Performance Loss in Dust Collection Systems: Where is the Problem?

In an industrial facility, a dust collection system is not considered successful simply because it is “running.” If your system’s suction power has decreased, your filter bags are filling up faster than usual, or there is an unexpected spike in your energy bills, your system is in a “performance crisis.”

As Asel Teknik, we have categorized the most common issues discussed in our webinar into four main headings:

1. Faulty Duct Design and “Collapsing” Efficiency

The efficiency of a system is measured not by the fan’s power alone, but by the air velocity within the ductwork. If the duct diameters are too wide, the air velocity drops, causing the transported dust to settle inside the pipes. Over time, this “clogs the arteries” of your system.

Solution: The ideal transport velocity ($V_{transport}$) must be determined through engineering calculations based on the type of dust, and the pipeline must be designed accordingly.

2. Errors in the Filter Cleaning Cycle

In many facilities, the Jet-Pulse cleaning system (cleaning bags with compressed air) is operated at random intervals. However, pulsing too frequently wears out the filter bags prematurely, while pulsing too infrequently leads to filter blinding.

Modern Approach: Instead of timer-based cleaning, use differential pressure (delta P) control. When the system detects the filter is full and cleans only when necessary, it saves energy and extends filter life.

3. Air-to-Cloth Ratio: Letting the System Breathe

Your system’s capacity is directly related to the total filter cloth area. If the volume of air being sucked in is too high relative to the filter surface area, dust particles become embedded in the pores of the fabric. This causes the fan to draw more current without providing effective suction.

Critical Point: A correctly selected “air-to-cloth ratio” is the most fundamental engineering criterion for reducing your operating costs.

4. Sealing and Air Leaks

Even the smallest leak in the discharge units (airlocks, etc.) under the cyclone or hopper disrupts the entire vacuum balance. Ambient air leaking in prevents the dust from discharging downwards and places an extra load on the filters. It’s like running the air conditioner in your car with the windows open; you consume energy but get no results.

Take a Step to Increase Efficiency

The dust collection system is the “lungs” of your facility. If you observe weak suction or high maintenance costs in your current system, these issues can usually be resolved with a professional engineering touch.

👉 To watch the full webinar and master the technical details, you can visit our YouTube channel by clicking here.