Smoke and dust removal equipment for particulate matter control

Smoke and dust removal equipment for particulate matter control

Zhengzhou Enviro Solutions supplies dry pulse-jet bag filters and high-voltage wet electrostatic precipitators (WESP) for coarse through ultrafine particulate, smoke, and mist—engineered for recovery, compliance, and safe handling of combustible dust where applicable.

Technology overview

• Pulse bag filtration—surface and cake filtration on woven/felt media with timed pulse cleaning.
• High-voltage wet ESP—ionization in a wetted field; charged droplets and particles migrate to grounded collectors and are flushed.

Key process

• Dust-laden gas enters the collector.
• Particles are captured on bags or in the ESP electric field.
• Clean gas exits the stack or fan suction.
• Dust is discharged via screw/conveyor or wet slurry, often automated.

System families

• ZZMCB series—pulse bag houses for dry dust and granular solids.
• ZZJD series—wet ESP for mist, smoke, and fine/submicron particles in saturated or scrubbed streams.

Custom engineering

Air-to-cloth ratio, bag materials, explosion protection, pre-cyclones, cooling, scrubber integration, and WESP electrode geometry are matched to dust properties, temperature, moisture, and emission limits.

Technical introduction

Process workflows

Pulse bag: Dusty gas → inlet plenum → hopper → filter bags → clean air plenum → outlet → pulse jet cleaning → dust discharge.

Wet ESP: Mist/smoke → inlet → conditioning → 72 kV DC negative field → charging → migration to anode tubes / collector → wash-down → clean gas discharge.

Filtration mechanisms (bag)

• Inertial impaction (>10 µm)
• Interception (1–10 µm)
• Diffusion (<1 µm)
• Electrostatic enhancement where applied (0.1–1 µm)
• Cake filtration once dust layer forms (all sizes)

Electrostatic precipitation (WESP)

• Gas ionization at high voltage (~72 kV class)
• Particle charging and drift in the field
• Collection on wetted electrodes
• Gravity / wash removal to sump

Target pollutants

Coarse and fine dust, ultrafine particles, combustion smoke, mists (0.01–100 µm droplets), metal, mineral, and organic dusts.

Indicative removal efficiency

Product classification

ZZMCB series — pulse jet bag filter

Model span: ZZMCB-24–ZZMCB-440. Flow (reference): 2,000–31,680+ m³/h. Certified layouts issued per project.

ZZJD series — wet electrostatic precipitator

Model span: ZZJD-5K–ZZJD-60K. Flow: 5,000–60,000 m³/h.

Filter bag materials

Equipment materials

• Carbon steel — standard, economical
• Stainless 304 / 316 — corrosive or hygienic duty
• FRP — acid/alkali wet sections

Setting configuration and structure

Pulse bag structure

• Upper box—clean air plenum
• Middle box—tube sheet, bags, cage, pulse headers
• Lower box—hopper, level / discharge, support
• Ancillaries—PLC, pulse valves, instrument air 0.4–0.6 MPa, rotary valve / screw, differential pressure

Wet ESP structure

• Shell—SS or FRP, view ports
• Electrodes—cathode frames / wires, anode tube bundle, insulator chest
• HV supply—regulated DC negative, ~72 kV class
• Collection zone—sump, flush water, sludge / blowdown

Standard configuration comparison

Both lines include casing, capture system (bags or ESP field), cleaning (pulse or wash), PLC/monitoring, dust or effluent removal, safety (vents / grounding / interlocks), and maintenance access.

Installation types

• Single unit — typically ≤30,000 m³/h class
• Parallel — higher flow or redundancy
• Multi-stage — high inlet loading
• Combined — cyclone + bag + ESP; cooling + bag; scrubber + WESP
• Polishing — final WESP or fine filter after bag

Material selection

Main structure

• Coated carbon steel 2.0–3.0 mm — general duty
• SS304 1.2–2.5 mm — corrosion
• SS316 — aggressive chemistry
• FRP 6–10 mm — wet acid/alkali

Filter media (bag)

PET, PP, aramid (Nomex-class), P84, PTFE, and glass per temperature and chemistry (see table above).

WESP electrodes

• Stainless cathode and anode components — 5+ year target with wash water quality control
• Ceramic insulators — HV standoff
• Shell SS304 or FRP — 10+ year in wet service with proper water treatment

Selection criteria

Temperature, chemistry, abrasion, explosibility (NFPA / ATEX strategy), budget, access for bag change or tube cleaning, and electrical safety grounding for ESP.

Technical characteristics

Bag media properties (typical)

• Cut-point near 0.3 µm class for fine finishes; permeability 200–400 L/m²·s (product-dependent)
• Tensile >1,500 N/5×20 cm (specimen basis); chemical resistance per fiber
• Service life 2–6 years depending on dust and cleaning energy

WESP operating window

• 72 kV DC class; current 100–500 mA range by size
• Mist removal ≥95% reference; power 5.5–30 kW (table)
• Hardware life 10+ years with water chemistry control

Design envelopes

Bag: inlet dust <1,000 g/m³ (with precollection as needed), T <280°C, RH <85%, face velocity 1–3 m/min, pulse air 0.4–0.6 MPa, ΔP 1,500–2,000 Pa.
WESP: T <80°C, mist loading <5 g/m³ (typical pre-scrub), saturated gas acceptable, 1–2 m/s, 72 kV DC negative, ΔP 300–500 Pa.

Safety

• Explosion venting / suppression / isolation for combustible dusts; grounding and bonding
• Fire and spark detection where specified; pressure relief; ESD interlocks
• Lock-out/tag-out; verified ESP ground grid before energization

Main features and advantages

Pulse bag highlights

≥99% efficiency on fine dust, automatic pulse cleaning, material recovery, flows 2,000–31,000+ m³/h, PLC control, compact modular rows.

WESP highlights

≥95% mist/smoke capture, submicron range, low ΔP (300–500 Pa), corrosion-resistant wet shell, long electrode life, suited after quench/scrubber.

Cost themes

Bag: medium CAPEX, low–medium OPEX, bag replacement cycles. WESP: medium–high CAPEX, water and power OPEX, minimal moving parts in field.

Technology comparison

Application fields

Industries

Cement and concrete batching, mining and crushing, metal fabrication, rubber and tire, tobacco, food, chemicals, grain, pharmaceutical, electronics soldering, smelting, textiles, woodworking, power (fly ash), glass, brick and ceramics.

Pollutant capability

Coarse through ultrafine dust, smoke and mist, ferrous/non-ferrous metal fines, silica/cement/clay, organic and food dusts, carbon black, fly ash—efficiencies per tables above.

Reference projects

Applicable standards

• GB 16297-1996 — Air pollutant emission limits
• GB 3095-2012 — Ambient air quality
• GB 9078-1996 — Industrial furnace emissions
• GB 13271-2014 — Boiler emissions
• Provincial DB limits and sector BREF-style guidelines

Pretreatment

• Cool or dilute bag inlet to media limit; control RH <85% for conventional bags
• Reduce loading with cyclone or pre-scrubber; manage sticky or hygroscopic dust
• Combustible dust hazard analysis; corrosive gas compatibility for metals and bags

System integration options

Combined systems

• Cyclone + bag (high loading); bag + WESP (fine/mist polish)
• Cooler + bag (temperature); scrubber + WESP (hot mist)
• Multi-compartment bags; full train cyclone + cooler + bag + ESP

Control functions

• PLC — timed or on-demand pulse; WESP current/voltage regulation
• ΔP, temperature, fault alarms; remote monitoring optional; data logging; emergency stop

Maintenance guidelines

Routine plan

• Daily — ΔP review
• Weekly — hopper level, WESP water quality / flow
• Monthly — bags, pulse valves, ESP electrodes and HV cabinet
• Quarterly — system walkdown; bags 2–6 yr; ESP wash as fouling dictates

Best practices

Bag: Track ΔP trends; maintain 0.4–0.6 MPa instrument air; inspect bags on shutdown; keep spare sets; train on combustible dust SOP.
WESP: Monitor kV/mA; keep wash nozzles clear; verify ground continuity; inlet <80°C; log inspections.

Care — do and do not

Numeric values are typical engineering references; certified layouts, explosion protection studies, and stack tests are issued per project.