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

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.

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

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

 

 

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

Part 3: Materials of Construction

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

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

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

 

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5 Signs Your Dust Collection System Needs a Pre-Filter

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

 

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

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

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

 

 

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

Part 2: Dust Removal Efficiency

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

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

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

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

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

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5 Signs Your Dust Collection System Needs a Pre-Filter

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

 

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

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

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

 

 

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

Part 1: Airflow and Pressure Drop

The most basic (and important) thing that affects the sizing of a cyclone is the airflow the cyclone will see.  Cyclones are a mechanical separator without any moving parts.  They are designed in such a way that the more air you put through the cyclone the greater the pressure drop the air will experience going through the cyclone.  To understand this better, a quick review of how a cyclone works will be beneficial. 

Air enters a cyclone near the top of the cyclone.  The inlet is designed so the air will rotate around the walls of the cyclone heading down towards the hopper.  This creates centrifugal forces which send the heavier, larger particles out towards the walls.  Once the air gets down to the hopper, the air goes through a process called vortex reversal.  This means the air turns 180° and goes up through the middle of the cyclone.  The air outlet is located on top of the cyclone.  Often times, the air inlet of the cyclone is located on the tangential, while the cyclone outlet pipe helps form the centrifugal motion.

The greater the airflow through a cyclone the higher the pressure drop the cyclone will have.  So a cyclone will have different pressure drops for different airflows through it.  The pressure drop is not dependent on material loading or cleaning cycles.  The chart shows the pressure drop an Aerodyne GPC-24 will have at a variety of airflows.

 

When picking a cyclone for your application, you will have to figure out what pressure drop you want through the cyclone.  With a lower pressure, you will have a smaller fan and larger cyclone.  Smaller fans will have lower initial and operational costs while larger cyclones have greater initial costs.

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5 Signs Your Dust Collection System Needs a Pre-Filter

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

 

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

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

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

 

 

When sizing a cyclone dust collector, there are many factors that have to be reviewed in order to pick the best model for your applications. Some of them are:

Airflow

What is the airflow going through the cyclone?  The cyclone size is directly tied to the amount of air going through it. The more air there is, the larger the cyclone required.  Without a doubt, this is the most important requirement for sizing a cyclone.

Temperature & pressure

The airflow volume is based on the temperature and pressure by the ideal gas law.  The cyclone need to be sized based on ACFM (actual).  Often times, customers provide SCFM (standard), which is the airflow when the temperature and pressure is 70°F and 1 atmosphere.  If SCFM is provided, then it needs to be converted to ACFM for the correct cyclone to be selected.  If not, the cyclone might be undersized, thereby increasing the pressure drop in the cyclone significantly, which can cause airflow issues.

Dust

The actual dust being collected also affects the cyclone selection.  Is the dust explosive?  What removal efficiency do you require?  What is the dust’s physical characteristics, such as does it bridge, is it sticky, is it abrasive?  All-of-these can affect the design of the cyclone.  Example, a dust that bridges might have a special hopper to help prevent bridging.

Location

The location where the cyclone will be installed has a great influence on the cyclone selection.  Is it located indoors or outdoors?  How much space is available?  Is there a height restriction? Will a vertical cyclone fit or must a horizontal cyclone be used.  Is the cyclone being used as a pre-filter or is it the final dust collection equipment? 

Fan

If this isn’t a new application, the static pressure the fan has available is extremely important.  The fan must have enough static pressure to overcome the pressure drop of the cyclone without decreasing the airflow through the system.  This may require modifying the fan, replacing the fan or installing a larger cyclone.

Material of Construction

The cyclone must be constructed of the proper materials so it doesn’t rust or react with the material going through it.  Often times the MOC will be carbon steel or a stainless steel.  Special material of construction might be used, or a coating is applied (either internal or external) to extend the cyclone’s life.

Special considerations

There are additional things that may need to be considered when selecting the cyclone.   Some examples include does it need to be cleaned often, so quick access is required?  Are special welds, material finishing, etc. required?

These are some of the main considerations that are taken into account when a cyclone is sized for a dust collection system.

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The GPC Dust Collector is an efficient way to handle your dust collecting needs.

Simply click the button below to find out more about the advantages and the specifications of the Aerodyne GPC Dust Collector.

 

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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.

 

 

A cyclone pre-filter offers multiple benefits to your dust collection system. One of these benefits and easiest to observe is extending filter life.

How Do Cyclone Dust Collectors work?

Cyclone dust collectors remove dust by using centrifugal motion.  The airflow enters the cyclone and spins around until it reverses and leaves the cyclone through the center of the vessel.  As the airflow spins, centrifugal motion pulls the dust towards the wall, leaving cleaner air in towards the center of the vessel.  So when the airflow reverses, the dust falls into the hopper while the clean air leaves through the center of the cyclone.

The larger and heavier a dust particle is, the greater the centrifugal force on it and the more likely it is to move towards the walls.  What this basically means is that the larger the particles the greater the removal of those particles in a cyclone.

A cyclone pre-filter will remove the larger particles from an airstream.  Often times this can be as much as 80-90% of the dust loading in the airflow.  Installing a cyclone pre-filter could decrease the loading on the filters by 80-90%, which in turn will allow a longer time between cleaning of the filters.

“Pulse-Jet” Baghouse   

In a “pulse-jet” baghouse the filters are cleaned by blasting compressed air through them.  This causes the filters to expand off their support.  The expansion causes the top layer(s) of dust to fall off the filters, thereby cleaning them.  Now each time the filter expands, the filter is weakened.  Over time, holes will develop in the filter, thereby allowing unfiltered air past.  This lowers the removal efficiency and could cause the system to be out of compliance.

Dust Built-Up Over Time

Another issue is over time, the top dust layers might not fully fall off.  So the total dust on the filters increases, making it harder for air to pass through.  This causes the pressure drop across the filters to increase, which will result in less air being collected at the collection points.

Installing the cyclone pre-filters decreases the dust getting to the filters, thereby requiring less cleaning (weakening of the filters) and lowering the amount of dust that builds up on the filters.  Together this can extend filter life by many months to a few years, which will lower your maintenance costs.

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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.