Dust Collection and Valves Blog

Compact Cyclone Perks Up Coffee Roasters | Aerodyne

Posted by Tom Hobson on Oct 23, 2020 10:41:45 AM

A prominent coffee bean roaster is planning on building a new roasting facility in New Jersey. The head engineer contacted Aerodyne about trying to find equipment that could separate the coffee beans as they are pneumatically conveyed from one portion of the facility to the other. The engineer specified that the problem the facility was facing was space.

How Aerodyne GPC operates Differently in Coffee Industry

After sending over the specs of the application, Aerodyne concluded that the roasting facility could easily house a GPC-20 horizontal dust collector for the operation. The Aerodyne GPC Dust Collector operates differently than other dust collectors. A sloped spiral inlet directs the dirty gas stream toward a fixed ground plate and hopper of the dust collector.

The ground plate forces vortex reversal to occur in a much shorter space, eliminating the need for a long, tapered body. As the dirty gas stream strikes the convex ground plate, fine particulate that has not completely made it to the dust collector walls is deflected into the hopper. The ground plate also shields collected particulate from the forces of the vortex reversal, acting as a barrier between the separation chamber and the collection hopper. This innovative design enables a compact dust collector to operate at high efficiency, even when installed horizontally.

The GPC offers a unique dust collection solution. With the compact size and excellent removal efficiencies, it is an economical and low maintenance solution to removing dust and particulate from an air stream.


Aerodyne GPC Used in Coffee Roaster's Process


To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, horizontal cyclone, GPC Cyclone, arirflow, particle size

Particle Size Helps in Selecting Dust Collector | Aerodyne

Posted by Tom Hobson on Sep 30, 2020 9:45:00 AM

In dust collection one of the most important dust characteristics to define is the particle size of the dust. The larger the dust the easier it is to capture. While the smaller the dust particle the harder it is to capture and remove from the airflow. This applies to both heavy and light particles. What this means is that in order to accurately predict your removal efficiency, you need to know the particle size distribution.

Breakdown of Particle Sizes

The most useful particle size distribution includes a breakdown of the particle sizes under 50 microns in size. Most dust collectors will pretty much capture all or nearly 99% of particles greater than 50 microns, so it isn’t as important to know if you have 5% dust at 51 microns and 3% at 55 microns, a simple 8% over 50 microns would be effective.

However, when dealing with dust less than 20 microns, knowing the particle size distribution is very important. For example, some cyclones might get you around 85% removal of 10 microns dust but 60% of 5 microns dust and only 30% of 2 microns dust. So, if you have that 60% of the dust is less than 10 microns, it isn’t known how much of that is in the 2 microns ranger or the 10 microns range. This means that when calculating your removal efficiency, the estimated removal efficiency could range from less than 30% to 85%. The only way to know is to have a breakdown of the particle sizes.

Particle Size with Standard Deviation

Another way of providing a particle size distribution is to provide a mean particle size with standard deviation. This provides a decent approximation of the particle size. Personally, I would prefer the actual test data, because you are providing actual test data and not approximations. Depending on the process of dust generation, the approximation accuracy will vary. It also requires the person estimating the removal efficiency to calculate a particle size distribution. This takes more time and increases the chance of an error being introduced.

So, when you are looking to get your dust collector engineered, remember it is important to provide the equipment manufacturer with a particle size distribution. Often times you can send a sample in to a lab and within a week or so have a full distribution curve for a few hundred dollars. This will allow the manufacturer to better understand what they have to capture and select the best equipment for your application.


How Do Horizontal Dust Collectors Work?


To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, horizontal cyclone, GPC Cyclone, arirflow, particle size

Do Cyclones Replace Dust Collectors (Baghouses, Wet Scrubbers)?

Posted by Tom Hobson on Jul 24, 2020 9:14:12 AM

In most applications, cyclones do NOT replace baghouses, cartridge collectors, wet scrubbers, electrostatic precipitators, etc. Modern air pollution regulations require dust collectors to provide greater removal efficiencies in the PM2 and PM10 than most cyclones can provide.

How Cyclones work?

Cyclones collect dust by having the contaminated air enter (usually on a tangent) and spin around the cyclones walls until they get to the bottom. The air then reverses and spins up the middle of the vessel and leaves from the top, while the dust falls into the hopper.

The centrifugal forces on the particles and droplets, force them out towards the walls and away from the air exiting the center of the vessel. Cyclones provide high removal of the larger, heavier dust particles and moisture droplets.

The Benefits of Cyclones

Cyclones remove very high percentages of the larger, heavier particles. This means they often remove as much as 80%-95% of the total particles. However the removal efficiency of the smaller, lighter dust isn’t very high. The PM2 and PM 10 particulate will often get through the cyclone in high enough concentrations that the system won’t comply with state, local, and federal standards.

When installed in front of a dust collector (baghouse, cartridge collector, etc.) as a pre-filter, they significantly reduce the loading on the primary dust collector. This helps extend the operational life of the dust collector, increase removal efficiency, and decrease maintenance. Cyclones are often used to lower the loading on a dust collector (baghouse, cartridge collector, wet scrubber). The cyclone removes the large material, allowing the dust collector to get the high removal efficiency on the PM 2 and PM 10 particulate.


Aerodyne GPC Cyclone Dust Collector

View the animation of the GPC Industrial Dust Collector to see the compact, high efficiency cyclonic design. Unlike typical cyclonic dust collectors, the GPC Industrial Dust Collector uses a ground plate to force vortex reversal in a much shorter space, eliminating the need for a long, tapered body.


To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, Dust Efficiency Clinic, GPC Cyclone, splitScream Cyclone, Compliant System, Cyclones pre-filter

How To Determine the Cost of a Cyclone - Part 6 | Aerodyne

Posted by Tom Hobson on Apr 30, 2020 9:15:00 AM

Part 6: Scope of Supply

Cyclones do not stand alone in most applications.  They require additional equipment for them to work.  Depending on your application, equipment can include an airlock, exhaust fan, explosion protection, instrumentation, insulation, vibrator, and even ductwork.  The cyclone can be purchased as a system with all the equipment required to operate or it can be purchased by itself and integrated into an existing system.  The system is then put together by the end user or a 3rd party.  Many times, the sum of the accessory equipment is greater than the cost of the cyclone.  A brief description of the potential accessories and how they affect the cyclone is below.

  1. Airlock

    An airlock is essential for the proper operation of a cyclone.  It isolates the cyclone from the outside atmosphere.  Without it, material will fly out the bottom or get re-entrained in the system.  Airlocks could be a simple extended hopper (55 gallon drum), rotary valve, or specialized valves like the double dump valve or trickle valve.  Special designed valves are available for quick cleaning applications and explosive applications.
  2. Explosion Protection

    Explosion Protection is a very important consideration for dust collectors as about 70% of dusts are explosive. The equipment that protects against explosions can add significant cost the cyclone.  Explosion protection equipment such as explosion vents, isolation valves, chemical suppression, and isolation systems can all quickly increase the price of a cyclone.  This equipment is required for explosive applications. 
  3. Exhaust fans 

    Exhaust fans are required on every dust collection system. They provide the motive force required to pull air through the system.  When selecting the fan, be sure to take into account all ductwork and equipment.    It is best to install the fan downstream of all dust collectors so that the most efficient impeller designs can be used.  This will save money on operational costs.  However, if the fan needs to be installed in high dust areas, there are impellers designed for these operations.
  4. Instrumentation 

    Instrumentation for cyclones are rather simple compared to other dust collectors. The main instrumentation used on cyclones are differential pressure gages/transmitters and level switches for the hoppers.  Explosive applications can have special instrumentation and some applications will monitor temperature and humidity for equipment downstream of the cyclone.  But for most standard cyclone applications, differential pressure is the only recommended measurement.
  5. Insulation, Heat Tracing, Steam Jacketing
    Insulation, heat tracing, steam jacketing are required for special applications. These can add significant expense to the cyclone.  Insulation and heat tracing can be done at the fabricator but usually are done onsite to prevent damage in shipping and installation.  Steam jacketing must be done in the design and fabrication phase and can add significant cost to the cyclone.
  6. Vibrators or Air Jets
    Vibrators or air jets are used for applications where material bridges in the hopper. Vibrators can usually be installed after installation and will help keep the hopper from bridging up.  Air jets blast air into the hopper, breaking up any bridging and letting material flow out of the airlock.  It is best to have the connections for these to be included in the cyclone design and installed once on site.

In summation, cyclone design and costs are based on the size and construction required in your specific application.  Special applications can require costly equipment and design changes that will increase the cyclone cost significantly.  When selecting a cyclone for your application, be sure to include all the factors in to your cost estimate so you are can accurately determine your budget.



To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.



To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, NFPA 652, horizontal cyclone, GPC Cyclone, splitScream Cyclone, arirflow

How To Determine the Cost of a Cyclone - Part 4 | Aerodyne

Posted by Tom Hobson on Mar 27, 2020 10:14:34 PM

Part 4: Application Requirements

Cyclones also need to be constructed so that they meet the specifications and requirements of the applications they are going in.  Some applications, like woodworking or where the material being collected is waste, don’t need any special constructions.  Applications such as food and pharmaceuticals can be very specific.  Every application, customer, process, and facility has their own set of requirements.  These could include a special quick clean access or a higher weld spec to prevent accumulation in the vessel.

  1. Quick Clean

    Quick Clean design allows for the cyclone to be easily accessed for cleaning. It is often used in food and pharmaceutical applications.  These applications usually have a strict cleaning protocol and/or require cleaning between batches.  The design changes required for quick clean design can often significantly increase the price of a cyclone.  Often times it will require redesign of the standard cyclone to allow access and minimize material buildup.  Horizontal cyclones are often best for these situations.
  2. Special Welds

    Special welds are required in most food applications. The welds are often areas where material can build up and contaminate the material being collected in the cyclone.  To prevent this, the welds are often required to be ground down.  This is a time consuming process and is done individually with power tools.  Depending on the specification, special welds can often significantly increase the price of the cyclone, even as much as doubling the cost.  Often times, the welds will require specific welders in a shop to work on the unit, thereby increasing the lead time and cost.  When you are specifying special welds, it’s often a good idea to have a sample or a picture of the weld you are looking for so the fabricator and end user are on the same page.  See the drawing below for an example of a sample.
  3. Special Finishing

    Special finishing of the materials of construction is another requirement in many stainless steel applications. Some food and pharmaceutical applications require the metal to be finished or polished to a certain specification.  Usually, the internal finishing is the most critical due to it being in contact with product, but often times the facility has a specification on the external too.  This is often for cleaning and uniformity in the facility.  Special finishing of the metals can often significantly increase the price of the cyclone.  Often times, with the higher finishes allowance has to be made in the pricing for discarding material that doesn’t meet to specification after it has been worked on.

How Do Horizontal Dust Collectors Work?



To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.



To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, NFPA 652, horizontal cyclone, GPC Cyclone, splitScream Cyclone, arirflow

Horizontal Cyclones: Solutions for Space Limitation | Aerodyne

Posted by Tom Hobson on Sep 30, 2019 10:30:30 AM

If you are like many plant engineers who are working within the confines of a limited work space, rest assured that you don’t need to compromise on the efficiency of your industrial dust collection system. A traditional, high-efficiency cyclone is not the best solution for facilities with low ceilings.

Space Limitation

If space limitations prevent you from properly orienting this type of cyclone in an upright position, this will result in a loss of efficiency due to particulate settling on the side of the collector and being carried out with the exhaust gas. Attempting to solve this problem by installing your vertically oriented dust collection cyclone outdoors may encourage condensation that can shorten service life and reduce efficiency.

Horizontal Cyclones

Today, more plant engineers are choosing a horizontal configuration for reliable, high-efficiency dust collection. These options include the Aerodyne GPC Cyclone and counter-cyclonic dust collectors, such as the Aerodyne SplitStream™ Dust Collector.  The SplitStream™ Dust Collector uses a secondary air stream that directs material toward the collection hopper, and may be installed horizontally with virtually no loss of efficiency.

Because this design does not rely on gravity to bring the dust to the hopper like conventional cyclones, its operational efficiency is not affected by horizontal installation. In addition, this type of dust collection system may be suspended from a ceiling, conserving valuable space on the manufacturing floor.

The SplitStream™ Dust Collector the ability to increase/decrease process temperature while collecting dust. The unique counter cyclonic design element of the SplitStream™ Dust Collector ensures that a minimal amount of particulate comes in contact with the interior walls. This eliminates excessive wear and enables abrasive particulate collection.

 


How Do Horizontal Dust Collectors Work?



To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com.



To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, NFPA 652, horizontal cyclone, GPC Cyclone, splitScream Cyclone, arirflow

Dust Collector Placement Part 4: Surrounding Areas | Aerodyne

Posted by Tom Hobson on May 29, 2019 9:21:48 AM

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 4 of 4)

Surrounding areas

As mentioned above, the area surrounding the dust collector significantly affects where the dust collector can be installed.  Location of utilities such as electricity and compressed (plant) air all affect the dust collector location.  Baghouses and cartridge collectors usually require compressed air for cleaning, wet scrubbers often require makeup water and a drain to either local or plant water treatment facilities. 

Dust Collector Interference

The dust collector may interfere with surrounding equipment and operations, such as cranes and vehicle traffic.  Dust collectors are often tall pieces of equipment requiring large head room when indoors.  And the noise and explosion protection could affect personnel space such as break rooms, rally points, foot and vehicle traffic, etc.

So when looking for a space to install your dust collector make sure you take into account all the different factors such as explosion protection, utilities, operations, and workers safety and comfort. And install the dust collector as close as possible when conforming to the above requirements.

To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com

 

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Topics: GPC Cyclone, dust collector placement, distance from process, surrounding areas

Dust Collector Placement Part 3: Distance from Process | Aerodyne

Posted by Tom Hobson on Apr 23, 2019 1:40:54 PM

 

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 3 of 4)

Distance from Process

Ideally installing the dust collector should be located next to the dust generation.  However, this isn’t always possible.  There are space constraints, safety and noise concerns and process requirements that all affect the placement of the dust collector.  However, based on this, you should place the dust collector as close as possible to the process.  This decreases cost with less ductwork required.  You will also want to use as straight as possible runs of ductwork .  Short, straight ductwork will keep the pressure drop of the system low allowing you to install a smaller quieter blower.  It also helps prevent dust build up in the ductwork which can cause operational issues and be a fire/explosion hazard.

Smaller Fans

Smaller fans usually mean lower horsepower motors.  This translates into lower operating cost for the fan.  And shorter ductwork requires less cleaning, thereby less time for maintenance on the whole system.  If long distances are required, look at using local pre-filters to lower dust loading going through ductwork.  This will help solve some of the issues such as dust buildup in the ductwork.

To learn more about dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com or click on the button below to get our whitepaper: Top 5 Reasons to Use a Cyclone as a Pre-filter.

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Topics: GPC Cyclone, dust collector placement, distance from process

Dust Collector Placement Part 2: Space Constraints | Aerodyne

Posted by Tom Hobson on Apr 12, 2019 9:30:00 AM

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 2 of 4)

Space Constraints in New Facility

In new facilities, the installation of dust collectors is often pretty easy.  Many times the building is designed around the equipment.  This doesn’t mean that compact equipment isn’t beneficial.    This can help lower ceilings, prevent the need for installation on the roof.  When placing a dust collector in new facilities, it would best to place them as near to the system as you can while conforming to all the NFPA and other specs.

Space Constraints in Existing Facility

Existing facilities pose much more issues than new facilities.  Often times existing facilities are constrained for space.  They have added / expanded lines in a building that weren’t built for its current use.  New regulations could require a new dust collector, larger dust collector, or modification to the dust collector (including explosion protection).  All of this could require finding room for a new dust collector or moving the existing one.

Noises from Dust Collector and Fan

If the dust collector is not going to be mounted indoors, it needs to fit under the existing ceiling.  Low profile units are often required.  It might be easier to use low profile point of use dust collectors than to find a place to install a large dust collector for multiple processes.  It is often beneficial to locate the dust collector as close to the processes it is collecting dust from.  This lowers the cost of the system by minimizing ductwork which in turn minimizes the fan size and HP.  When installing the dust collector you should remember to take into account noise from the dust collector and the fan.  Fan silencers and noise blankets may be required if the equipment is too loud.  And as discussed above, enough space should be available for installing all the explosion protection required.

Protect Dust Collection Equipment from Weather

If the dust collector is not going to be mounted indoors, height is usually not an issue.  Some facilities do have outdoor height restrictions.  Sometimes it’s the local city and sometimes it is to keep a low profile with the neighbors.  The dust collection equipment must also be protected from the local weather.  Equipment in the Midwest often requires freeze protection, while the Gulf Coast need to withstand high winds.  When locating the dust collector outside you should install it as close as possible to the process, so as to minimize ductwork and power requirement.

Conform with NFPA

Many customers when installing equipment have to deal with local ordinances on the appearances of the outside of the facility.  Other times, the company wants the facility to be aesthetically pleasing, and / or they want their neighbors to be comfortable with the appearances so as to minimize any issues in the future.  And as mentioned before, the dust collector should conform with NFPA when installed on an explosive application.

To learn more about compact dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com or click on the button below to get our whitepaper: 5 Ways to Save Costs by Using Small Dust-Collection Cyclones.

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Topics: GPC Cyclone, dust collector placement, Space constraints

Dust Collector Placement Part 1: Explosive Dust | Aerodyne

Posted by Tom Hobson on Mar 26, 2019 9:45:11 AM

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 1 of 4)

Explosive dust

One of the most important factors to take into account is the explosibility of the dust.  If the dust is explosive you will have to make sure the location of the dust collector conforms with the appropriate NFPA specification.

The NFPA specifications require dust collectors to be located outdoors if they have explosive dust, unless specific explosion venting or mitigation equipment is being used.  Even if your dust collector is located outdoors, it should still have venting, because you don’t want your collector to create shrapnel during and incident.

Explosive Vent

One of the most common and least expensive explosion protection methods is the installation of explosion vents on the dust collector.  The explosion vent directs the pressure wave out of the vessel through an area, thereby controlling the explosion.  This protects the dust collector from the worst of the damage.

When using explosion vents, it does matter if your dust collector is indoors out outside.  When located indoors, the explosion is required to be vented outside.  The vent is connected to ductwork to an opening in an outside wall or roof.  When this is used, the dust collector should usually be within 5 feet of the wall.

When the dust collector is outdoors it should be orientated so that the explosion vents are directed away from the building and any other equipment.  The vents should also be directed away from any walkways, roadways, and areas where employees would be. (Ex. Rally points, picnic tables, etc.)

Flameless Vent

A flameless vent can be used instead, which allows the dust collector to be installed inside without venting it outdoors.  The flameless vent directs and vents the explosion as a standard vent, but it has metal fins mounted on the vent so the explosive wave travels past the fins.  The metals fins rapidly cool the wave, stopping the flame, so only a hot pressure wave is left.  Enough room must be left around the flameless vent so that adjacent equipment isn’t damaged.  The vent area should not be an area where workers are or a walkway.

Chemical Suppression

Chemical suppression is another technology that is used to protect dust collectors from explosions.  The technology uses non-explosive chemicals to flood the dust collector and prevent an explosion.  Sensors located in the dust collector and the ductwork measure the temperature and pressure to monitor for an explosion.  When they detect an explosion the chemical suppression system is activated.

Chemical suppression systems require yearly maintenance to make sure the system is still protected.  So the sensors and chemical canisters need to be accessible for the maintenance checkups.  This means platforms or open spaces for portable lifts should be located around the equipment.

To learn more about which dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com

Click below and watch our Webinar that offers a thorough explanation of the changes in NFPA 68 and how they may affect your existing system design.

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Topics: GPC Cyclone, flameless vent, chemical suppression, explosive dust, dust collector placement, explosive vent

Aerodyne Environmental: Home of the Horizontal Cyclone and  Vacu-Valve® Airlock Valve

Inspired To Be Different.

At Aerodyne, we choose to take a different approach to collecting dust and handling materials. Our cyclones are unique in design to address common issues such as problematic dusts and space constraints. Our airlocks are chosen to fit your specific application instead of hastily installing traditional equipment options. We believe that when we see things differently, we can solve problems effectively. That's why so many people turn to us for help in solving their tough dust problems.

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