Comparing FS Reverse Air and Pulse Jet Dust Collectors: An In-Depth Analysis

FS Reverse Air Dust Collectors

FS reverse air dust collectors clean the filter bags by introducing a low-pressure, reverse airflow. This process occurs in isolated sections of the baghouse, allowing for continuous operation in other compartments. The reverse airflow gently dislodges the dust cake accumulated on the surfaces of the bags, causing it to fall into the hopper below. Key characteristics include:

• Gentle Cleaning Mechanism: Extends the lifespan of filter bags due to reduced mechanical stress.
• Lower Maintenance Costs: Less frequent bag replacement and reduced downtime.
• Suitable for High-Temperature Applications: Can handle gases up to 500°F (260°C) with appropriate bag materials.
• Smaller Footprint: FS flat bag design requires less space than a similar air-to-cloth ratio pulse jet system

Pulse Jet Dust Collectors

Pulse jet dust collectors utilize short bursts of high-pressure compressed air to clean the filter bags or cartridges. The sudden pulse creates a shock wave that flexes the bags, dislodging the dust cake from the outer surfaces. Notable features include:

• Efficient Cleaning: Allows for continuous operation without interrupting airflow.
• Versatility: Suitable for a wide range of dust types and concentrations.
• Higher Energy Consumption: Requires a supply of compressed air, increasing operational costs.

Pulse Jet Round High Pressure Dust Collector

These are special Pulse Jet Dust Collectors that meet ASME BVLC Section VIII, Division 1, Pressure Equipment Directive (PED) 2014/68/EU and DIN EN 14460. Solutions can be up to 25ft. (7.5m.) diameter, up to 725 psig (5.0 MPa) and 600°C

• ASME-Certified Pressure Vessels: Designed for safety-critical environments, including explosive dust zones and applications requiring high-performance containment.
• Optimized Pulse Efficiency: High-pressure tanks allow more effective cleaning with fewer pulses, improving dust release and reducing compressed air consumption over time.
• Compact Modular Design: Especially useful where space is limited or higher dust-loading per unit area is required.

Detailed Comparison Table

Characteristic	FS Reverse Air Dust Collector	Pulse Jet Rectangular Dust Collector	Pulse Jet Round High Pressure Dust Collector
Cleaning Mechanism	Low-pressure Reverse airflow	High-pressure Compressed air pulse	High-pressure Compressed air pulse
Static Pressure Filter Rating	6,000 pa (24 in. water)	10,000 pa (40 in. water)	> 10,000 pa
Bag Life	4+ years (It runslower operating pressure, lower velocities and reduced abrasion from dust and cleaning)	1-3 years (higher filter velocities, increasing abrasion and wear, shortening bag life due to constant air blasts)	1-3 years (higher filter velocities, increasing abrasion and wear, shortening bag life due to constant air blasts)
Cleaning Operation	Semi-continuous (offline cleaning in compartments)	Continuous (online cleaning without stopping airflow)	Continuous (online cleaning without stopping airflow)
Noise	Avg. noise 82 dB(A) (with higher, intermittent noise levels during cleaningcycles)	Avg. noise 86 dB(A) to 100 dB(A) (as filters become more seasoned, pulse cleaningbecomes more frequent)	Avg. noise 86 dB(A) to 100 dB(A) (as filters become more seasoned, pulse cleaningbecomes more frequent)
Maintenance	Lower frequency bag replacements	Higher frequency bag replacement	Highest frequency bagreplacement
Footprint Size	Smaller footprint size (vs similar air-to-cloth ratio pulse collectors)	Larger footprint size (vs to similar air-to-cloth ratio FS dustcollector)
Emissions Level	Typically <5 mg/m³ or lower with polyester bag	30-100 mg/m³ or higher with polyester bag; <5 with ePTFE bag	30-100 mg/m³ or higher with polyester bag; <5 with ePTFE bag (Typically mid-stream operation)
Energy Consumption	Lower 3-8 kW (no compressed air required)	Higher 5-15 kW (requires compressed air system)	Higher 5-15 kW (requires compressed air system)
Temperature Limits - Both with specialized systems able to withstand up to 250°C (482°F)	Typically up to 80-100°C (176-212°F).	Typically up to 150-200°C (302-392°F)	Typically up to 150-200°C (302-392°F)
Dust Load Handling	Heavy Dust Loads (suited for handling heavy, fluctuating, orintermittent dust loads)	Heavy Dust Loads (suited for handling heavy, fluctuating, orintermittent dust loads)	Moderate or Stable Dust Loads (ideal for applications with constant or steady dustloads)
Applications	Recommneded for industries withdust generated from furnaces, such as Asphalt, Cement, manufacturing, Incinerators, Foundries, and Smelters where PM2.5 emissions are of specific concern	Recommended for large volumes of nuisance dust industrial applications such as Grains Processing and Mining where dust loads need to be captured efficiently	Recommended for hazardous or valuable industrial applications such as Pharmaceuticals, Chemicals, Thermoplastics, and Natural Gas where ultra-low emissions is required or when high pressure is requried

Additional Considerations

• Installation Space: With the high air-to-cloth ratio from the flat bag design, FS reverse air dust collectors require less installation space than typical baghouses. This helps in facilities with space constraints.
• Emission Levels: Both systems are effective, but pulse jet collectors may achieve lower emissions due to more efficient cleaning cycles depending on the application.
• Compressed Air Quality: Pulse jet systems depend on clean, dry compressed air; poor air quality can lead to maintenance issues.

Optimizing Dust Collection

To achieve optimal performance, you should also consider:

• Filter Media Selection: Choose appropriate bag or cartridge materials based on temperature, chemical compatibility, and dust characteristics.
• System Design: Ensure the dust collector is properly sized and configured for the specific application.
• Maintenance Practices: Regular inspections and maintenance enhance system longevity and efficiency.

Selecting between a reverse air and a pulse jet dust collector depends on various factors, including the nature of the dust, operational temperatures, space availability, and cost considerations. Reverse air systems are ideal for heavy-duty applications requiring gentle cleaning and durability, especially in high-temperature environments. In contrast, pulse jet systems offer efficient, continuous operation, suitable for a wide array of industries handling fine to medium dust particles.

Contact us today if you have any questions about which dust collector would work best for your application. Nederman MikroPul supplies both reverse air and pulse jet dust collectors that can fit your application.