Dust Collection and Valves Blog

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.



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

Dust Collector Placement Part 4: Surrounding Areas | Aerodyne

Posted by Tom Hobson on May 29, 2019 9:21:48 AM

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 4 of 4)

Surrounding areas

As mentioned above, the area surrounding the dust collector significantly affects where the dust collector can be installed.  Location of utilities such as electricity and compressed (plant) air all affect the dust collector location.  Baghouses and cartridge collectors usually require compressed air for cleaning, wet scrubbers often require makeup water and a drain to either local or plant water treatment facilities. 

Dust Collector Interference

The dust collector may interfere with surrounding equipment and operations, such as cranes and vehicle traffic.  Dust collectors are often tall pieces of equipment requiring large head room when indoors.  And the noise and explosion protection could affect personnel space such as break rooms, rally points, foot and vehicle traffic, etc.

So when looking for a space to install your dust collector make sure you take into account all the different factors such as explosion protection, utilities, operations, and workers safety and comfort. And install the dust collector as close as possible when conforming to the above requirements.

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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Topics: GPC Cyclone, dust collector placement, distance from process, surrounding areas

Dust Collector Placement Part 3: Distance from Process | Aerodyne

Posted by Tom Hobson on Apr 23, 2019 1:40:54 PM

 

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 3 of 4)

Distance from Process

Ideally installing the dust collector should be located next to the dust generation.  However, this isn’t always possible.  There are space constraints, safety and noise concerns and process requirements that all affect the placement of the dust collector.  However, based on this, you should place the dust collector as close as possible to the process.  This decreases cost with less ductwork required.  You will also want to use as straight as possible runs of ductwork .  Short, straight ductwork will keep the pressure drop of the system low allowing you to install a smaller quieter blower.  It also helps prevent dust build up in the ductwork which can cause operational issues and be a fire/explosion hazard.

Smaller Fans

Smaller fans usually mean lower horsepower motors.  This translates into lower operating cost for the fan.  And shorter ductwork requires less cleaning, thereby less time for maintenance on the whole system.  If long distances are required, look at using local pre-filters to lower dust loading going through ductwork.  This will help solve some of the issues such as dust buildup in the ductwork.

To learn more about dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com or click on the button below to get our whitepaper: Top 5 Reasons to Use a Cyclone as a Pre-filter.

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Topics: GPC Cyclone, dust collector placement, distance from process

Dust Collector Placement Part 2: Space Constraints | Aerodyne

Posted by Tom Hobson on Apr 12, 2019 9:30:00 AM

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 2 of 4)

Space Constraints in New Facility

In new facilities, the installation of dust collectors is often pretty easy.  Many times the building is designed around the equipment.  This doesn’t mean that compact equipment isn’t beneficial.    This can help lower ceilings, prevent the need for installation on the roof.  When placing a dust collector in new facilities, it would best to place them as near to the system as you can while conforming to all the NFPA and other specs.

Space Constraints in Existing Facility

Existing facilities pose much more issues than new facilities.  Often times existing facilities are constrained for space.  They have added / expanded lines in a building that weren’t built for its current use.  New regulations could require a new dust collector, larger dust collector, or modification to the dust collector (including explosion protection).  All of this could require finding room for a new dust collector or moving the existing one.

Noises from Dust Collector and Fan

If the dust collector is not going to be mounted indoors, it needs to fit under the existing ceiling.  Low profile units are often required.  It might be easier to use low profile point of use dust collectors than to find a place to install a large dust collector for multiple processes.  It is often beneficial to locate the dust collector as close to the processes it is collecting dust from.  This lowers the cost of the system by minimizing ductwork which in turn minimizes the fan size and HP.  When installing the dust collector you should remember to take into account noise from the dust collector and the fan.  Fan silencers and noise blankets may be required if the equipment is too loud.  And as discussed above, enough space should be available for installing all the explosion protection required.

Protect Dust Collection Equipment from Weather

If the dust collector is not going to be mounted indoors, height is usually not an issue.  Some facilities do have outdoor height restrictions.  Sometimes it’s the local city and sometimes it is to keep a low profile with the neighbors.  The dust collection equipment must also be protected from the local weather.  Equipment in the Midwest often requires freeze protection, while the Gulf Coast need to withstand high winds.  When locating the dust collector outside you should install it as close as possible to the process, so as to minimize ductwork and power requirement.

Conform with NFPA

Many customers when installing equipment have to deal with local ordinances on the appearances of the outside of the facility.  Other times, the company wants the facility to be aesthetically pleasing, and / or they want their neighbors to be comfortable with the appearances so as to minimize any issues in the future.  And as mentioned before, the dust collector should conform with NFPA when installed on an explosive application.

To learn more about compact dust collector, please contact our experts at 440-543-7400 or visit our website: www.dustcollectorhq.com or click on the button below to get our whitepaper: 5 Ways to Save Costs by Using Small Dust-Collection Cyclones.

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Topics: GPC Cyclone, dust collector placement, Space constraints

Dust Collector Placement Part 1: Explosive Dust | Aerodyne

Posted by Tom Hobson on Mar 26, 2019 9:45:11 AM

When it is time to add a dust collector to your application, you have to find a place for the dust collector.  This isn’t always easy.  New facilities are usually designed around the equipment that is being installed.  However when a system in an existing facility is modified or installed, you will have limited space to install the dust collector system.  There are four factors that you should take into account when finding a place for your dust collector. (Part 1 of 4)

Explosive dust

One of the most important factors to take into account is the explosibility of the dust.  If the dust is explosive you will have to make sure the location of the dust collector conforms with the appropriate NFPA specification.

The NFPA specifications require dust collectors to be located outdoors if they have explosive dust, unless specific explosion venting or mitigation equipment is being used.  Even if your dust collector is located outdoors, it should still have venting, because you don’t want your collector to create shrapnel during and incident.

Explosive Vent

One of the most common and least expensive explosion protection methods is the installation of explosion vents on the dust collector.  The explosion vent directs the pressure wave out of the vessel through an area, thereby controlling the explosion.  This protects the dust collector from the worst of the damage.

When using explosion vents, it does matter if your dust collector is indoors out outside.  When located indoors, the explosion is required to be vented outside.  The vent is connected to ductwork to an opening in an outside wall or roof.  When this is used, the dust collector should usually be within 5 feet of the wall.

When the dust collector is outdoors it should be orientated so that the explosion vents are directed away from the building and any other equipment.  The vents should also be directed away from any walkways, roadways, and areas where employees would be. (Ex. Rally points, picnic tables, etc.)

Flameless Vent

A flameless vent can be used instead, which allows the dust collector to be installed inside without venting it outdoors.  The flameless vent directs and vents the explosion as a standard vent, but it has metal fins mounted on the vent so the explosive wave travels past the fins.  The metals fins rapidly cool the wave, stopping the flame, so only a hot pressure wave is left.  Enough room must be left around the flameless vent so that adjacent equipment isn’t damaged.  The vent area should not be an area where workers are or a walkway.

Chemical Suppression

Chemical suppression is another technology that is used to protect dust collectors from explosions.  The technology uses non-explosive chemicals to flood the dust collector and prevent an explosion.  Sensors located in the dust collector and the ductwork measure the temperature and pressure to monitor for an explosion.  When they detect an explosion the chemical suppression system is activated.

Chemical suppression systems require yearly maintenance to make sure the system is still protected.  So the sensors and chemical canisters need to be accessible for the maintenance checkups.  This means platforms or open spaces for portable lifts should be located around the equipment.

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

Click below and watch our Webinar that offers a thorough explanation of the changes in NFPA 68 and how they may affect your existing system design.

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Topics: GPC Cyclone, flameless vent, chemical suppression, explosive dust, dust collector placement, explosive vent

Why Install Dust Collectors Even If It Is Not Required | Aerodyne

Posted by Tom Hobson on Feb 25, 2019 10:30:00 AM

The most basic reason to install dust collectors is because the EPA, OSHA or other regulatory agency requires you to.  However there are other reasons to install a dust collector even if you aren’t required to.

  1. Health and safety
    • Dust can cause health issues, even if the material isn’t a carcinogen or sub-micron. Dusty air can cause issues breathing, allergies, etc.  All of this can cause operators to be sick more often or want a new job.  This can cause increased operating expenses and less efficiency as you have to cover for absences or have to train a replacement.   Small local dust collectors can help clean the air around operators.
    • Some dust is explosive, and the regulatory agencies are requiring that you test the dust to make sure it isn’t. Even if they haven’t gotten around to it yet, a fire or explosion will cause property damage and possibly injury to employees.
  2. Maintenance – Dust will get into mechanical equipment and cause increased wear on them. This increases the maintenance on the equipment, lower productivity and increase operational expenses.  Installing a local dust collector can minimize the dust getting to the surrounding equipment, thereby extending their life.  While there are many factors that affect when equipment needs maintenance, minimizing dust in the air will definitely help extend the time between maintenance.
  3. Recycling of material – Local dust collection can help capture product / raw material dust before it is contaminated by other material. This dust can then be reused or recycled, thereby lowering the cost of your process.  Cyclonic dust collectors are especially good at collecting un-contaminated material since they have no filters to retain dusts and can be cleaned out.
  4. Environmental responsibility – Local dust collection will help you keep fugitive dust from escaping the building and into the environment. While rain and wind often deposit dust back on the ground, the more dust escaping will cause the air to be dirtier. This could cause smell or dust clouds that neighbors will dislike.  Beyond being a good direct neighbor, you may just have a goal to be a better inhabitant on the earth.
  5. Higher morale – A cleaner, healthier environment will help your employees be happier at work. If they aren’t irritated from dusty air, there is a better chance they will enjoy work better and be more productive.  This will allow you to produce more at a lower cost.  And the company will make more money allowing the employees to get better raises.

To learn more about which dust collector, please contact our experts at 440-543-7400 or click on the button below to get our Whitepaper: 4 Potential Dangers to Collectors! How Cyclone Pre-Filters Can Help!

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Topics: dust collector, GPC Cyclone, dust collection system efficiency, clamp together ductwork

The Benefits and Restrictions of Clamp Together Ductwork | Aerodyne

Posted by Tom Hobson on Jan 24, 2019 2:00:01 PM

The use of clamp together ductwork has increased over the past few years. There are multiple suppliers of clamp together ductwork which helps to keep the prices down. Clamp together ductwork is easy to design and install. 

The Benefits of Clamp Together Ductwork 

  • Easy to design - One of the main benefits of clamped ductwork is that extremely accurate measurements aren’t required. The clamp together ductwork allows you to adjust the length.  This makes installation of the ductwork much easier than standard flanged ductwork.  So when you are designing your ductwork, you just sketch the ductwork out.  From the sketch you figure out the pieces that you require and then order them from your preferred supplier.
  • Easy to transport - Clamp together ductwork is also easier to transport, as the ductwork usually comes in 5 foot sections.
  • Easy to install - When it comes time to install the ductwork, all you need to do is begin installing it and trim any pieces that are too long.
  • Ideal for mobile systems – Portable applications that require frequent disassembly and re-assembly.

The Restrictions of Clamp Together Ductwork

One thing to be aware of is that clamp together ductwork cannot be used as the ductwork between a dust collector and the no-return/ isolation valve.  NFPA specifications require that the ductwork be flanged together and strong enough to prevent a breach in case of an explosion.  This means when you are designing and installing the system, this ductwork needs to be ordered as flanged ductwork.  The no-return / isolation valve will have specifications on the distance it needs to be from the dust collector.  They may also have guidelines on elbows etc.  Most clamp together ductwork suppliers offer flanged ductwork too.  So you just need to order the required flanged ductwork when you are ordering the rest of your ductwork.

 

To learn more about which dust collector, please contact our experts at 440-543-7400 or click on the button below to get our Dust Collection System Evaluation Guide.

 

 

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Topics: dust collector, GPC Cyclone, dust collection system efficiency, clamp together ductwork

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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