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Carbon black is produced, sized and conveyed in a powdered form. Dust collectors (baghouses) are used to efficiently collect the carbon black particulate and to control fugitive emissions. The manufacturer faced the need to increase airflow through the reactor (to increase production) and wanted to extend the service life of the filter bags in order to save costs.

A carbon black manufacturer faced the need to lower dP in the baghouse in order to increase airflow through the reactor – and, as a result, increase production. The manufacturer also wanted to extend the service life of its filter bags to lower the overall cost of ownership.

A carbon black manufacturer faced a need to maintain filtration emissions to the lowest level possible to ensure regulation compliance and increase energy production  efficiency.

The emissions were eliminated increasing particulate capture efficiency and productivity. Filter bag life increased from 4 to 18 months.

Lower operating DP (5"-7" DP) improved cake release, allowing increased airflow through collector. Bleed-through stopped, allowing capture of product. First set of bags lasted more than five years.

Airflow increased by 10%. Production rated increased. Lower operating DP 1-2". Improved cake release eliminated product discoloration and product contamination. Bags attained 5+ years of service.

Results showed no visible emissions, excellent and consistent product yield, and secondary filter blinding significantly reduced. No bag failures since installation.

Solution involved installing GORE Fabric Filter Bags. Results were sixty months of continuous, problem-free service, with excellent pressure differential.

High production levels and low pressure drop. Increased mill efficiency yielded considerable energy savings by producing a set tonnage in a much shorter period. The excellent cake-release characteristics enabled the collector to be operated continuously for 12 months at a maximum pressure drop of 5" w.g. The emission problem was eliminated.

Bag life is now between 9 and 18 months, as opposed to the previous 2-4 months. Energy savings due to low DP is about $2,000/year. Emissions are virtually non-detectable with 0% opacity. Improved product recovery provided over $10,000/year of additional salable products. Less downtime and improved airflow equated to a production increase of over 10%.