What are the benefits of using a cyclone as pre-filter for a baghouse / cartridge collector?

If you are working with a high value material or product, have high maintenance costs to the baghouse/cartridge collector, or want to avoid cross-contamination, then you should investigate using a cyclone ahead of your baghouse or cartridge collector. The cyclone will allow you to recover the dust without contamination from the filters. The filters in a baghouse or cartridge collector use a dust layer built up on the filters to collect the dust from the airstream. During the process of filter cleaning, dust from this layer is dislodged and falls into the hopper. Any particulate from prior batches can cause contamination of the dust.

A cyclone, on the other hand, collects the dust and deposits it in the hopper continuously. There is very little dust buildup inside of a cyclone. This minimizes the chances of contamination from prior batches. Since there aren’t any filters, a cyclone can be washed or wiped out to remove the prior batch particles.

How does ductwork affect my system?

Ductwork is usually by far the largest component and often the most overlooked. Depending on the size of your system, the ductwork can span hundreds of feet and have dozens of side streams. The ductwork is like railroad tracks, it moves the dusty air from one place to another.

Often times, additional lines will be added to a dust collector system after installation. Without proper evaluation of the system, this could negatively affect the performance of the whole system.

This means that just because the dust collector system was operating correctly before, it might not after an additional pickup point or hood is added. What happens is that when you add additional pickup points, you change the balancing of the system. This could change the airflow to each and every hood and pickup point in the system, so while the system was originally adequately venting an area, it might not after a change.

A few things can be done to address this, such as changing fan speed, adding dampers, modifying ductwork, etc. The main thing you need to keep in mind is that if you slow the airflow through ductwork too much, you begin to build up dust within the line. This will further restrict your airflow and it can become a fire / explosion hazard.

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

Double dump valves are available in both motorized and pneumatic actuation. To figure out which would be better for you we need to consider your application. A double dump valve is really two (2) valves with flapper plates in series controlled by the same mechanism. At least one of the flapper plates is closed at all time. The main things we need to know are the pressure, temperature, and flow rates along with the area classification the double dump valve will go in.

Motorized Double Dump Valve

A motorized double dump valve uses a cam rotated by a motor and gearbox to open and close each of the dump valves in series. The cam is designed so that at least one valve is closed at all time, thereby providing an airlock. The cam also provides a certain amount of cycles each minute, which controls the amount of material that is available to pass through the valve.

Pneumatic Double Dump Valve

A pneumatic double dump valve uses one pneumatic cylinder on each dump valve to control the operation of it. A timer is used to control the cylinders. The timer cycles cylinders so that one valve is closed at all times.

Differences Between Pneumatic and Motorized Double Dump Valve

Pressure - Motorized double dump valves are limited in the amount of pressure they can handle. The cam drive doesn’t provide direct force on the flap plates. This means that higher pressures and weights will push the flap plate open. The pneumatic valve, however, provides direct pressure on the flap plate so it can handle higher pressures and weights.

Temperature – A motorized double dump valve has a gearbox and motor located next to the housing of the valve. At higher temperatures, this can cause issues with the grease in the gearbox and motor. Also, the cam drive uses wear plates that might degrade faster at higher temperatures. The pneumatic valve, however, can be supplied with high temperature seals on the pneumatic cylinder.

Material Flow Rates – Unlike a rotary valve, which is continuously passing material through, double dump valves fill one chamber while emptying the other. This significantly cuts down on the flow rate through the valve. A motorized double dump valve size is limited due to the cam design. A spool piece cannot easily be installed to increase the volumetric flow through each chamber. While with a pneumatic design, each flap plate is controlled by its own pneumatic cylinder, a spool piece can easily be installed to allow additional material to flow through.

Area Classifications – The electrical classification of the area the valve is being installed can also effect the valve selection. A pneumatic valve has very few electric parts and can be designed to be intrinsically safe. A motorized unit has an electric motor, so the motor must be selected to for the area classification.

When selecting the best double dump valve for your application, look at the pressure, temperature, material flow rate, and area classification.

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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 you have a dust collector capturing valuable material, you often have to regularly clean the dust collector to remove the material and if it is perishable, remove it before it contaminates the other material. Some dust collectors are easier to clean than others.

Wet Scrubbers

Wet Scrubbers are pretty much self-cleaning. Since they use water to capture the dust, it pretty much washes the walls and internals regularly. The main issue with wet scrubbers are that if you are trying to use the material (whether in the process or as a product) then you will need to remove it from the water stream (unless having it in a water stream is desirable).

Cyclones

Cyclones are very low maintenance. Since they use centrifugal motion to remove the material, there isn’t much buildup inside the cyclone. So there really aren’t many places to build up. Designing the vessel with access doors will help keep the cleaning easy. Aerodyne’s horizontal cyclone has a unique design that allows you access to the whole cyclone through its back plate.

Fabric Filters

Fabric filters collect the material on the filters (bags/ cartridges). This builds up a layer of material which remains on it for the life of the filter. During cleaning, the material falling off might have recently been captured or material that has been on the filter for an extended period of time. This could contaminate the material being collected.

1. Baghouses require the bag to be removed in order to be cleaned or replaced. Often times this is a very time consuming process and can often require workers to enter the baghouse. If contamination is a serious concern, baghouses should not be used.
2. Cartridge collectors are much easier with replacing the cartridges. Often times this can be done in minutes compared to hours of a baghouse. So you can remove the cartridges, clean them and re-install. This will allow you to clean or replace the filters after each batch, thereby minimizing any contamination.

One option is to install a cyclone dust collector as a pre-filter before your baghouse or cartridge collector. The cyclone will capture the majority of the material without contaminating it for use in your process / product. While the smallest fines will then be captured in the baghouse / cartridge collector for disposal or treatment. This allows you to capture as much of your valuable material with minimal cleaning / contamination while also providing the high removal efficiency for the environment.

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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.

 

 

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.

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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

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.

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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.

 

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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

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.

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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. 

 

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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

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.

 

 

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.

---

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.