Dust Collection and Valves Blog

Dust Collector Frequently Asked Questions: Part 1 | Aerodyne

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

What information do I need to size my dust collector?

The attached Questionnaire will provide most of the questions that would be asked for a dust collector. The information that absolutely must be provided for a dust collector to be sized and quoted are:

  1. What is the airflow through the dust collector?
  2. What is the temperature and pressure the dust collector will experience?
  3. What is the dust being collected?
  4. Is it explosive?
  5. What removal efficiency do you require?

The five above will allow a supplier to provide a quote. However, with only the above information, the dust collector performance cannot be guaranteed.

See dust collector questionnaire.

Is my dust explosive?

To help answer this question, NFPA has released NFPA-652 and 654. A combustible dust is defined as a finely divided combustible particulate solid that presents a flash fire or explosion hazard when suspended in air or the process-specific oxidizing medium over a range of concentrations.

Basically, what this means is when the dust is in the air and its concentration is enough to cause a flash fire or propagate a deflagration or explosion if exposed to a spark or heat source, then it’s considered combustible. Continue Reading.


Airlocks FAQ Volume 1

Airlock valves are important components in many dust collection and process systems, yet they are often overlooked. We hope this helps you choose your next airlock.

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5 Common Mistakes When Selecting a Dust Collector

The video presents a quick, do-it-yourself examination that helps identify symptoms of possible inefficient dust collection.

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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: dust collector, pre-filter cyclone, compact cyclones, Dust Collector filters

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

Air Velocities and Your Ductwork Design | Aerodyne

Posted by Tom Hobson on Sep 21, 2020 1:49:35 PM

When designing a dust collection system, the ductwork is like the highways of the system. They allow the dust to move from the area of production to the dust collector. The dust should move fast enough so it doesn’t fall out while not moving too fast to cause undue wear and pressure drop. What this means is when you are designing your dust collector ductwork, pay attention to the ductwork diameters. When picking the ductwork diameters throughout the system, make sure the velocities correlate with the design velocities shown below.

Low Velocity Causes Dust Build-Up

A velocity that is too low will cause major issues in your ductwork. Dust will fall out and begin to pile up in the ductwork. This will do three (3) things:

  • The dust builds up, decreasing the area of the ductwork, until the open area is large enough to get the velocity back up within the range to prevent further dust buildup.
  • Dust buildup will increase the weight of the ductwork, and could cause issues with the support of the ductwork.
  • If the dust is explosive, the dust buildup creates fuel for an incident and could cause serious problems.

The table below is from the Industrial Ventilation Booklet (5-1) and gives the velocity ranges of various applications and dusts.

Nature of Contaminant

Examples

Design Velocity

Vapor, gases, smoke

 

Any desired velocity (1000-2000 FPM suggested)

Fumes, metal smokes

Welding

2000 – 2500 fpm

Very fine light dust

Cotton lint, wood flour, litho powder

2500 – 3000 fpm

Dry dusts & powders

Fine rubber dust, Bakelite molding, powder dust, jute lint, cotton dust, shavings (light), soap dust, leather shavings

3000 – 3500 fpm

Average industrial dust

Grinding dust, buffing lint (dry), wool jute dust (shaker waste), coffee beans, shoe dust, granite dust, silica flour, general material handling, brick cutting clay dust, foundry (general), limestone dust, packaging and weighing asbestos dust in textile industries

3500 – 4000 fpm

Heavy dusts

Sawdust (heavy and wet), metal turnings, foundry tumbling barrels and shake-out, sand blast dust, wood blocks, hog waste, brass turnings, cast iron boring dust, lead dust

4000 – 4500 fpm

Heavy or moist dusts

Lead dust with small chips, moist cement dust, buffing line (sticky), quick-lime dust

4500 fpm and up

 


How Tough Dust Can Affect Your Dust Collection System

Watch this video from the Dust Efficiency Clinic and learn how to deal with all these tough dust issues.

As always the Dust Efficiency Clinic offers its ‘outside the box’ thinking and solutions to your tough dust problems.

 


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.

Free Consultation

 

 

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Topics: dust collector, Dust Efficiency Clinic, explosive vent, Compliant System, Mini DHA, Dust Hazard Analysis

Installing Explosion Vents Indoor vs Outdoor | Aerodyne

Posted by Tom Hobson on Aug 31, 2020 9:30:00 AM

When protecting vessels from explosions, one of the most common ways is to install explosion vents. The explosion vent is an engineered weak spot in the vessel that fails when the internal pressure reaches a certain point. This failure allows the pressure to be released in a controlled way so that the entire vessel doesn’t explode. The explosion vent needs to be installed so that the venting is away from any equipment, walkways, roads, picnic areas, etc.

Explosion vents are primarily used when the vessels are located outdoors, however they can be used indoors, if certain criteria is met. To install an explosion vent indoors, the vessel has to be located by an exterior wall. The vent would then be ducted through the wall, so in case of an explosion it is directed outdoors. An indoor explosion vent will usually need to be larger than an outdoor explosion vent. This is due to additional combustion of material in the duct and the inertia of the air mass in the ductwork.

The following is an explanation taken from FM Global 7- 76 Section 3.1.8

During the early part of the venting process, unburned dust is ejected into the duct ahead of the flame front from the vessel. When the flame front moves into the duct, dust starts to burn within the duct and generate additional combustion products. Those combustion products expand in ALL directions, thus slowing down or even reversing the flow out of the vessel and the pressure builds up within the vessel.

Inertia of the air within the duct also increases explosion pressure within the protected vessel. When the explosion vent opens and combustion gases first start flowing into the duct, those gases must push all the air out of the duct. During the time required to eject the air, the pressure continues to grow within the vessel because the combustion gases are obstructed from reaching the open atmosphere. In a long duct, that mass of air can delay the venting of the combustion gases enough to significantly increase the pressure in the vessel.

So if you’re installing a vessel indoors and you want to vent it outside, keep it as close to the outside wall as possible.


Are you in compliance with the 2018 version of NFPA 68?

Simply click the button for direct access to the webinar to learn more about how to these recent changes may require modifications to your system.

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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.

Free Consultation

 

 

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Topics: dust collector, Dust Efficiency Clinic, explosive vent, Compliant System, Mini DHA, Dust Hazard Analysis

How History and Dust Collection Mirror Each Other | Aerodyne

Posted by Tom Hobson on Aug 26, 2020 10:00:00 AM

The saying goes that “Those who forget history are doomed to repeat it” and this is true of dust collection too.

Dust collections systems are often seen as an install and forget equipment. You turn it on and then do maintenance when you need to. However, the system was designed for a specific system or piece of equipment. This means the hoods, duct-work, airflow, dust collector, etc. are all taken into account in the design.

Then over time, equipment in the system is changed, repaired, optimized, etc. Additional pickup points are added and/or removed, filters are changed, process conditions change, new products are made and/or new components are used in the process. All of this can change the operation of the dust collector system. Anytime something changes in the dust collector system, the system should be reviewed to make sure it is still operating as required.

At this time, the change should be noted in the system manual so that in the future when another change is done or the system isn’t operating as required, the information is readily available. If the information isn’t noted on the system, history will be repeated in that the whole system will have to be re-designed to figure out what airflow is required and where the issues are. This will end up taking more time, and if the proper data isn’t available, could cause further issues down the line.


Solutions Sourcebook

Learn how industrial dust collectors and material handling valves can help your application.

 

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5 Common Mistakes When Selecting a Dust Collector

The video presents a quick, do-it-yourself examination that helps identify symptoms of possible inefficient dust collection.

Watch Video

 


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

Read More

Topics: dust collector, pre-filter cyclone, compact cyclones, Dust Collector filters

What Advantages Do Cyclones Provide Dust Collector Systems? | Aerodyne

Posted by Tom Hobson on Jul 29, 2020 9:30:00 AM

Cyclone pre-filters offer multiple advantages to existing dust collection systems. They lower the dust loading going into the dust collector, thereby allowing them to concentrate on the smallest particles. Here we will discuss the benefits for both wet collectors and dry collectors.

Wet Scrubbers

Wet Scrubbers – cyclones remove the particulate before the particles see the liquid. Wet scrubbers use liquid (often times water) to capture the dust. The water droplet surrounds the particulate, thereby increasing the particle size of the particle so it is easier to collect. Once the particulate is in the water droplet, it falls into the scrubber sump and is removed from the air-stream. The problem is that as more and more droplets enter the sump tank, a slurry is formed and will require a blow-down to prevent plugging up the nozzles, pump and packing, etc. This requires adding additional liquid and removing slurry.

Benefits of Cyclone Pre-Filter on Wet Scrubbers

By installing the cyclone pre-filter, you are decreasing the amount of particulate entering the wet scrubber. This means less particles will be in the sump tank, lowering the amount in the slurry and requiring less blowdown. This decreases the amount of liquid you need to add to the system. Lowering the blowdown rate also decreases the cost to treat the blowdown liquid. The blowdown slurry is often sent to a waste water treatment facility (facility or municipal). Each gallon of blowdown must be treated so that it doesn’t contaminate the ecosystem. This additional cost is often forgotten about when evaluating a wet scrubber.

Fabric Filters

Fabric filters (baghouses, cartridge collectors, HEPA filters) – Cyclone pre-filters provide many benefits for fabric filters. Fabric filters work by building up a dust layer which then lets air pass, but not dust particles. As the layer gets thicker it is harder for air to pass through.   Baghouses and cartridge collectors often clean the filters periodically by blowing compressed air in them, causing the filters to expand and shake off the top layers of dust.

Benefits of Cyclone Pre-Filter on Fabric Filters

The cyclone pre-filter minimizes the amount of dust coming to the filters. They also collect the largest dust, only allowing the fine dust to get to the filters. The fine particles will then more evenly collect on the filters.   The lower dust loading mean that the filters will not require as much cleaning which extends the life of the filters. Since the filters are cleaned by blowing compressed air into them, the expansion will eventually cause tears. And over time, less and less particulate will fall off as dust works its way into the filter.

Filters also have issues with certain type of dusts. Dust that is sticky and hygroscopic can cause filters to plug up faster, especially if there is humidity in the area. Abrasive dust can cause premature holes in the filters and those holes in the filter allow dust to pass through the collector and out into the environment. Again, by minimizing the dust going to the filter, you extend the filter life and minimize the possibility of filters plugging.

The other big savings is that by installing a pulse-on-demand controller, with a cyclone pre-filter, you will be able to control your cleaning cycles. Therefore, you will only clean the filters when it’s needed. This will save your filters and minimize your plant air usage.

The other benefit that cyclones provide is that they capture the dust before it reaches the filters. Since the filters have a dust layer at all times, the dust that is collected is contaminated by all dust that it has seen before in the life of the filters. If the material you are collecting is expensive, perishables or are controlled substances (pharmaceutical manufacturing), then collecting in a baghouse could cause issues due to contamination from the filters. The cyclone will collect the material and can be easily cleaned between batches.


Top 5 Reasons to Use a Cyclone as a Pre-Filter Whitepaper

Find out ow pre-filters help to extend bag or filter life, and improving removal efficiencies.

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How the Aerodyne SplitStream Cyclone Works

The SplitStream Cyclone Collector is designed for dust collection systems where tough dust like abrasive, sticky, fibrous, hygroscopic or granular persist. 

Watch Video

 


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: dust collector, pre-filter cyclone, compact cyclones, Dust Collector filters

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.

Free Consultation

 

 

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

Why Is Particle Size Distribution Important? | Aerodyne

Posted by Tom Hobson on Jun 29, 2020 10:30:00 AM

There are multiple ways to collect dust from the air. The most common are:

The Important of Particle Size

The particle size of the dust is important in all three of these techniques. Basically the larger the dust particles are the easier it is to capture. And inversely, the smaller the particle is the harder it is to capture, which means it’s more likely to pass through the dust collector and out of the exhaust. Bags and filters build up a dust layer that allows air to pass but prevents particles from passing. Cyclones use centrifugal motion to capture particles, which means the larger and heavier the particle is the faster it spins out of the air-stream. Wet scrubbers use water droplets to increase the particle size of the dust, thereby making them easier to capture.

Particle Size Distribution

What this means is that to figure out how effective your dust collector is, a particle size distribution is required. For example, cyclones have a removal efficiency curve that tells you what percentage of particles will be removed at a certain particle size. This can be used to calculate the total removal efficiency when a particle size distribution is provided. Filter bags and cartridges get high dust removal down to around 1 micron in size; however, if most of your dust is sub-micron in size, they will not provide high removal efficiency. And wet scrubbers can be used to increase particle size, but the design must take into account the particle size.

So one of the first steps to correctly select and design a dust collection system is to run a particle size distribution test. This will allow you to pick the best equipment for your application and to make sure it will provide the removal efficiency you require.


Are you in compliance with the 2018 version of NFPA 68?

Simply click the button for direct access to the webinar to learn more about how to these recent changes may require modifications to your system.

Get Webinar Now

 


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.

Free Consultation

 

 

Read More

Topics: dust collector, Dust Efficiency Clinic, Compliant System, Mini DHA, Dust Hazard Analysis, particle size distribution

5 Signs You Need A Checkup On Your Dust Collection System | Aerodyne

Posted by Tom Hobson on Jun 25, 2020 2:37:29 PM

Dust collectors are required in facilities for multiple reasons. After installation, they are often forgotten about until something isn’t working right.  In order to fix the problem, the system has to be almost re-engineered to figure out what the design originally was. The following things are signs your dust collector isn’t working how it was designed and you need to perform a checkup.

1. Area around the air inlets are dusty

The dust collector inlets/hoods capture the dust from your process. If you are noticing greater dust in those areas, then your dust collector isn’t operating correctly or something changed in the process. Either way, having an expert come in and look at the system is your 1st step to solving the issue.

2. High pressure drop through the dust collector

Baghouses and cartridge collectors use filters to capture the dust. They are cleaned regularly to prevent dust buildup, but they will plug over time. Once the dust builds up, less air will be pulled through system thereby allowing more dust to escape. You might not notice this change at the hoods, but the pressure gages across the filters will tell you when the pressure drop is high.

3. Material collected in the dust collector is less than before

As less air is being pulled into the system, more dust is escaping the system, which means less dust is being collected by the dust collector. One way of noticing this is when you’re not hauling away the dust from the hopper as much. An example would be normally you are replacing the 55 gallon drum once per week but now it’s once every two weeks.

4. Equipment in the area requires high maintenance

Dust can coat equipment and get into crevices. This can cause increased wear on rotating equipment, contaminate fluids, and plug air filters. All of these can cause an increase in equipment break downs. Equipment that is wearing down usually isn’t operating at its highest efficiency, thereby needing more energy. So if you are noticing an increase in equipment maintenance in a specific area, the dust collector might not be working as it should.

5. Workers are complaining about dusty areas or are calling off work more often

Dusty air can cause issues with the workers in the area. Dust can cause inflammations in the respiratory system which can cause people to be more susceptible to sickness. Workers might complain about the dusty air or just get sick more often.

Usually, combinations of these signs are happening at the same time. However, some might be more noticeable than others. So if you are seeing one of these signs, check for the others and then schedule a dust collector evaluation to get your system back into working order.


Bridging Dust?

Try the Aerodyne Mighty Whopper.

Aerodyne’s Mighty Whopper rotary valve has over-sized rectangular inlet and outlet. 

Download Brochure

 


5 Signs Your Dust Collection System Needs Maintenance

Is your dust collection system working at peak efficiency? A quick, do-it-yourself examination may identify symptoms that your system needs a check-up.

Watch Video


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: dust collector, airlocks valve, compact cyclones, Rectangular airlocks, Mighty Whopper

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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