Dust Collection and Valves Blog

My Cyclone Should Be Constructed Out Of… | Aerodyne

Posted by Tom Hobson on Jul 30, 2021 9:30:00 AM

Material of construction is extremely important to the durability of a piece of equipment. The suitability of the materials of construction is based on the process, which includes the different components, phases, temperature, and pressure. For example: a cyclone’s material of construction would be dependent on the following:

Material (dust) Being Collected

Properties of the dust being might dictate the materials of construction. Food or pharmaceuticals will usually require stainless steel to prevent / minimize contamination. Carbon steel is often acceptable for wood applications. Other times, the material properties require a special material. For example, abrasive material might require AR steel or a coating to help prevent erosion of the cyclone.

Chemical Composition

The chemical composition of the process can dictate the materials of construction. If a component will react with the materials of construction, it could cause premature failure. For example, water or high humidity can cause rusting of carbon steel so stainless steel might be better suited. Or if an acid is a component of the gas stream, then a high alloy metal or fiberglass construction might be better suited.

Temperature and Pressure

High or low temperature can cause materials to change their properties. Material can become brittle or they may react more with components. For example fiberglass can’t handle higher temperatures whereas metals usually can. And some material might have good compatibility at lower temperatures but very poor compatibility at higher ones. Sometimes pressure can affect the material properties, but usually it will affect the thickness of the walls.

Aesthetics

Some customers have plant requirements for their equipment. For example, a food or pharmaceutical facility may require stainless steel construction even though the equipment is on the waste process and everything will be disposed of.   In a similar vein, the finishing of the equipment might be determined because all the other equipment has a high polished finish and the customer wants it to fit in.

So, when determining the materials of construction, there are many factors that contribute. It is best if the end user, with help from the vendor(s), determine the materials of construction. The end user usually knows the process better than the equipment manufacturer and therefore is in the best position to determine the materials of construction.



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

Why Does My Airlock Jam and What Can I Do About It? | Aerodyne

Posted by Tom Hobson on Jul 23, 2021 1:45:00 PM

Rotary valves will occasionally jam. This can happen when material gets between the rotor and the housing or when oversized material cannot fit into the rotary valve pockets.   Depending on the type of jamming that is happening you handle the situation differently.

Space Between Rotor and Housing

Rotary valves have a space between the rotor and the housing. This space allows the rotors to rotate freely but it can also allow air to leak across the valve. When materials falls on the rotor edge it can buildup and jam the rotary valve. So for existing rotary valves, you might have to replace or modify the existing rotor. Beveling or chamfering the rotor edges help the material to fall off the edge and into the valve pockets.

When Jams Caused by ...

For jams caused by oversized material, a valve with larger pockets is required. This could mean a larger rotary valve or replacing the rotor with a rotor containing one less pocket. Please note if the rotary valve is on an explosive application, NFPA requires a minimum of six vanes on the rotor. If these options aren’t possible, looking into a double dump valve might provide larger clearance for oversized material to pass through.


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

How does particle size distribution affect my process explosibility?

Posted by Tom Hobson on Jun 25, 2021 9:45:00 AM

One of the issues when figuring out if your dust is explosive is the particle size of the dust and the location where you are assessing the dust. Material that consists of very large particles sizes (larger than 500 micron) tend not to be explosive. While larger particles can catch fire, they tend to prevent explosions. However, this might not be as straight forward as you think.

Is the Process Explosive?

Let’s assume that you have a conveyor belt that feeds a grinder which then empties onto another conveyor belt which feeds a bagging station. Let’s assume that the material starts out with a particle size distribution of 10% less than 500 micron and 90% greater than 500 micron of a combustible material. After it is fed into the grinder, its target size is around 200 microns. The question is, is this process explosive? Your 1st thought would be that before the grinder, the dust is too large to be explosive, and you might want to take the material leaving the grinder and have it tested. So you test the material leaving the grinder on the conveyor and find out it isn’t explosive. Therefore you assume the whole process isn’t explosive. However, this might give you a false reading.

Is the Dust Cloud Explosive?

For example, the material falling on the conveyor belt that feeds the grinder creates a dust cloud. That dust cloud is made up of the finer particles, so it is probably made up mostly of the 10% that’s less than 500 micron. And this material could be explosive. Not only that, but if that 10% of the material particle size distribution has a significant amount of dust less than 100 micron, this could very well be the dust cloud which is much more likely to be explosive. And since the smaller the particle size the better the chance of the material being explosive, your dust cloud could be explosive dust. This would then float in the building and layer the surrounding equipment or rafters with explosive dust.

Now looking at the material leaving the grinder, even though it tested as not explosive this is the material on the conveyer or that was bagged. If the grinder feed creates a dust cloud then this will again be the finer dust. So while the majority of your material is around 200 micron, there is a small portion (now much greater than the initial amount that was less than 100 micron) that is very fine. And again, this portion of the dust is the dust that is creating the dust clouds at the exit of the grinder and in the bagging section.

So when you are collecting dust to see if it is explosive, be sure to collect the material that is pertinent. You should try to collect dust that is actually forming a cloud to make sure it is explosive and not lump it in with material that won’t form the cloud. If you have an existing baghouse or cartridge collector, use the material that is collected in the dust collector for testing.


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

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.



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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.

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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.

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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.

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Topics: dust collector, Dust Efficiency Clinic, GPC Cyclone, splitScream Cyclone, Compliant System, Cyclones pre-filter

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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