Dust Collection and Valves Blog

Aerodyne Vacu-Valve ® vs. Traditional Rotary Valve | Aerodyne

Posted by Tom Hobson on Sep 30, 2019 2:15:00 PM

Do the rotary valves under your dust collectors cause maintenance headaches?  Are they clogging?  Are you having to drop everything and assign extra labor to fix them?

The disadvantages of Rotary Valve

Most dust collectors are equipped with a motor-driven rotary airlock valve that empties contents from the hoppers. Rotary valves have been used for many years and are probably the most widely used airlock design. However, maintaining rotary valves is difficult and time consuming. These valves run continuously, regardless if dust is present, which leads to wasted electricity. In addition, the valves can wear out rapidly, resulting in costly repairs and replacements.

Best Alternative: Aerodyne Vacu-Valve ®

A highly cost-effective alternative is Aerodyne’s Vacu-Valve ®  Trickle Valve System. The Vacu-Valve relies on the negative pressure of the material handling system to hold the duckbill sleeve closed. As the dust or material builds up, the sleeve is forced open, allowing the contents to discharge. Once emptied, the negative pressure then immediately closes the duckbill again. This trickle valve system requires no lubrication, power, or controls. Materials that would normally jam or wear out a rotary airlock valve, the Vacu-Valve handles with ease. There is a variety of duckbill sleeve options designed for specific applications; and the Aerodyne Vacu-Valve ® is available in an open or closed design, to further accommodate the particular application.

Aerodyne’s Vacu-Valve ® is the solution! Have a look at this infographic and to learn how the Vacu-valve solves these issues and improves the discharge efficiency of your baghouse, filters and cyclones.

Vacu-Valve is a Simpler Solution

 


How Do Vacu-Valve Dust Valves Work?



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



To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, rotary valves, trickle valve, airlocks, airlocks valve, aerodyne vacu-valve

Horizontal Cyclones: Solution to Space Limitation | Aerodyne

Posted by Tom Hobson on Sep 30, 2019 10:30:30 AM

If you are like many plant engineers who are working within the confines of a limited work space, rest assured that you don’t need to compromise on the efficiency of your industrial dust collection system. A traditional, high-efficiency cyclone is not the best solution for facilities with low ceilings.

Space Limitation

If space limitations prevent you from properly orienting this type of cyclone in an upright position, this will result in a loss of efficiency due to particulate settling on the side of the collector and being carried out with the exhaust gas. Attempting to solve this problem by installing your vertically oriented dust collection cyclone outdoors may encourage condensation that can shorten service life and reduce efficiency.

Horizontal Cyclones

Today, more plant engineers are choosing a horizontal configuration for reliable, high-efficiency dust collection. These options include the Aerodyne GPC Cyclone and counter-cyclonic dust collectors, such as the Aerodyne SplitStream™ Dust Collector.  The SplitStream™ Dust Collector uses a secondary air stream that directs material toward the collection hopper, and may be installed horizontally with virtually no loss of efficiency.

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. In addition, this type of dust collection system may be suspended from a ceiling, conserving valuable space on the manufacturing floor.

The SplitStream™ Dust Collector the ability to increase/decrease process temperature while collecting dust. The unique counter cyclonic design element of the SplitStream™ Dust Collector ensures that a minimal amount of particulate comes in contact with the interior walls. This eliminates excessive wear and enables abrasive particulate collection.

 


How Do Horizontal Dust Collectors Work?



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



To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, NFPA 652, horizontal cyclone, GPC Cyclone, splitScream Cyclone, arirflow

Level Switches in Dust Collector Hoppers | Aerodyne

Posted by Tom Hobson on Aug 30, 2019 8:23:41 AM

As maintenance staffs become smaller and have less time to do preventative maintenance, technology needs to step in and help. 

Level Switches

That is where level switches in dust collector hoppers fit in.  An airlock works by allowing dust from the dust collector to leave the vessel while preventing air from leaking in or out of the system.  Some airlocks operate by emptying the hopper as soon as dust falls and some require a buildup above them to help seal the valve and provide motive force. 

The main thing is, that dust often times will not constantly be falling through the valve.  This means that walking next to a vessel won’t always tell you if the airlock is operating correctly. 

Installing a level switch in the hopper will help.  The level switch measures the amount of material in the hopper and if too much is in the hopper it will provide a signal (alarm).  This will tell maintenance that the airlock is not operating correctly and it needs to be investigated.  Depending on the system’s controls, the alarm can be a local alarm (light and/or horn) or feed into the central computer.


Dust collection systems can range from being fairly simple to extremely complex. 

It’s important to know that you have the proper system for your application. Some questions always come up when looking at dust collection systems.

To make life easier, we have put together some common questions we get asked along with answers and explanations. Have a look.

Volume 1: Get FAQ Now 

Volume 2: Get FAQ Now

 


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


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, airlocks, explosive dust, maintenance cost, arirflow, lead switch

Heavy Dust Loading Leads to High Maintenance in Dust Collector | Aerodyne

Posted by Tom Hobson on Aug 23, 2019 3:31:39 PM

Heavy dust loading in the dust collector leads to high maintenance dust collectors.  Since most dust collectors are fabric filters (baghouse, cartridge collectors, shakers, etc.), heavy dust loading will cause/require high frequency of cleaning of the filters.  Most filters are cleaned by injecting high pressure air into the clean side, causing the filters to expand a bit.  This causes dust to fall off the filters.  Filters wear out due to the frequent expanding and contracting.  So the more often you have to clean a filter, the faster the filters will wear out.

Pleated Filters

This is made even worse if the filters are pleated.  Pleated filters have valleys and ridges which increase the surface area available for air to diffuse through the filter.  However, high dust loading can cause the pleated filter valleys to fill up and not properly clean during a cleaning cycle.  This will severely restrict the surface area available for airflow, which will lead to higher velocities through the filters.  A higher velocity increases the chances of dust getting through the filters.  This can cause holes to develop in the filter.  It can also cause dust to plug a pathway through the filter, thereby further restricting airflow.  It can also cause a decrease in removal efficiency.

So if you have high dust loading in your dust collector, it might be beneficial to install a pre-filter to increase filter life and make maintenance much less of a hassle.


Pre-filtering may reduce operating and maintenance costs by extending bag or filter life and improving removal efficiencies. This video discusses five warning signs that your dust collection system needs a pre-filter.

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

Get Whitepaper


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



To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

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Topics: dust collector, combustible dust, NFPA 652, explosive dust, heavy dust loading, maintenance cost, arirflow

Is Your Dust Explosive? | Aerodyne

Posted by Tom Hobson on Jul 31, 2019 9:45:00 AM

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.

Combustible Dust Testing

Unless you know for sure that your dust isn’t combustible, you should send the dust sample to a lab for testing. The lab will provide one of three responses – no reaction, combustible but not propagating, or propagating. 

Usually the lab will initially do a Go/ No-Go test. If the dust doesn’t exhibit combustion, the testing will stop. If it does exhibit combustion, they will then do further tests and provide explosion properties ( Kst and Pmax) of the dust. The Kst tells you how quickly the explosion will propagate, while Pmax tells you the power behind the event.

 

Common Knowledge about Combustible Dust

  1. A combustible dust mixed with non-combustible dust may or may not pass the go / no-go test; therefore, if you have both in a mixture, get a test.
  2. Material that may not burn can still be combustible as a dust, unless you know for sure, getting a test is the safe bet.
  3. If you have made a process change that changes the composition, relative concentrations, etc. of the dust, then the combustibility of the dust may have changed and a new test should be done.
  4. If you have combustible dust in your facility, then a hazard analysis of the area must be done every five years.

 


Dust Collector FAQ Volume 1

To make life easier, we have put together some common questions we get asked along with answers and explanations. Have a look.

Get FAQ Now


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


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

Free Consultation

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Topics: dust collector, combustible dust, NFPA 652, explosive dust

Why You Need Space Saving Pre-filter Cyclones | Aerodyne

Posted by Tom Hobson on Jul 19, 2019 10:33:59 AM

As regulations to minimize dust emissions became more stringent, the reliance on filter media became more prevalent.  This means baghouses and cartridge collectors have become the most common dust collectors around. 

Dust Collector Filter

The filters allow air to pass, while dust is captured on the filter surface area.  A filter cake of dust forms, allowing the highest removal efficiency of the filters.  Periodically, the filters will be cleaned to drop dust off the filters/ filter cake, allowing more air through the filters.  The higher the concentration of dust, the faster the filters will require cleaning to keep the pressure drop down.  Every time the filters are cleaned the fabric of the filter wears a bit.  So, if you can minimize the cleaning, then the filters will last longer.

Cyclone Pre-Filter and Dust Collector Filter

Cyclone pre-filters capture a high percentage of the dust before it even gets to the filters; therefore, allowing less clean cycles on the filter media.  Cyclones use centrifugal force to capture dust and droplets and remove them from the airstream.  Unlike filters, the higher the concentration of dust in the airstream, the better the cyclone performs.  Cyclones provide very good removal of larger dust particles, often getting removal efficiencies as high a 99% for 30-40 micron dust particles.  But they do remove lower amounts of smaller particles.  So the cyclone is a perfect companion for dust collection filters as they will remove most of the larger particulate.  This can often be 80-90% of the total dust loading of a system by weight.  The cyclone pre-filter then allows the filters to deal with only the fine dust that gets past the cyclone.  The lower loading of dust on the filters allows the filters to last longer and conserve energy as the cleaning cycle isn’t used as much.

Compact Cyclones

Compact cyclones, such as the Aerodyne GPC, allow cyclone pre-filters to be used in existing facilities where larger (taller) cyclones won’t fit.  The Aerodyne horizontal GPC cyclone provides one of the most compact designs - often ⅓ the height of traditional cyclones.  This can often allow the cyclone to be installed inside or in smaller areas of an existing system.  Traditional cyclones typically require outdoor installation, unless the facility has high ceiling.

So if your filter dust collection system is experiencing operational issues, look into compact cyclone pre-filters as a possible solution before you decide to scrap your current unit and install a new one.

 


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. 

Watch Video

 


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


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

Free Consultation

 

 

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Topics: dust collector, Dust Efficiency Clinic, compact cyclones, Dust Collector filters, Cyclones pre-filter

Mini DHA for Adding Cyclone to Compliant System | Aerodyne

Posted by Tom Hobson on Jun 25, 2019 9:42:09 AM

Not only do NFPA regulations require a DHA (Dust Hazard Analysis) to be done on all systems that might have explosive dust, they also require the DHA to be updated every 5 years and whenever the system changes. 

Simple Changes in Documentation

The change can be adding , removing,  or changing equipment or changes in the material going through the system. 

Since a DHA has already been done, the scope of the change is much less.  Using the information in the original DHA, the equipment that is being changed can be analyzed to make sure it complies with NFPA.  This report will then be added to the existing DHA so that a record of change is documented.  Usually the report is considered a mini-DHA or System DHA. 

The mini-DHA or System DHA often can be conducted by a 3rd party consultant working with the equipment manufacturer.  This usually can be done without a site visit.  Aerodyne offers the Mini-DHA/ System DHA for our cyclone separators.

 


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

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

Get Webinar Now

 


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


To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

Free Consultation

 

 

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

How Do I Inspect My Dust Collection System? | Aerodyne

Posted by Tom Hobson on Jun 21, 2019 11:49:43 AM

We all know that getting the oil change in our car regularly is important to the car being able to get you around when you need it.  However, your dust collector needs regular maintenance too.  The dust collector system consists of hoods, ductwork, air-material separators (cyclones, baghouse, cartridge collectors, wet scrubbers, etc.), explosion protection equipment, airlocks, instrumentation, and exhaust fans. 

All of these items should be checked at least once a year to make sure they are operating correctly.  The following points briefly describe what each piece of equipment needs:


1. Hoods

  • Visual inspection to make sure they haven’t been damaged during the year.
  • Measure airflow velocity to make sure they are collecting the design airflow.
  • If a local damper is located by hood for balancing, make sure it is operable and in the correct position.

2. Ductwork

  • Visual inspection to make sure no holes have developed.
  • Measure air velocity through ductwork to make sure designed airflow is correct.
  • If possible, visual inspection of duct internal to make sure dust isn’t building up.

3. Air Material Separators

  • Measure pressure drop across the separator to see if it is within parameters.
  • Inspect cleaning process (baghouses and cartridge collectors) that they are operating properly (timing, valves opening, air pressure, etc.). See operations and maintenance manual.  Often time, listening to the system will let you know if it is operating correctly.
  • Monitor recycle line pressure and overflow in wet scrubbers.
  • Visual inspection of vessel walls to be sure there are no holes.

4. Explosion Protection Equipment

  • NFPA requires yearly inspection, following the manufactures manual is very important so the explosion protection equipment will protect the facility, equipment, and workers as it was designed.
  • Some explosion protection equipment such as chemical suppression should be done by factory trained personnel.

5. Airlocks

  • Rotary valves
    • Should be checked to see they are still spinning
    • Bearings should be greased and temperature measured to make sure they aren’t overheating
    • On explosive applications the rotor clearance should be measured to make sure it still complies with NFPA 69.
  • Pneumatic valves (slide gates, double flap valves, etc.)
    • Valves should be tested to make sure they are still operating as designed.
    • Air pressure should be measured, to be sure it is still within design parameters.
  • Motorized valves (rotary valve, double flap valves, etc.)
    • Bearings should be greased
    • Bearing temperature should be measured to be sure they aren’t overheating
  • Trickle valves
    • The sleeve should be inspected to be sure it is still sealing
    • During operation confirm that material is still draining and material hasn’t bridged above it.

6. Instrumentation

  • Level gages, pressure gages, VFDs, pH meters, zero speed switches, etc. all have different maintenance requirements.
  • Follow the manual of the specific model for maintenance and inspection.

7. Exhaust Fans

  • The fan housing should be inspected to make sure no holes are present.
  • The voltage and amps should be measured to make sure it is operating at its design condition.
  • The bearings should be greased and temperature checked to be sure they aren’t overheating.
  • The fan’s vibration should be checked along with checking to see if any abnormal noise is emanating from the fan.

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

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click below to start with a free 20-minute phone consultation by clicking the button.

Free Consultation

 

 

Click below and watch our video to identify five signs that may diagnose a sluggish system so that you can return your system to full efficiency.

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Topics: dust collector, airlocks valve, Dust Efficiency Clinic

Importance of Keeping Dust Collector Records | Aerodyne

Posted by Tom Hobson on May 31, 2019 8:30:00 AM

 

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Topics: dust collector, dust collector records keeping

Dust Efficiency Clinic Helps Facilities Get into Compliance | Aerodyne

Posted by Tom Hobson on Mar 28, 2019 9:15:00 AM

OSHA-AerodyneOSHA is issuing citations and fines to companies with unsafe combustible dust hazards, using their general duty clause and NFPA 652: Standard on the Fundamentals of Combustible Dust as a guideline. Any industrial facility that creates dusts or uses powders was mandated by NFPA 652 to complete a Dust Hazard Analysis by September, 2020 to identify the presence of combustible dusts and establish a plan for eliminating or mitigating potential risks associated with these dusts in their facilities. The DHA is essentially the framework around which NFPA 652 is built, and the starting point for getting a facility into compliance with the standard as a whole.

Dust Hazard Analysis (DHA) Complexity

The complexity of performing a DHA varies with the complexity of the facilities and processes being analyzed.  For instance, a small wood cabinet making shop with a limited number of dust generating machines will present a less daunting task than a large scale manufacturing facility that use powdered raw materials and performs cutting and grinding of its finished product. It should also be noted that performing a DHA should not be viewed as a “one and done” procedure that is completed and forgotten. As new processes or raw materials that have the potential for impacting a facility’s combustible dust profile are introduced in the facility, the DHA needs to be modified to incorporate these changes accordingly.

Dust Hazard Analysis (DHA) Preparation

Dust Efficiency Clinic-DHA

Preparation for a Dust Hazard Analysis can also be incorporated into a more comprehensive review of a facility’s dust collection system that examines overall system design, efficiency, and safety. Aerodyne Environmental’s Dust Efficiency Clinic offers dust collection system evaluation services that do just that. An Aerodyne dust collection specialist will review a facility’s equipment, installation, controls, and protective devices with an eye toward improving overall system performance, decreasing maintenance costs, prolonging equipment life, and improving safety and regulatory compliance.

Dust Hazard Analysis (DHA) Report

At the end of the system review, a report is generated that summarizes the existing state of the dust collection system and offers targeted suggestions for areas that can be improved. This valuable service offers facility and plant managers outside expertise in boosting the performance and safety of their systems, and is a logical first step in preparation for a DHA.

To learn more about Aerodyne’s Dust Efficiency Clinic consulting services, call Dan Navicky at (440) 543-7400 or tollfree at (800) 358-7546, or email dc@dustcollectorhq.com.

 

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Topics: dust collector, compliance

Aerodyne Environmental: Home of the Horizontal Cyclone and  Vacu-Valve® Airlock Valve

Inspired To Be Different.

At Aerodyne, we choose to take a different approach to collecting dust and handling materials. Our cyclones are unique in design to address common issues such as problematic dusts and space constraints. Our airlocks are chosen to fit your specific application instead of hastily installing traditional equipment options. We believe that when we see things differently, we can solve problems effectively. That's why so many people turn to us for help in solving their tough dust problems.

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