Farrleey Filtration Co,.Ltd. Cases

I. Severe Consequences of Wrong Filter Selection ⚠️ Real Case Alerts: A metal processing plant suffered $2M+ explosion damage due to non-explosion-proof filters A food factory saw 45% higher energy consumption and $80k annual maintenance costs from clogged filters

Body: Shipbuilding and repair operations represent demanding environments for fume extraction. Confined compartments, high-spatter processes, toxic metal fumes (e.g., Cr⁶⁺ from stainless welding), and stringent regulations necessitate advanced dust collection technologies. As filtration specialists, we address critical operational constraints: Operational Constraints: Submicron Hazardous Particulates: Fumes contain respirable metal oxides (Fe, Mn, Cr, Ni) and carcinogens requiring high-efficiency capture beyond conventional media capabilities. Pyrophoric Hazards: Cutting sparks >1000°C demand intrinsically flame-resistant media to prevent ignition events. Spatial Limitations: Confined spaces (compartments, pipe chases) require compact, high-capacity mobile solutions with optimized footprint. Regulatory Compliance: OSHA/ILO near-zero PM₁ exposure thresholds mandate ultra-high filtration efficiency. Performance-Critical Solution: Engineered Membrane Media For maritime applications, inherently flame-retardant membrane media delivers essential performance: ▶ PTFE-Membrane Glass Fiber/PPS Substrates: • HEPA-Grade Filtration (EN 1822 H13/H14): >99.97% capture efficiency on PM₀.₃ including Cr/Ni compounds. • Intrinsic Flame Resistance (NFPA 701/EN ISO 15025): Withstands 1300°C direct spark impingement. • Surface-Loading Mechanism: Non-penetrating filtration enables 50% higher pulse-cleaning efficiency and 3x service life versus depth-loading media. Application-Optimized Systems: • Centralized Extraction (Block Assembly): High-pleat-count PTFE membrane cartridges provide 40% increased dust-holding capacity for continuous operations. • Mobile Source Capture (Compartment Work): Star-pleated membrane cartridges (Ø

Welding is a critical part of many industrial processes, but it comes with inherent risks to workers' health, particularly when it comes to airborne dust and fumes. As a manufacturer of advanced filtration materials, we recognize the significance of protecting the health of welders who work in enclosed spaces. This article discusses the health risks associated with welding-related dust exposure and how our solutions help businesses safeguard their employees' well-being. The Health Risks of Welding Dust Welding produces hazardous airborne particles and fumes that can pose significant health risks to workers, especially in indoor environments where ventilation is inadequate. Common health problems caused by prolonged exposure to welding dust include: Respiratory Issues: Inhalation of welding fumes, which contain harmful chemicals such as metal oxides, gases, and particulates, can lead to respiratory conditions such as asthma, bronchitis, and even more severe chronic diseases. Welders are at a heightened risk of developing lung diseases, including welding fume-induced pneumonia and metal fume fever. Eye and Skin Irritation: Dust particles from welding, combined with intense heat, can cause eye irritation and burns, leading to long-term damage. The skin can also suffer from exposure to chemicals and high temperatures. Long-Term Health Conditions: Certain metals, like chromium, nickel, and manganese, found in welding fumes are classified as carcinogens. Long-term exposure to these substances increases the risk of developing lung cancer, neurological diseases, and kidney damage. Reduced Productivity: Poor air quality directly impacts workers' concentration and productivity. When workers experience discomfort due to dust exposure, it leads to higher absenteeism and a decline in overall performance. How We Help Protect Welders and Employers As a leading provider of dust filtration solutions, our company is dedicated to helping businesses create healthier working environments for welders. Our advanced filtration materials, such as PTFE (Polytetrafluoroethylene) and aramid nonwoven fabrics, are designed to capture harmful dust and fumes, ensuring clean air and reducing health risks. Here's how we help: Effective Dust Collection: Our dust collection systems use high-performance filter fabrics to capture fine particles generated during the welding process. By removing harmful particulates from the air, these systems drastically reduce the risk of respiratory issues for workers. Our PTFE nonwoven fabrics, known for their excellent chemical resistance and high temperature tolerance, are particularly effective in filtering welding fumes. Improved Air Quality: Installing proper filtration systems ensures that the air quality in the workspace is continuously monitored and maintained at safe levels. With our filtration materials, businesses can create a cleaner environment, helping to improve the overall health and safety of welders. Compliance with Safety Regulations: Ensuring a safe workplace is not only about protecting employees but also about adhering to health and safety regulations. Our filtration systems meet the strictest industrial standards, helping companies comply with OSHA regulations and other relevant guidelines for indoor air quality. Long-Term Savings: Healthier employees are more productive and less likely to take sick leave. Moreover, reducing the need for frequent medical treatments or compensation claims saves businesses significant costs in the long run. Implementing our filtration systems helps companies minimize the financial burden caused by work-related illnesses. Why Choose Our Filtration Materials? Durability: Our filter materials, including aramid and PTFE fabrics, are known for their high resistance to heat, chemicals, and abrasion. They can withstand extreme conditions, providing long-lasting performance even in harsh environments. High Efficiency: Our filtration systems are designed to remove even the smallest particles from the air, ensuring that welders are exposed to a minimum amount of harmful dust. With high-efficiency filtration, the risk of health problems caused by dust inhalation is significantly reduced. Customization: We offer tailored solutions based on the specific needs of your facility. Whether you need high-temperature resistance for industrial welding applications or specialized filtration for a certain type of dust, we can provide customized solutions to meet your needs. Conclusion: Investing in Health and Safety At Farrleey Filtration, we believe that investing in the health and safety of workers is an investment in the long-term success of the business. Protecting welders from the harmful effects of indoor dust exposure not only improves their well-being but also increases productivity and reduces costs related to workplace injuries and illnesses. In the welding industry, the risks of dust and fumes are undeniable, but with the right filtration systems in place, these risks can be mitigated. Our advanced filtration materials help companies maintain safe, clean air in the workplace, ensuring that employees can perform their work in a healthy environment. Let's work together to protect your employees and create a safer, healthier workplace for everyone.

Common Abnormalities and Solutions for Cartridge Dust Collectors Issue: Filter Element Caking and Hardening Impact:Filter cartridge caking and hardening can cause a sharp decline in the air permeability of the filter elements, leading to increased operating resistance and higher energy consumption. In severe cases, it may even result in the dust collector failing to operate properly. Cause Analysis: 1. Condensation-Induced Caking:When the operating temperature of the dust collector falls below the acid dew point, water vapor in the flue gas condenses into liquid water, which mixes with dust and adheres to the surface of the filter elements, resulting in caking. Additionally, if the compressed air used for pulse cleaning has an excessively low temperature, it can cause the upper portion of the filter element to cool rapidly, leading to condensation. 2. Adhesive Caking:Some types of dust inherently have strong adhesive properties, such as oily particles or ammonium sulfate generated during denitrification. When these particles come into contact with the fibers of the filter media, they adhere to the surface. Other types of dust may not be inherently sticky but can absorb moisture from the flue gas and undergo recrystallization reactions, forming new water-hardening or crystalline substances, such as calcium sulfate. These substances can create a "crust" on the surface of the filter elements. 3. Structural Caking:Issues with the dust removal system or the structural design of the filter elements can lead to ineffective cleaning, allowing dust to gradually accumulate and harden. Additionally, improper dust collector design or operational issues, such as air leakage, can also contribute to filter bag caking. Measures to Take: 1. Control the operating temperature of the dust collector to ensure it remains above the acid dew point, avoiding condensation. 2. Use dry and clean compressed air for pulse cleaning to prevent moisture, oil, and other impurities in the compressed air from causing the filter bags to become damp. 3. Regularly clean and maintain the filter elements, promptly removing dust and crusted substances from their surfaces. 4. Perform regular maintenance on the pulse jet system components to ensure proper operation and effective pulse cleaning.

Common Abnormalities and Solutions for Cartridge Dust Collectors   Issue: High-Temperature Particle Burn-Through Impact: Dust can directly enter the exhaust system through the damaged areas, leading to a significant increase in emission concentration, making it impossible to meet environmental discharge standards. This negatively impacts the entire dust collection system and production.   Cause Analysis: 1. Direct Contact of High-Temperature Particles With The Filter Element: When high-temperature particles directly contact the surface of the filter element, they rapidly transfer heat to the filter element material. If the material's heat resistance is insufficient, it can cause thermal damage to the surface or internal structure of the filter element, potentially leading to burn-through. 2. Insufficient Heat Resistance of The Filter Element Material: The heat resistance of the filter element depends largely on its material. Some common materials, such as polyester fibers, have low heat resistance, typically below 130°C. If the filter element material cannot withstand the high temperatures caused by hot particles, burn-through is likely to occur. 3. Thermal Stress in High-Temperature Environments: In high-temperature environments, temperature gradients within the filter element can cause thermal stress. This stress can lead to deformation or rupture of the filter element material. 4. Chemical Reactions with High-Temperature Particles: Certain high-temperature particles may chemically react with the filter element material, reducing the material's strength and stability, which increases the risk of burn-through.   Measures to Take: 1. Choose High-Temperature Resistant Filter Element Materials: Select filter element materials with better heat resistance based on the specific operating conditions. 2. Pre-Cooling Treatment: For high-temperature dust, implement pre-cooling treatments to reduce the dust temperature and minimize the direct impact of hot particles on the filter element. 3. Enhance Filter Element Protection Measures: Install protective devices, such as metal screens or shields, at the filter element inlet to block high-temperature particles from directly entering the filter element. 4. Regular Inspection and Maintenance: Perform regular inspections of the filter element’s condition, promptly identifying and replacing damaged filter elements to prevent high-temperature particles from entering the dust collector.

Common Abnormalities and Solutions for Cartridge Dust Collectors   Issue: Cutting The Surface Impact: Dust can directly enter the exhaust system through the damaged areas, leading to a significant increase in emission concentration, making it impossible to meet environmental discharge standards. This negatively affects the entire dust collection system and production.   Cause Analysis: 1. Improper Operation: a. Incorrect Installation: If the filter element is installed in the wrong direction, inaccurate position, or not securely fixed, it       can result in uneven stress on the filter element, causing it to rub against other components and become damaged. b. Excessive Cleaning: Using tools to clean the filter element can damage its fibers, leading to breakage. c.Improper Handling: During unpacking or transportation, the filter element may come into contact with sharp objects, causing cuts or tears. 2. Impact of Dust Particles: a. Hard Dust: Hard and coarse dust particles cause significant wear on the filter element, making it prone to tearing. b. Moist or Sharp Dust: These types of dust can directly damage the filter structure of the filter element. 3. Equipment Manufacturing Issues: a. Installation Problems: Issues such as misaligned pulse jet pipes, excessive pulse pressure, or overly frequent pulse cleaning can lead to filter element damage. b. Filter Element Material Issues: If the material of the filter element is not suitable for the application, such as being prone to wear or chemical corrosion, it can tear more easily during use. c. Structural Issues: Problems with the equipment structure, such as poorly sealed joints, welds, or airflow design, can cause turbulence, leading to erosion and damage to the filter media.   Measures to Take: 1. Proper Installation: Install the filter element strictly according to the operating procedures, ensuring the correct direction, position, and fixation method of the filter element. 2. Filter Element Material: Select filter element materials that are wear-resistant and chemically resistant based on the characteristics of the dust and operating conditions. 3. Inspection and Replacement: If filter element damage is found, immediately assess the extent of the damage. If the damage is severe, replace the filter element with a new one in a timely manner. 4. Adjust Operations: Optimize the operational procedures to avoid excessive cleaning, and ensure correct installation and use of the filter element. 5. Improve Equipment: Check the pulse jet system and the installation of the filter element. Adjust the direction and pressure of the pulse air to ensure even stress distribution on the filter element.

Common Abnormalities and Solutions for Cartridge Dust Collectors   Issue: Filter Element Caking and Hardening Impact: Dust enters the clean air chamber through the deformed gap in the sealing ring or the area where the filter element head cover and sealing ring do not properly align, leading to a significant increase in emission concentration and making it impossible to meet environmental discharge standards.   Cause Analysis: 1. Incorrect Installation Direction: If the sealing ring is installed in the wrong direction, it cannot properly align with the sealing surface, leading to an incomplete seal. 2. Improper Installation Force: Applying too much or too little force during installation can prevent the sealing ring from fully expanding or fitting properly with the hole in the flower plate. 3. Use of Improper Tools: Using overly sharp or rough tools during installation can damage the sealing ring. 4. Unclean Surfaces: If the surfaces of the flower plate or sealing ring contain impurities or dirt, it can affect the sealing performance. 5. Size Mismatch: If the size of the sealing ring does not match the hole in the flower plate, the sealing ring cannot be installed correctly.   Measures to Take: 1. Proper Installation: Recheck the installation position and method of the sealing ring to ensure it is placed flatly in the flower plate hole, avoiding twisting or deformation. 2. Clean the Flower Plate: Thoroughly clean the flower plate and sealing ring before installation, removing oil, dirt, and other impurities to ensure the sealing ring can fit tightly. 3. Recheck Installation: Perform a careful inspection. If visual blind spots prevent full inspection, use hands to check. From the side, the sealing ring should appear flat, and the head cover should fit tightly with the sealing ring. 4. Installation Force: Adjust the force during installation to ensure the filter cartridge head cover and sealing ring fully expand and fit the flower plate hole, avoiding excessive compression or insufficient compression. 5. Regular Inspections: Regularly check the condition of the sealing ring and promptly replace any worn or damaged sealing rings to prevent improper installation due to aging or damaged seals.

Common Abnormalities and Solutions for Cartridge Dust Collectors   Issue: Improper Lifting and Handling   Impact: The filter element is deformed and damaged due to external force, compression, or collision, making it unusable or ineffective. This can also affect the normal operation of other filter elements.   Cause Analysis: 1. Improper Tools: The lifting tools used are not suitable for the weight or size of the filter element, causing uneven stress during the lifting process and leading to compression and deformation.   2. Improper Operation: The operators lack lifting experience and are unfamiliar with the lifting requirements and precautions for the filter elements, making it easy to make mistakes during the lifting process.   Measures to Take: 1. Choose Appropriate Tools: Select suitable lifting tools based on the weight and size of the filter element, ensuring the tools can handle the element's weight and distribute the lifting force evenly. 2. Enhance Training: Provide operators with professional lifting and handling training to improve safety awareness and ensure they can correctly lift and handle the filter elements. 3. Regular Inspections: Inspect the filter elements before lifting to ensure there is no obvious deformation or damage. After lifting, check to confirm the proper installation of the filter elements.    

High-temperature working conditions – filter media easily burns or degrades Issue: Foundry processes (especially melting, casting, and shakeout) generate large volumes of hot gases that can easily damage standard filter media. Solution: Recommend high-temperature resistant filter media such as Aramid (Nomex) or Fiberglass, possibly with PTFE membrane for added protection. Dust with corrosive or sticky properties Issue: Metallic oxides or additives in the dust can clog or chemically damage the filter media, reducing its service life. Solution: Use membrane-coated filter media, anti-corrosion treatments, or surface treatments that improve dust release, helping extend operational lifespan. High dust concentration and heavy particles – media breaks or pressure drop rises quickly Issue: Large dust loads and frequent pulse cleaning create stress on the filter, leading to early damage or performance decline. Solution: Use reinforced filter structures, enhanced seam stitching or thermal bonding, and stronger internal cages to maintain integrity. Tightening environmental regulations with stricter emission limits Issue: Excessive emissions can lead to production shutdowns, especially during inspection periods. Solution: Apply high-efficiency membrane filter media (e.g., ePTFE) to ensure emission compliance and avoid penalty risks. Frequent filter replacement increases downtime and maintenance costs Issue: Every filter change requires halting production, which is costly in continuous 24/7 operations. Solution: Recommend long-lifespan filter media, such as imported fiber blends or heat- and fatigue-resistant composites, to reduce replacement frequency. Low dust collector efficiency leads to poor air quality and health risks Issue: Inefficient filtration results in dusty working conditions, affecting worker health and safety. Solution: Besides upgrading filter media, we also support system audits to evaluate dust collector design and check for issues like excessive air-to-cloth ratio.

1、Industry challenges and the need for green transformation   Against the backdrop of the global economy's transformation to green and low-carbon, the steel industry, as an important part of traditional heavy industry, is facing the dual challenges of environmental upgrading and technological innovation. Especially in the raw material handling process, the dust emission problem has become a key bottleneck restricting the industry's green development. In the process of raw material processing, crushing, screening and mixing of ores and coal will produce a large amount of high hardness and large particles of dust, and conventional folded cartridges usually encounter wear and tear of the filter media and large particles of dust stuck in the folding slits (as shown in the figure below), which puts forward high requirements for the filtration efficiency and durability of the dust removal system. In response to this problem, Farrleey offers a complete solution for the steel industry with its leading UOXXON® folded filter cartridge, a highly wear-resistant and easy-to-clean construction.     2、UOXXON® folded filter cartridge：Powerful assistant for green transformation Farrleey's UOXXON® folded filter cartridge, with its excellent abrasion resistance and easy-to-clean structure design, has become a powerful assistant in the green transformation of the steel industry. The product is designed with advanced Farrtex® abrasion-resistant material and reinforced abrasion-resistant process, which can effectively cope with the scouring of high hardness dust particles and significantly extend the service life. At the same time, the design of the folded cartridge is optimised for the dust characteristics of the raw material process, which improves the dust stripping rate and the risk of large dust particles getting stuck, ensures the continuity and stability of the production process, and reduces maintenance costs and energy consumption.   3、Successful cases: Jiangsu a steel enterprise dust removal system upgrade transformation A steel company in Jiangsu Province has upgraded its dust collector in the batching section of the raw material process with Farrleey's UOXXON® folded filter cartridge, a highly wear-resistant and easy-to-clean technology. Since the project was put into operation in early 2023, the CEMS online monitoring shows that the concentration of dust particles has been stable at

  To meet the ultra-low emission standard 5mg/m3 follow the latest Chinese Environmental Regulation, Farrleey R&D team worked hard to develop customized pleated cartridge filter for iron and steel industry. Over 160 Thousand pieces of cartridges have been installed in the dust collectors in the most of steel plants in China, like BAOSTEEL Group, SHOUGANG Group etc since2018. Farrleey® Pleated cartridge filters can be retrofitted the existing bag filter dust collectors without any construction modification. After replacement of the filters, the filtration velocity decreased about 30%, the filter area increased around 40%, and last but not least, the particle emission from 30-50 mg/m3 dropped to no more than 10mg/m3 to meet latest emission regulation for iron and steel industry . Our customers will be in normal production under more and more strict environmental regulation in China. If you need further more technical information, please feel free to contact us.

Farrleey® Dust Pleated Bag Cartridge Applied In Cement Industry One of our customers in cement industry, which clinker production line capacity is 5000 T/D, but the assorted cement grinding mill filter bag dust collector emission was 20mg/m3, in order to drop to no more than 10mg/m3 to meet Chinese environmental latest ultra-low emission regulation, the bid for this transformation project was won by Farrleey. Base on the on-site investigation and evaluation of the dust collector's operation condition, dust characteristic, dust cleaning mechanism and production and energy consumption , finally the overall optimization and transformation scheme for bag filter was finalized. The core filter element was chosen Uoxxon® pleated bag cartridge, filter media is needle felt, which is a very specialized media to suit cement application.