Some producers replace filter bags 'on demand'. Typically, they delay the inevitable, waiting to replace at the point of failure. Although it might seem a good way to manage maintenance costs, it brings about not just greater risks of failure and non-compliance, but also higher costs and emission levels.

Looking at the problem rationally, there are significant economic and production benefits for replacing all bags at once, following a clear replacement strategy. But why do producers choose to ignore this? For many, the perceived high upfront costs of a full bag replacement strategy outweigh its benefits. Some may even not be aware of the dangers of partial replacements.

Performance measures

When researching the effectiveness of different bag replacement strategies and assessing baghouse filter performance, FLSmidth’s R&D team completed calculations based on hard data, gathered over various parameters. These included the following:

- Emission levels
- Differential pressure (dP)
- Filter media permeability
- W&T percentage over the filter lifetime

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