Electric Arc Furnaces (EAFs) are widely used in modern steelmaking due to their flexibility and high productivity. However, EAF operations generate large volumes of fine, abrasive, and high-temperature dust containing metal oxides, lime, and carbon fines. Effective dust collection is critical—not only for environmental compliance, but also for worker safety, equipment protection, and stable plant operation.
This case study examines a real-world dust control application in a steel plant’s Electric Arc Furnace system, with a focus on filter bag and cage selection, installation performance, and operating results.
 
Case Background
A medium-scale steel plant operating a 120-ton Electric Arc Furnace was facing persistent dust collection challenges. The existing baghouse system experienced frequent bag failures, high pressure drop, and uneven airflow distribution, resulting in increased maintenance costs and unplanned downtime.
The plant required a robust filtration solution capable of handling:

• High dust loading
• Elevated operating temperatures
• Abrasive and fine particulate matter
• Continuous, cyclic furnace operation

 
Dust Characteristics and Operating Conditions
Understanding dust properties was essential for selecting the correct filter bags and cages.

• Dust Type: EAF fume dust (iron oxide, zinc oxide, lime, carbon)
• Particle Size: Predominantly sub-5 micron
• Dust Loading: High and variable during melting cycles
• Gas Temperature: 120–180°C (with short-term peaks)
• Cleaning Method: Pulse jet compressed air

These harsh conditions ruled out standard filter media and lightweight cages.
 
Filtration Solution: Filter Bag Selection
After technical evaluation, the steel plant selected high-temperature needle felt filter bags designed specifically for metallurgical dust collection.
Filter Bag Type Used:

• Material: Aramid (Nomex®) needle felt
• Optional Treatment: PTFE membrane laminated surface
• Weight: 500–550 g/m²
• Operating Temperature: Continuous up to 200°C
• Filtration Efficiency: >99.9% for fine EAF dust

Why This Filter Bag Was Chosen

• Aramid fiber provides excellent resistance to heat and mechanical stress
• PTFE membrane improves fine particle capture and surface filtration
• Reduced dust penetration extends bag life under abrasive conditions
• Stable performance during frequent temperature fluctuations

In areas with higher moisture risk, a PTFE-coated aramid felt was used to prevent dust adhesion and bag blinding.
 
Filtration Solution: Filter Cage Selection
Filter cages play a critical role in maintaining bag shape, cleaning efficiency, and service life—especially in pulse jet EAF systems.
Filter Cage Type Used:

• Material: Carbon steel wire
• Wire Diameter: 3.8–4.0 mm (vertical wires)
• Ring Spacing: ≤150 mm
• Surface Treatment: Hot-dip galvanized + epoxy coating
• Design: Venturi integrated top for pulse efficiency

Why This Cage Design Was Selected

• Heavy-duty wire prevents deformation under high pulse pressure
• Tight ring spacing ensures uniform bag support and cleaning
• Anti-corrosion coating protects cages from acidic dust components
• Smooth welds and surface finish reduce bag abrasion

The reinforced cage design significantly reduced premature bag wear at contact points.
 
System Configuration Data Table

Parameter	Specification
Application	Electric Arc Furnace dust control
Steelmaking Process	EAF – scrap melting
Dust Type	Iron oxide, ZnO, lime, carbon
Filtration Equipment	Pulse jet baghouse
Filter Bag Material	Aramid (Nomex®) needle felt
Bag Surface Treatment	PTFE membrane / PTFE coating
Bag Weight	500–550 g/m²
Continuous Operating Temp.	≤200°C
Filter Cage Material	Carbon steel
Cage Surface Treatment	Galvanized + epoxy coated
Cage Wire Diameter	3.8–4.0 mm
Ring Spacing	≤150 mm
Cleaning Method	Pulse jet compressed air
Filtration Efficiency	>99.9%

 
Performance Results After Implementation
Following installation of the upgraded filter bags and cages, the steel plant achieved significant improvements:
Stable Pressure Drop
Differential pressure across the baghouse remained stable, even during peak melting phases.
Extended Filter Bag Life
Average filter bag service life increased by more than 30%, reducing replacement frequency.
Improved Dust Capture
Visible emissions at the stack were eliminated, ensuring compliance with local environmental regulations.
Lower Maintenance Costs
Reduced bag failures and cage deformation led to fewer shutdowns and lower labor costs.
 
Why Filter Bag and Cage Matching Matters in EAF Systems
This case highlights a critical lesson: filter bags and cages must be designed as a matched system. High-performance filter media alone cannot deliver results if cages deform, corrode, or damage the bags.
For Electric Arc Furnace dust control, successful filtration depends on:

• High-temperature, abrasion-resistant filter bags
• Rigid, well-coated filter cages with smooth surfaces
• Proper cage geometry to support effective pulse cleaning

 
FilterWorkshop Expertise in Steel Plant Filtration
At FilterWorkshop, we supply filter bags and cages engineered for metallurgical applications, including Electric Arc Furnaces. Our solutions are designed to withstand:

• High temperatures and thermal cycling
• Abrasive, fine metal dust
• Long-term pulse jet cleaning

With consistent quality control and application-focused design, FilterWorkshop supports steel plants in achieving reliable, compliant, and cost-effective dust collection.
 
Conclusion
This Electric Arc Furnace dust control case demonstrates that selecting the correct filter bag material and cage structure is essential for successful steel plant filtration. By using aramid needle felt filter bags with PTFE treatment and heavy-duty, corrosion-resistant cages, the plant achieved cleaner emissions, longer service life, and reduced operating costs.
For steel producers seeking dependable dust control solutions, FilterWorkshop filter bags and cages provide a proven foundation for high-performance EAF filtration systems.