Maintaining a clean and safe working environment is essential, especially in workshops and industrial settings where dust and airborne particles are common byproducts. A well-designed dust collection system is crucial for both the health of workers and the longevity of machinery. We will explore various ways to enhance the performance of your dust collection system, ensuring optimal efficiency and effectiveness.

1. Assess Your Current System

Begin by evaluating your existing dust collection system. Identify any bottlenecks, leaks, or areas where the system might be underperforming. Consider factors such as ductwork layout, filter condition, and the capacity of the collection unit. This initial assessment will provide valuable insights into the specific areas that need improvement.

2. Proper Ductwork Design

Efficient ductwork design is fundamental to the success of any dust collection system. Ensure that the ducts are appropriately sized to maintain a consistent airflow velocity. Minimize bends and turns in the ductwork, as these can lead to pressure drops. Straight and smooth ducts allow for better particle transport, reducing the likelihood of dust settling and clogging the system.

3. Optimize Airflow and Velocity

Achieving the right balance of airflow and velocity is critical for an effective dust collection system. Too much or too little airflow can compromise performance. Consult equipment manuals or an HVAC professional to determine the optimal airflow rate for your machinery and workspace. Adjust the system accordingly to maintain a consistent and efficient collection of dust particles.

4. Regular Maintenance

Frequent maintenance is key to the longevity and efficiency of your dust collection system. Check and replace filters as needed, inspect ductwork for leaks, and clean out any accumulated dust or debris. Neglecting regular maintenance can lead to reduced system performance and potential safety hazards. Develop a maintenance schedule and adhere to it diligently.

5. Invest in High-Quality Filters

The effectiveness of a dust collection system heavily relies on the quality of its filters. Consider upgrading to high-efficiency filters that can capture smaller particles, providing a cleaner and healthier workspace. HEPA (High-Efficiency Particulate Air) filters are an excellent choice for trapping even the tiniest airborne particles, contributing to improved air quality.

6. Utilize Secondary Filtration

In some cases, incorporating secondary filtration can enhance the overall performance of your dust collection system. Cyclone separators and baghouses are examples of secondary filtration devices that can capture larger particles before they reach the main filter. This not only extends the life of the primary filter but also prevents premature clogging.

7. Consider Variable Frequency Drives (VFDs)

Variable Frequency Drives (VFDs) enable you to adjust the speed of your dust collection system's fan motor. By varying the speed based on demand, you can optimize energy consumption and maintain consistent airflow. This not only contributes to cost savings but also ensures that the system is operating at peak efficiency.

A well-designed and properly maintained dust collection system is a valuable asset for any workspace. By assessing your current system, optimizing ductwork design, maintaining regular upkeep, and investing in high-quality filters, you can significantly improve the efficiency and effectiveness of your dust collection system. Implementing these improvements not only contributes to a healthier working environment but also enhances the longevity and performance of your machinery.

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Baghouses and Cartridge collectors are very good at removing dust from their air. However, when the dust concentration is high, or the dust is abrasive, wet, sticky or fibrous, the baghouse filters can have issues.  

• High concentration will plug of filters quickly.
• Abrasive dust will cause holes to develop in the filters.
• Wet and sticky dust will plug up the filter and/or cause filter failure.
• Fibrous dust will not easily fall to the hopper causing filters to plug.

Installation of a cyclone pre-filter is an ideal way of extending filter life.  The cyclone uses centrifugal forces to capture the dust and remove it from the airstream.  Often times the cyclone will remove 80-90% of the dust before a baghouse or cartridge collector.  This allows the filters to concentrate on the smaller dust that makes it past the cyclone.

And if you have a pulse-on-demand controller for your baghouse, you will further extend the filter life, as the filters will only be cleaned when required.

What is a cyclone dust collector?

Cyclone dust collectors are dust collectors that use centrifugal motion to remove dust from an airstream. They don’t have any moving parts and don’t use filters for dust removal. Most cyclones are vertical in design, even though Aerodyne Environmental has compact horizontal cyclone designs. They are often used as pre-filters to increase baghouse, cartridge collector and wet scrubber system efficiencies.

What is a cyclone pre-filter?

Cyclone pre-filters are cyclones installed before a baghouse or cartridge collector to increase the removal efficiency of the system.  They extend filter life and lower utility usages. The cyclone pre-filter is often used on those applications that have “Tough” dust.  “Tough” dust would be dust that is abrasive, hygroscopic, fibrous and/or wet. Often times this dust will cause operational issues with baghouse and cartridge collectors.

Why install a cyclone pre-filter?

Cyclone pre-filters are installed to optimize a dust collection system. This could mean increasing the removal efficiency of an existing dust collection system. It could be to extend filter life by decreasing the dust loading the filters are seeing, thereby decreasing the cleaning required. 

Additionally, cyclone pre-filters will lower compressed air/plant air usage by increasing the intervals between cleaning when a pulse-on-demand control system is used with it. And in those special applications, the Aerodyne SplitStream cyclone can add hot or cold air into the dirty airstream, thereby treating the air while collecting dust.

Signs You Need a Pre-Filter

The following are some signs that your dust collector isn’t operating up to par and you should look at installing a cyclone pre-filters.

1. There is a high pressure drop across your filters. This is caused by the dust building up on the filters and not being cleaned off fast enough.  The high pressure drop causes the fan to pull less air to compensate, thereby letting more dust out on to the shop floor.
2. Filters are being replaces too fast! The most common filter failures are by developing holes or plugging up.  Both failures are tied to high dust loadings.
3. Valuable product or raw material is being disposed in the dust collector waste due to contamination. As stated above, filters build up dust layers to provide the removal efficiency. Those filters will retain the material over time. If the material is valuable, this can be a lot of money that is going to waste. Pre-filters will allow the material to be collected and used in the process or product before it can be contaminated in the filters.
4. Do you have a high cost of water treatment and disposal of the scrubber blowdown? When wet scrubbers capture particulate, slurry is formed. This slurry will then have to be disposed. It will often be sent to a water treatment plant. The water treatment plant might be dedicated to the facility or municipal. Either way, additional costs are added to treat the slurry before it is disposed of or reused. A pre-filter removes a portion of the material before it is put into slurry, thereby saving costs on waste-water treatment.
5. Similar to above, since wet scrubbers form slurries, any valuable material collected in the wet scrubber will be in that slurry. So, unless the desired state of the material is within the slurry, it will have to be processed to make it useful. This means additional steps (and expense) are required to recycle the material. A cyclone pre-filter removes the material dry, before it is in slurry, thereby saving costs.

So, before you decide to purchase a new dust collector, look into the benefits of installing a cyclone pre-filter.  You just might save yourself money!

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Designing a ventilation system always involves considering space constraints. Ductwork, which is essential for air distribution, occupies space within the facility, and its design must efficiently use the available area while ensuring optimal airflow.

Furthermore, complying with NFPA regulations often requires placing dust collectors outside the primary working area due to safety concerns. This external placement adds an extra layer of space management complexity. Additionally, dust collectors are typically mounted on structural supports known as skids, which simplify installation and relocation but also consume additional space within the facility. Therefore, creating an effective ventilation system design requires careful consideration of how these elements harmonize within the given space while meeting safety and efficiency requirements.

Aerodyne's GPC cyclone offers a practical solution for applications where space is a premium concern. Its compact design and efficient performance allow it to seamlessly replace bulkier equipment, making it a space-saving choice for a wide range of industries. By doing so, it not only maximizes available workspace but also simplifies maintenance and enhances operational efficiency. This versatility makes the GPC cyclone a valuable asset, offering a viable and efficient alternative to traditional, space-consuming equipment in various applications. 

Aerodyne GPC Cyclone

The GPC cyclone's compact design offers remarkable space-saving advantages, as it can be accommodated in areas that are only half to a third of the size required for traditional cyclones, as shown in the attached documentation. This compactness often permits indoor placement, aligning with NFPA-654 7.13.1.1.2 (2) regulations. Various industries, including those operating clean rooms, mines, vehicles, and portable systems, can capitalize on these space-efficient attributes.

Furthermore, the GPC cyclone's design introduces the opportunity for installation in smaller spaces, potentially replacing the need for extensive ductwork, including 90° elbows. Additionally, it can serve as an effective pre-filter for existing cartridge collectors, baghouses, and electrostatic precipitators. This adaptability opens doors to innovative system configurations, such as positioning it above a conveyor belt to recapture particulate matter and reintroduce it onto the conveyor, showcasing the versatility and space-saving capabilities of the GPC cyclone.

The GPC cyclone by Aerodyne provides an added advantage by eliminating the need for an equipment skid. Many companies accustomed to traditional cyclones may hesitate to incorporate a pre-filter or cyclone dust collector into their skid or unit due to space constraints. However, GPC cyclones can be conveniently mounted on various equipment, such as on top of a dryer, behind a crusher, or at the inlet of a cartridge collector, without requiring a skid. This flexibility simplifies installation and ensures that space considerations do not impede the adoption of efficient dust collection solutions.

Moreover, the adaptability of GPC cyclones extends to marine applications, where space efficiency is paramount. Unlike traditional cyclones that demand multiple levels of a vessel's decks, a GPC cyclone can be installed on a single deck, greatly enhancing the practicality, serviceability, functionality, and feasibility of incorporating cyclone-based dust collection systems on ocean or lake vessels. This versatility underscores the GPC cyclone's ability to provide effective dust collection solutions without imposing significant space-related limitations. 

With these savings in space, facilities can operate more efficiently and avoid floor space issues. For more information on the GPC, click on the link below or contact Aerodyne at dc@dustcollectorhq.com or by phone at (440) 543-7400.

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Aerodyne manufactures two different types of cyclones - the GPC (Ground Plate Cyclone) and the SplitStream Collector. These Aerodyne cyclones are not the traditional cyclones with which you are probably familiar. Both cyclones can be designed for vertical or horizontal installation; traditional cyclones can only be vertical. The Aerodyne GPC and SplitStream cyclones also provide high particulate removal efficiency. The following describes the different cyclones that are available along with their advantages and disadvantages.

Traditional Cyclone

The typical cyclone design consists of a tangential inlet and a long-tapered body. Centrifugal forces force particulate out toward the walls, and gravitational forces direct the dirty gas stream downward through the narrowing body. As the gas stream becomes constrained in the narrow end of the cyclone body, a phenomenon known as “vortex-reversal’’ occurs in which a secondary inner-vortex is generated and moves upward through the center of the primary vortex where it is exhausted from the collector. Dust near the walls fall into the cyclone hopper and out of the airstream. The traditional cyclone must be vertical in design to operate effectively.

Vortex-reversal is one of the primary causes for inefficiencies in cyclonic dust collectors. As the inner vortex travels up through the cyclone, it takes with it any fine dust particulates that did not have the inertia to be forced tight to the collector walls.

Another issue that can develop with traditional cyclones is that an integral hopper could have dust re-entrainment into the clean airstream. Oftentimes, traditional cyclones will install a dust trap to prevent re-entrainment. The dust trap is located below the cyclone hopper and is designed to minimize particulate re-entrainment. If you’ve seen a cyclone with what looks like a pocket underneath it, it has a dust trap.

Aerodyne GPC Cyclone

The GPC cyclone uses a combination of a sloped spiral inlet and fixed ground plate to provide several distinct advantages over the traditional cyclone dust collector described above. 

First, a spiral inlet directs the dirty gas stream toward the ground plate and hopper of the collector. This efficiently begins the centrifugal motion of the air without any dead spots. The fixed ground plate, utilized by the GPC removes the requirement of a long-tapered hopper. The ground plate provides the vortex-reversal, rather than the geometry of the tapered hopper in traditional cyclones.

As the dirty gas stream strikes the convex ground plate; fine particulate, which has not completely made it to the collector walls, is deflected into the hopper. The ground plate also shields collected particulate from the clean air, acting as a barrier between the separation chamber and collection hopper; Therefore, no separate dust trap is required.

The GPC design allows it to be much smaller than traditional cyclones and includes 6 sizes under 8ft3 per NFPA 654. A GPC cyclone is usually less than half the height of a traditional cyclone. The ground plate also removes the requirement of gravity, so it can be designed for a horizontal installation, with virtually no effect on collection efficiency. The horizontal GPC is around 1/3 of the height of a traditional. The removal efficiency is high (99% of 20 micron particulate*).

* spherical dust, specific gravity of 1

Aerodyne SplitStream Collector

The Aerodyne SplitStream Collector uses two airstreams to remove particulate in the air. The primary air stream enters the cyclone and proceeds through a mechanical spinner. The spinner imparts centrifugal motion into the airstream, thereby forcing dust particulate toward the cyclone walls.

A secondary airflow enters the cyclone near the clean air exit. The secondary air proceeds through nozzles or vanes as it enters the cyclone. The secondary air then rotates around the outer edge of the cyclone, collecting particulates and delivering them into the hopper. The secondary air then reverses direction and joins the primary air and leaves the cyclone. Since the SplitStream Collector has no moving components, it is capable of handling a wide range of materials, while requiring minimal maintenance.

Particulate that is abrasive, fibrous, friable, sticky, or hygroscopic can be separated and collected for air pollution control or reclamation. The secondary air ensures that the dust doesn’t contact the walls. This minimizes wall abrasion for abrasive applications and areas. For particulate that is sticky, the secondary airflow keeps the dust from building up on the walls.

The SplitStream Collector has a very high removal efficiency of light, fluffy particulate that floats in the air. The secondary airstream also gives the option to heat up or cool down the process air and material. Removal efficiencies as high as 99% of 7- 10 micron dust range are normal*.

* as measured in limestone testing

To learn more about the different types of Dust Collection Methods, click here to download our free white paper. To request a brochure of the Aerodyne GPC Dust Collector, please visit www.DustCollectorHQ.com. For more information regarding the full line of Aerodyne industrial dust collection products and material airlock valves, call (440) 543-7400, toll-free at (800) 358-7546, or e-mail dc@dustcollectorhq.com.

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Look under almost any dust collector and you will see a rotary airlock valve spinning its rotor and emptying the collected contents from the hopper. These valves have long been used to maintain a seal in vacuum dust collection systems while simultaneously providing an escape route for the dust. 

The advantages of a rotary airlock for dust collectors include automatic hopper emptying, minimal vacuum pressure loss, and the many options available to meet specific application needs. Rotary valves can be custom fit to handle high temperatures, harsh chemical environments, and abrasive materials. Rotary valves do, however, have a few major drawbacks.

Rotary Airlocks Drawbacks

Because rotary airlocks are sealed tight to the atmosphere they can be very difficult to clean. Cleaning a rotary valve often involves removing the drive assembly, end plate, and finally the rotor. This process can take hours to perform. Rotary valves are also expensive to operate. Typically, these valves are left running continuously, even when there is no dust present in the hopper. This not only wastes electricity but puts undue wear on the valve. Repair and replacement parts for rotary airlock valves can be quite costly as well. Even with these shortcomings, the rotary airlock remains the industry standard for most dust discharge applications.

Non-Powered Automatic Dust Discharge Valve

One alternative which has been gaining popularity is a non-powered automatic dust discharge valve. These valves, like the Armadillo and Platypus Vacu-Valves from Aerodyne, rely on the negative pressure (max -18″ W.C.) of a dust collector to hold a rubber sleeve closed to maintain an airlock. As the weight of the dust in the hopper builds up, the sleeve is forced open and dust is discharged from the valve. Leaf springs inserted into the valves sleeve also help to counterbalance the vacuum. 

 

The valves are available with a variety of sleeve materials for different applications. While these valves cannot be used in every dust collection system they are a very economical alternative to expensive rotary valves.

The Vacu-Valves from Aerodyne are priced at a fraction of the cost of standard rotary airlock valves and require no electricity to operate. These valves have no controls and require no lubrication. They easily handle abrasive materials that would jam or wear out a rotary valve.

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One challenge to designing a manufacturing process is choosing an effective dust collection system that will fit the limited available plant space. Low ceilings pose a challenge for high-efficiency cyclones due to their long-tapered bodies. In many cases, the dust collector must be placed outdoors or partially protruding through the roof. This can be an unfavorable arrangement.

Counter-cyclonic dust collectors, such as the Aerodyne SplitStream™ Dust Collector, use a secondary air stream that directs material toward the collection hopper, and may be installed horizontally with virtually no loss of efficiency.

As the dust-laden gas stream is drawn into the collector, it passes through a stationary spinner which imparts a rotational flow and forces particulate toward the walls of the collector. A powerful secondary air stream is injected into a manifold where it enters the separation chamber through a series of nozzles. The secondary air stream intercepts the collected particulate and carries it to the hopper. 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.

 

This type of dust collector may be suspended from a ceiling, conserving valuable space on the manufacturing floor. It also saves money compared to cutting a hole through the roof or building a site for the dust collector outdoors. Outdoor installation may also encourage condensation that can shorten service life and reduce efficiency. Finally, horizontal, high-efficiency cyclones may be maintained without the need for tall scaffolding that can pose a safety hazard to workers.

 

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For the past several decades, industrial facilities in a wide variety of industries have deployed dust collection systems as part of its manufacturing process. As technology and filtration techniques have improved, these systems have changed and evolved to become more sophisticated, and at times complex.

Dust collectors are used in many industries to improve air quality and remove harmful particles from the air. There are several types of dust collectors that are commonly used in industrial and commercial settings. Here are some of the most common types:

Baghouses

A baghouse consists of a vessel with many filters (bags) inside. The bags are located in rows and mounted on a tube sheet. The tube sheet separates the dirty air from the clean air. Dirty air enters the bag house near the bottom. The dirty air is forced through porous bags which have a built-up filter cake. Clean air goes through the filter/bag and leaves through the top of the vessel, while the dust falls down to be discharged through the hopper.

Cartridge Collectors

Cartridge collectors operate similar to baghouses except they use pleated cartridges to provide much higher surface areas in smaller filter volume than bag filters.  This means they are much smaller than baghouse for the same air volume.  However, the cartridges have lower temperature limits and can plug easily. They are used in the following applications: grinding, sandblasting, welding fumes, laser and plasma cutting fumes, graphite, pharmaceutical powders, acid fine chemical powders, and more. When dusts are difficult to handle, hygroscopic, or high temperature, a baghouse is a better alternative for trouble free dust collection and longer filter life.

 

Cyclone

The cyclone is the simplest design of all dust collectors. It is a mechanical way to remove dust from an air stream. The cyclone uses centrifugal and gravitational forces to force the dust to the vessel walls and then let gravity collect it. The cyclone requires only a discharge valve and fan for operation. Cyclones require very little maintenance. Cyclones are often used as prefilters for other dust collectors.  They can provide high removal efficiencies of larger dust particles, thereby decreasing the loading on the main dust collector, this can increase total removal efficiency, decrease system maintenance and extend equipment life, not to mention collect material before contamination.

ESP (Electro Static Precipitator)

ESPs use high voltage to electrically charge particulate in the air. The charged particulate is collected on charged plates as the air stream passes. ESPs use large amounts of electricity and can get collection efficiencies as high as 99% for many applications. ESPs provide good removal of sub-micron particulate. ESP are expensive and require high operating and maintenance costs.

Wet Scrubbers

Wet Scrubbers are available in a variety of designs including cyclones, venturi, packed towers, cloud chambers and fluidized beds. Wet scrubbers spray water into the dirty airstream allowing dust and water droplets to contact, thereby making them easier to collect.  Wet scrubbers have high removal efficiency but can be expensive to operate and treat the slurry leaving. The wet cyclone is just like a regular cyclone except that they spray water in the cyclone.

 

 

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A dust collector is a mechanical device used to remove dust from an air stream. The dust collection system consists of a hood (or air collection device), the dust collector, the motive fan and any inter-connecting ductwork, stack, dampers, controls, etc. Aerodyne Environmental manufactures cyclone dust collectors and the dust handling valves (airlocks) mounted on the dust collectors. 

To properly specify a dust collector, certain information is required:

1. Dust collector type – Cyclone, baghouse, etc.
2. Airflow (CFM) – The amount of air going through the collector. The airflow is critical to sizing a dust collector and without airflow no collector can be sized.
3. Temperature, pressure, humidity of airflow – Higher temperature, pressure, and humidity will affect collector materials of construction, size and may require special valves and controls.
4. Dust description* – The better you describe your dust the better your dust collector will operate. Example a sticky dust will bind a cartridge collector which will require frequent cleaning and/or replacing of the cartridges. While cyclones are well suited for sticky particulate.
   
   a. SG or density of the dust/particulate – the greater the density, the easier it is to remove.
   
   b. Dust/particulate loading (lbs/hr) – amount of dust.
   
   c. Particulate size distribution (microns) – how big is the dust (smaller dust is removed in baghouse but larger dusts can be effectively removed in a cyclone).
   
   d. Fibrous, abrasive, hydroscopic, granular, tendency to bridge, sticky, etc. (dust with these properties can wreck havoc on baghouses and cartridge collectors.
5. Removal efficiency required – The greater the removal efficiency, the more expensive the design will be.
6. Materials of construction required – from carbon steel to stainless and high alloy steel, the materials of construction affects price. Process conditions (temperature, gas/air composition, dust composition and humidity) can require specific materials of construction. (Example: salt in a humid environment requires stainless steel to prevent corrosion.)
   
   *If unknown, a pilot unit can often be rented from the manufacturer to test on your existing system.

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Dust collection systems pick up dust generated by process equipment and move it away for disposal or to be recycled. They use hoods to gather the air around the dust generation equipment. The dusty air is then sent to the dust collection equipment through ductwork. The dust collection equipment often consists of a pre-filter to help collect the dust followed by the main dust collector. An exhaust fan is often at the end and it powers the system by pulling the air through each of these components.

Cyclones

Cyclone dust collectors are very dependent on the airflow that is going through them. Cyclone pressure drops are based on many factors, but the two most important are the geometry of the cyclone and the volumetric airflow through the cyclone. The pressure drop formula of a cyclone has the square of the volumetric airflow through the cyclone. So, doubling the airflow will quadruple the pressure drop (2x ACFM leads to 4x dp). If your airflow changes through the system, the pressure drop through your cyclone can fluctuate. 

Since dust collection system static requirements are all related, the exhaust fan will find its operating condition naturally. However, if the airflow decreases, then the removal efficiency of cyclone will decrease too. This means the cyclone will remove less of the finer dust particles, thereby sending them on to the filters. That will cause greater dust loading for the filters, which could increase the frequency of cleaning (more plant air usage, greater filter wear, etc.) and decrease the lifespan of the filters.

Filter Collectors

Filter collectors would actually benefit from lower airflow. The lower airflow would decrease the air to cloth ratio, which can extend the life of the filters. However, as described in the rest of this paper, the overall performance of the dust collector system will decrease. And if the system has a cyclone dust collector, the benefits gained by a lower a/c ratio could be counteracted by higher dust loading coming through the cyclone.

Higher airflow will increase the air to cloth ratio and could put more strain on the filters. The velocity of the air going through the filter could increase enough that holes in the filters could develop, thereby causing dust to bypass the filters.

However, filter collectors have a pretty good range of airflows they can handle without significant effect on the system. Unlike cyclones, the pressure drop in a filter is based less on airflow and more on the filter pack on them.

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The exhaust fan provides the motive force for the dust collection system. The exhaust fan has a performance curve that defines how much airflow it will pull at a certain static pressure. When you turn on a fan, it will ramp up and increase the airflow until reaching the maximum static pressure it can provide.

As most exhaust fans are centrifugal fans, the curves show that the lower the airflow, the higher the static pressure. This means that as the airflow increases the static pressure decreases. When the airflow in a system changes, this means the static pressure required in the system has changed, so the system performance has changed per the exhaust fan curve.

When The Airflow Is Higher

With higher airflow, the operating point will move further right on the fan curve. Generally, this won’t affect the fan much. The efficiency of the fan could change, but the overall affect would be minimal. If this change takes the fan off its curve, then you could develop operational issues with the fan. However, this isn’t a common occurrence.

When The Airflow Drops

A much greater issue is when the airflow drops. This moves the operational point to the left of the curve. Most centrifugal curves have the static pressure of the fan level out as the airflow decreases. If you get to this flat part of the curve, the fan could provide unstable performance, where the airflow jumps around. For example, the fan curve can show that between 0 ACFM and 800 ACFM the fan provides 12” W.C. This means when you get into this area your airflow can fluctuate anywhere from 0 to 800 ACFM. This can cause issues throughout your system and isn’t a good place on the curve for the fan to operate.

When you are operating a dust collection system it is imperative that you maintain the airflow in the system within design criteria. If it increases too much it can cause added expenses, maintenance, and product loss. If it decreases too much it will let dust escape, lower removal efficiency, and possibly create dangerous environments. So, we highly recommend regular, if not continuous, monitoring of your process airflows to be sure you’re operating within design parameter.

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