Analysis and Solutions for Dust Collector "Failure to Inject" Problem

"Unable to inject air for cleaning, dust cannot be discharged"—pulse jet cleaning system malfunctions are a common problem in baghouse dust collectors. Statistics show that 70% of dust collector efficiency reductions are directly related to pulse jet cleaning failures. This article analyzes the root causes of these problems in high-frequency industrial scenarios and provides practical solutions.

I. Why the "Failure to Inject"? Five Core Faults Revealed

Three major causes of pulse valve "failure":

• Circuit abnormalities: Solenoid valve coil burnout, short circuits (especially in rainy weather) leading to command interruption.

• Insufficient compressed air: Weak injection when pressure is below 0.4MPa, often due to air line blockage or compressor failure.

• Valve body blockage: Oil, moisture, or welding slag jamming the valve core (common in unpurged air supply systems).

Injection pipe "malfunctions": Detachment and perforation

• Causes of perforation: Dust erosion of the pipe wall after filter bag damage (accounts for 35% of failures); small pipe bend radius, causing debris to rebound and impact the pipe wall (R≥350mm recommended).

• Main cause of detachment: Defective positioning device or installation deviation, preventing airflow from entering the filter bag.

Compressed air "operating with defects"

• Containing oil and water: Causes filter bag caking and pulse valve jamming (daily drainage required).

• Pressure fluctuations: Insufficient pressure stabilizing air tank capacity or pipeline leakage.

 Control system "command failure"

• PLC program disorder, improper cleaning cycle settings (too short damages filter bags, too long causes resistance to skyrocket).

Filter bag "hindrance": Blockage and damage

• Bag blinding: Dust caking when flue gas humidity > 8% (PTFE coated filter material required);

• Damage and dust leakage: Burr abrasion of the cage or high-temperature burning. 

II. Practical Solutions: From Emergency Response to Long-Term Effectiveness

• Pulse Valve Troubleshooting Guide

• Immediate Action:

• Measure circuit voltage and replace burnt-out coils;

• Disassemble and clean the valve body, removing oil and grease with alcohol.

• Preventive Upgrade: Install a heater on the air source three-way unit to prevent freezing in winter.

• Blowpipe Repair and Optimization

• Anti-perforation Design: Pre-coat with lime powder to block oily dust;

• Upgrade bent pipes to stainless steel material, increasing the curvature to 400mm.

• Resetting Technique: Use a laser alignment instrument to adjust the concentricity of the blowpipe and filter bag (deviation ≤ 2mm);

• Compressed Air System Purification

• Three-stage Treatment: Refrigerated dryer → oil-water separator → air storage tank (manual drainage daily).

• Intelligent Control Upgrade

• Adopt a dynamic dust removal strategy:

• Automatically shorten the blowing interval when the pressure difference > 1500Pa;

• Filter Bag Lifespan Extension Secrets

• Anti-damage: Control the filtration wind speed at 0.8-1.0m/min (≤0.8m/min for the cement industry); the frame is coated with silicone to prevent corrosion.

• Anti-clogging: Maintain the inlet temperature > 25℃ above the acid dew point (add an emergency cooling system).

III. Long-Term Maintenance: 3 Key Actions

• Daily Inspection:

• Pulse valve action test + air bag drainage;

• Monthly Maintenance:

• Blowpipe positioning bolt reinforcement + filter bag pressure difference recording and analysis;

• Annual Overhaul:

• Complete replacement of pulse valve diaphragms + airtightness test (air leakage rate < 3%).

Source: Hanheng Environmental Protection Butler Official Account

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