Case Study: Power Industry, USA – PrimaFlow

Eliminating Frequent Failed Bags in Coal-Fired Power Plant’s Baghouse

For this Coal-Fired Power plant, Micronics, now a part of Cleanova, began with a thorough evaluation. A solution was needed that would clear the exposure of the filter media to the dust-laden gas stream blasting horizontally over the top of the inlet baffle.

PrimaFlow™ was selected as the engineered filtration solution, providing an improved filtration area and helping to lower the baghouse air-to-cloth ratio.

After an initial successful trial in 3 of the 14 compartments, the plant leadership was convinced that our PrimaFlow™ was the appropriate option for addressing the inherent issues with their baghouse system and proceeded with full baghouse deployment.

As of 2025, the initial PrimaFlow™ installation has already yielded a four-year lifespan. Learn more about this Power Plant Success Story below.

 

Interactive Case Study Summary

Challenge

A 650 MW power plant in south-central USA was operating a 14-compartment baghouse filtering flue gas from a boiler burning powder river basin coal. The client was experiencing frequent failed bags, typically with the failure mode being in the middle of the bag, just above the top of the inlet baffle.

The frequent bag failures meant increased maintenance expenses, plant operation at a reduced baghouse capacity, and an ongoing risk of being out of compliance with emissions requirements.

The power plant turned to us for a baghouse solution that would address the set of issues eroding the middle of the existing filter bags, which were 28-ft long filter bags with a 2-piece cage design.

Solution

Our selection of PrimaFlow™ as the filter media in the client’s baghouse resulted in only a 12-month ROI and numerous quantifiable improvements:

  • 99% baghouse demand availability.
  • Reduction in maintenance expenses from weekly expenditures to an annual inspection.
  • 30% reduction in differential pressure drop for our PrimaFlow™ vs. traditional bags.
  • 35% reduction in future baghouse changeout expenses since the PrimaFlow™ utilized a single-piece cage design vs. the prior 2-piece cage design.
  • Eliminating the ongoing threat of emissions excursions and associated penalties due to failed bags.

You can rely on our team to be your proven single source for solving complex baghouse challenges.

Before and After Photos

PrimaFlow Case Study

Contact Our Experts

Micronics, now a part of Cleanova, is your trusted partner for engineered filtration solutions. We offer end-to-end solutions from filter media to industry-leading filtration equipment, to spare parts & accessories, to on-site field services and in-house laboratory services. Whether for your Filter Press, Belt Press, Leaf Filter, Vacuum Filter, or Baghouse, you can count on Micronics’ deep industry and applications knowledge for the right engineered filtration solution to meet your needs. We look forward to working with your team.

Request a Quote