As the core equipment of particulate matter pollution control, industrial bag dust collector undertakes the dual mission of environmental protection and safe production in high-energy-consuming industries such as steel, cement and electric power. However, high energy costs, frequent bag replacement and complex maintenance procedures often make enterprises face cost control problems. Henan Xinxiang Lifelte Filter Co., Ltd. based on 20 years of dust removal technology accumulation, through system optimization design, intelligent operation and maintenance and material innovation, built a whole life cycle cost reduction solution to help industrial customers achieve a two-way breakthrough in environmental protection and economic benefits.
The energy consumption of traditional bag dust collector is mainly concentrated on the fan power and ash cleaning system. Liffert R & D team used CFD (computational fluid dynamics) simulation technology to topologically optimize the flow field inside the dust removal box, and improved the airflow distribution uniformity to more than 98% by adjusting the curvature of the air intake, the Angle of the baffle and the structure of the ash bucket. Taking LFE-1200 pulse dust collector as an example, the system resistance of the optimized equipment is reduced from 1200Pa to 850Pa, and the energy consumption of the fan is reduced by 23% compared with the same air volume.
The energy consumption control of the ash cleaning link relies on the "intelligent pressure difference feedback ash cleaning system". The system monitors the ash accumulation status of the filter bag through the multi-point pressure sensor in real time. When the local pressure exceeds the set threshold, the PLC controller only activates the pulse valve in the corresponding area for accurate ash cleaning, avoiding the energy waste caused by the The cost reduction of industrial bag dust collectors is not the result of a single technical improvement, but the co-evolution of system design, material science, intelligent control and operation and maintenance strategies. Liffert's cost reduction program from the perspective of the whole life cycle not only provides quantifiable economic benefits for industrial enterprises, but also promotes the sustainable development paradigm shift of the dust removal industry through technological iteration. Under the dual challenges of environmental compliance and cost control, this systematic innovation will become the core competitiveness source of industrial pollution prevention and control.traditional timing ash cleaning mode. After the application of this system in a cement production line, the While traditional passive maintenance models often result in diseased or overmaintained equipment, Liefert's "Dust Removal System Health Management System (DCHMS)" enables condition prediction through iot technology. The system collects 62 operating indicators such as cleaning frequency, pressure difference fluctuation and current load in real time, uses AI algorithm to establish equipment degradation model, and automatically triggers early warning when the health index is below 80%. After a chemical enterprise connected to the system, the fault response time was shortened from 48 hours to 2 hours, and the annual maintenance cost was reduced by 37%. The offline diagnostic toolkit further improves O&M efficiency. The fault map generated by DCHMS is linked to the Liefert knowledge base to accurately locate 95% of common problems, such as broken filter bags and stuck pulse valves, and provide a standardized disposal process. The AR maintenance assistance system developed in support of the development can reduce the novice maintenance time by 60% through 3D animation to demonstrate the dismantling steps.annual compressed air consumption is reduced by 156,000 cubic meters, which is equivalent to saving about 120,000 yuan in electricity.
The replacement cost of filter bag accounts for 40%-60% of the operation and maintenance cost of bag dust collector, and Lifelt breaks the life bottleneck from the double dimension of the material end and the process end. For high temperature flue gas scenarios, the company's self-developed PTFE coated filter material achieves a balance between filtration accuracy and permeability through nanoscale pore control technology, and has a continuous operating life of more than 3 years at 350℃. In the high humidity environment, the composite filter bag mixed with hydrolytic fiber can effectively inhibit dew corrosion through surface hydrophobic treatment, and its service life is 2 times longer than that of traditional polyester filter bag. More critical is the construction of "condition - filter material fit database". The database integrates the operating data of more than 2,000 dust removal systems around the world, and provides customers with customized filter material selection solutions through multi-parameter analysis of flue gas composition, temperature, dust particle size, etc. After the application of adaptive filter bags in the sintering workshop of a steel plant, the replacement cycle was extended from 4 months to 8 months, and the annual procurement cost of filter bags was saved by a single equipment of 280,000 yuan.
With the advancement of Industry 4.0, the reduction strategy of bag dust collector will show three major trends: 1) the large-scale application of energy recovery technology, such as the waste heat utilization type dust removal system can convert the exhaust heat energy into process steam; 2) The breakthrough of regenerative filter material technology, through physical or chemical methods to restore the performance of the filter bag, to achieve recycling; 3) The deep application of digital twin technology, the construction of virtual and real synchronous dust removal system, to achieve nanoscale precision operation and maintenance.
Liffert Filter Co., Ltd. is working with a number of universities to develop a "smart dust removal ecosystem" that combines edge computing, adaptive control and new material technologies to reduce dust removal costs to 50% of current levels. In the future, technological innovation will continue to restructure the cost structure of environmental protection equipment and provide stronger economic momentum for industrial green transformation.
