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.

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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.

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

• Using filters such as bags and pleated filters
• Using centrifugal motion in a cyclone
• Using water (as in a wet scrubber)

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.

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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.

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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.

 

 

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 1^st 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.

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Bridging Dust?

Try the Aerodyne Mighty Whopper.

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

 

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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.

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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

When designing a dust collection system, the static pressure required of the system is extremely important.  The reason is because the exhaust fan must be able to pull the design airflow at the design static pressure in order to get the design performance.  Usually the higher the static pressure is the greater power is required by the fan at a constant airflow.  This means, dust collector system designers usually try to keep the total static pressure low, in order to go with a smaller fan that costs less to operate.

Cyclones Pressure Drop

However, when it comes to cyclones, this is not always the best policy.  A cyclones pressure drop is based on the amount of air going through it.  So a 24” diameter cyclone might have a 3” pressure drop at 1500 CFM and a 5.5” pressure drop at 2000 CFM.  So a smaller cyclone can handle a higher airflow at a higher pressure drop.  This would lower the fabrication cost of the cyclone, and allow it to fit in a more confine space, but have a higher operational cost (more HP required).

Higher Pressure Drop

But using a smaller cyclone also has another benefit, the higher your pressure drop, the more efficient the cyclone will be.  This increase in removal efficiency usually will not allow you to use a cyclone only for dust control, but it will help remove smaller particulate before your primary filter.  This will allow you to capture more material before contamination, lower the loading on your filters, and decrease utility usage (water or plant air).

So when you are designing a dust collection system, don’t look for the cyclone with the lowest pressure drop, but look at all the aspects that affect the system.  Will a smaller cyclone fit better?  Will higher removal efficiency in the cyclone be beneficial to the main dust collector?

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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. Configured horizontally or vertically, the cyclone’s low-profile design is perfect for mounting in space-restricted areas.

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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.

 

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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

Many dust collectors spend their time operating far below their potential.  Whether the system was designed incorrectly, the process has changed, slow maintenance, or a combination of these, the dust collector isn’t operating at its finest.    One possible solution is to install a pre-filter before your dust collector to help your dust collector to be all it can be!

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

Filter Collectors (baghouse, cartridge collector, HEPA filters, etc.)

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. 
    
   1. One of the ways holes develop is filter cleaning. Pulse-jet dust collectors use high pressure air blown down through the center of the filter to expand the filter off its support structure.  When the pressure disappears the filter returns to its normal size, causing the top layer(s) of dust to fall off the filter.  This regular expansion and contraction will cause holes and tears in the fabric, which then let unfiltered air and dust through the unit. 
   2. Plugging of the filters happens with “Tough” dust or a deficiency of cleaning of the filters. As the filters plug up, the removal efficiency will actually get better because very little air will get through, but this will cause dust to escape from the pickup points  as less and less air is pulled through the system.  So the dust collector system will not be doing the job it is supposed to do.
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.

Wet Scrubbers

1. 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.  These costs are usually much more than disposing of dry material.  One reason being that dry material weighs much less because there isn’t any water added and the other being that regulations prevent slurries from being put into landfills, etc.  A pre-filter removes a portion of the material before it is put into slurry, thereby saving costs on waste water treatment.
2. 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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5 Signs Your Dust Collection System Needs a Pre-Filter

Watch the video from the Dust Efficiency Clinic discusses how using a pre-filter will optimize your dust collection 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.

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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.

 

 

Part 6: Scope of Supply

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

1. Airlock
   
   An airlock is essential for the proper operation of a cyclone.  It isolates the cyclone from the outside atmosphere.  Without it, material will fly out the bottom or get re-entrained in the system.  Airlocks could be a simple extended hopper (55 gallon drum), rotary valve, or specialized valves like the double dump valve or trickle valve.  Special designed valves are available for quick cleaning applications and explosive applications.
2. Explosion Protection
   
   Explosion Protection is a very important consideration for dust collectors as about 70% of dusts are explosive. The equipment that protects against explosions can add significant cost the cyclone.  Explosion protection equipment such as explosion vents, isolation valves, chemical suppression, and isolation systems can all quickly increase the price of a cyclone.  This equipment is required for explosive applications. 
3. Exhaust fans 
   
   Exhaust fans are required on every dust collection system. They provide the motive force required to pull air through the system.  When selecting the fan, be sure to take into account all ductwork and equipment.    It is best to install the fan downstream of all dust collectors so that the most efficient impeller designs can be used.  This will save money on operational costs.  However, if the fan needs to be installed in high dust areas, there are impellers designed for these operations.
4. Instrumentation 
   
   Instrumentation for cyclones are rather simple compared to other dust collectors. The main instrumentation used on cyclones are differential pressure gages/transmitters and level switches for the hoppers.  Explosive applications can have special instrumentation and some applications will monitor temperature and humidity for equipment downstream of the cyclone.  But for most standard cyclone applications, differential pressure is the only recommended measurement.
5. Insulation, Heat Tracing, Steam Jacketing
   Insulation, heat tracing, steam jacketing are required for special applications. These can add significant expense to the cyclone.  Insulation and heat tracing can be done at the fabricator but usually are done onsite to prevent damage in shipping and installation.  Steam jacketing must be done in the design and fabrication phase and can add significant cost to the cyclone.
6. Vibrators or Air Jets
   Vibrators or air jets are used for applications where material bridges in the hopper. Vibrators can usually be installed after installation and will help keep the hopper from bridging up.  Air jets blast air into the hopper, breaking up any bridging and letting material flow out of the airlock.  It is best to have the connections for these to be included in the cyclone design and installed once on site.

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

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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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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.

When selecting the cyclone for a dust collection process, there are different factors affecting sizing and cost of the cyclone.  The cyclone should be sized to compliment the airflow of the system and the required dust removal efficiency.  Process conditions will dictate suitable materials of construction as well as any special design requirements.

Part 5: Cyclone Orientation (Horizontal vs Vertical)

The cyclone orientation can affect pricing and cyclone selection.  A vertical cyclone has slightly better removal efficiency than a horizontal cyclone.  Horizontal cyclones are much shorter so they can often fit in spaces where vertical cyclones can’t be placed.  The horizontal cyclone can be accessed easier for cleaning and is easier for installing explosion vents when needed.  However, horizontal cyclones have limitations with high concentrations of dust and cost more than vertical cyclones.

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

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5 Signs Your Dust Collection System Needs a Pre-Filter

Watch the video from the Dust Efficiency Clinic discusses how using a pre-filter will optimize your dust collection system. 

 

If you prefer this valuable information in white paper form, get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-filter.

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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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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.

 

 

Part 4: Application Requirements

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

1. Quick Clean
   
   Quick Clean design allows for the cyclone to be easily accessed for cleaning. It is often used in food and pharmaceutical applications.  These applications usually have a strict cleaning protocol and/or require cleaning between batches.  The design changes required for quick clean design can often significantly increase the price of a cyclone.  Often times it will require redesign of the standard cyclone to allow access and minimize material buildup.  Horizontal cyclones are often best for these situations.
2. Special Welds
   
   Special welds are required in most food applications. The welds are often areas where material can build up and contaminate the material being collected in the cyclone.  To prevent this, the welds are often required to be ground down.  This is a time consuming process and is done individually with power tools.  Depending on the specification, special welds can often significantly increase the price of the cyclone, even as much as doubling the cost.  Often times, the welds will require specific welders in a shop to work on the unit, thereby increasing the lead time and cost.  When you are specifying special welds, it’s often a good idea to have a sample or a picture of the weld you are looking for so the fabricator and end user are on the same page.  See the drawing below for an example of a sample.
3. Special Finishing
   
   Special finishing of the materials of construction is another requirement in many stainless steel applications. Some food and pharmaceutical applications require the metal to be finished or polished to a certain specification.  Usually, the internal finishing is the most critical due to it being in contact with product, but often times the facility has a specification on the external too.  This is often for cleaning and uniformity in the facility.  Special finishing of the metals can often significantly increase the price of the cyclone.  Often times, with the higher finishes allowance has to be made in the pricing for discarding material that doesn’t meet to specification after it has been worked on.

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How Do Horizontal Dust Collectors Work?

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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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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.

When selecting the cyclone for a dust collection process, there are different factors affecting sizing and cost of the cyclone.  The cyclone should be sized to compliment the airflow of the system and the required dust removal efficiency.  Process conditions will dictate suitable materials of construction as well as any special design requirements.

Part 3: Materials of Construction

Cyclone costs are largely dependent on the materials of construction.  They can be constructed of materials from plastics to special alloys such a Hastelloy or Monel.  The materials of construction should be selected based on the process requirements more than costs. 

These requirements include chemical and corrosion resistance, industry standards, and cleanability. Plastic cyclones are not really suitable for most industrial applications.  They can provide low cost dust control for garage woodworking shops and can be used in wet applications, but they don’t usually last long in dry applications and can have issues with static electricity.

The following chart shows relative costs for cyclones based on the material of construction.

 

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5 Signs Your Dust Collection System Needs a Pre-Filter

Watch the video from the Dust Efficiency Clinic discusses how using a pre-filter will optimize your dust collection system. 

 

If you prefer this valuable information in white paper form, get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-filter.

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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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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.

 

 

When selecting the best cyclone for your process, there are many different factors that affect the sizing and cost of the cyclone.  The cyclone must be sized so that it handles the airflow of the system and components.  The proper design for the required removal efficiency must be used.  The process will also dictate the materials of construction and special requirements.  The location where the cyclone will be installed will influence the cyclone orientation.  Cyclones aren’t a stand-alone piece of equipment; support equipment is required for proper operation.  Therefore, the scope of supply will affect the cyclone costs and design.  The following is a brief description of the different elements that affect cyclone sizing and pricing.

Part 2: Dust Removal Efficiency

The main purpose of a cyclone is to remove material from the airstream.  A cyclone will remove a certain percentage of material based on the size of the material.  The larger the material, the higher the removal efficiency of the material will be.  The density of the material also plays a part in the removal efficiency.  Heavier material will see greater removal efficiency. 

Faster air velocity in the cyclone will create greater centrifugal motion and a greater force pushing the material out towards the walls.  What this means is the higher your pressure drop through the cyclone, the greater the removal efficiency will be.  (Assuming the pressure drop isn’t from a badly designed cyclone inlet and outlet) The chart below shows the removal efficiency of a GPC-24 at different pressure drops with material having a specific gravity of 1.0.

Please note the particle shape will also affect the removal efficiency.  Spherical material is the easiest to predict while abnormal shapes are the hardest to predict.    The above chart assumes a spherical dust.

When selecting the cyclone size, you will have to balance the requirement for the highest removal efficiency against the lowest pressure drop.  A smaller cyclone for a specific airflow will provide greater removal efficiency with a lower cyclone cost, but higher operational costs (larger fan due to larger pressure drop).

Specially designed cyclones are available that will increase the material removal efficiency.  Ex. Aerodyne manufactures the SplitStream cyclone.  These special cyclones are more expensive than standard cyclones but usually can provide higher removal efficiency and other benefits beyond standard cyclones.

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5 Signs Your Dust Collection System Needs a Pre-Filter

Watch the video from the Dust Efficiency Clinic discusses how using a pre-filter will optimize your dust collection system. 

 

If you prefer this valuable information in white paper form, get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-filter.

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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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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.