assurance and worker safety to a new level.

GORE Low Emission Filter Bag

GORE Low Emission Filter Bags have a PTFE-based seam tape that makes it virtually impossible for dust to leak through the stitch holes.

In addition to robust constructions and highly durable, efficient membranes, GORE Low Emission Filter Bags are seam-taped to prevent any leaks through the stitching holes created during manufacturing. This allows the bags to meet the strictest lead emissions regulations — good news for workers and each plant’s overall compliance — while providing the same level of quality and reliability as our standard filter bags.

What is unique to Gore is the ability to tape high temperature, chemically resistant filters with a newly engineered and patented high-durability, PTFE seam tape covering all stitches on the filter bag. The PTFE is resistant to cracks despite continuous cleaning cycles, high temperatures and chemical exposure, allowing the bags to comply with the strictest emissions in the world.

When designing filter bags for our secondary lead customers, we always target zero emissions. With the GORE Low Emission Filter Bags, we can reliably strive for that target for the benefit of your plant and your workers.

Ferroalloys

In order to stay competitive in today’s world, ferroalloys producers are constantly looking for ways to improve and increase the capacity of their furnace systems, without adding significant costs to their plant off-gas systems. In a world of increasingly stringent environmental regulations, the baghouse and fume extraction systems are constantly being stressed and operated at their maximum capability.  In this environment, consistent operation, premium performance and reliability plays a more important role in ensuring constant plant operations.

The goal, then, is to find a filter bag that reliably ensures emissions control while maintaining a consistently high extraction volume from the furnace. That’s what at Gore we seek to achieve for our customers — and even add proven cost-effectiveness.

Innovative Products for ferroalloys producers

GORE Filter Bags are superior for ferroalloys production because they capture the fine particulates typical in Fe-alloy systems while providing better airflow. This results in increased capture efficiencies and lower overall particulate emissions. Because of the high-performing, PTFE-based membranes in our filters, binding of the filtration media is prevented and a consistent airflow is maintained in the process. GORE Filter Bags can operate at 1.5 to 2 times the air-to-cloth ratio of non-membrane filters and are designed to last longer than any other filter on the market.  Gore combines high performance filter media with over 30 years of durable bag design experience to provide the ferroalloy industry a filter bag with the lowest total cost of ownership. 

Additionally, we offer GORE® Low Drag Filter Bags for the utmost in emissions control. These filter bags deliver the lowest filter drag and emissions combination in the market. They can allow for upgrades and changes to furnace operations while still using the existing APC equipment.  Just by replacing your filters, your risk of non-compliance is minimized, and your current equipment becomes more effective and lucrative — helping you maximize production with a simple filter change.

Non-Ferrous Metals

It takes a great amount of energy to smelt non-ferrous metals like copper, aluminum, platinum and zinc. At the same time, this process results in a significant amount of particulate emissions, which are regulated by the EPA and other environmental agencies. To meet these regulations while hitting their bottom lines, non-ferrous metal plants need efficient filtration solutions.

Innovative Products for metal refiners and producers

GORE® Low Drag Filter Bags provide excellent particulate capture while allowing for greater airflow than alternatives. The result: less energy needed to smelt non-ferrous metals and faster and more frequent production cycles — without the risk of exceeding emissions limits.

The key to the high performance of our filter bags is their ePTFE membranes. Because of our membrane’s low filter drag — the lowest available in the industry — our filters provide the highest airflow and lowest pressure drop available while also providing the highest particulate capture efficiency available to the industrial filtration market. 

Despite our filters’ high particulate capture, they stay “clean” and unclogged after each cleaning.  As a result, more air can flow through the baghouse, and the evacuation process requires less energy. This means stable production and a lower overall cost of ownership.

We offer a number of different ePTFE membrane filter media, each with different performance capabilities and price and can design each to fit your application. For the successful and energy-efficient smelting of non-ferrous metals, GORE® Low Drag Filter Bags provide the best value and assurance that you’ll meet all environmental regulations in the most cost-effective manner.

Reliability

More than 40 years ago, Gore invented ePTFE membrane-based filter bags that quickly demonstrated their superiority (e.g. cleanability) over conventional filter bags. Our reputation for reliability is based on many years of experience in the field, but starts with the materials which we use.  All our membranes are made from ePTFE (expanded polytetrafluoroethylene), essentially the most stable polymer on the planet. This material is

  • chemically inert
  • resistant to extreme temperatures
  • hydrophobic
  • mechanically tough

As the industry has evolved, we have worked to understand and continuously improve our filtration product designs, to meet and/or exceed our customers’ expectations. Over the years we have perfected the form, fit and function of our designs. These qualities make our filter bags highly durable. Time and again, GORE Filter Bags are proven to last longer than our competitors’, which means lower maintenance costs, less unexpected downtime, and lower overall cost of ownership for our customers.

Finally, we have a dedicated manufacture system. Our worldwide manufacturers complete production of our filter bags by following our strict production and testing measures, ensuring they perform just as they’re designed to.

Bottom line: Once your GORE Filter Bags are installed, you can rely on them to work as intended — during the first production cycle, and long after installation.

Our System Approach

When you buy filter bags from Gore, you’re buying a partnership with one of the world’s most trusted, time-honored manufacturers and a systems approach tailored to your specific needs.

As part of our system approach, we:

  • determine, design and manufacture the filter bags that uniquely fit your specific application and process
  • thoroughly test and inspect our bags for their weight, size, permeability and performance
  • provide technical support and troubleshooting for the lifetime of the filter bags

This means you’ll receive expert support not just on bag design and installation, but also on how to optimize the flow parameters of your system to get the absolute best productivity. This process-specific product design and applications engineering approach has proven to be the lowest risk way to optimize your system's performance.

We understand that you don’t always have filter bag experts on staff. As your partner, we will be on call to get you back up and running if you experience any problems related to your filter system operation.

What Do Filter Bags Cost?

Our filter bags deliver the filtration industry’s lowest available total cost of ownership, which goes beyond the price of filter bags to consider what your filtration system will cost you over time. Several factors impact the total cost of ownership for a baghouse, including:

  • purchase price of filter bags
  • labor cost to install filter bags
  • duration of product life
  • energy cost of fans that move air through a baghouse
  • costs of maintenance and cleaning

GORE Filter Bags deliver exceptional value. With your bags, you get a cutting-edge membrane laminate, robust filter bag design and construction, a system approach optimized for your baghouse and technical support for the life of your filter bags — along with the reliability our customers come to expect from Gore. With these factors combined, we provide the lowest total cost of ownership available in a filtration system.

Determine Your Total Cost

We’d like to help you get a sense of what your filter bags will initially cost and the overall cost of ownership you can expect. To begin our conversation, please contact us.

Success Stories

Metals manufacturers have found success using GORE Filter Bags to filter a wide range of products. Learn the story of a secondary lead smelter who lowered emissions with help from GORE® Low Emission Filter Bags.

Eliminating Stitch-Hole Emissions

A secondary lead smelter was operating a shaker baghouse off a reverberatory furnace. To control emissions, woven ePTFE membrane filter bags were installed with “normal”-sewn seams. However, upon startup, the plant immediately noticed that fine lead oxide fume was leaking through the bags’ stitch holes. The plant’s initial stack testing showed unacceptably high stack emissions that exceeded allowable stack emission limits.

Even though the original supplier used a high-efficiency ePTFE membrane laminate, the leakage was found to be excessive. The plant was operating under extremely strict emission requirements and couldn’t take a chance that the lead oxide fume would plug the stitch holes.

To immediately address the emissions problem, an emergency order was placed for GORE Low Emission Filter Bags. The new filters were rushed to the plant site and the leaking filters were completely replaced.

Once in place, our seam-sealed ePTFE membrane filters successfully addressed the issue; no fume leaks were found through seams or elsewhere. Currently, the plant measures stack emissions well below 0.5 mg/Nm3 total particulate (less than 0.2 mg/Nm3 of lead), which keeps them in full compliance with the latest U.S. MACT and NESHAP stack emission requirements for the secondary lead industry.

We continue to work with the plant to improve the efficiency and durability of our technology and optimize the overall filtering system, enabling the plant to maximize the filters’ ongoing performance.

Read the full case study.

Product Comparison

Gore produces a wide range of filter bags that vary by material and resistance to temperatures, moisture, oxygen, acid and alkali.

In steel, ferroalloy and non-ferrous metal plants where manufacturers need to weigh EPA regulations against production needs, we recommend GORE Low Drag Filter Bags. With the lowest drag of all filter bags on the market, our bags allow for both excellent particulate capture and increased airflow. As a result, our customers have seen a 10–15% increase in airflow achieved through their off-gas system.

In secondary lead plants, where zero emissions is always the goal, we recommend GORE Low Emission Filter Bags. The bags are seam-taped to prevent any lead particulate leaks and meet the strictest emissions regulations — including NESHAP — while providing the same level of quality and reliability as our standard filter bags.

The following basic information will help us to chose the right material for you:

  • filterbag size, current material and quantity
  • baghouse operating parameters (e.g.: airflow rate, temperature, differential pressure)
  • particulate description (ideally including concentration, particle size, bulk density)
  • cleaning cycle parameters (e.g.: pulse jet pressure, cycle time)

Please contact us to discuss which solution is right for your industrial application.


 

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