The foundry industry, known for its demanding environments and complex processes, requires reliable, efficient equipment to maintain productivity and minimize downtime. Aerodyne Environmental, a leader in industrial air quality solutions, has been serving the foundry sector since the 1970s with innovative products that optimize dust collection and material handling.

Aerodyne’s Legacy in Foundry Innovation

Aerodyne Environmental's journey in the foundry industry began with the Vacu-Valve airlock, a game-changer for dust collection systems. Unlike traditional rotary valves, which are costly and challenging to maintain, the Vacu-Valve offers a simple yet effective solution. The Vacu-Valve's simple design uses the vacuum located in the hopper to seal the hopper from the outside. As material builds up inside the hopper, gravity slowly allows the material to flow through the sleeves, ensuring efficient dust management with minimal maintenance.

The GPC Cyclone: Compact Efficiency for Dust Collection

Dust collection is a critical challenge in foundry operations, especially when dealing with heavy particulate loading. Aerodyne's GPC cyclone stands out with its compact size and unique horizontal design, making it ideal for integration into existing systems. When used as a pre-filter for baghouses or cartridge collectors, the GPC cyclone removes larger particles upfront. This allows the primary filters to focus on finer material, effectively extending filter life, reducing maintenance costs, and improving the overall efficiency of the dust collection system.

Advanced Solutions for Material Handling

Aerodyne offers additional solutions tailored to the specific needs of the foundry industry:

• Vacu-Valve: Cost-effective with minimal operating costs, ideal for non-explosive applications.
• Double Dump Valve: Engineered for low-leakage air locking, this valve ensures effective handling of materials in dust collection systems while maintaining system integrity.
• StopTight Knife Gate: Designed for hopper control, this valve provides a reliable method to regulate material flow, enhancing operational control and efficiency.

The Benefits of Aerodyne Products

Decades of experience and a commitment to innovation establish Aerodyne as a trusted partner for the foundry industry. The products not only address the challenges of dust collection and material handling but also contribute to:

• Cost Savings: Solutions like the Vacu-Valve eliminate the need for expensive rotary valves and reduce ongoing maintenance expenses.
• Enhanced System Performance: By integrating products like the GPC cyclone, foundries can improve the lifespan and efficiency of their dust collection systems.
• Seamless Integration: Compact and thoughtfully designed, Aerodyne’s equipment is easy to incorporate into existing systems, minimizing disruptions during installation.

Conclusion

Aerodyne Environmental continues to set the standard for efficiency and reliability in the foundry industry. With products like the Vacu-Valve, GPC cyclone, Double Dump Valve, and StopTight Knife Gate, foundries can achieve better dust management, material handling, and system performance. These solutions not only help meet operational demands but also provide long-term benefits, ensuring smoother, more cost-effective foundry operations.

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The mining and quarry industries are known for their inherent risks and hazards. For the workers and companies in these fields, safety is not just a priority—it’s a lifeline. Yet, these industries continue to face critical challenges that demand attention, including fire hazards, dangerous dust, and the need to protect both employees and nearby communities. Thankfully, modern dust collection systems are transforming the way we manage these risks, offering safety benefits, environmental protections, and even financial advantages.

The Risks of Inadequate Ventilation and Dust Exposure

One of the most dangerous threats in mines and quarries is the potential for fires and explosions. In enclosed mining spaces, inadequate ventilation can lead to a buildup of flammable gases, creating an environment where even a small spark could trigger a devastating blast. Proper ventilation, combined with reliable dust collection, is essential to controlling these risks.

But the danger doesn’t stop at fires and explosions. Workers are often exposed to dust-laden air that can be hazardous to their health. Inhaling fine dust particles over time can lead to serious respiratory issues, including silicosis and other lung diseases. Silica dust, a common byproduct of mining and quarrying, is particularly harmful and requires careful control to prevent health risks to those on-site. Improving air quality is not only a matter of regulatory compliance; it’s also a key component in fostering a safer, healthier work environment.

The Role of Dust Collectors: A Multi-faceted Solution

Dust collectors serve as an essential solution to many of the challenges faced in mining and quarry operations. These systems work by capturing and removing dust from the air, helping to create a safer and cleaner environment. By allowing dust-free air to be vented outside and drawing fresh air into the mine, dust collectors significantly improve air quality and mitigate the risks associated with dust exposure. This process reduces the likelihood of respiratory issues for workers and helps maintain visibility on-site, which further contributes to safety.

In above-ground quarries, dust collectors are equally important. Here, they control “nuisance dust” that can affect neighboring communities and ecosystems. Dust carried off-site can pollute the air, soil, and water, affecting local environments and potentially leading to health complaints from nearby residents. By containing dust at its source, companies can be better neighbors, fulfilling their corporate responsibility to protect both the workforce and the surrounding areas.

Economic Benefits: Recovering Valuable Materials

Beyond safety and environmental protection, dust collectors also offer economic benefits by capturing valuable materials that would otherwise be lost. Many types of dust collected in mining and quarrying contain recoverable raw materials that can be repurposed or sold. This process not only reduces waste but can also generate revenue, making dust collection systems a valuable investment for mining and quarry operations.

Aerodyne Dust Collectors: Meeting the Unique Needs of Mining and Quarry Sites

Aerodyne, a leader in industrial dust collection solutions, manufactures dust collectors specifically designed for the demanding conditions of the mining and quarry industries. Aerodyne’s GPC (Ground Plate Cyclone) and SplitStream dust collectors offer exceptional efficiency and are available in horizontal configurations, ideal for limited space in underground mining environments.

Click here to download Mining Industry Handbook

Both models are designed to handle challenging dust loads and offer the durability needed for harsh environments. The GPC, for instance, operates with minimal maintenance needs, making it a practical choice for long-term, reliable dust control in mines and quarries. Meanwhile, the SplitStream model is ideal for applications where large particles or heavy dust loads are present, delivering high performance in a compact package.

Dust Collectors as Essential Tools for Safety and Sustainability

With the hazards that mining and quarrying present, investing in reliable dust control systems like those offered by Aerodyne is not just a regulatory requirement—it’s a commitment to safety, health, and environmental responsibility. Dust collectors protect workers, create safer sites, reduce environmental impacts, and offer the added bonus of material recovery, adding to their value. In an industry where safety and efficiency are paramount, dust collectors are an invaluable asset.

For companies looking to enhance their dust management practices, Aerodyne’s tailored solutions can meet the specific demands of the mining and quarry sectors, creating a safer and more sustainable future for the industry.

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When you are dealing with dust collection system, the most important component is having the correct airflow going through your system so that the dust collection is properly done. While this initially appears to be simple it is the most complex part of a dust collection system. To put it simply, every component from the pickup hoods to the exhaust stack affect the airflow going through the system. And any changes, whether deliberate (ex. changing filters) or accidental (filters plugging) the airflow in the system will be affected. The following explains the different components in the dust collection system and how they affect the airflow.

Pickup Points/ Hoods

Most dust collection system have pickup points/hoods that are used to collect the dust by pulling the air around the location into the dust collection system. The amount of air and the profile of the airflow is based on the hood design. Some hoods are located close to the dust source while other hoods are used to pick up dust across a large area. Using the correct hood is very important when you are designing the dust collector. If you are using a hood designed for pinpoint collection but need to collect over a wide area you will not get the dust collection you are looking for. If you use a wide area hood for pinpoint collection you will be collecting more airflow that is required, thereby increasing the size of you dust collection system.

Ductwork

Now that we have captured the dust in our hoods, we must transport the dust from the hoods to the dust collector. Sometimes you located the dust collector right next to the area you are collecting the dust and sometimes it is located all the way on the other side of the facility. Some dust collectors are dedicated to a single area or process while others handle multiple areas (hoods). All of this requires ductwork to transport the air from one place to another.

Click here to get the complete version of the article: Airflow Through a Dust Collection System.

Dust Collectors

There are many different types of dust collectors that you can use in the system. Each of them have certain strengths and weaknesses. The most common are baghouses, cartridge collectors and wet scrubbers.

Baghouses and cartridge collectors use a filter media that builds up dust and prevents the dust from passing. The filters will be periodically cleaned (by shaking or with compressed air). Over time the dust layer will increase, causing the pressure drop across the filters to increase.

There are multiple types of wet scrubbers used for dust collection. The most common are venturi scrubbers and what can be described as cloud chambers. Cloud chambers use high pressure nozzles to create very small particles to make contact with the dust. While venturi scrubbers force the airflow and water through a small diameter section, forcing the water and dust to contact. Afterward both units have mist eliminators and/or packed towers to collect the water droplet.

Auxiliary Equipment and Accessories

The dust collection system might have auxiliary equipment such as pre-filters, HEPA filters, isolation valves, manifolds and control dampers which could affect the airflow in the system. They all could have pressure drops associated with them, which would need to be added to the system total static pressure for the proper airflow to be achieved by the system.

Exhaust Fan

The exhaust fan is usually the motive power behind the dust collection system. And usually the exhaust fan is a centrifugal blower. One of the characteristics of the centrifugal blower is that the airflow produced by the fan is directly tied to the static pressure produced by the fan at a specific speed. Each centrifugal blower has a performance curve which shows what the airflow and static pressure will be.

The main thing to remember is that if for some reason the pressure drop in the system increases, the airflow through the system will decrease according to the fan performance curve. Often times it is a good idea to install a variable frequency drive (VFD) on the fan so that you can adjust the speed of the fan allotting for changes in filter conditions and other process upsets.

So, to summarize, the dust collection system is sized and designed based on the total airflow going through it. Each of the components has an effect on the whole system, which often times are cumulative. Any modification of the system could affect every other piece of equipment, thereby affecting the total effectiveness of the system. As described above, the dust collection at the pickup points are entirely dependent on the airflow going through them. Any upset, modification, maintenance issue, etc. could affect that airflow, thereby causing the dust collector system not to provide the performance it was designed to do. Therefore, constant monitoring of the airflow in the system is the best way to monitor the dust collection system.

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Once you’ve selected and sized your dust collector to meet the specific needs of your application, it’s crucial to address several additional factors to ensure that this vital piece of equipment operates both efficiently and reliably. Whether you’re installing a baghouse, cartridge filter, cyclone, or a combination of these dust collection systems, meticulous attention to detail during both the pre-installation and post-installation phases can significantly impact performance and longevity. Here’s an expanded guide covering essential aspects to ensure a seamless installation and optimal operation of your dust collection system:

Sizing and Placement

1. Verify Dimensions and Fit:
   
   
   • Detailed Measurements: Before proceeding with installation, meticulously recheck the overall dimensions of the dust collector. This includes not only the dust collector unit itself but also the space required for ancillary components such as fans, discharge valves, collection containers, and ductwork.
   • Planning for Future Needs: Consider future expansion or modification needs. If you anticipate additional equipment or changes in the system, ensure that the space you allocate can accommodate these future upgrades without requiring significant reconfiguration.
2. Allow for Maintenance Access:
   
   
   • Routine Maintenance Space: Adequate space around the dust collector is essential for routine maintenance tasks such as changing filters, inspecting components, and performing necessary adjustments. This space should also facilitate safe and efficient work, reducing downtime and improving overall system reliability.
   • Emergency Access: Plan for easy access in case of emergencies. Quick access points can make it easier to address unexpected issues or system failures, minimizing potential operational disruptions.
3. Consider Environmental Factors:
   
   
   • Ventilation: Ensure that the installation location has adequate ventilation to prevent overheating and to maintain the effectiveness of the dust collection system. Poor ventilation can lead to decreased performance and increased wear on equipment.
   • Temperature and Humidity Control: Evaluate and manage environmental conditions, including temperature and humidity. Extreme temperatures or high humidity levels can affect the performance and lifespan of the dust collector, potentially causing operational problems or premature equipment failure.
4. Space for System Components:
   
   
   • Clearances for Components: Account for the space needed for all system components, including bracing, supports, and controls. Adequate clearance helps prevent interference with system operations and facilitates easier installation and future maintenance tasks.
   • Accessibility for Ductwork: Ensure that there is sufficient space for installing and accessing ductwork. Proper ductwork design and installation are critical for maintaining efficient airflow and preventing dust buildup within the system.

Discharge Airlock Valve

1. Select the Appropriate Valve:
   
   
   • Compatibility with Dust Type: Choose a valve that is suited to handle the specific type of dust being collected. For example, abrasive dust may require a valve with durable components, while sticky dust might need a valve designed to prevent clogging.
   • Airlock Efficiency: The valve should provide a reliable airlock to prevent pressure drops within the system. Proper airlock functionality ensures that dust is efficiently removed from the collector without disrupting the overall system pressure.
2. Regular Inspection for Wear and Leaks:
   
   
   • Check for Component Wear: Regularly inspect the valve for signs of wear and tear. Components such as flanges, shafts, and seals should be checked for damage or degradation, as these can lead to leaks and reduced efficiency.
   • Leak Detection: Implement routine checks for leaks around the valve. Addressing leaks promptly can prevent reduced system performance and minimize potential operational disruptions.
3. Evaluate Valve Options:
   
   
   • Automatic vs. Manual: Consider the benefits of automatic valves over manual ones. Automatic valves can provide power and maintenance savings and enhance the consistency of dust removal. They can also integrate with automated control systems for improved efficiency.
   • Power and Maintenance Costs: Analyze the total cost of ownership, including power consumption and maintenance requirements. Automatic valves may offer long-term cost benefits by reducing manual intervention and optimizing performance.
4. Integration with Control Systems
   
   
   • Automation and Monitoring: Integrate the discharge valve with your control systems for real-time monitoring and performance management. Automated systems can provide valuable insights into valve operation, detect issues early, and facilitate proactive maintenance.
   • Data Collection and Analysis: Utilize data collected from control systems to analyze valve performance and identify trends. This information can help in making informed decisions about maintenance schedules and system adjustments.

While these considerations might seem fundamental, neglecting them can lead to significant challenges and increased costs. Addressing the dimensions, placement, and operational aspects of the dust collector and its components with careful planning and attention to detail can enhance the efficiency and longevity of your dust collection system. By prioritizing proper installation, maintenance, and monitoring, you can avoid common pitfalls, reduce downtime, and ensure that your dust collection system remains a reliable and effective component of your process equipment.

Investing time and effort into these preparatory steps will pay off in the form of a smoother installation process, improved system performance, and reduced long-term costs

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A common problem that the dust collection industry faces is that once a dust collection system is installed, the records of the system are often lost or forgotten. Typically, the engineer who designed the system moves to another position or eventually retires, and the details are not passed along to the next person. This lack of continuity can lead to significant challenges when issues develop.

The Challenge of Lost Knowledge

When an issue arises, the new engineer responsible for fixing the problem often doesn't know what the unit was originally designed for or many other critical details. This knowledge gap can complicate troubleshooting and maintenance efforts. Sometimes, the equipment manufacturer has the specifications available, but these records are not always easy to locate. As a result, when experts are called in to help resolve the issue, the system often has to be reverse-engineered.

The Cost of Reverse Engineering

Reverse engineering a dust collection system means dedicating additional time and resources to figure out the original design. This process is not only time-consuming but also carries no guarantee that the recreated design will match the original specifications. Any discrepancies can lead to suboptimal system performance and increased operational costs.

The Impact of Undocumented Changes

Another common issue is that changes made to dust collection equipment are not always documented. Modifications can include adding or removing pickup points, altering ductwork, changing fans, or updating filters. All these adjustments can significantly affect the system's performance. Without proper documentation, these changes can create confusion and hinder effective problem-solving when issues arise.

Best Practices for Documentation

To mitigate these problems, Aerodyne suggests maintaining a comprehensive file that reflects the current design of the dust collection system. This file should include:

• Up-to-date drawings
• Airflow measurements
• Pressure drop data
• Equipment specifications

It's crucial that this file is accessible to multiple people within the facility. This accessibility ensures that if someone leaves or transitions to a different role, the information is not lost. A centralized, easily accessible record-keeping system can significantly improve the efficiency of maintenance and troubleshooting processes.

Implementing a Documentation Strategy

Here are some practical steps to ensure your dust collection system documentation remains current and accessible:

1. Establish a Documentation Protocol: Develop a standardized procedure for documenting all aspects of your dust collection system. This should include creating detailed records of any changes made to the system.
2. Regular Updates: Schedule regular reviews of the documentation to ensure it reflects the current system configuration. Any modifications should be promptly added to the records.
3. Digital Record Keeping: Utilize digital tools and software to store and organize documentation. Digital records are easier to update, search, and share compared to physical files.
4. Training and Awareness: Train staff on the importance of maintaining accurate records and how to access the documentation. Ensure that multiple team members are familiar with the documentation process and location.
5. Backup Systems: Implement backup systems for digital records to prevent data loss. Regularly back up files to secure locations.

Conclusion

Effective documentation is vital for the smooth operation and maintenance of dust collection systems. By keeping detailed and accessible records, facilities can avoid the pitfalls of lost knowledge and undocumented changes. This proactive approach ensures that when issues arise, they can be addressed swiftly and accurately, minimizing downtime and maintaining optimal system performance.

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In industrial settings, dust collection systems are vital for maintaining clean and safe work environments. Most dust collectors are equipped with a motor-driven rotary airlock valve that efficiently empties contents from the hoppers. Rotary valves have been a staple in dust collection technology for many years due to their reliability and effectiveness in managing dust discharge. They offer certain advantages, such as the ability to handle a continuous flow of dust and debris. However, these traditional systems come with several significant drawbacks.

One of the main challenges with rotary valves is the difficulty and time-consuming nature of their maintenance. Cleaning rotary valves is a cumbersome process that often requires system downtime, which can disrupt operations and lead to productivity losses. Additionally, rotary valves operate continuously, regardless of the presence of dust. This constant operation results in unnecessary electricity consumption, leading to increased energy costs.

Moreover, the continuous running of these valves accelerates their wear and tear. Rotary valves can wear out rapidly, especially when handling abrasive materials, leading to frequent and costly repairs or replacements. The need for regular maintenance and replacement parts adds to the overall operating costs, making rotary valves less economical over time.

To address these issues, Aerodyne has developed a highly cost-effective alternative: the Vacu-Valve® Trickle Valve System. This innovative solution leverages the principles of negative pressure within the material handling system to function efficiently without the drawbacks associated with traditional rotary valves.

The Aerodyne Vacu-Valve® Trickle Valve

The Vacu-Valve operates using a simple yet effective mechanism. It features a duckbill sleeve that remains closed under the system's negative pressure. As dust or material accumulates, the pressure forces the sleeve open, allowing the contents to discharge smoothly. Once the material has emptied, the negative pressure immediately reseals the duckbill sleeve, preventing any backflow or leakage. This process repeats as necessary, ensuring efficient and controlled discharge of dust and materials.

One of the standout features of the Vacu-Valve system is its low maintenance requirements. Unlike rotary valves, the Vacu-Valve requires no lubrication, power, or complex controls. This reduces the need for regular maintenance and eliminates the associated downtime and costs. The absence of moving parts that require constant operation means there is significantly less wear and tear, further extending the lifespan of the system.

The Vacu-Valve system is also highly versatile, with a range of duckbill sleeve options designed for specific applications. Whether dealing with fine dust, coarse particles, or abrasive materials, there is a Vacu-Valve configuration to suit the need. Additionally, the Vacu-Valve is available in both open and closed designs, offering flexibility to accommodate various operational requirements.

In summary, the Aerodyne Vacu-Valve® Trickle Valve System represents a significant advancement in dust collection technology. By eliminating the need for continuous operation, reducing maintenance demands, and offering adaptable solutions for different materials, the Vacu-Valve provides a cost-effective and efficient alternative to traditional rotary airlock valves. For industries looking to enhance their dust collection systems, the Vacu-Valve offers a reliable, economical, and low-maintenance solution.

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One challenge to designing a manufacturing process is choosing an effective dust collection system that will fit the limited available plant space. Low ceilings pose a challenge for high-efficiency cyclones due to their long-tapered bodies. In many cases, the dust collector must be placed outdoors or partially protruding through the roof. This can be an unfavorable arrangement.

Counter-cyclonic dust collectors, such as the Aerodyne SplitStream™ Dust Collector, use a secondary air stream that directs material toward the collection hopper, and may be installed horizontally with virtually no loss of efficiency.

As the dust-laden gas stream is drawn into the collector, it passes through a stationary spinner which imparts a rotational flow and forces particulate toward the walls of the collector. A powerful secondary air stream is injected into a manifold where it enters the separation chamber through a series of nozzles. The secondary air stream intercepts the collected particulate and carries it to the hopper. Because this design does not rely on gravity to bring the dust to the hopper like conventional cyclones, its operational efficiency is not affected by horizontal installation.

 

This type of dust collector may be suspended from a ceiling, conserving valuable space on the manufacturing floor. It also saves money compared to cutting a hole through the roof or building a site for the dust collector outdoors. Outdoor installation may also encourage condensation that can shorten service life and reduce efficiency. Finally, horizontal, high-efficiency cyclones may be maintained without the need for tall scaffolding that can pose a safety hazard to workers.

 

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For the past several decades, industrial facilities in a wide variety of industries have deployed dust collection systems as part of its manufacturing process. As technology and filtration techniques have improved, these systems have changed and evolved to become more sophisticated, and at times complex.

Dust collectors are used in many industries to improve air quality and remove harmful particles from the air. There are several types of dust collectors that are commonly used in industrial and commercial settings. Here are some of the most common types:

Baghouses

A baghouse consists of a vessel with many filters (bags) inside. The bags are located in rows and mounted on a tube sheet. The tube sheet separates the dirty air from the clean air. Dirty air enters the bag house near the bottom. The dirty air is forced through porous bags which have a built-up filter cake. Clean air goes through the filter/bag and leaves through the top of the vessel, while the dust falls down to be discharged through the hopper.

Cartridge Collectors

Cartridge collectors operate similar to baghouses except they use pleated cartridges to provide much higher surface areas in smaller filter volume than bag filters.  This means they are much smaller than baghouse for the same air volume.  However, the cartridges have lower temperature limits and can plug easily. They are used in the following applications: grinding, sandblasting, welding fumes, laser and plasma cutting fumes, graphite, pharmaceutical powders, acid fine chemical powders, and more. When dusts are difficult to handle, hygroscopic, or high temperature, a baghouse is a better alternative for trouble free dust collection and longer filter life.

 

Cyclone

The cyclone is the simplest design of all dust collectors. It is a mechanical way to remove dust from an air stream. The cyclone uses centrifugal and gravitational forces to force the dust to the vessel walls and then let gravity collect it. The cyclone requires only a discharge valve and fan for operation. Cyclones require very little maintenance. Cyclones are often used as prefilters for other dust collectors.  They can provide high removal efficiencies of larger dust particles, thereby decreasing the loading on the main dust collector, this can increase total removal efficiency, decrease system maintenance and extend equipment life, not to mention collect material before contamination.

ESP (Electro Static Precipitator)

ESPs use high voltage to electrically charge particulate in the air. The charged particulate is collected on charged plates as the air stream passes. ESPs use large amounts of electricity and can get collection efficiencies as high as 99% for many applications. ESPs provide good removal of sub-micron particulate. ESP are expensive and require high operating and maintenance costs.

Wet Scrubbers

Wet Scrubbers are available in a variety of designs including cyclones, venturi, packed towers, cloud chambers and fluidized beds. Wet scrubbers spray water into the dirty airstream allowing dust and water droplets to contact, thereby making them easier to collect.  Wet scrubbers have high removal efficiency but can be expensive to operate and treat the slurry leaving. The wet cyclone is just like a regular cyclone except that they spray water in the cyclone.

 

 

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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.

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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.

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