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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Simple Timers

For many years, pulse-jet baghouses were cleaned by simple timers.  The timers would start the cleaning cycle every so many minutes.  You would be able to change how often your filters are cleaned by changing the time between each cleaning.  This design makes sure that the filters are cleaned regularly, whether they need to be cleaned or not.  The main issue with this is that every time a filter is cleaned, it increases the chances of it failing.  Filters are cleaned by pulsing high pressure air into the filter.  This expands the filter, which causes the top layers of dust to fall off.  But that expansion can also cause holes or rips in the filters.

Pulse-On-Demand Controller

So it would be beneficial to minimize the cleaning of the filters to only when it’s needed.  The pulse-on-demand controller does just this.  It measures the pressure drop across the filters.  When the pressure drop gets over a certain amount, it will begin the cleaning process.  Many of these controllers also have “bag break” technology, which will tell you when one of the filters has a hole.  You will then be able to replace the filters only when they are needed.  Some controllers can even isolate the row where the broken bag is located, so you won’t have to replace all the filters.

Installing a Clean-on-Demand controller, “bag break” technology, and cyclone pre-filters (Check out other Aerodyne blogs for more info) can help you decrease the maintenance on your filters, extend filter life, and lower operating costs (less air usage).

 

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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.

 

The airflow in a dust collection system is extremely important, since the air collected at the hoods is removing the dust from the affected areas.  This air is then sent to the dust collector to remove the dust from it.  While it is always desirable to use the least amount of air as possible in your dust collection system, you must have enough air so that it is actually doing the job it is meant to.   If not enough air is going through the system, you will not capture all the dust from the pickup areas, thereby allowing dust to escape into the facility, cause health / nuisance issues and/or fire hazards.  If the airflow is too high, you could be picking up product/ raw materials, wasting energy and increasing maintenance issues.

There are many reasons that the airflow through a dust collection system can change.  A few of them include:

• Environmental changes – temperature, humidity, etc.
• Changes in the system – such as opening/ closing dampers, dust buildup in the ductwork, damage to the ductwork and/or hoods.
• Dust collection issues – such a plugged filters, old filters, holes in the filter, etc.
• Damage to the exhaust fan – such as bearings, damaged impellers, etc.

Unlike liquids, there is no easy and inexpensive way to monitor airflow in a dust collection system.  The most common way is to periodically manually measure the airflow by inserting a pitot tube in the ductwork and measuring the air velocity.  The airflow is then calculated.

One option to monitor your airflow is to install a cyclone pre-filter ahead of the filters.  A cyclone’s pressure drop increases as the airflow increases in them.  Usually the manufacturer of the cyclone can provide a curve, showing the relationship between the pressure drop and the airflow.  So if you monitor the pressure drop through the cyclone, you will notice if the airflow suddenly increases or decreases.  And if the pressure drop drifts too far from a certain pressure drop you will know to troubleshoot the system.

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper: Top 5 Questions To Ask When Considering A Cyclone Dust Collector.

 

 

Dry dust collectors and humidity don’t react well together.  Baghouses and cartridge collectors operate by having dirty (dusty) air enter the housing.  Multiple filters (bags or cartridges) are located in the housing.  The air travels through the filter and then exits the dust collector.  The filters are a mesh of fibers that allow air to travel through small holes, while dust is too large to pass.  The dust builds up a layer (dust cake), further limiting the subsequent dust’s ability to pass through while allowing the air to pass.  From time to time the dust collector will clean the filters by shaking them or using compressed air to expand them.  This causes the outer layer of the dust cake to fall off.

Humidity can cause problems in the process described above.  Humidity is a way to express the amount of water in the air, (the higher the humidity, the higher the amount of water in the air).  When high humidity air enters a dust collector with fabric filters, there is a chance that the water vapor will condense and create water droplets or the dust on the filters will absorb the water as the airflow passes through.  Many dusts change their physical properties when the water content increases.  Some become sticky, some become hard like concrete, etc.  When this happens to the dust cake, it affects the ability of the air to pass through and the ability of the dust to fall off during cleaning.

When dust becomes sticky, it will adhere to neighboring dust particles and not want to fall during cleaning.  Dust that becomes hard (like concrete) will prevent air from passing through.  When one of these issues develop in a dust collector the pressure drop across the dust collector will increase.  Over time, an increased pressure drop will lower the airflow being pulled through the system.  This will decrease the airflow being picked up at hoods, therefore lowering dust collection at where operators are located.

Humidity can also be introduced in the dust collector in the compressed air.  When air is compressed, the temperature of the air increases, thereby increasing the water content of the air.  The compressed air is at its saturation point.  As the air moves through the line, it cools, thereby condensing water in the system.  If additional drying technology isn’t installed, the compressed air will have water droplets in it as it is used in the dust collectors.  This will cause the filter cake to wet and cause issues as described above.  This is why it is important to dry compressed air when dealing with dust that is affected by water.

However, sometimes no matter how you treat your compressed air, you continue to have issues.  This could be because the airline travels outside and in winter time it gets very cold. It could be because you are located near a large body of water, and humidity is high.  One way to minimize the effect on your dust collector is to minimize the dust getting to your dust collector.  Cyclone pre-filters are ideal for these applications.  Cyclones collect dust and water droplets using centrifugal motion.  This means they aren’t affected by the changes to the dust as a filter is.  Cyclone pre-filters can often remove up to 80% of the dust before a dust collector with filters.  This means you can lower the number of water droplets going into your dust collector and minimize the cleaning required, thereby not getting as much water from the compressed air system. 

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-Filter.

 

 

At one time mechanical dust collectors were the industry standard in dust collection and air pollution control. However, with an ever increasing focus on air quality, EPA regulations regarding dust collection have steered the manufacturing world toward the higher efficiency capabilities of fabric filter baghouses, cartridge filters, and other dust collection equipment utilizing filter media. This change has undoubtedly helped to reduce the amount of harmful emissions released into the atmosphere in manufacturing processes. Unfortunately, the use of these fabric filter baghouse collectors is not without cost. The limitations of filter media such as moisture, heat, and high particulate volumes have added to the challenges of successful dust collection. Additionally, the high cost of bag or cartridge replacement, maintenance issues, and expensive pulse-jet controls to clean filter media can add up. The solution to these headaches for many has been the use of mechanical dust collectors before final-stage filtration.

Mechanical dust collectors use a cyclonic air flow to separate particulate from an air stream. The centrifugal force created by the rotary flow throws the dust out of the air stream and toward the walls of the collector. In a typical cyclone, the particulate strikes the wall of the collector and falls to a hopper below for collection. Cleaned air is then vented through the top of the collector. While this form of collection can be highly efficient in dealing with large, dense particulate, extremely fine dust lacks the inertia to escape the air stream and is subsequently carried out with the cleaned air. Some high efficiency cyclones like the Aerodyne 'S' Series, use two air streams, to more efficiently separate the dust. The Aerodyne's powerful secondary air stream intercepts the particulate before it contacts the side wall, reducing wear when handling abrasive materials. This secondary air stream also helps to sustain the cyclonic action inside the collector, thereby increasing its efficiency.

 

Filter media dust collectors such as baghouses and cartridge filters use a fine filter media to remove dust from an air stream. The dust-laden air is drawn into the collector where it passes through the filter media and particulate is intercepted. Dust builds up on the filter until it is cleaned or replaced. Cleaned air is then vented out of the collector.

Many manufacturing processes involve circumstances that make it very difficult to rely completely on a baghouse. Heavy dust loading can be a maintenance nightmare for a filter media collector. A rock crushing operation based out of Minnesota realized the benefits of placing a cyclonic dust collector before its baghouse. The enormous amount of rock dust generated in the crushing operation was blinding the bags and causing frequent shutdowns. The decision was made to install a cyclonic dust collector to receive the dust before being sent through the bag house. The cyclone captured the vast majority of the rock dust, leaving only a small amount of fine particulate for the bag house to handle. The cost of the additional equipment was quickly recovered through fewer shutdowns and less frequent bag replacement.

Processes involving high temperature exhaust gas also plague filter media collectors. The hot air temperatures exhausted from foundries, glass making plants, and power plants can burn the filter media used by most baghouses. While high temperature filter bags and cartridge filters are available, they can be an expensive addition and are still not completely immune to the heat. Used as a spark arrestor, a cyclonic dust collector can be placed before a bag house to both reduce the temperature of the air stream and the particulate loading before it enters a final stage filter.

While a mechanical dust collector may not be necessary in every application, the benefits that can be gained from this proven technology are evident. As emission standards become more stringent and process costs continue to rise, any advantage that can be taken should be considered. By comparing process costs such as materials, labor, and downtime with the expense of a cyclone, a decision can be made as to the need for such equipment.

To learn more about the different types of Dust Collection methods,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Not Your Grandfather's Cyclone. 

 

Dust collection system design can be a very complicated process. Beyond determining variables such as air volumes, drop sizes, and capture velocities, there is perhaps no more important design consideration than fire prevention. This is especially true in systems that are used in hot work applications, such as sawing, grinding, or sanding, where sparks can potentially be generated. If a spark is drawn into a system’s ductwork, it has the possibility of travelling all the way to the system filters which are typically constructed of combustible materials. If this happens, the filters can catch on fire, which can lead to catastrophic destruction of the dust collection system, the entire building, or result in serious injury or loss of life.

Any well thought out system will take this scenario into consideration and incorporate preventive measures to reduce the likelihood of this happening. Installing a spark arrestor in the duct work before the baghouse is a method that is commonly used to reduce fire risk. Spark arrestors vary in design, but most of them are designed with the intent of slowing the spark down, allowing it to cool down and burn out before it can do any damage to the baghouse or cartridge collector.

Another option is incorporating a pre-filter cyclone before the fabric filters. A cyclone works on the same principle when it comes to spark arresting, using centrifugal force to direct any sparks to the cylindrical surface of the cyclone, spinning them along the metal walls of the cyclone where they are drained of their energy via conduction. The cyclone has the added benefit of removing the majority of heavier particulate before it reaches the filters, which alleviates overall system loading.

The ongoing emphasis by OSHA and NFPA on combustible dusts and dust collection systems in general means that regulatory compliance will become increasingly important for any facility that uses dust collectors.  Prevention and suppression devices such as sprinklers in the ductwork, explosion vents, chemical suppression systems, and pre-filter cyclones can all be used to reduce and possibly eliminate the risk of fire. The type of dust being collected, the combustibility of the dust, dust particle size, and filter construction are among the factors that must be considered when selecting the appropriate fire protection for your system.

Which prevention or suppression system does your dust collection system need? Asking that question is the first step in protecting your system, your facility, and the people who work in your facility.

To learn more about how Aerodyne can help you keep your dust collection filter cleaning system operating efficiently,  please contact our experts at 440-543-7400 or click on the button below to get our whitepaper, Top 5 Reasons to Use a Cyclone as a Pre-filter.

 

Because of their overall effectiveness and reliability, baghouses and cartridge collectors are the most widely used dust collectors in industry today. The filters in these systems are very effective at capturing several types of particulate matter and have the benefit of being able to be regularly cleaned, which keeps overall system efficiency at peak levels.

But, some types of dusts can prove to be problematic for filters. For instance, fibrous dusts, such as those generated in paper or textile processing facilities, can become embedded in filter media and fail to release during cleaning cycles. Wet or sticky dusts that are common in food processing applications or in facilities with high humidity can provide similar challenges with wet or sticky particulate material becoming caked on the filter surfaces. Many types of filter media are also adversely affected by being exposed to moisture because it may cause the filter to degrade rapidly, allowing holes to develop.

With so much of the efficiency of a dust collector relying on the integrity of its filters, any circumstance that might allow the filters to become impeded with wet, sticky, or fibrous material needs to be prevented. If not, the entire system will experience higher pressure drops, lower airflows, decreased efficiency, and possibly lead to unsafe working conditions or violations of air emission permits.

One proven method of keeping filters from becoming impeded by problematic dusts is to install a pre-filter cyclone in the dust collection system. The cyclone is designed to remove larger, heavier dust, while allowing smaller particles to pass through the cyclone and through the filters. In many applications, 80-90% of the particulate matter entering the cyclone is removed, which is a significant reduction in overall system loading. This is especially true when dealing with wet, sticky, or fibrous dust.  With this decreased volume of dust reaching the filters, filter life is extended, with cleaning and replacement needed less frequently. This means reduced maintenance cost while sustaining optimal operating efficiency.

To learn more about pre-filter cyclones, click on the button below.

For dust collection systems to operate as they are designed, baghouse and cartridge collector filters need to be regularly cleaned.  Many systems employ compressed air for this purpose, periodically sending blasts of air through the filters which effectively removes particulate matter from them. The frequency of these cleaning cycles can be controlled by various methods, such as a pressure drop monitor that allows for detection of a filter that is beginning to clog, or with a simple timer. Air flow is typically controlled with the use of a solenoid operated diaphragm valve.

These valves are the critical component in keeping a system operating at peak efficiency. A valve that is stuck in the closed position or does not open when required will not allow the filters to be cleaned, which will result in an overloaded system that could potentially allow higher than expected levels of particulate to be discharged into the atmosphere or lead to premature system failure due to increased loading.  Conversely, a valve that gets stuck in the open position will result in costly compressed air being constantly sent through the filters.

Maintaining the health of these valves is obviously an essential factor in promoting the long term effectiveness of a dust collection system. The simplest way to achieve this is by making sure that the valves are included in a preventive or predictive maintenance program, so that any issues can be addressed before they become major problems. More advanced systems provide continuous monitoring of valve operation, which can alert maintenance personnel to any problems with the valves or the system in general.

To learn more about how Aerodyne can help you keep your dust collection filter cleaning system operating efficiently,  please contact our experts at 440-543-7400 or click on the button below to watch Dust Collection System Maintenance Video.