Dust Testing & Efficiency Clinic
An efficient dust collection system provides many benefits to a company, its workers, and the environment. Compliance with emission standards, enhancing worker safety, protection against fire and explosion and the long-term cost savings are all reasons for a well-designed system.
A member of our engineering team performing dust testing on a customer sample.
Aerodyne offers a variety of services to help you analyze your needs, design the right solution, or maintain, improve and expand your dust collection system. Dust collection systems routinely evaluated and inspected are efficient, and Aerodyne can assist you in keeping your system running at its full capacity.
Aerodyne offers:
- Dust Testing (particle size, removal requirements)
- System Evaluations (equipment evaluations, dust safety and collection assessments, DHA and PHA)
Dust Collection Support
Dust collection systems can range from being straightforward and simple to extremely complex. Matching the proper system to your application is important. We’ve compiled and answered commonly asked questions faced when considering a dust collection system solution.
Airlock Support
Airlock valves are vital components in dust collection and process systems. They form a gateway between the conditions inside and outside the dust collector while allowing the accumulated dust material to pass through. An improperly operating airlock can cause issues with the entire system operation, including removal efficiency, constant repairs, and downtime for maintenance. To provide you with more information, we’ve compiled some of the more frequently asked about airlock valves.
Frequently Asked Questions
How can I get my dust tested?
We recommend you contact us to talk to an engineer about your application or request the Dust Testing Brochure.
What are the different kinds of cyclones offered by Aerodyne?
Aerodyne offers a GPC (ground plate cyclone) cyclone, a SplitStream cyclone, and a traditional TR cyclone. We also offer horizontal options. These can be customized to your specific application.
- The GPC– this cyclone is our compact high efficiency cyclone. Because it has a ground plate, it does not require a long, tapered body for effective dust separation, and its unique compact design is available in horizontal or vertical configurations.
- The SplitStream– this cyclone is best suited for tough dust and the issues that come with it. It’s capable of handling a wide range of materials with no major moving components, horizontal capability, and requires little maintenance.
- Traditional TR cyclone- This more traditionally built cyclone allows for the collection of large particles in an airstream when installed as a prefilter, and lowers loading strain on the system. This is a reliable, economic option.
Aerodyne also offers custom cyclones.
What are the different kinds of valves offered by Aerodyne?
Aerodyne offers trickle valves, double dump valves, knife gate valves, and rotary valves. Airlock valves are necessary on dust collection systems to prevent air leakage and pressure changes, which cause a variety of other issues within the system.
- Trickle Valves like the Vacu-Valve– Trickle valves are passive, non-powered discharge valves. The Vacu-Valve has a rub
- Double Dump Valve– This is an industrial airlock valve with two tandem doors to discharge material without losing pressure or jamming.
- Knife Gate Valve – Designed of hopper control, the knife gate is a basic airlock
- Rotary Valve – Aerodyne offers a high capacity, non-NFPA rotary valve for non-combustible applications
Why is dust bypassing my cyclone separator?
Dust can bypass your cyclone separator for a variety of reasons, but common causes we see are:
- Air leaks in the collection area as a result of airlock failure or seal failure
- Improper airflow or incorrect fan size creating too much or too little force for centrifugal motion to occur
- Dust particle size not matched properly with the cyclone’s capabilities, or tough dust causing issues by bridging or sticking
- Abrasion or damage to the cyclone itself
Why is dust settling or plugging in my ductwork?
Dust can settle and plug in ductwork for a variety of reasons, but a common issue is low airflow in the system, meaning the velocity will also increase in the ductwork and cutting off airflow. When air velocity becomes too low in ductwork, dust will begin dropping out of the airstream and building up within the ductwork. This can cause the ductwork to become heavy and risk falling or damage, which is especially dangerous for explosive applications.
Why is my dust collector experiencing high pressure drop? What causes this?
Dust collector pressure drop is typically related to filter (baghouse or cartridge collector) issues. Common causes we see are:
- Heavy dust loading that plugs filters quicker than cleaning cycles can keep up with
- Wet or humid dust causing premature plugging (especially for hygroscopic dust or pleated filter applications)
- Abrasive dust wearing away at baghouse diverters and creating uneven dust distribution among filters
- Humid compressed air during cleaning cycles can exacerbate filter plugging
- Ineffective cleaning systems resulting from damaged air valves, misaligned venturi, bags stuck on cages, and weak compressed air streams (filters are cleaned by expanding the bag to remove the dust layer, so ineffective expansion will cause dust to linger)
- When the airflow is too high in a collector’s ductwork, the air velocity will increase and can cause increased pressure drop and erosion of collector walls, furthering air pressure issues
- Improperly sized cyclones
These issues can be prevented by having a professional maintenance onsite to regularly inspect and maintain your dust collecting equipment. A system evaluation is also recommended.
Why is my dust collector losing suction?
Your dust collector could be losing suction at a variety of points throughout the system, so it is important to evaluate:
- Pickup points: leaky airlocks can decrease airflow at pickup points, causing a decrease in the amount of dust collected.
- Dust blowing out of airlocks: again, if the airlock is leaking too much, collected dust can be blown out of the airlock and cause dust to scatter around the collector.
- Dust reacting with water: Humidity from the surrounding environment can cause dust to become sticky, bridge, or even explosive in some circumstances.
- Oxygen deficient systems- outside air from a leaky airlock can introduce oxygen into the system, which can feed a dangerous reaction
- High pressure or low vacuum systems- leaking airlocks can bleed pressure or allow air into a high vacuum, forcing the pressure control system to work harder
Issues like this are typically airlock related.
