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Introduction
This Article takes an In-depth look at Dust Collectors
You will learn more about topics such as:
The History of Dust Collectors
What Is a Dust Collector?
Dust Collecting Systems
Types of Dust Collection Systems
Used Dust Collectors
The History of Dust Collectors
During the Industrial Revolution in 1852, when companies began producing high volumes of industrial waste like fine dust, wood dust, and other particles, an American named S.T. Jones applied for the first dust collector patent, a single bag filter. Jones’ work was followed in 1921 by Wilhelm Beth, a German inventor, who patented a three-filter dust collector design with a focus on filtering air and gas.
Later, in the 1950s, the air filter industry was transformed by pulse jet filtration systems, which brought down the number of mechanical parts involved in air cleaning. Since the 1970s and 1980s, when air quality requirements and pollution restrictions became more stringent, dust collectors have become essential. Today, the dust-collecting industry is developing smaller, cleaner, and more efficient separating and filtering equipment for dust collection.
What Is a Dust Collector?
Dust collectors are air cleansing equipment designed to improve commercial or industrial air quality by capturing particulate matter. They filter pollutants and solid particles that the government has banned in response to the air pollution crisis and trap them. Particles released during manufacturing are hazardous and can lead to respiratory damage as well as other health problems. Dust collection systems transform contaminated air, through a system of filters or separators, by collecting them.
The Occupational Safety and Health Administration (OSHA), founded in 1971, has established regulations regarding the quality of air in industrial facilities. The Environmental Protection Agency (EPA), founded in 1970, regulates the limits of emissions from companies for dust, smoke, and fumes that could be released into the atmosphere. Industrial operations must adhere to the regulations of these organizations or face severe penalties up to being required to close their operations.
Manufacturers and producers rely on dust filtration systems and collectors to meet these stringent guidelines. The type of pollution and manufacturing process determines the type of collector. Only collectors that have received the approval of OSHA and the EPA are permitted to be installed. Companies are very careful to select a system that fits their manufacturing process and must make regular checks for the ratio of particulates to pure air.
Air pollution is measured using the air quality index (AQI). As the index rises, air pollution becomes unhealthy. Every country determines what they believe to be an acceptable level of air quality. The daily air pollution readings are measured and converted into a numerical equivalent from zero upward. Any AQI below fifty is considered good, while air quality values of 300 to 500 indicate hazardous health conditions.
Air Quality Index for Ozone Levels and Particulate Pollution
Daily AQI Color
Level of Concern
Values of Index
Description of Air Quality
Green
Good
0 to 50
Air quality is satisfactory, and air pollution poses little or no risk.
Yellow
Moderate
51 to 100
Air quality is acceptable. However, there may be a risk for some people, particularly those who are unusually sensitive to air pollution.
Orange
Unhealthy for Sensitive Groups
100 to 150
Members of sensitive groups may experience health effects. The general public is less likely to be affected. Some members of the general public may experience health affects; members of sensitive groups may experience more serious health effects.
Red
Unhealthy
151 to 200
Some members of the general public may experience health affects; members of sensitive groups may experience more serious health effects.
Purple
Very Unhealthy
201 to 300
Health alert: The risk of health effects is increased for everyone.
Maroon
Hazardous
301 and higher
Health warning of emergency conditions: everyone is more likely to be affected.
Dust Collecting Systems
Dust collecting systems are equipment that works to minimize dust particle contamination in workshops, plants, and manufacturing facilities. For example, fabrication industries use processes that release millions of hazardous particles. To protect workers and conform to EPA regulations, companies install dust-collecting equipment.
Although dust collecting systems can take up a lot of space and are not easy to reconfigure once designed, the benefits of using effective, efficient dust collecting systems can improve equipment longevity and worker health.
The components of a dust collecting system include overhead ductwork, capture arms, suction hoods, and a central suction unit to pull in the collected dust from other units. Systems can include a single collector or multiple ones depending on their design. The main part of a dust collecting system is the blower, which has an engine, fan blades, and rotor motor. Filters include a blow pipe, housing and hopper, clean plenum, tube plate, compressed air header, bag, and cage.
The first dust collectors used bag filters that trapped dust by having it blown by a fan into a bag, which was followed by a series of filters. The present systems come in two types – positive and negative – and are classified by where the fan and blower are placed. Positive air pressure is where air is blown into the filter, while negative pressure is where dirt is pulled into the filter. The negative type is placed in an enclosure to create a negative pressure space, a vacuum. It is a more efficient design that provides greater control and includes safety and functionality features.
Variations on dust collectors include portable collectors for collecting small amounts of dust. They use a small fan to draw air into a cartridge filter where the dust is collected, releasing clean air. Certain downdraft dust collectors are portable as well. The portable versions have one or two extraction arms. One of the arms can be removed to convert the dust collector into a downdraft collector.
Leading Manufacturers and Suppliers
Types of Dust Collection Systems
With the growing concern for the environment and the number of contaminants released in the past, engineers are constantly searching for new ways to filter and clean the air released by industrial processes. As a result, the dust control and collecting systems industry has been growing rapidly since its inception in the 19th century.
The main types of dust-collecting processes are inertial separators, fabric filters, wet scrubbers, electrostatic precipitators, and unit collectors. Each of the different types is designed to meet the needs of specific industries regarding the type of particulate material to be collected.
The function of dust collectors can vary according to their purpose. For example, industries that produce fine granular products may use a dust collector to collect material that has escaped during the production process. Fume and smoke collectors can filter extremely small particles.
Below is a brief description of the various methods and are just a few examples of the techniques presently used for dust collection and air purification.
Dust Control Systems
Dust control systems are installed to prevent the promulgation of particulate matter, contaminants, and provide a solution for removing concentrations of dust from work areas. All dust control systems have a similar structure and serve the same purpose with their basic components being a blower, cleaning system, ductwork, and a method for collecting captured particles. In each of the different dust control systems, the basic components are arranged differently to meet the dust collecting requirements, which vary according to the size of the particles and their concentration.
The use of dust control systems has become increasingly important due to the rising concerns in regard to air quality. Industrial manufacturing processes produce pollutants that have to be removed from the air stream before the air is released into a factory’s work environment and the atmosphere. Carefully engineered dust control systems clean the air and filter and cleanse the air stream as it passes through a system of devices. Shakers, pulse jets, cartridge collectors, cyclone collectors, and electrostatic precipitators pull dirty contaminated air into their system, clean the air, and release purified air.
The complete process used by dust control systems protects the health of workers and ensures the environment is not contaminated with pollutants. Dirty air enters at one end of dust control systems and clean air exits out the opposite end. The type of dust control system a manufacturer may use varies in accordance with the types of contaminants an industry produces. Companies that burn coal have to have a more aggressive approach to dust control systems while companies that heat metals or melt plastics may not require such an aggressive approach.
Industrial Dust Collectors
Industrial dust collectors are devices used to minimize the presence of various pollutants in order to maintain a high standard of clean air in workshops, plants, manufacturing facilities, or any commercial or industrial space. Regulatory and insurance agencies require dust collectors to be used to maintain healthy work environments due to the potential hazards to worker health and concerns related to air quality. Regulations stipulate certain degrees of soundproofing be installed around dust collecting machines to further protect workers.
Since the types of industrial pollutants vary between industries, the methods of dust collecting differ and are targeted to the needs of an industry. Regardless of the differences in pollutants, all industrial dust collectors operate by drawing in dust and particulate matter and passing it through a filtration system, which releases purified air back into the work environment.
The components of an industrial dust collector include a blower, dust filter, filter cleaning system, dust receptacle, and dust removal system. Included in industrial dust collectors are baghouses, inertial separators, cartridge collectors, wet scrubbers, and electrostatic precipitators. Of the various types of industrial dust collectors, baghouse dust collectors have the highest efficiency and are the most commonly used.
The Occupational Safety and Health Administration (OSHA) does not have regulations in regard to dust except for its accumulation, exposure to employees, and potential for being a fire hazard. The National Fire Protection Association (NFPA) has regulations for vent safe (NFPA 68), explosion prevention (NFPA 69), and combustible dust (NFPA 652 and 654), which are followed closely by dust collector manufacturers and are outlined during the installation and demonstration process.
Cyclone Dust Collectors
Cyclone dust collectors are inertial separators that use centrifugal, or cyclonic, air movement within a hopper chamber to separate particles from the air. The heavier particles are thrown against the outer wall of the hopper and fall to the bottom into a collection chamber.
Cyclone dust collectors are available in a wide range of sizes and configurations for increased efficiency for different applications, from massive multi-cyclone outdoor collectors designed for the cement industry to "lab-scale" mobile cyclone dust collectors designed for use in pharmaceutical pill and tablet manufacturing. Whatever the precise application, cyclone dust collecting systems can help ensure worker health and equipment longevity.
Inertial Separators
Inertial separators use gravitational, centrifugal, and inertial forces to separate dust particles from a stream of gas. The three types of inertial separators are settling chambers, baffle chambers, and centrifugal collectors.
Settling chambers reduce the speed of the air stream. As the air stream loses momentum, the heavier particles settle out. Larger particles fall faster than smaller ones, making this process more effective for pre-cleaning and environments with large particulate emissions.
Baffle chambers have a baffle plate that forces the air stream to suddenly change direction. The inertia of the heavier particles forces them against the plate from which they fall to the bottom of the chamber. Baffle chamber cleaners are used as pre-cleaners to remove large air particles.
The Centrifugal collectors use cyclonic forces to separate contaminants from the air. The air stream enters the dust collecting chamber at an angle where it is spun. The rapid circular motion pushes the heavier-than-air particulates against the wall of the chamber. As they hit the chamber wall, they lose momentum and fall into the collector.
Baghouses
Baghouses, also known as bag filters or fabric filters, are a type of dust collector, which is any system or machine that draws dust out of the air into a filter or separator. In this same group are equipment like air scrubbers, electrostatic precipitators, wet scrubbers, unit collectors, and inertial separators. By removing contaminated air particles from the environment around them, baghouse and dust collecting systems like them improve air quality and worker health and safety.
Baghouses are most often made from fiberglass, cotton, or other synthetic materials. Call a trusted dust collection professional today to determine the best baghouse materials and configurations for your application. Once you have your baghouse, make sure to care for it properly by paying attention to the following factors of its performance: gas temperature, pressure drop, opacity, and gas volumetric flow rate. Provided all of these elements are monitored and corrected when wrong, a baghouse will clean air efficiently for many years to come.
Shaker Dust Collectors
Shaker dust collectors are a form of baghouse dust collector that are used when compressed air is not available to clean the filter bag. The filters for a shaker dust collector are hung from the top of the unit with the bottom of the filter attached to a tube. Mechanical shaking of the bags cleans the filters. During cleaning, it is necessary to take filters off line to be cleaned, which is the reason that shaker dust collectors have several filter bags such that one filter can be shut off from the system as it is cleaned while the other filters in the system can continue to filter the air.
The filter bags for shaker dust collectors are made of woven or light weight fabric polyester sateen, shaker felt, aramid, fiberglass, and beane knit. Polyester sateen is used in applications with temperatures under 275°F, is abrasion resistant, and has a low cost. Shaker dust collectors are designed to handle high air volume with moderate dust loads. The key to shaker dust collectors is their shaking motor that gently shakes the bags to clean them.
In a shaker dust collecting system, large particulate matter is immediately captured as the air stream enters the filtering system and falls into the hopper. Fine small particles are pulled into the surface of the bag fibers. The electric shaker motor is activated by a PLC control system and shakes the bags to release the smaller particles into the hopper. Of the different types of dust collecting systems, shaker dust collectors operate the quietest due to the absence of diaphragm valves used by other systems.
Cartridge Dust Collectors
Cartridge dust collectors use pleated fabric filters that have more filtering surface area per cubic feet due to the pleated design that reduces the air to cloth ratio and the size of the dust collector. The filters for cartridge dust collectors come in various shapes including round, oval, square, or rectangular and have expanded metal mesh on the inside, outside, or both. Other forms of cartridge dust collector filters use fabric bands to maintain their shape. The materials for cartridge filters are a blend of polyester and cellulose covered in a nanofiber coating for filtration efficiency.
The operation of a cartridge dust collector includes a fan that moves the air stream into the collector, an area referred to as the dirty air plenum. Air moves through the filter where dust and particulate matter is captured to release clean air into the clean air plenum, which is sealed with gaskets along a sheet of metal, which is called the tube sheet. Cartridge dust collectors can be configured horizontally or vertically with metal yoke supports and gaskets to seal doors, area between filters, and the tube sheet.
The filter cleaning system for cartridge dust collectors includes pulses of compressed air that moves through the filter in the opposite direction of the dirty air. Dust and particles are blown off the filter and fall into a collection container. Depending on the types of contaminants and their size, filters for cartridge dust collectors can last for months or years. The end of the life of a cartridge filter is evidenced by a slow down of airflow measured in differential pressure.
Dust Control Booths
Dust control booths make it possible to isolate and control dust from certain processes within a larger facility. They enclose the source of dust to prevent it from spreading. Referred to as walk-in booths or isolation booths, dust control booths offer an extra level of dust and contaminant collection that is located at the site where the dust is created. Dust control booths are commonly used for processes that are being completed by one worker and involve grinding, polishing, sanding, cutting, welding, and deburring operations.
It is common for finishing operations to generate concentrations of dust, smoke, and small particles that are better handled where they are created than left to be collected by a large dust collection system. Dust control booths are self contained environmentally sound methods for immediately removing particulate matter when it is created. Contaminants are kept from workers outside the booth, prevented from interfering with other operations, and ensure that the work environment is free of harmful pollutants.
Cartridge dust control booths use high efficiency nanofiber cartridge filters that are placed vertically for effective air cleaning. The filters are cleaned by an automated system that consists of a solenoid, dump valves, and blow down pipes. Low speed blowers move the air stream from the booth to the cartridge filters, which come in various shapes to fit the design of the booth.
Panel filter dust control booths are designed for moderate dust control operations such as buffing or polishing. The design of panel filter dust control booths makes it possible to use a wide range of filter configuration with many panel booths having multistage filtration systems with pre-filters and secondary filters.
Wet dust control booths are used with explosive dust, aluminum, magnesium, and mixed metals. A wet filter system has particulate matter pumped directly into the filtration system located at the rear of the booth where it is filtered and exhausted out into the ambient air of the facility. The filtration process of a wet dust control booth is continuous due to the nature of the material being filtered.
Laser Pack Dust Collectors
Thermal cutting processes, such as plasma cutting and laser cutting, produce fumes and flammable particulate matter that has to be carefully handled. Laser pack dust collectors are designed to remove the emissions created from thermal cutting processes. They are equipped with spark arrestors and spark discharge units to collect hot particles in a collection bin.
Laser pack dust collectors are designed with inlets that have overlapping sections that forces the air stream to be constantly making 90° turns to ensure separation. Materials that are being treated with a laser beam release gases that expand and generate dangerous particles during the cutting process. The particles form a fume cloud made up of fine dust particles that can harm the skin and lungs of workers.
A major concern with laser cutting is fire, which requires that laser pack dust collectors include a spark arrestor, flame retardant filters, and fire detector shutoff fan. The most common types of filters for laser pack dust collectors are pleated cartridge filters. The selection of a laser pack dust collector depends on the wattage of the laser cutter, The cutting speed, materials being cut, and the thickness of the material. For additional protection, the clean air side of the filters has a fire suppression system in the plenum. If smoke is detected in the clean air plenum, the controls of the dust collector shuts off the fan.
Downdraft Tables
Downdraft tables are installed in a work table. Depending on their design, they can either automatically clear dirt away from the work area or be activated by a worker. They are normally located under the work surface and have one or two-foot openings that can be two, three, four, or more inches wide. Before downdraft tables, worktables had a hole to shove waste materials into similar waste containers at fast food restaurants.
Downdraft tables are designed to contain and exhaust heavier-than-air particles, lighter-than-air particles, fumes, fine particulates, and powders. The top of a downdraft table is a rigid, perforated grill through which airflow is both possible and uniform. Once air is pulled down through the perforated top, it enters an exhaust chamber mounted directly underneath the top. The exhaust chamber contains filters that can capture particles as small as .5 microns.
Pulse Jet Dust Collectors
Pulse jet dust collectors are a specific type of baghouse dust collector that uses pulse jets of air to shake dust-caked fabric bag filters free of dirt. Differential pressure sensors read the air pressure of the dirty air and the clean air. When the pressures get too high, the filter cleaning system is initiated.
Pulse jet dust collectors are one of the most widely used types of dust collecting systems because they require little maintenance, can clean high-density dust, and offer excellent filter efficiency. However, pulse jet dust collectors take up more space than most other types of dust collectors, often requiring outdoor installation. Industries that benefit from pulse jet dust collectors include pharmaceutical, cement, iron and steel, petrochemical, agricultural, food processing, automotive, and mining. Ideal applications for pulse jet dust collectors include product recovery, dust capturing, separating and filtering explosive media, metalworking chips, toxic media, central vacuum cleaning, and pneumatic conveying.
Fabric Filters
Fabric filters, or baghouse filters, use an enclosure filled with bags that filter the air and remove pollutants. Contaminated air is pulled into a hopper-shaped baghouse with fabric filters made of cotton, glass fiber, or synthetic material. A vacuum-creating fan pulls the air stream through the fabric bags. The bag lets air pass through but captures the particles and pollutants. The cleaned air exits through an outlet. The collected particles remain in the filter or settle to the bottom of the hopper.
The main type of baghouse dust collectors are pulse jet dust collectors, which have bags mounted at the top of the baghouse. Air flows from the outside to the inside of the bag. The bags are cleaned by pulse jets of air.
Dust Collection Equipment
Dust collection equipment encompasses a wide variety of devices and systems designed to minimize air particle contamination in workshops, plants, manufacturing facilities or any commercial or industrial space. The pollutants produced in these environments, such as volatile organic compounds, metalworking chips, hydrocarbon, and solvent fumes, can have serious environmental and biological ramifications if not properly removed from the air and disposed of.
While systems can be singular, most high-use equipment employ multiple filtration devices, some using up to four filter components. Baghouses, cartridge collectors, wet and pulse jet dust collectors, ambient units, collection booths, downdraft tables, and overhead hoods are all specific pieces of equipment. Baghouses are the most common apparatus employed due to efficiency and versatility. Units may be portable dust collectors or stationary.
Portable Dust Collectors
Portable dust collectors maintain the air quality of a variety of commercial and industrial facilities, such as those that conduct manufacturing processes like carbon machining and woodworking, by capturing contaminated air then filtering it. Other environments that benefit from their presence include those involved in metal grinding, concrete grinding, blasting, composite manufacturing, welding and pharmaceuticals. Still other applications they serve are in post-flood/fire/disaster building restoration. Among the most common portable dust collector types are wet scrubbers, air scrubbers, unit collectors, bag houses, electrostatic precipitators and inertial separators.
Common applications for portable dust collectors include the collection of welding smoke, plastic dust, chemical fumes, pharmaceutical dust, soldering fumes, wood dust, grinding dust, dust debris, and other fine particles. Industries that benefit from portable dust collectors include pharmaceutical, metal grinding, woodworking, composite manufacturing, blasting, and welding. As the dust collecting industry advances, smaller and more efficient portable dust collection equipment is being developed to meet increasingly strict environmental regulations.
Industrial Dust Collectors
Industrial dust collectors are devices used to minimize the presence of various pollutants in order to maintain a high standard of clean air in workshops, plants, manufacturing facilities, or any commercial or industrial space. Because of the potential hazards to worker health as well as other concerns related to air quality, regulatory and insurance agencies sometimes require that dust collectors be used to maintain healthy work environments. Some regulations even require certain degrees of soundproofing to be installed around these commonly loud machines to further protect workers.
Wet Scrubbers
Wet scrubbers, or wet dust collectors, use a scrubbing liquid that collects particulates and gasses. Water is the most common solvent. An encapsulated container is filled with water. Contaminated gasses are passed through the container, where the water absorbs the contaminants and clean air exits the container.
Other liquids used for wet scrubbers have to meet certain standards. For one to be selected, it must have a chemical composition that will combine with pollutants. An absorbing solution can be positively charged, negatively charged, or uncharged. The composition of the liquid must match the pollutant’s chemical makeup and be able to bind with it.
Electrostatic Precipitator
An electrostatic precipitator uses electrostatic force to grab and hold contaminants. It is made with wires and collection plates. The air becomes electrically charged and ionized when high voltage is applied from an electrostatic field between the wires and plate. The particles get charged with the air, causing them to attach to the collecting plate. The remaining electrically charged air moves out, leaving the particles behind.
The collected particles are removed in a variety of ways, which include shaking, scraping, or simply washing the plate. Once collected, they are disposed of. The cleaning process can be scaled up for ash or similar particles that require more energy.
Spark Arrestors
Spark arrestors have a long history and were first used when fire in a hearth was the only method of heating. To prevent embers from going up the chimney and igniting, wire frames were placed inside to trap them. The principle behind modern-day spark arrestors is to trap or pulverize carbon particles larger than 0.023 of an inch. Properly installed and maintained spark arrestors reduce the risk of fires. The most common type is a variation on wire in a chimney.
One form of spark arrestor traps carbon particles from an exhaust system. The large carbon particles are screened by centrifugal force where they are collected. Centrifugal spark collectors use the same principle as centrifugal dust collectors. In some cases, a spark arrestor is included as part of a centrifugal dust collector.
Industrial spark arrestors are used in metal and low-load material processing. They cool sparks through turbulence in the air flow stream, which disturbs the thermal bubble surrounding the spark by lowering the temperature of the gas stream. The process is used in conjunction with other dust collecting devices.
Used Dust Collectors
Dust collectors for industrial use are expensive. However, a used dust collector is less expensive and more cost-effective for small start-up businesses that require a pollution control device. Used dust collectors are just as efficient as new ones. Suppliers purchase used equipment and follow a strict refurbishing process to clean, restore, test, and repair them for resale. In most cases, it is difficult to tell the difference between a used one and a new one.
Resellers offer training and guidance regarding the installation and use of the equipment, with manuals that outline equipment use and the types of particles that will be captured. The variety of used dust collectors includes booths, cartridge collectors, mist collectors, portables, ceiling-hung, bin vent systems, wet scrubbers, and downdraft.
When shopping for a used dust collector, it is wise to examine the essential parts such as the motor, types of filters, suction arms, hoods, electrical panels, and exhaust ducts. Doing research and being familiar with the workings of a dust collector can be beneficial in making a wise purchase.
Most dust collectors rely on an electrical motor to power the system, which can have a power cord or run on battery power. Filtration systems of dust collectors vary depending on their function, the manufacturer, and the design. Suppliers usually have information about filters and can supply them. The best type of filter is the high-efficiency particle type (HEPA), which is recommended by the majority of producers.
Size, area of the workspace, industry, needed capacity, and air purity requirements are issues that need to be discussed with the supplier. These factors will help in selecting the best type of equipment to fit the user’s needs. Another important factor is the air quality requirements for the community, which radically vary depending on the location of the business.
As with any form of industrial equipment, air cleaning systems require regular maintenance. Most suppliers offer a maintenance agreement that guarantees routine system checks on a weekly, monthly, or bi-monthly basis. Purchasing these agreements is an excellent way to avoid problems from a lack of information. Regardless, it is wise to know how to check the filtering device and be able to determine if there is a problem.
There are ever-growing concerns about the environment and pollutants. OSHA and the EPA have specific regulations regarding dust collection equipment that must be strictly followed. All suppliers are well aware of the stipulations and ensure that collection systems will comply.
Leading Manufacturers and Suppliers
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