Dust Collection and Valves Blog

Plan Your Parts and Inspections Before Plant Shutdowns | Aerodyne

Posted by Tom Hobson on Jun 10, 2021 10:30:00 AM

Now that it is spring, it’s time to start thinking about summer shut down! If you are planning on doing maintenance on your dust collection system now is the time to order your parts.

If you are changing bags also look into doing the following:

  1. Pull your airlock off and perform any needed maintenance on it (replace bearings, change out rotors or plate, replace Vacu-Valve sleeves, etc.)
  2. Have someone check your exhaust fan a few weeks before shutdown so that if the fan needs rebalancing or bearings replaced, you can schedule it during the shutdown.
  3. Inspection of your baghouse a few months before shutdown so any damage in the housing, bad air valves, tube sheet, etc. can be replaced during the process.
  4. Inspect the ductwork and look for holes and dust buildup. Make sure dampers are working.
  5. Look into installing a cyclone pre-filter to
     
    1. Increase filter life
    2. Decrease compressed air usage
    3. Collect dust before contamination in the filters
  6. Inspect explosion protection equipment and have any chemical isolators/suppression equipment maintained. Be sure to have the clearance of the rotary valve measured to be sure it is still in compliance with NFPA requirements.
  7. Schedule a Dust Efficiency Clinic to evaluate the system performance so any modifications can be installed during plant shutdown.

Doing the above will help you revitalize your dust collection system and make sure you get the best possible performance out of it.


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, cleaning baghouse filter, horizontal cyclone, GPC Cyclone, splitScream Cyclone, Dust Collector filters, arirflow

The Importance of a Proper Hood | Aerodyne

Posted by Tom Hobson on May 21, 2021 8:45:00 AM

A dust collection system consists of four major components. The pickup hood, ductwork, dust collector, and exhaust fan. For the system to operate efficiently all four components much be sized and used correctly. Unfortunately, one of the main components (the hood) is often overlooked. The hood design is crucial for the operation of the dust collector system. And without the proper hood design, your dust collector will not provide the dust pickup required for the safety of the equipment and workers.

The hood should be designed so that it will capture the dust without letting dust escape. This can often be difficult as the hood will need to be designed to pull air from all the areas generating dust while also provide the required access of the operator / machine.

Using the wrong hood can cause:

  • Dust to escape the hood, thereby causing health, safety, and maintenance issues.
  • Too much dust is captured, removing product or components from the process.
  • Too much air is used, increasing the system size and cost.

When you are looking to install a dust collector system, pay attention the hood design of the system. Spend time selecting the proper hood for the application and don’t just go with the least expensive hood, as this could cause your entire dust collection system to fail at its job.


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, cleaning baghouse filter, horizontal cyclone, GPC Cyclone, splitScream Cyclone, Dust Collector filters, arirflow

How Vibrators Can Help Hopper Flow? | Aerodyne

Posted by Tom Hobson on Apr 28, 2021 4:00:00 PM

Dust collectors have hoppers under the collection chambers to channel the dust out of the system for use or disposal. The hoppers are not designed to be used to collect and store the material, but rather as a place for the material to temporarily collect before passing through the airlock and out of the system. 

Dust Build-Up in Hopper

Depending on the material being collected and the characteristics of it, dust may temporarily build up in the hopper until it can pass through the airlock. Applications that have periodic high loading or applications that have materials with irregular shapes, are sticky, or hygroscopic could all build up in the hopper and form a bridge or rat hole by the dust discharge opening. When this happens, one of the most common solutions is to install a vibrator on the hopper.   The vibrator works by hitting the side of the walls which can cause the material to break up and fall through the dust discharge flange and leave the system.

The Purpose of Vibrator on Hopper

Vibrators can be driven pneumatically or electronically. They also can be used to continuously agitate the hopper preventing any bridging from developing, or they can be periodically turned on to break up any bridging that has developed. When you are installing a vibrator, it is important that you let the manufacturer know how you are planning on using the vibrator so they can recommend the correct vibrator for your application.


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, cleaning baghouse filter, horizontal cyclone, GPC Cyclone, splitScream Cyclone, Dust Collector filters, arirflow

Top 5 Questions to Ask When Considering A Cyclone Dust Collector

Posted by Tom Hobson on Feb 19, 2021 10:15:33 AM

Designing a dust collection system can be quite a daunting task. With so many collector options and so many application variables to consider, it is difficult to know where to begin. Cyclones are among the oldest and still most reliable methods of dust collection available. Because they require very little maintenance, have low up-front cost, and offer unmatched versatility, cyclone collectors remain a viable solution to many air-handling challenges. Although heightened environmental regulations and collection efficiency needs have shifted industry toward the use of filter-media collectors, cyclonic dust collection still plays a vital role in many air-handling systems. These five questions will help determine if a cyclone dust collector is right for your application.IMG_0688

  1. How big is my dust?

    Cyclonic dust collection relies on inertial forces to separate dust particles from an air stream. The larger and denser the particulate is, the greater its inertia. This is the reason cyclones have such high collection efficiencies when handling relatively large dust particles.

  2. How much dust is too much?

    Grain loading or dust loading refers to the amount of dust particulate that is suspended in a gas stream. This is typically measured in the number of grains per cubic foot of gas. This is an important number to consider when designing a pollution control system. Not only will this factor into the size requirement of a dust collector, but it will also determine the appropriate type of dust collector. The strict air pollution control standards in the United States often necessitate a “filter-media” dust collector, such as a bag house, for the final collection stage.

  3. Can I reuse the dust I am collecting? Particle Size

    Dust generated by handling dry bulk materials can be hazardous but also valuable. Unfortunately, most filter-type dust collection systems are designed for disposal rather than product reclamation. Filter media collectors such as cartridge filters and bag houses often do not allow collected particulates to be recovered for reuse due to contamination or particulate size issues.

  4. Do I have heat or humidity concerns?

    Air handling in manufacturing processes is often a delicate balance with a number of variables to contend with. Process heat and humidity in the air stream create a difficult challenge when it comes to dust collection. Collection of red-hot dust particulate is simply not possible with many bag houses because cotton filters are flammable and flame retardant filters can be costly.
  5. How much should I spend?

    Perhaps the most important and most difficult question asked when designing a dust collection system is how much to spend. The simple answer is, it depends. It depends on what the overall goal of the system should achieve. The best dust collection systems are those that were designed with several functions in mind: capacity, operation costs, maintenance costs, and product/ material value.


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, dust collector, cleaning baghouse filter, horizontal cyclone, GPC Cyclone, splitScream Cyclone, Dust Collector filters, arirflow

How Do I Extend the Life of My Filters? | Aerodyne

Posted by Tom Hobson on Jan 27, 2021 3:15:00 PM

Dust collection filters such as the bags in baghouses, cartridges in cartridge collectors, and HEPA filters all filter out dust particles by collecting them in between their fibers. Dust builds up on the bags and cartridges to form a filter cake over the filter further restricting the ability of dust particles and airflow to pass through the filter. This restricting of airflow causes a pressure drop (resistance) which is directly related to the amount of dust built up on the filters. As the pressure drop increases, the airflow through the collector will decrease. Most baghouses and cartridge collectors have cleaning cycles which remove some of the dust from the filters keeping the pressure drop low.

The cleaning process on the filters usually consists of blowing higher pressure air through the filters, thereby causing it to expand slightly. This knocks off some of the top layer(s) of the filter cake which lowers the pressure drop through the filters. Other units have the filters connected to a mechanical shaking system. The airflow through the filter will be stopped during the cleaning process. The mechanical shaker system will gently shake the filters dislodging the dust to fall into the hopper.

Even with these cleaning functions, the filters will eventually plug up and significantly decrease the amount of air they allow to pass. This will starve the pickup points of airflow, allowing dust to escape and never enter the collection system. Depending on the application, this can happen within months or years of putting in new filters. The process of replacing the filters usually requires the system to be turned off. Cartridge collectors are usually easier to replace than bag, but either way the time and labor it takes to change are significant.

Ways to Extend Filter Life

It is therefore very advantageous to extend the time between filter replacements. The following are a few ways to extend filter life.

  • Install a pre-filter before the dust collector. The greater the concentration of dust getting to the filter, the faster the filter will plug up or fail. So if you can lower the dust concentration, you will extend the life of the filters. Pre-filters include cyclones and dropout boxes. Pre-filters remove most of the larger particles, leaving only the smallest to be handled by the filters.
  • Install pulse-on-demand controllers. A pulse-on-demand controller monitors the pressure drop across the filters. And when the pressure drop gets too high, the unit will activate the cleaning process until the pressure drop falls below a shutoff point. This extends life by preventing unnecessary cleaning of filters which can cause holes to develop in the filters. It also can save money on compressed air and keep the airflow within desired range.
  • Install different filters. Not all filters are the same. Some filters are designed to minimize issues with wet dust. Others have higher temperature ratings so they won’t degrade. If you are replacing filters too often, contact your filter supplier or system manufacturer to see if there are other filters that are more suitable. These special filters are more expensive, so it might be prudent to look at adding a pre-filter and pulse-on-demand controller to extend life even further at the same time.
  • If you are plugging up the filters with hygroscopic dust, check the collector housing for leaks that might allow humidity into it. Also, check the compressed air supply to make sure humidity isn’t being added to the system.
  • Install insulation on the dust collector if you have high humidity. Insulation will help prevent water vapor from condensing at night or during winter, thereby preventing water droplets from damaging the filters or causing dust to plug up in the filters.
  • Install a spark arrester before the dust collector. Depending on the process being vented, sparks can be pulled into the dust collector which, thereby cause the filters to catch on fire. Installing a spark arrester prevents this. Often times a pre-filter (cyclone or dropout box) provide the same protection.

If you are replacing filters too often then think about making some of the above changes to your system next time you are due to replace filters. That way you can extend your filter life and operate for longer periods of time without maintenance.

 


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, cleaning baghouse filter, horizontal cyclone, GPC Cyclone, splitScream Cyclone, Dust Collector filters, arirflow

Proper Placement of Your Dust Collector Depends on the Job | Aerodyne

Posted by Tom Hobson on Nov 24, 2020 10:30:00 AM

Dust collectors can be used for a variety of reasons. Some dust collectors are placed around applications that create dust such as saws, grinders, lathes, etc. The dust collector system is used to pull air from the area producing the dust via a hood and through some ductwork until it gets to the dust collector. The dust collector then separates the dust from the air. The cleaned air is then vented out of the dust collector through an exhaust fan and either outside or back to the facility. Other dust collectors are used to clean the air in a facility. The dust collector collects air away from the equipment and processes generating the dust. Many times this air is collected up near the ceiling of the facility. The air is then sent through the dust collector and vented outside or back into the building.

Whenever possible, you should try to capture the dust as close to the process generating the dust as you can. The reason is it is easier to capture the dust closer to where it is generated. If you are collecting the air near the dust generation equipment you will not have to collect as much air, which allows you to size a much smaller system, thereby saving money on capital expenses and operational expenses. Whereas if you are trying to capture the dust away from where it is generated, you will have to process more airflow to capture the dust.

However, there are times that you cannot place hoods right by the dust generating equipment. In those situations you will need to design your dust collection system so that it is big enough to capture the dust while keeping it as small as possible. This might mean building special hoods, using curtains, etc. all to help minimize the airflow required while maximizing the dust entrainment.

Dust collectors can also be used in vacuum systems. A vacuum system allows you to vacuum up dust around the facility without using portable vacuums. This might be advantageous when dealing with explosive applications, since most portable vacuums aren’t rated for explosive applications. And with the NFPA specifications requiring housekeeping of the dust facilities as a main action item, having vacuum systems for explosive dust is desirable.


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, horizontal cyclone, GPC Cyclone, splitScream Cyclone, arirflow

Do Cyclones Replace Dust Collectors (Baghouses, Wet Scrubbers)?

Posted by Tom Hobson on Jul 24, 2020 9:14:12 AM

In most applications, cyclones do NOT replace baghouses, cartridge collectors, wet scrubbers, electrostatic precipitators, etc. Modern air pollution regulations require dust collectors to provide greater removal efficiencies in the PM2 and PM10 than most cyclones can provide.

How Cyclones work?

Cyclones collect dust by having the contaminated air enter (usually on a tangent) and spin around the cyclones walls until they get to the bottom. The air then reverses and spins up the middle of the vessel and leaves from the top, while the dust falls into the hopper.

The centrifugal forces on the particles and droplets, force them out towards the walls and away from the air exiting the center of the vessel. Cyclones provide high removal of the larger, heavier dust particles and moisture droplets.

The Benefits of Cyclones

Cyclones remove very high percentages of the larger, heavier particles. This means they often remove as much as 80%-95% of the total particles. However the removal efficiency of the smaller, lighter dust isn’t very high. The PM2 and PM 10 particulate will often get through the cyclone in high enough concentrations that the system won’t comply with state, local, and federal standards.

When installed in front of a dust collector (baghouse, cartridge collector, etc.) as a pre-filter, they significantly reduce the loading on the primary dust collector. This helps extend the operational life of the dust collector, increase removal efficiency, and decrease maintenance. Cyclones are often used to lower the loading on a dust collector (baghouse, cartridge collector, wet scrubber). The cyclone removes the large material, allowing the dust collector to get the high removal efficiency on the PM 2 and PM 10 particulate.


Aerodyne GPC Cyclone Dust Collector

View the animation of the GPC Industrial Dust Collector to see the compact, high efficiency cyclonic design. Unlike typical cyclonic dust collectors, the GPC Industrial Dust Collector uses a ground plate to force vortex reversal in a much shorter space, eliminating the need for a long, tapered body.


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, GPC Cyclone, splitScream Cyclone, Compliant System, Cyclones pre-filter

How To Determine the Cost of a Cyclone - Part 6 | Aerodyne

Posted by Tom Hobson on Apr 30, 2020 9:15:00 AM

Part 6: Scope of Supply

Cyclones do not stand alone in most applications.  They require additional equipment for them to work.  Depending on your application, equipment can include an airlock, exhaust fan, explosion protection, instrumentation, insulation, vibrator, and even ductwork.  The cyclone can be purchased as a system with all the equipment required to operate or it can be purchased by itself and integrated into an existing system.  The system is then put together by the end user or a 3rd party.  Many times, the sum of the accessory equipment is greater than the cost of the cyclone.  A brief description of the potential accessories and how they affect the cyclone is below.

  1. Airlock

    An airlock is essential for the proper operation of a cyclone.  It isolates the cyclone from the outside atmosphere.  Without it, material will fly out the bottom or get re-entrained in the system.  Airlocks could be a simple extended hopper (55 gallon drum), rotary valve, or specialized valves like the double dump valve or trickle valve.  Special designed valves are available for quick cleaning applications and explosive applications.
  2. Explosion Protection

    Explosion Protection is a very important consideration for dust collectors as about 70% of dusts are explosive. The equipment that protects against explosions can add significant cost the cyclone.  Explosion protection equipment such as explosion vents, isolation valves, chemical suppression, and isolation systems can all quickly increase the price of a cyclone.  This equipment is required for explosive applications. 
  3. Exhaust fans 

    Exhaust fans are required on every dust collection system. They provide the motive force required to pull air through the system.  When selecting the fan, be sure to take into account all ductwork and equipment.    It is best to install the fan downstream of all dust collectors so that the most efficient impeller designs can be used.  This will save money on operational costs.  However, if the fan needs to be installed in high dust areas, there are impellers designed for these operations.
  4. Instrumentation 

    Instrumentation for cyclones are rather simple compared to other dust collectors. The main instrumentation used on cyclones are differential pressure gages/transmitters and level switches for the hoppers.  Explosive applications can have special instrumentation and some applications will monitor temperature and humidity for equipment downstream of the cyclone.  But for most standard cyclone applications, differential pressure is the only recommended measurement.
  5. Insulation, Heat Tracing, Steam Jacketing
    Insulation, heat tracing, steam jacketing are required for special applications. These can add significant expense to the cyclone.  Insulation and heat tracing can be done at the fabricator but usually are done onsite to prevent damage in shipping and installation.  Steam jacketing must be done in the design and fabrication phase and can add significant cost to the cyclone.
  6. Vibrators or Air Jets
    Vibrators or air jets are used for applications where material bridges in the hopper. Vibrators can usually be installed after installation and will help keep the hopper from bridging up.  Air jets blast air into the hopper, breaking up any bridging and letting material flow out of the airlock.  It is best to have the connections for these to be included in the cyclone design and installed once on site.

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.



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, NFPA 652, horizontal cyclone, GPC Cyclone, splitScream Cyclone, arirflow

How To Determine the Cost of a Cyclone - Part 4 | Aerodyne

Posted by Tom Hobson on Mar 27, 2020 10:14:34 PM

Part 4: Application Requirements

Cyclones also need to be constructed so that they meet the specifications and requirements of the applications they are going in.  Some applications, like woodworking or where the material being collected is waste, don’t need any special constructions.  Applications such as food and pharmaceuticals can be very specific.  Every application, customer, process, and facility has their own set of requirements.  These could include a special quick clean access or a higher weld spec to prevent accumulation in the vessel.

  1. Quick Clean

    Quick Clean design allows for the cyclone to be easily accessed for cleaning. It is often used in food and pharmaceutical applications.  These applications usually have a strict cleaning protocol and/or require cleaning between batches.  The design changes required for quick clean design can often significantly increase the price of a cyclone.  Often times it will require redesign of the standard cyclone to allow access and minimize material buildup.  Horizontal cyclones are often best for these situations.
  2. Special Welds

    Special welds are required in most food applications. The welds are often areas where material can build up and contaminate the material being collected in the cyclone.  To prevent this, the welds are often required to be ground down.  This is a time consuming process and is done individually with power tools.  Depending on the specification, special welds can often significantly increase the price of the cyclone, even as much as doubling the cost.  Often times, the welds will require specific welders in a shop to work on the unit, thereby increasing the lead time and cost.  When you are specifying special welds, it’s often a good idea to have a sample or a picture of the weld you are looking for so the fabricator and end user are on the same page.  See the drawing below for an example of a sample.
  3. Special Finishing

    Special finishing of the materials of construction is another requirement in many stainless steel applications. Some food and pharmaceutical applications require the metal to be finished or polished to a certain specification.  Usually, the internal finishing is the most critical due to it being in contact with product, but often times the facility has a specification on the external too.  This is often for cleaning and uniformity in the facility.  Special finishing of the metals can often significantly increase the price of the cyclone.  Often times, with the higher finishes allowance has to be made in the pricing for discarding material that doesn’t meet to specification after it has been worked on.

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.

Free Consultation

Read More

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

Horizontal Cyclones: Solutions for 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.

Free Consultation

Read More

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

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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