When a Baghouse Wasn’t the Right Fit for a Grinding Wheel Manufacturer
Aerodyne SplitStream™ Dust Collector Handles High Temperatures and Abrasive Dust from Rotary Kiln Operation
The Problem: A grinding wheel manufacturer in Niagara Falls, New York, needed a better way to collect dust generated from one of its rotary kilns. A baghouse seemed like an obvious solution, but the application presented several challenges that a baghouse couldn’t handle. The kiln exhaust contained abrasive dust and operated at temperatures reaching 700°F or higher. Moisture concerns, collection efficiency requirements, and the potential maintenance demands of a baghouse also had to be considered.
The solution: Using specifications from the plant’s existing cyclone, the application was initially estimated to require handling approximately 4,000 CFM of gas at 700°F. Based on those conditions, an Aerodyne Model 4500 SplitStream™ Dust Collector was selected and installed.
Once the system was integrated and airflow measurements were taken, plant personnel discovered that the actual operating conditions were lower than expected. The kiln only required about 2,500 CFM at 500°F for proper ventilation. Even with the reduced airflow, the collector performed exceptionally well.
Results: Operators reported no visible carry-over, and the SplitStream™ Collector captured finer material that had been missed with the previous application. Critically, the company avoided many of the maintenance concerns that originally made a baghouse less attractive for the application.
After several months of operation, inspections showed no noticeable abrasion wear inside the collector despite the abrasive nature of the dust stream.
The successful installation gave the manufacturer confidence that they had selected the right piece of equipment for the job. They later purchased two additional Model 4500 SplitStream™ Dust Collectors.
For applications involving high temperatures and abrasive materials, eliminating filter media can provide significant advantages. Because the SplitStream™ Collector relies on Aerodyne’s mechanical separation design rather than filters, it avoids many of the maintenance and wear issues commonly associated with traditional dust collection equipment in demanding environments.
Summary of this application of the Model 4500 SplitStream TM Collector:
- Effectively collected dust from rotary kiln operation
- No visible particulate carry-over observed
- Captured finer material than the previous system
- Operated successfully in elevated-temperature conditions
- No significant abrasion wear after months of service
- Reduced maintenance concerns compared to a baghouse installation
- Led to the purchase of two additional collectors
