Our Solutions
Engineering dust & gas control systems that perform consistently.
At IntelligentAir, we offer a full spectrum of dust and gas filtration solutions built for the demanding conditions of process industries. Every solution is engineered for high uptime, low emissions, and sustainable operations — tailored to the specific dust properties, furnace outputs, and thermal parameters of your plant.
Pulse Jet Bag Filter Systems
High-Efficiency Filtration for Industrial Furnaces & Material Handling Units
We design and install bag filters for:
- Electric Arc Furnaces (EAFs), Rotary Furnaces, Induction Furnaces
- Zinc/Copper/Lead smelting units
- Coke handling, Silo discharge, Packaging dust control
Features:
- Long bag technology (up to 8m length) for reduced footprint and longer bag life
- Emission levels as low as <1–10 mg/Nm³
- Designed for sticky, high-temperature dusts (ZnO, Cu, Pb, HF, SO₂)
- On-line & off-line pulse jet cleaning
- Energy-optimized compressed air usage (only 4 bar)
Why it matters: Achieve pollution control compliance, reduce bag change frequency, and prevent unplanned downtime
Cyclonic Bag Filters
Dual-stage dust collection with built-in cyclone pre-separation
These filters combine the principles of cyclone separation with bag filtration for higher dust loading applications.
Ideal for:
- Raw material handling zones
- High-particulate cement, refractory, and steel processes
Features:
- Long bag technology (up to 8m length) for reduced footprint and longer bag life
- Emission levels as low as <1–10 mg/Nm³
- Designed for sticky, high-temperature dusts (ZnO, Cu, Pb, HF, SO₂)
- On-line & off-line pulse jet cleaning
- Energy-optimized compressed air usage (only 4 bar)
Why it matters: Lower bag wear, better bag cleaning, and longer system life.
Gas Cooling Heat Exchangers
Air-to-Air Cooling of Flue Gas from 750°C to 220°C
Our custom heat exchangers handle:
- Flue gases from rotary furnaces and kilns
- Sticky dust loads (7–10 g/Nm³)
- Fluctuating thermal loads with VFD-controlled cooling fans
Designed to operate at:
- 33,000+ Am³/hr
- Continuous duty at 200–220°C outlet temperature
- Fully PLC-integrated with temperature sensors & safety interlocks
Why it matters: Keeps bag filters above acid dew point (SO₃ + HF), preventing corrosion, clogging, and failure.
Retrofit & Performance Upgrades
Breathe new life into failing or outdated systems
We offer complete system overhauls — keeping only the outer shell while redesigning:
- Tube sheets
- Bag cleaning systems
- Air flow distribution
- Filter media and cages
- Ducting & RAV systems
Examples:
- Lead fume system retrofitted from 150 mg/Nm³ → 10 mg/Nm³
- Sinter plant emissions cut from 300+ to <75 mg/Nm³, bag life improved from 6 months to 3+ years
Why it matters: Achieve compliance without investing in a full new system.
Emission Audits & Technical Evaluations
End-to-end diagnostics of underperforming DES/BH systems
We perform:
- Air flow, pressure drop & suction mapping
- PM10 / PM2.5 / stack SPM measurement
- Thermal profiling for dew point & condensation risk
- CAN velocity optimization
Why it matters: Identify root causes of failure, justify upgrades, or submit CPCB/NGT compliance reports.
Specialty Features & Customization
- Lime dosing systems to neutralize SO₂ / HF
- Differential pressure monitoring with SMART HART transmitters
- SS 316 cages, PTFE membranes, high-temperature bags for corrosive applications
- Rotary airlock valves, hoppers with auto dust level control, screw conveyors for zero manual intervention
Sustainability Comes Built-In All our systems are designed for:
- Lower compressed air & power consumption
- Safe working environments for operators
- Acid-resistant design to ensure longer life
- Emission compliance with Indian and international norms