Dust collectors are vital components in many industrial settings, responsible for maintaining air quality and ensuring the safety of workers. However, despite their importance, some companies hesitate to replace their aging dust collection systems. In this blog post, we'll delve into the reasons behind this hesitation and explore why upgrading dust collectors is crucial for both worker safety and operational efficiency.

Cost Concerns

One of the primary reasons companies avoid replacing dust collectors is the perceived cost. Purchasing and installing a new dust collection system can indeed involve a significant upfront investment. However, it's essential to consider the long-term savings and benefits, such as improved efficiency, reduced maintenance costs, and compliance with regulations.

Lack of Awareness

In some cases, companies may not fully understand the importance of modern dust collection systems or the potential risks associated with outdated equipment. Educating decision-makers about the benefits of newer technologies, such as advanced filtration systems and energy-efficient designs, can help dispel misconceptions and encourage investment in upgrades.

Maintenance Overhaul

Over time, older dust collectors may become less effective due to wear and tear, leading to increased maintenance requirements and downtime. Some companies opt to continue repairing and maintaining existing systems rather than investing in replacements. However, constant repairs can be costly and may only provide temporary solutions. Upgrading to a newer model can reduce maintenance needs and improve overall reliability.

Regulatory Compliance

Regulations governing air quality and workplace safety are continuously evolving, placing greater emphasis on the need for efficient dust collection systems. Outdated equipment may struggle to meet current standards, putting companies at risk of non-compliance and potential fines. Investing in modern dust collectors ensures adherence to regulations and protects workers from exposure to harmful airborne particles.

Performance Limitations

As industrial processes evolve and production volumes increase, older dust collectors may struggle to keep up with the demand. Inefficient filtration, inadequate airflow, and outdated control systems can lead to decreased performance and compromised air quality. Upgrading to a newer model with enhanced capabilities can optimize dust collection efficiency and support growing operational needs.

While the decision to replace dust collectors may initially seem daunting, the benefits far outweigh the challenges. By investing in modern, efficient systems, companies can improve worker safety, enhance operational efficiency, and ensure compliance with regulations. Overcoming cost concerns, increasing awareness of the importance of dust collection, addressing maintenance issues, and prioritizing performance upgrades are essential steps in safeguarding both workers and business operations. Ultimately, embracing technological advancements in dust collection is a proactive measure that pays off in the long run, promoting a safer and healthier work environment for all.

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.

In industrial processes, the value of efficient material recovery is an important aspect and emphasizes the pivotal role that cyclonic dust collector technology plays in the recovery of highly valuable materials during production. One noteworthy example highlighting the significance of this technology in the manufacturing of active pharmaceutical ingredients (API), particularly in the context of drying systems.

Traditionally, bag or cartridge filters have been used in most dust collection applications. However, in API production, such conventional filtration methods can create issues such as potential contamination problems causing production delays. The use of cyclonic dust collectors can eliminate these issues.

Specialized Design for Exceptional Efficiency

The cyclonic dust collector is designed to collect fine, low-density particles in applications like API production. Efficiency and reliability make dust collecting cyclones a logical solution for the recovery of highly valuable materials. Unlike traditional filters, the counter-cyclonic technology prevents contamination and possible delays providing a more efficient production process.

Boosting the Bottom Line through Increased Efficiency

There is a direct correlation between the efficiency of material reclamation and cost saving. In industries where process materials are expensive even minimal waste can be costly. The design of cyclonic dust collectors enhances the efficiency of product reclamation.

In the realm of API manufacturing, process consistency is essential. The use of cyclonic material collection technology allows the effective recovery of valuable material lost during operation. The result is a smoother production process minimizing valuable material loss contributing to the overall profitability of an operation.

Economic Advantages: Minimal Maintenance

Apart from impressive efficiency, a cyclonic dust collector offers other cost savings to a process operation. Unlike filtration systems that rely on bag or cartridge filters, cyclonic collectors have no moving parts. This simplifies operation while minimizing maintenance cost.

The GPC™ cyclonic dust collector also offers a hinged door for additional cost savings on the horizontal designed unit. The optional door provides cleaning access to the collector’s interior versus more traditional cyclones.

Versatility and Ease of Installation

The GPC™ cyclonic dust collector provides versatility offering either vertical or horizontal orientation to adapt to possible space constraints and operational setups.

This versatility not only makes the installation process smoother but allows integration of the collector into existing production processes. The result is businesses can utilize the benefits of advanced dust collection technology without significant changes to ongoing operations.

In conclusion, for businesses engaged in the processing of high-value materials, like API manufacturing, investing in advanced dust collection technology it is a strategic move that can positively impact production efficiency and maintenance cost. GPC™cyclonic dust collectors offer technological advantages beyond traditional filtration methods, offering exceptional efficiency, minimal maintenance requirements, and unmatched versatility in installation particularly in industries where the recovery of highly valuable materials is critical.

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.

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

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

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

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

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

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

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

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

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

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.

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

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

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

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

What is a cyclone dust collector?

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

What is a cyclone pre-filter?

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

Why install a cyclone pre-filter?

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

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

Signs You Need a Pre-Filter

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

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

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

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.

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

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

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

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

Cyclones

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

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

Filter Collectors

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

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

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

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.

1. Use pulse-on-demand controller for baghouse and cartridge collectors
   
   Pulse-on-demand controllers allow you to clean your filter less often. Less pulses helps you save compressed air and reduces wear and tear on the filters. Cutting down on compressed air means less electricity is required in the compressors and less wear and tear on the filter means they last longer.
2. Install a cyclone pre-filter
   
   A cyclone pre-filter will help remove dust before it gets to your filters. This means that the dust loading on the filters will decrease, which helps extend their life by requiring less cleaning and plugging them up less. The cyclone can also allow you to recycle the material without contamination and possibly increase the total removal efficiency of the system.
3. Monitor airflow in the dust collection system
   
   Dust collection systems are designed to capture dust and they should be operating at design specifications. By monitoring the airflow, you are confirming that the unit is operating correctly. If the airflow is off from its design condition, then you will not be capturing the material that it was designed to capture. Measuring the airflow is similar to measuring the temperature in an oven. Without measuring it, you won’t know if you are at the correct performance and the end result may be off.

4. Install Aerodyne Vacu-Valve (if appropriate)

Dampers are used in dust collection systems to control the airflow to specific branches of the ductwork.  This is done by opening or closing the damper.  Air, like water, travels the path of least resistance.  By using a damper, you are changing the resistance to the air.  Every dust collection system should have a manual damper near each hood/pickup point to balance the system.  This makes sure that the system is properly operating.  An unbalanced system could cause too much air to be pulled from one area (causing loss of product) while in another area not enough airflow is available to capture dust.  Other times, a soft connect (space between flanges) is used to control airflow at a pickup point.  However, this isn’t very efficient.  This keeps the airflow in that area constant, but it’s picking up air from an area where it isn’t required.  A damper would work much better, since you are only moving the air in the area you need.  Soft connects are only advantageous when you are looking to cool down an airflow using outside air.  Dampers can also be used to shut off portions of the system that are not being used, thereby allowing a smaller system.

So when you are looking at your dust collector system, don’t forget dampers.  They allow you to optimize your system.

If you are having operational issues on your dust collection system, contact Aerodyne at 440-543-7400 or dc@dustcollectorhq.com.

Dust collection systems consist of four major items.  All of them are important and can cause a dust collection system to underperform.  The major items are the exhaust fan, dust collector, ductwork, and hoods/pickup points.   While the exhaust fan provides the motive power to collect the dusty air, its performance is affected by each of the components.  This means that if one of the other components isn’t operating as designed, the whole system will be affected.  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 become a fire / explosion hazard.

So when you are looking at changing your dust collector system, review the system parameters or hire someone to review so that you do not cause additional issues.

Learn about the questions you should be asking to make sure you're buying the right dust collector for your application. Get your whitepaper now.

If you are having operational issues on your dust collection system, contact Aerodyne at 440-543-7400 or dc@dustcollectorhq.com.

Now in its third year, Ceramics Expo is the world's largest annual free-to-attend expo for the advanced ceramic and glass community.

The massively expanded event stands as a unique showcase for all the latest start materials, industrial equipment, technical ceramic components, processing expertise, analysis and testing devices, thermal technologies and precision finishing systems that keep this sector at the forefront of manufacturing advances.

Due to its tightly focused approach and by maintaining a close relationship with all core stakeholders, Ceramics Expo guarantees the participation of respected and innovative suppliers. As the premier US ceramics exhibition, it draws in thousands of genuine decision makers and aims to set the agenda for ceramics manufacturing and applications.

Aerodyne Environmental's industrial dust collection products feature unique, low-maintenance designs that will enhance the performance of your processing operations. Our industrial dust collectors, which work horizontally or verticaly, can extend the life of your baghouse or cartridge filters. And, Aerodyne offers a variety of durable material handling valves for every application, including the Vacu-Valve Trickle Valve System, a cost-effective solution to rotary valves.