Technical Upgrade Project for the Dust Collector of the Detergent Spray Drying Tower

In recent years, the detergent manufacturing industry has increasingly adopted direct-fired coal-fired hot air furnaces as the direct heat source for pressure spray towers. Direct-fired coal-fired hot air furnaces offer notable advantages, such as high primary hot air temperature, high overall thermal efficiency, and low fuel consumption, which is why they have been widely adopted by manufacturers. However, as national environmental regulations have become increasingly stringent—particularly following the enactment of what has been called the “strictest environmental law in history” this year—exhaust emissions from spray towers have become a major headache for many manufacturers.

Recently, our company carried out a comprehensive overhaul of the dust removal system for Kunming Libai, a detergent manufacturer.

Previously, the manufacturer used a baghouse dust collector. While the system performed well during the initial operation with new bags, after one month of use, the resistance of the bags increased significantly, production capacity dropped, and dust leakage from the bags became more frequent, resulting in emissions that failed to meet standards. The company was forced to halt production for several days each month to perform maintenance and replace the bags. With hundreds of bags to handle, workers complained bitterly during each replacement, and some even resigned or “fled the scene.” The frequent start-ups and shutdowns caused financial losses and numerous adverse effects on the company’s production.

In recent years, Mingxing Drying Equipment Company has made significant strides in the field of dust collection equipment and has established a strong market presence. The company’s management approached us, and we immediately dispatched personnel to the site to conduct a comprehensive inspection of the system. The inspection revealed that the baghouse dust collection system was undersized, with insufficient equipment capacity. The air velocity through the bags was excessively high during the initial phase of operation. As the micro-pores in the bags became completely clogged over time, the cleaning mechanism could no longer thoroughly remove accumulated dust. This led to a significant decline in the bags’ permeability and a quadratic increase in system air resistance, necessitating the replacement or cleaning of the bags to resume production. Although the company had previously implemented technical upgrades—such as increasing the power of the air compressor, replacing solenoid valves and cylinders, and switching to different types of filter bags—the results were not significant, and the problem remained unresolved. Furthermore, the annual cost of replacing filter bags amounted to hundreds of thousands of yuan, which undoubtedly had a severe impact on the company’s production costs.

After understanding the client’s needs, Star Company thoroughly redesigned the system and diagnosed the issues. Through consultation with the client, the company developed a practical and feasible plan for selecting and installing dust collection equipment. With minimal investment, the company carried out a comprehensive overhaul of the enterprise’s dust collection equipment. Star Company recommended a multi-chamber modular high-efficiency cyclone dust collector unit paired with a high-tower scrubber for the client. This configuration was integrated into the powder spraying tower’s dust collection system, yielding excellent results during trial runs. The overall dust removal efficiency reached 99.9%. Since implementing this system, the client has eliminated compressed air costs and the hassle of replacing filter bags, saving significant annual expenses on consumables. Furthermore, the process required no production downtime, generating substantial benefits for the enterprise and earning the client’s satisfaction and approval.

Mingxing Company is a rising force in the industry with over two decades of manufacturing and R&D experience in energy-efficient drying, eco-friendly dust removal, and heat source equipment. We are dedicated to the R&D of large-scale equipment and technological innovation for the chemical, pharmaceutical, food, and non-mining industries. We warmly welcome customers to choose our products to achieve mutual benefit and win-win outcomes!