Industrial Dust Control for Mobile Construction Applications

Cyclone Pre-filters can filter out 90% or more particulate before it reaches downstream filters, significantly reducing fabric filter wear and protecting other industrial dust collection equipment.

The Unique Dust Challenges In Foundries:

Foundries are hot, dusty places—factories where metal castings and other casting services come to life. Castings are produced by melting metal into a liquid, pouring it into molds, and allowing it to solidify. Sand, characterized as an abrasive, is used in metal casting for molding and core making, and silica is typically a key ingredient in molten metal shaping due to its uniform physical characteristics. Unfortunately, silica poses major health risks to humans if inhaled, and so the airborne dust created from sand molds and casting cleanups must be managed properly. The majority of manufactured goods rely in some way on the castings produced by foundries, and like other areas of manufacturing, the dust they produce must be managed via a dust collection system to keep the working environment safe and compliant.

Why Fabric Filters Struggle With Heavy Loading:

Baghouse and cartridge filter collectors are a core piece of many foundry dust collection systems, and are generally very well suited to filter dust from the air in these operations; situated towards the end of the dust collection system, they take on heavy loads of metal, sand, and silica. Depending on the particle size and loading rate of the dust particulate, these fabric filters can suffer from plugging or overloading, inhibiting the airflow of the dust collection system and allowing dust to escape and settle in work areas.

This is a serious concern for foundry personnel because of the increased risk of health hazards and potential explosions.

How Cyclone Pre-filters work:

Enter the cyclone pre-filter. Widely endorsed as a proactive measure for reducing filter loading and increasing dust collection system efficiency, they can be placed upstream of fabric filters to separate out the majority of particulate before it comes in contact with said filters. Cyclones also serve as spark arrestors, increasing the amount of time a spark has to travel before it reaches the filter, and helping to cool down sparks that touch the walls but are not captured—an added bonus for foundry applications.

Cyclones use centrifugal force to capture and remove dust from the airstream, and can often remove 90% or more particulate before it comes in contact with downstream fabric filters. They’re one of the simplest dust collectors available on the market: dirty air enters the cyclone’s inlet and swirls around the separation chamber, where centrifugal forces then force dust out towards the walls.

Once the mixture of air and dust gets down near the hopper, the air changes direction (called vortex reversal) and leaves through the center of the cyclone separation chamber. The solid particles that were concentrated near the wall fall into the hopper and are then removed from the hopper via the airlock.

Any small dust that makes it through the cyclone is then captured by downstream fabric filters, easing the load on the filters themselves and drastically changing the way that dust is managed in the system. Any sparks from the process and the majority of abrasive dust are removed before they can reach the filters, reducing filter cleaning requirements, fire risk, and the amount of compressed air required for cleaning (pulse jet type). Significant savings can be seen if the compressor loading can be downsized for a facility. Ultimately, less dust escapes into the surrounding work areas—lowering the risk of silica damage to employees, and decreasing the risk of explosions or fires.

Aerodyne’s GPC cyclones are compact models with removal capacities comparable to those of traditional cyclones; they differ from traditional cyclones in that they’re shorter, can be configured horizontally, and have an internal ground plate that acts as an integral vortex breaker. Cyclones can be installed in close proximity to areas where dust is generated, and where a larger, traditional cyclone may not fit, which allows the material to be collected and then directly re-entered into the process. This is critical in foundries, where much of the sand and casting materials are recycled heavily. An optional cleanout door can be configured on the cyclone’s backplate for easy access.

GPC Cyclone Specifications:

• proactive measure for reducing filter loading and increasing dust collection system efficiency by filtering majority of particulate ahead of filters
• serves as a spark arrestor
• designed to be installed vertically or horizontally with little effect on collection efficiencies
• utilizes centrifugal force + a ground plate to maximize collection potential
• handles abrasive materials
• eases filter loading to reduce cleaning cycles and increase filter lifetime
• can be installed in close proximity to areas where dust is generated and then directly re-entered into the surrounding processes
• optional “easy clean door”
• 7 sizes under 8 ft³ per NFPA 654
• Ideal for applications with limited space

Dust collection systems perform best in any industry when each of their components is optimized for its role in the system. When fabric filters like baghouses or cartridge collectors take the brunt of heavy dust loading by themselves, it’s a matter of time before efficiency becomes an issue. Implementing a high-efficiency cyclone pre-filter like the GPC shifts the heavy loading burden upstream, often capturing 90% or more of particulate, helping to intercept sparks, and ultimately stabilize airflow before it reaches the filters.

The GPC’s compact footprint and flexibility of installation make it particularly suited for space constrained foundry applications. Improving dust collection system performance doesn’t always translate to replacing the collector itself, but improving the system around the collector by evaluating upstream separation.

In industries that require effective dust collection systems, cyclones are well-known for their efficiency in removing dust and other particulate matter from air streams. They work as excellent pre-filters, reducing the load on baghouses or cartridge collectors and minimizing the risk of contamination. However, the challenge many facilities face is the limited headroom to install a traditional vertical cyclone or the lack of space to add a cyclone to an existing dust collection system. This is where horizontal cyclones provide a game-changing solution.

Challenges with Traditional Cyclone Dust Collectors

Traditional cyclone dust collectors are tall, vertical structures that often require significant installation space. For facilities with limited ceiling height, installing one of these cyclones can be impractical. In some cases, a roof penetration is required, adding both expense and complexity. Outdoor installations may also increase dust collector maintenance because of exposure to weather and environmental conditions.

The Solution: Horizontal Cyclones

Horizontal cyclones provide a compact, space-saving solution for facilities with limited space. By reorienting the cyclone horizontally, it becomes approximately one-third the height of a traditional cyclone while maintaining excellent dust collection efficiency. With both the inlet and outlet located on the same horizontal plane, these cyclones can replace a 90-degree ductwork turn, reducing installation costs and simplifying system layouts.

What sets horizontal cyclones apart is their ability to deliver high dust removal efficiencies. Some designs perform as well as — or even better than — larger vertical cyclones. This allows facilities to install a smaller cyclone dust collector while maintaining excellent performance, reducing both material and installation costs.

The Aerodyne GPC Cyclone: Compact Yet Powerful

One of the best examples of a high-efficiency horizontal cyclone is the Aerodyne GPC Cyclone. Available in both horizontal and vertical configurations, the GPC offers remarkable efficiency while maintaining a compact form factor. The GPC Cyclone eliminates the need for the long, tapered body traditionally required by cyclones. This streamlined design makes it a perfect solution for facilities with limited space, offering an efficient dust collection system without the need for excessive installation room.

Key Benefits of the GPC Cyclone

• Pre-filter for baghouses and fabric filters, reducing dust loading on downstream equipment.
• Improves dust collection efficiency and overall industrial dust control.
• Extends filter life by removing larger particles before they reach the primary filtration system.
• Available in both horizontal and vertical configurations.
• Compact design for facilities with limited floor space or overhead clearance.
• Available in six sizes, each with less than 8 cubic feet of capacity, helping facilities comply with NFPA 654 requirements.

Additionally, the GPC Cyclone’s versatility extends to mobile units, making it ideal for various industrial applications. It’s also available with custom designs and easy-clean options for industries such as food processing, pharmaceuticals, and pigments.

The Aerodyne SplitStream Cyclone: Dual-Stream Design for Tough Dust Challenges

For facilities dealing with especially challenging dust types—such as abrasive, fibrous, sticky, or hygroscopic materials—the Aerodyne SplitStream Cyclone offers a unique solution. This cyclone design combines two airstreams, providing high-efficiency dust removal without sacrificing space. Available in both horizontal and vertical configurations, the SplitStream can be integrated into existing systems or installed in space-constrained areas.

One of the major benefits of the SplitStream Cyclone is its minimal maintenance. With no major moving components, the SplitStream is designed for durability and efficiency, reducing wear and tear from abrasive particulates. Its innovative design also allows it to handle variations in process temperature while efficiently collecting dust, making it suitable for a wide range of industrial applications.

Key Features of the SplitStream Cyclone:

• Handles a wide range of materials: Perfect for industries dealing with challenging dust types.
• Minimal maintenance: No major moving components mean less upkeep and fewer chances for failure.
• Space-saving design: Fits in horizontal spaces and can be installed in both new and existing facilities.
• Handles abrasive and sticky materials: Reduces wear and allows for effective collection of tough dust types.

Horizontal cyclones, such as the Aerodyne GPC Cyclone and Aerodyne SplitStream Cyclone, are revolutionizing dust collection systems by offering efficient, space-saving solutions that can be easily integrated into existing setups. Whether you’re facing limitations with headroom or looking to optimize dust collection efficiency without taking up valuable space, these compact cyclones can provide the answer. By reducing both installation and material costs and boosting overall efficiency, horizontal cyclones are an excellent investment for industries focused on dust control and air quality.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click here to start the conversation with a member of our engineering team. 

Furthermore, complying with NFPA regulations often requires placing dust collectors outside the primary working area due to safety concerns. This external placement adds an extra layer of space management complexity. Additionally, dust collectors are typically mounted on structural supports known as skids, which simplify installation and relocation but also consume additional space within the facility. Therefore, creating an effective ventilation system design requires careful consideration of how these elements harmonize within the given space while meeting safety and efficiency requirements.

Aerodyne’s GPC cyclone offers a practical solution for applications where space is a premium concern. Its compact design and efficient performance allow it to seamlessly replace bulkier equipment, making it a space-saving choice for a wide range of industries. By doing so, it not only maximizes available workspace but also simplifies maintenance and enhances operational efficiency. This versatility makes the GPC cyclone a valuable asset, offering a viable and efficient alternative to traditional, space-consuming equipment in various applications. 

Aerodyne GPC Cyclone

The GPC cyclone‘s compact design offers remarkable space-saving advantages, as it can be accommodated in areas that are only half to a third of the size required for traditional cyclones, as shown in the attached documentation. This compactness often permits indoor placement, aligning with NFPA-654 7.13.1.1.2 (2) regulations. Various industries, including those operating clean rooms, mines, vehicles, and portable systems, can capitalize on these space-efficient attributes.

Furthermore, the GPC cyclone’s design introduces the opportunity for installation in smaller spaces, potentially replacing the need for extensive ductwork, including 90° elbows. Additionally, it can serve as an effective pre-filter for existing cartridge collectors, baghouses, and electrostatic precipitators. This adaptability opens doors to innovative system configurations, such as positioning it above a conveyor belt to recapture particulate matter and reintroduce it onto the conveyor, showcasing the versatility and space-saving capabilities of the GPC cyclone.

The GPC cyclone by Aerodyne provides an added advantage by eliminating the need for an equipment skid. Many companies accustomed to traditional cyclones may hesitate to incorporate a pre-filter or cyclone dust collector into their skid or unit due to space constraints. However, GPC cyclones can be conveniently mounted on various equipment, such as on top of a dryer, behind a crusher, or at the inlet of a cartridge collector, without requiring a skid. This flexibility simplifies installation and ensures that space considerations do not impede the adoption of efficient dust collection solutions.

Moreover, the adaptability of GPC cyclones extends to marine applications, where space efficiency is paramount. Unlike traditional cyclones that demand multiple levels of a vessel’s decks, a GPC cyclone can be installed on a single deck, greatly enhancing the practicality, serviceability, functionality, and feasibility of incorporating cyclone-based dust collection systems on ocean or lake vessels. This versatility underscores the GPC cyclone’s ability to provide effective dust collection solutions without imposing significant space-related limitations. 

With these savings in space, facilities can operate more efficiently and avoid floor space issues. 

 Click here to talk to a member of our engineering team to about whether the GPC cyclone could improve your process. 

Traditional Cyclone

The typical cyclone design consists of a tangential inlet and a long-tapered body. Centrifugal forces force particulate out toward the walls, and gravitational forces direct the dirty gas stream downward through the narrowing body. As the gas stream becomes constrained in the narrow end of the cyclone body, a phenomenon known as “vortex-reversal’’ occurs in which a secondary inner-vortex is generated and moves upward through the center of the primary vortex where it is exhausted from the collector. Dust near the walls fall into the cyclone hopper and out of the airstream. The traditional cyclone must be vertical in design to operate effectively.

Vortex-reversal is one of the primary causes for inefficiencies in cyclonic dust collectors. As the inner vortex travels up through the cyclone, it takes with it any fine dust particulates that did not have the inertia to be forced tight to the collector walls.

Another issue that can develop with traditional cyclones is that an integral hopper could have dust re-entrainment into the clean airstream. Oftentimes, traditional cyclones will install a dust trap to prevent re-entrainment. The dust trap is located below the cyclone hopper and is designed to minimize particulate re-entrainment. If you’ve seen a cyclone with what looks like a pocket underneath it, it has a dust trap.

Aerodyne GPC Cyclone

The GPC cyclone uses a combination of a sloped spiral inlet and fixed ground plate to provide several distinct advantages over the traditional cyclone dust collector described above. 

First, a spiral inlet directs the dirty gas stream toward the ground plate and hopper of the collector. This efficiently begins the centrifugal motion of the air without any dead spots. The fixed ground plate, utilized by the GPC removes the requirement of a long-tapered hopper. The ground plate provides the vortex-reversal, rather than the geometry of the tapered hopper in traditional cyclones.

As the dirty gas stream strikes the convex ground plate; fine particulate, which has not completely made it to the collector walls, is deflected into the hopper. The ground plate also shields collected particulate from the clean air, acting as a barrier between the separation chamber and collection hopper; Therefore, no separate dust trap is required.

The GPC design allows it to be much smaller than traditional cyclones and includes 6 sizes under 8ft3 per NFPA 654. A GPC cyclone is usually less than half the height of a traditional cyclone. The ground plate also removes the requirement of gravity, so it can be designed for a horizontal installation, with virtually no effect on collection efficiency. The horizontal GPC is around 1/3 of the height of a traditional. The removal efficiency is high (99% of 20 micron particulate*).

* spherical dust, specific gravity of 1

Aerodyne SplitStream Collector

The Aerodyne SplitStream Collector uses two airstreams to remove particulate in the air. The primary air stream enters the cyclone and proceeds through a mechanical spinner. The spinner imparts centrifugal motion into the airstream, thereby forcing dust particulate toward the cyclone walls.

A secondary airflow enters the cyclone near the clean air exit. The secondary air proceeds through nozzles or vanes as it enters the cyclone. The secondary air then rotates around the outer edge of the cyclone, collecting particulates and delivering them into the hopper. The secondary air then reverses direction and joins the primary air and leaves the cyclone. Since the SplitStream Collector has no moving components, it is capable of handling a wide range of materials, while requiring minimal maintenance.

Particulate that is abrasive, fibrous, friable, sticky, or hygroscopic can be separated and collected for air pollution control or reclamation. The secondary air ensures that the dust doesn’t contact the walls. This minimizes wall abrasion for abrasive applications and areas. For particulate that is sticky, the secondary airflow keeps the dust from building up on the walls.

The SplitStream Collector has a very high removal efficiency of light, fluffy particulate that floats in the air. The secondary airstream also gives the option to heat up or cool down the process air and material. Removal efficiencies as high as 99% of 7- 10 micron dust range are normal*.

* as measured in limestone testing

To learn more about the different types of Dust Collection Methods, download our free white paper. To request a brochure of the Aerodyne GPC Dust Collector, please visit www.DustCollectorHQ.com. For more information regarding the full line of Aerodyne industrial dust collection products and material airlock valves, call (440) 543-7400, toll-free at (800) 358-7546, or e-mail dc@dustcollectorhq.com.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. To discuss your application with a member of our engineering team, click here. 

The post Traditional Cyclones vs. Aerodyne Cyclones first appeared on Aerodyne Environmental.]]> https://www.dustcollectorhq.com/horizontal-and-high-efficiency-cyclone/ Mon, 26 Aug 2024 19:25:00 +0000 https://www.dustcollectorhq.com/horizontal-and-high-efficiency-cyclone/ One challenge to designing a manufacturing process is choosing an effective dust collection system that will fit the limited available plant space. Low ceilings pose a challenge for high-efficiency cyclones due to their long-tapered bodies. In many cases, the dust collector must be placed outdoors or partially protruding through the roof. This can be an unfavorable arrangement. Aerodyne […]

Cyclone collectors

Because cyclone dust collectors are dependent on the airflow that travels through them, cyclone pressure drops are based on many factors. The two most important factors include the geometry of the cyclone collector and the volumetric airflow through it. The pressure drop formula of a cyclone has the square of the volumetric airflow through the cyclone. So, doubling the airflow will quadruple the pressure drop (2x ACFM leads to 4x dp). If your airflow changes through the system, the pressure drop through your cyclone can fluctuate. 

Since dust collection system static requirements are all related, the exhaust fan will find its operating condition naturally. However, if the airflow decreases, then the removal efficiency of the cyclone collector will decrease too. This means the cyclone will remove less of the finer dust particles, thereby sending them on to the filters. That will cause greater dust loading for the filters, which could increase the frequency of cleaning (more plant air usage, greater filter wear, etc.) and decrease the lifespan of the filters.

Filter Collectors

Filter collectors would actually benefit from lower airflow. The lower airflow would decrease the air to cloth ratio, which can extend the life of the filters. However, as described in the rest of this paper, the overall performance of the dust collector system will decrease. And if the system has a cyclone dust collector, the benefits gained by a lower a/c ratio could be counteracted by higher dust loading coming through the cyclone.

Higher airflow will increase the air to cloth ratio and could put more strain on the filters. The velocity of the air going through the filter could increase enough that holes in the filters could develop, thereby causing dust to bypass the filters.

However, filter collectors have a pretty good range of airflows they can handle without significant effect on the system. Unlike cyclones, the pressure drop in a filter is based less on airflow and more on the filter pack on them.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click here to start the conversation about more effective maintenance on your cyclone collector and/or fabric filters! 

How does GPC technology shrink the size of a cyclone without hurting efficiency?

Cyclone dust collectors are designed with a descending cone. Particulate laden air enters an inlet at the top and rotates down, exiting at the bottom while clean air is exhausted from the top. Dust is thereby separated from the airstream for recovery or later disposal. Distinct cyclones have emerged on the market that use GPC technology. These changes the shape and structure of the cyclone to make it just as efficient as much longer cyclones for the same volume of airflow passing through them.

GPCs have a ground plate located inside the cyclone. It intercepts dust in the airstream, causing particulate to divert toward the hopper, and also to lose momentum and fall out of the airstream. It also intercepts the airflow, thereby preventing dust re-entrainment from the hopper. What’s more, this technology is less dependent on gravity, enabling horizontal installation of the cyclone—very helpful where overhead space is limited.

Can a small cyclone reduce the cost of explosive dust applications?

More than 70% of industrial dusts are explosive, so venting for explosive dust is a common feature of plants. Potentially explosive dust requires the use of an explosive vent and ductwork in strict compliance with NFPA (National Fire Protection Association) standards. In general, in the event of an explosion in a cyclone, the goal is to control the location of the explosion, i.e. outside the building and away from people. Often it is more practical to locate the cyclone outside. This adds additional costs for a concrete pad and long ductwork runs. It also introduces the effect of weather that can shorten the lifetime of equipment.

Are horizontal cyclones easier to clean?

Standard cyclones may be time-intensive to clean, owing to flanges and small access doors.

A horizontally installed GPC cyclone typically features a wide removeable backplate, allowing it to be cleaned in a fraction of the time that a traditional cyclone requires. The bolts on the backplate can even be replaced with quick-disconnect clamps, further reducing maintenance time.

How can point-of-use dust collection cut costs?

Small dust collection cyclones are easier to install at the point of use, i.e. directly adjacent to a dust production area. This allows reclamation before the dust is mixed with other dusts in a central dust collection system. It’s always better to recover as much of your product as possible so you can sell it or reuse it, instead of letting it go into costly filters.

Point-of-use dust collection also minimizes buildups of material in the ductwork, as much less dust is travelling through the ducts to reach the main collector.

Can small GPC cyclones be used on mobile dust collection applications?

Any mobile dust collection application needs to maximize the available space and minimize weight. A big cyclone takes up precious space on a vehicle. Often a cyclone must be lowered before travel, to fit under obstructions such as bridges, and then raised to a vertical position when it gets to the job site.

Compact enough to fit on semi-trucks, trains, and ships, horizontal cyclones don’t need to be raised and lowered. The cyclone will already be in operational position while also easily fitting under bridges or into small spaces.

Aerodyne experts make a big deal out of small. For a consultation about the cost savings of small cyclones, or to discuss maximizing the efficiency of your current system with NFPA compliance, contact the experts at (440) 543-7400 or DC@DustCollectorHQ.com.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click here to start the conversation with a member of our experienced engineering team. 

Aerodyne SplitStream^™ Cyclone Dust Collector

The volume of gases being handled was estimated at 4,000 CFM at 700°F, according to the specifications of their previous cyclone. Using this information, a S4500 SplitStream grinding dust collector was selected and installed.

When the collector was started and the flows were checked, the company discovered that only 2,500 CFM at 500°F was needed to ventilate the kiln. Even at this lower-than-expected inlet flow rate, the results were excellent. No visible carry-over was detected, and the SplitStream dust collector captured materials much finer than previously collected.

The plant was satisfied it had made the correct decision and avoided the headaches and maintenance issues of a bag house. After several   months in operation, abrasion   wear   was   not   evident  on   the   collector. Consequently, the company ordered two more Model 4500 SplitStream grinding dust collectors.

The lack of a filter media and Aerodyne’s unique design make the SplitStream collector perfect for applications involving high temperatures and abrasive materials.

The Aerodyne SplitStream dust collector achieves high efficiency by forcing dirty gases into a powerful centrifugal motion. The centrifugal action throws dust particulate out of the gas stream. A secondary air stream carries the dust particulate to the hopper, keeping dust away from the collector walls and reducing sticking and abrasion. As a result, the SplitStream dust collector virtually eliminates maintenance problems common to other types of cyclones. The prevention of particulate contact with external walls is a major factor in the unit’s ability to achieve high efficiency ratings.

For more dust collection and material handling literature, visit the library tab on our website at www.dustcollectorhq.com.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Click here to connect with our engineering team with questions or for more information about the dust collection and material handling services offered by Aerodyne Environmental. 

We all know that if we don’t regularly maintain our cars, we will end up having issues in the future. If we forget to change the oil, change the brakes or get a tune up, it will eventually catch up to us. Why do we think our dust collection system is any different? Dust collectors are made of various pieces, all of which have to be operating correctly for the system to operate as desired. Usually, a dust collection system consists of the dust collector, exhaust fan, ductwork, and hoods/pickup points. Additional accessories such as airlocks, controls, instrumentation, and dampers all can affect the operation of the system.

The following questions with quick explanations will help you evaluate your dust collector. If after going through this guide you think your dust collector needs a tune-up, contact a local expert or Aerodyne Environmental and have them come in to help you get your system working properly.

Pickup Points

1. Are the areas near the pickup points dusty? Is there any dust in the air, is it hazy, or is breathing in the area a bit difficult?

2. Are there dust piles around the area? Dust piles and layers of dust can become airborne and if the dust is explosive, it can lead to an explosion causing significant damage and injury.

3. Can you feel airflow being pulled into the hood or pickup point?Often times, dust collection systems will be modified and this could cause a loss of airflow at other areas in the system.

4. Did the dust collection system ever work as expected? Sometimes a dust collection system has never fulfilled expectations. This doesn’t mean that changes can’t be made to get it working better.

Ductwork

1. Does the ductwork have holes? Holes allow air to leak into the system, this will cause less air to be picked up at your hoods and pickup points.

2. Are you plugging up your ductwork? Plugged up ductwork is caused by low air velocities through the ductwork. This will cause low airflow at your hoods and is an explosion danger.

3. Have you added or de-commissioned pickup points on your system? Adding or removing pickup points can cause the system to be out of balance. If you have done this without re-evaluating the whole system, your system may not be operating correctly.

Dust Collector

There are a variety of different dust collectors available—baghouse and cartridge collectors, cyclones, and wet scrubbers. Each one of them has different things to look at. We will only address a few of them here. Contacting a dust collection expert such as Aerodyne Environmental can help you diagnose issues.

Baghouse and Cartridge Collectors

1. When was the last time you changed filters? Some customers have to change filters twice a year, others haven’t changed them since they were installed. Both examples could have issues.

2. What is the pressure drop across your filters? Pressure drops over 6” W.C. usually tells you that you need new filters soon. A low pressure drop can mean that you have holes in your filters or haven’t properly developed a dust cake on the filter.

3. When was the last time you did a maintenance check on your dust collector? If you haven’t done it in the past year or two, it might be time. Filters, tube sheets, diffusers, air valves, manifolds and a variety of other items can all develop issues.

Cyclone

1. Have you checked your cyclone for holes? Cyclones often wear faster than other dust collectors, so a yearly check for pin holes or wearing is always a good idea.

2. Do you have a filter after your cyclone? Since cyclones have lower removal efficiencies than most other dust collectors, if your cyclone doesn’t have a filter afterward, you might want to monitor the emissions regularly to make sure you’re not emitting too much dust.

Wet Scrubbers

1. What is the pressure drop through the wet scrubber? Higher than normal or lower than normal pressure drops always tell you something is happening. Higher pressure drops usually means that dust is building up in the system. Lower pressure drop usually means that less airflow is going through the system.

2. Do you monitor your water usage and the particulate loading of the overflow? The overflow stream of the wet scrubber removes the particulate and the dissolved solids from the system.

3. Are you taxing your water treatment plant? Water treatment is expensive so if you can lower the amount of water going to it, you could save money.

Exhaust Fan

The exhaust fan usually provides all the motive force in a dust collection system; therefore, if the fan isn’t working properly the whole system will be having issues.

1. Is the fan vibrating excessively?
2. Is the fan making more noise than usual?
3. Are the bearings in the fan running hot?

Excessive vibrating and unusual noises can mean that something is wrong with the fan. Damage to the impeller or dust build up on the impeller could cause this. Some fans do get unbalanced over time and could cause the fan to stop working. A bearing running hot could be caused by an issue with the fan or an issue with the bearing. Hot bearings, while unlikely, have been known to cause fires or explosions if all the conditions are right.

Miscellaneous

Other items to check on your dust collection system include dampers, airlocks, controllers and instrumentation. Dampers not operating correctly, or accidently opened/closed can cause operating issues. Airlocks under dust collectors can cause air leakage into the system or prevent dust from leaving the system. Controllers and instrumentation can cause the system to shut down, or provide wrong reading, thereby affecting the operation of the system.

For more dust collection and material handling literature, visit the library tab on our website at www.dustcollectorhq.com.

To improve efficiency and safety, there is no substitute for an on-site inspection by an experienced expert. Our engineering team is available here to answer any questions you have about improving or evaluating your setup. 

The post Questions to Ask When Evaluating Dust Collection System | Aerodyne first appeared on Aerodyne Environmental.]]>