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.

OSHA is issuing citations and fines to companies with unsafe combustible dust hazards, using their general duty clause and NFPA 652: Standard on the Fundamentals of Combustible Dust as a guideline. Any industrial facility that creates dusts or uses powders was mandated by NFPA 652 to complete a Dust Hazard Analysis by September, 2020 to identify the presence of combustible dusts and establish a plan for eliminating or mitigating potential risks associated with these dusts in their facilities. The DHA is essentially the framework around which NFPA 652 is built, and the starting point for getting a facility into compliance with the standard as a whole.

Dust Hazard Analysis (DHA) Complexity

The complexity of performing a DHA varies with the complexity of the facilities and processes being analyzed.  For instance, a small wood cabinet making shop with a limited number of dust generating machines will present a less daunting task than a large scale manufacturing facility that use powdered raw materials and performs cutting and grinding of its finished product. It should also be noted that performing a DHA should not be viewed as a “one and done” procedure that is completed and forgotten. As new processes or raw materials that have the potential for impacting a facility’s combustible dust profile are introduced in the facility, the DHA needs to be modified to incorporate these changes accordingly.

Dust Hazard Analysis (DHA) Preparation

Preparation for a Dust Hazard Analysis can also be incorporated into a more comprehensive review of a facility’s dust collection system that examines overall system design, efficiency, and safety. Aerodyne Environmental’s Dust Efficiency Clinic offers dust collection system evaluation services that do just that. An Aerodyne dust collection specialist will review a facility’s equipment, installation, controls, and protective devices with an eye toward improving overall system performance, decreasing maintenance costs, prolonging equipment life, and improving safety and regulatory compliance.

Dust Hazard Analysis (DHA) Report

At the end of the system review, a report is generated that summarizes the existing state of the dust collection system and offers targeted suggestions for areas that can be improved. This valuable service offers facility and plant managers outside expertise in boosting the performance and safety of their systems, and is a logical first step in preparation for a DHA.

To learn more about Aerodyne’s Dust Efficiency Clinic consulting services, call Dan Navicky at (440) 543-7400 or tollfree at (800) 358-7546, or email dc@dustcollectorhq.com.

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.

The most basic reason to install dust collectors is because the EPA, OSHA or other regulatory agency requires you to.  However there are other reasons to install a dust collector even if you aren’t required to.

1. Health and safety
   • Dust can cause health issues, even if the material isn’t a carcinogen or sub-micron. Dusty air can cause issues breathing, allergies, etc.  All of this can cause operators to be sick more often or want a new job.  This can cause increased operating expenses and less efficiency as you have to cover for absences or have to train a replacement.   Small local dust collectors can help clean the air around operators.
   • Some dust is explosive, and the regulatory agencies are requiring that you test the dust to make sure it isn’t. Even if they haven’t gotten around to it yet, a fire or explosion will cause property damage and possibly injury to employees.
2. Maintenance – Dust will get into mechanical equipment and cause increased wear on them. This increases the maintenance on the equipment, lower productivity and increase operational expenses.  Installing a local dust collector can minimize the dust getting to the surrounding equipment, thereby extending their life.  While there are many factors that affect when equipment needs maintenance, minimizing dust in the air will definitely help extend the time between maintenance.
3. Recycling of material – Local dust collection can help capture product / raw material dust before it is contaminated by other material. This dust can then be reused or recycled, thereby lowering the cost of your process.  Cyclonic dust collectors are especially good at collecting un-contaminated material since they have no filters to retain dusts and can be cleaned out.
4. Environmental responsibility – Local dust collection will help you keep fugitive dust from escaping the building and into the environment. While rain and wind often deposit dust back on the ground, the more dust escaping will cause the air to be dirtier. This could cause smell or dust clouds that neighbors will dislike.  Beyond being a good direct neighbor, you may just have a goal to be a better inhabitant on the earth.
5. Higher morale – A cleaner, healthier environment will help your employees be happier at work. If they aren’t irritated from dusty air, there is a better chance they will enjoy work better and be more productive.  This will allow you to produce more at a lower cost.  And the company will make more money allowing the employees to get better raises.

To learn more about which dust collector, please contact our experts at 440-543-7400 or click on the button below to get our Whitepaper: 4 Potential Dangers to Collectors! How Cyclone Pre-Filters Can Help!

The airflow in a dust collection system is extremely important, since the air collected at the hoods is removing the dust from the affected areas.  This air is then sent to the dust collector to remove the dust from it.  While it is always desirable to use the least amount of air as possible in your dust collection system, you must have enough air so that it is actually doing the job it is meant to.   If not enough air is going through the system, you will not capture all the dust from the pickup areas, thereby allowing dust to escape into the facility, cause health / nuisance issues and/or fire hazards.  If the airflow is too high, you could be picking up product/ raw materials, wasting energy and increasing maintenance issues.

There are many reasons that the airflow through a dust collection system can change.  A few of them include:

• Environmental changes – temperature, humidity, etc.
• Changes in the system – such as opening/ closing dampers, dust buildup in the ductwork, damage to the ductwork and/or hoods.
• Dust collection issues – such a plugged filters, old filters, holes in the filter, etc.
• Damage to the exhaust fan – such as bearings, damaged impellers, etc.

Unlike liquids, there is no easy and inexpensive way to monitor airflow in a dust collection system.  The most common way is to periodically manually measure the airflow by inserting a pitot tube in the ductwork and measuring the air velocity.  The airflow is then calculated.

One option to monitor your airflow is to install a cyclone pre-filter ahead of the filters.  A cyclone’s pressure drop increases as the airflow increases in them.  Usually the manufacturer of the cyclone can provide a curve, showing the relationship between the pressure drop and the airflow.  So if you monitor the pressure drop through the cyclone, you will notice if the airflow suddenly increases or decreases.  And if the pressure drop drifts too far from a certain pressure drop you will know to troubleshoot the system.

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper: Top 5 Questions To Ask When Considering A Cyclone Dust Collector.

Dry dust collectors and humidity don’t react well together.  Baghouses and cartridge collectors operate by having dirty (dusty) air enter the housing.  Multiple filters (bags or cartridges) are located in the housing.  The air travels through the filter and then exits the dust collector.  The filters are a mesh of fibers that allow air to travel through small holes, while dust is too large to pass.  The dust builds up a layer (dust cake), further limiting the subsequent dust’s ability to pass through while allowing the air to pass.  From time to time the dust collector will clean the filters by shaking them or using compressed air to expand them.  This causes the outer layer of the dust cake to fall off.

Humidity can cause problems in the process described above.  Humidity is a way to express the amount of water in the air, (the higher the humidity, the higher the amount of water in the air).  When high humidity air enters a dust collector with fabric filters, there is a chance that the water vapor will condense and create water droplets or the dust on the filters will absorb the water as the airflow passes through.  Many dusts change their physical properties when the water content increases.  Some become sticky, some become hard like concrete, etc.  When this happens to the dust cake, it affects the ability of the air to pass through and the ability of the dust to fall off during cleaning.

When dust becomes sticky, it will adhere to neighboring dust particles and not want to fall during cleaning.  Dust that becomes hard (like concrete) will prevent air from passing through.  When one of these issues develop in a dust collector the pressure drop across the dust collector will increase.  Over time, an increased pressure drop will lower the airflow being pulled through the system.  This will decrease the airflow being picked up at hoods, therefore lowering dust collection at where operators are located.

Humidity can also be introduced in the dust collector in the compressed air.  When air is compressed, the temperature of the air increases, thereby increasing the water content of the air.  The compressed air is at its saturation point.  As the air moves through the line, it cools, thereby condensing water in the system.  If additional drying technology isn’t installed, the compressed air will have water droplets in it as it is used in the dust collectors.  This will cause the filter cake to wet and cause issues as described above.  This is why it is important to dry compressed air when dealing with dust that is affected by water.

However, sometimes no matter how you treat your compressed air, you continue to have issues.  This could be because the airline travels outside and in winter time it gets very cold. It could be because you are located near a large body of water, and humidity is high.  One way to minimize the effect on your dust collector is to minimize the dust getting to your dust collector.  Cyclone pre-filters are ideal for these applications.  Cyclones collect dust and water droplets using centrifugal motion.  This means they aren’t affected by the changes to the dust as a filter is.  Cyclone pre-filters can often remove up to 80% of the dust before a dust collector with filters.  This means you can lower the number of water droplets going into your dust collector and minimize the cleaning required, thereby not getting as much water from the compressed air system. 

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-Filter.

The use of clamp together ductwork has increased over the past few years. There are multiple suppliers of clamp together ductwork which helps to keep the prices down. Clamp together ductwork is easy to design and install. 

The Benefits of Clamp Together Ductwork 

• Easy to design - One of the main benefits of clamped ductwork is that extremely accurate measurements aren’t required. The clamp together ductwork allows you to adjust the length.  This makes installation of the ductwork much easier than standard flanged ductwork.  So when you are designing your ductwork, you just sketch the ductwork out.  From the sketch you figure out the pieces that you require and then order them from your preferred supplier.
• Easy to transport - Clamp together ductwork is also easier to transport, as the ductwork usually comes in 5 foot sections.
• Easy to install - When it comes time to install the ductwork, all you need to do is begin installing it and trim any pieces that are too long.
• Ideal for mobile systems – Portable applications that require frequent disassembly and re-assembly.

The Restrictions of Clamp Together Ductwork

One thing to be aware of is that clamp together ductwork cannot be used as the ductwork between a dust collector and the no-return/ isolation valve.  NFPA specifications require that the ductwork be flanged together and strong enough to prevent a breach in case of an explosion.  This means when you are designing and installing the system, this ductwork needs to be ordered as flanged ductwork.  The no-return / isolation valve will have specifications on the distance it needs to be from the dust collector.  They may also have guidelines on elbows etc.  Most clamp together ductwork suppliers offer flanged ductwork too.  So you just need to order the required flanged ductwork when you are ordering the rest of your ductwork.

To learn more about which dust collector, please contact our experts at 440-543-7400 or click on the button below to get our Dust Collection System Evaluation Guide.

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.

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 undo 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.

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. A video demonstration of how this works is available here. The valves are available with a variety of sleeve materials for different applications. While these valves can not 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.

To learn more about which dust collector valve is right for you, please contact our experts at 440-543-7400 or click on the button below to get our infographic, Vacu-Valve is a Simpler Solution.

At one time mechanical dust collectors were the industry standard in dust collection and air pollution control. However, with an ever increasing focus on air quality, EPA regulations regarding dust collection have steered the manufacturing world toward the higher efficiency capabilities of fabric filter baghouses, cartridge filters, and other dust collection equipment utilizing filter media. This change has undoubtedly helped to reduce the amount of harmful emissions released into the atmosphere in manufacturing processes. Unfortunately, the use of these fabric filter baghouse collectors is not without cost. The limitations of filter media such as moisture, heat, and high particulate volumes have added to the challenges of successful dust collection. Additionally, the high cost of bag or cartridge replacement, maintenance issues, and expensive pulse-jet controls to clean filter media can add up. The solution to these headaches for many has been the use of mechanical dust collectors before final-stage filtration.

Mechanical dust collectors use a cyclonic air flow to separate particulate from an air stream. The centrifugal force created by the rotary flow throws the dust out of the air stream and toward the walls of the collector. In a typical cyclone, the particulate strikes the wall of the collector and falls to a hopper below for collection. Cleaned air is then vented through the top of the collector. While this form of collection can be highly efficient in dealing with large, dense particulate, extremely fine dust lacks the inertia to escape the air stream and is subsequently carried out with the cleaned air. Some high efficiency cyclones like the Aerodyne 'S' Series, use two air streams, to more efficiently separate the dust. The Aerodyne's powerful secondary air stream intercepts the particulate before it contacts the side wall, reducing wear when handling abrasive materials. This secondary air stream also helps to sustain the cyclonic action inside the collector, thereby increasing its efficiency.

Filter media dust collectors such as baghouses and cartridge filters use a fine filter media to remove dust from an air stream. The dust-laden air is drawn into the collector where it passes through the filter media and particulate is intercepted. Dust builds up on the filter until it is cleaned or replaced. Cleaned air is then vented out of the collector.

Many manufacturing processes involve circumstances that make it very difficult to rely completely on a baghouse. Heavy dust loading can be a maintenance nightmare for a filter media collector. A rock crushing operation based out of Minnesota realized the benefits of placing a cyclonic dust collector before its baghouse. The enormous amount of rock dust generated in the crushing operation was blinding the bags and causing frequent shutdowns. The decision was made to install a cyclonic dust collector to receive the dust before being sent through the bag house. The cyclone captured the vast majority of the rock dust, leaving only a small amount of fine particulate for the bag house to handle. The cost of the additional equipment was quickly recovered through fewer shutdowns and less frequent bag replacement.

Processes involving high temperature exhaust gas also plague filter media collectors. The hot air temperatures exhausted from foundries, glass making plants, and power plants can burn the filter media used by most baghouses. While high temperature filter bags and cartridge filters are available, they can be an expensive addition and are still not completely immune to the heat. Used as a spark arrestor, a cyclonic dust collector can be placed before a bag house to both reduce the temperature of the air stream and the particulate loading before it enters a final stage filter.

While a mechanical dust collector may not be necessary in every application, the benefits that can be gained from this proven technology are evident. As emission standards become more stringent and process costs continue to rise, any advantage that can be taken should be considered. By comparing process costs such as materials, labor, and downtime with the expense of a cyclone, a decision can be made as to the need for such equipment.

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Not Your Grandfather's Cyclone. 

Dust collection system design can be a very complicated process. Beyond determining variables such as air volumes, drop sizes, and capture velocities, there is perhaps no more important design consideration than fire prevention. This is especially true in systems that are used in hot work applications, such as sawing, grinding, or sanding, where sparks can potentially be generated. If a spark is drawn into a system’s ductwork, it has the possibility of travelling all the way to the system filters which are typically constructed of combustible materials. If this happens, the filters can catch on fire, which can lead to catastrophic destruction of the dust collection system, the entire building, or result in serious injury or loss of life.

Any well thought out system will take this scenario into consideration and incorporate preventive measures to reduce the likelihood of this happening. Installing a spark arrestor in the duct work before the baghouse is a method that is commonly used to reduce fire risk. Spark arrestors vary in design, but most of them are designed with the intent of slowing the spark down, allowing it to cool down and burn out before it can do any damage to the baghouse or cartridge collector.

Another option is incorporating a pre-filter cyclone before the fabric filters. A cyclone works on the same principle when it comes to spark arresting, using centrifugal force to direct any sparks to the cylindrical surface of the cyclone, spinning them along the metal walls of the cyclone where they are drained of their energy via conduction. The cyclone has the added benefit of removing the majority of heavier particulate before it reaches the filters, which alleviates overall system loading.

The ongoing emphasis by OSHA and NFPA on combustible dusts and dust collection systems in general means that regulatory compliance will become increasingly important for any facility that uses dust collectors.  Prevention and suppression devices such as sprinklers in the ductwork, explosion vents, chemical suppression systems, and pre-filter cyclones can all be used to reduce and possibly eliminate the risk of fire. The type of dust being collected, the combustibility of the dust, dust particle size, and filter construction are among the factors that must be considered when selecting the appropriate fire protection for your system.

Which prevention or suppression system does your dust collection system need? Asking that question is the first step in protecting your system, your facility, and the people who work in your facility.

To learn more about how Aerodyne can help you keep your dust collection filter cleaning system operating efficiently,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-filter.