Significantly reducing premature failure rate


An American Coal-Fired Power plant approached SOLAFT to solve an issue of premature filter bag failure, generally occurring within 2-3 weeks of installation.


The plant found that they were making excessive filter bag changes due to premature failure. This resulted in higher operating costs, significant diversion of scarce labour resources from other valuable tasks and lost production.  The method of failure was holing between the middle and the bottom of the bag, particularly for those bags in line with the inlet of the dust collector.


SOLAFT proposed introducing a shorter StarBags™, which represented a significant reduction in filter bag length from the existing 8.5m bags. The increased surface area of the StarBags™ relative to a standard bag of the same length enabled the reduced length without compromising particulate capture and production rates. The reduction in filter bag length enabled the filter bags to be removed them from the line of the direct inflow thereby eradicating the premature failure.


The trial was a success, and the benefits to the Coal-Fired Power Generation plant were:

  • Operating DP was reduced 30% whilst maintaining gas flow
  • Pulse pressure was reduced 50%
  • Significantly improved uptime and reduced maintenance cost
  • Air-to-Cloth ratio remained unchanged

Read more about this case study here – Excessive filter bag failure in the baghouse