Case Study

Cleaning on Demand in a Gypsum Plant

Challenge
A gypsum plant in Wyoming faced issues with the operation of their baghouse systems. During a baghouse training session, it became evident that their cleaning systems were set to continuous cleaning. The differential pressure in their baghouses was significantly low, indicating over-cleaning of the filter bags.
Key Problems Identified

â–º Compressed Air Wastage: Continuous cleaning consumed excessive compressed air, a major operational expense.

â–º Component Wear & Tear: Constant pulsing accelerated the wear on diaphragms and increased the likelihood of contaminants like oil, dirt, or water entering the compressed air lines.

â–º Filter Bag Degradation: Over-cleaning weakened the filter bags prematurely due to repeated flexing and stress.

Solution

The training introduced the plant operators to the benefits of cleaning on demand—a method where cleaning is triggered only when differential pressure reaches a set threshold. This approach optimizes cleaning frequency and addresses the problems caused by continuous cleaning.

The plant decided to implement cleaning on demand across their systems and sought assistance to retrofit their equipment. The solution involved:

â–º Installing Timer Boards: Updated systems to enable demand-based cleaning.

â–º Adding Photohelic Gauges: These allowed precise monitoring and control of differential pressure to trigger cleaning cycles effectively.

â–º Technical Support: Guidance and training on implementing the new cleaning strategy.

Outcome

After implementing cleaning on demand, the gypsum plant saw:

â–º Cost Savings: A significant reduction in compressed air usage, leading to lower operating costs.

â–º Extended Equipment Life: Reduced wear on diaphragms and filter bags.

â–º Environmental Incentive: The plant secured state funding for the upgrade due to the operational improvements and energy savings.

Key Takeaway

Cleaning on Demand proves to be a cost-effective and efficient solution compared to continuous cleaning in most applications. It minimizes compressed air consumption, reduces equipment wear, and extends the life of filter bags. Continuous cleaning should be reserved for specific scenarios requiring constant cleaning.