High differential pressure is a symptom, not a diagnosis. Replacing bags without understanding airflow, cleaning energy, dust behaviour and process changes can reproduce the same problem.
Check whether the process changed
Compare the current operating window with the period when the baghouse performed normally.
- Gas volume / production rate
- Inlet temperature and moisture
- Fuel or raw-material change
- Dust loading and particle-size change
- Gas-conditioning or reagent change
Check cleaning energy and distribution
Insufficient or uneven pulse energy can leave excessive residual cake even when the media itself is sound.
- Compressed-air pressure at the header
- Pulse duration / interval
- Diaphragm and solenoid condition
- Blow-pipe alignment / blocked nozzles
- Offline-cleaning sequence where applicable
Inspect the dust cake and media surface
Sticky, cohesive or moisture-affected dust can blind the surface. Excessive finishing or an unsuitable permeability / surface can also change cleaning behaviour.
Look at compartment-to-compartment data
A global DP number can hide localized cleaning or airflow problems. Compare compartments, rows and the timing of DP changes after cleaning.
Do not optimise DP in isolation
Very low resistance is valuable only if emissions, mechanical life and cleaning stability remain acceptable. The correct objective is stable lifecycle performance.
