There is no one-size-fits-all approach when it comes to large industrial dust collectors. Your equipment supplier should be able to customize your system to fit your space, application and maintenance protocols.
Dust collection equipment is essential in many types of industrial settings to ensure a safe work environment and compliance with local, state and federal air pollution regulations. The design of a dust collection system depends on several key factors:
Ease of Installation
Industrial dust collection systems are costly, but the long-term ROI in terms of reduced health costs and insurance premiums, fewer regulatory fines, lower equipment maintenance and energy savings makes them well worth it. The true cost of a system is measured in both upfront and ongoing expenses, including energy usage, labor, ducting and filters. Choosing the right system requires careful consideration of the types and sizes of facilities, major dust-emission points and conditions and a clear understanding of the nature of the material to be filtered.
During operation, a dust collector draws air into the unit and passes it through one or more fans, which capture contaminant particles and adhere them to the filter. Clean air is then recirculated to ensure that all areas remain free of hazardous vapors and particulate matter.
The type of dust to be filtered will have an impact on the overall size of the system, as well as the type and number of filters, fan size and operating temperature. Additional specialized components may also be needed to achieve optimal filtration for oils, moisture, harsh chemicals and highly abrasive or combustible materials.
To reduce energy consumption, a large system should be located in an area with sufficient power availability and with large industrial dust collectors low humidity and temperatures. Ideally, the system should be located near a point where waste products can be easily disposed of.
Ease of Maintenance
When you install a large industrial dust collector, you can reduce dangerous particulate contaminant matter in the air in your factory or plant. Its effectiveness depends on your ability to maintain it. The equipment may also help you meet compliance regulations for your industry.
You can enhance the performance of a dust collection system by adding various accessories. Some are safety-related, such as OSHA-compliant railed or caged platforms for changing filters. They prevent workers from slipping and falling during the pulsing of filter pulses. Others are designed to make the maintenance process more efficient. For example, a filter monitoring system lets you track differential pressure trends over time and alerts you when the pressure has reached its manufacturer-defined limits.
Some industries must use large industrial dust collectors to handle challenging particles, such as abrasive, combustible, sticky or hygroscopic fine materials. In these cases, the equipment must be designed with explosion protection to prevent a dust accumulation and ignition.
The most common method of explosion prevention is to vent the dust collector. Explosion vents open when predetermined pressure levels are reached inside the collector. They relieve the internal pressure and allow flames to escape before they can reach the worker inlet. Another option for handling explosive dust is an electrostatic precipitator, which separates soot and ash from exhaust gases by using static electricity.
Ease of Repair
Dust collectors may not be the flashiest equipment in a manufacturing facility, but they’re vital to keep production running smoothly. Regular inspections, cleaning, and maintenance can help ensure a healthy working environment and extend the lifespan of these workhorses.
Maintaining a dust collection system requires understanding that there are many critical components to this complex piece of machinery. The dust collector type, filter media, fan performance and placement, dampers, silencers, duct and capture hoods all need to be properly matched in order to maximize collection efficiency. This typically involves walkthrough large industrial dust collectors factory inspections that point out areas where design errors or wear and tear are evident.
The ductwork itself needs to be sized and configured for consistent airflow and velocity. A higher velocity reduces the amount of abrasion and corrosion within the ductwork, and this extends the duct’s life. The ductwork must also be designed for adequate differential pressure, which helps to avoid clogging the clean air side of the dust collector with too much debris.
Performing regular inspections, changing or replacing filters and collection bags, emptying the collection bins, and lubricating the system is a vital part of a good maintenance program. This schedule should be based on the manufacturer’s guidelines, which provide detailed instructions for inspecting intervals, cleaning requirements and more. Inspections should be conducted monthly (or more frequently for large or heavily-used systems) and be documented by maintaining daily, weekly, monthly, and yearly inspection logs as recommended by the manufacturers.
Ease of Service
Many industrial businesses must meet strict air quality standards set by regulatory agencies like the EPA, National Fire Protection Agency (NFPA), OSHA, and local governing entities such as AQMD in California. Efficient dust collection systems are crucial for maintaining the health and safety of workers, reducing risk, and keeping products high in quality.
Large industrial dust collectors work by utilizing fans to pull air into the filtration system, where it passes through the filter and any particles attached to it will be trapped. Clean air is then recirculated back into the workplace. Depending on the application, baghouse or cartridge dust collectors are commonly used. Baghouse systems are able to handle abrasive and sticky materials, while cartridge units can be easily cleaned and can handle higher temperature applications.
Since some types of dust are combustible, it’s important to ensure the equipment is fitted with deflagration venting. The explosion vents open when predetermined pressures are reached inside the unit, preventing overpressures and allowing the excess gas to escape into a safe area.
Understanding what your facility produces on a daily basis is critical in selecting the right type of dust collection system. Factors such as the size and speed of your machinery, ducting system requirements, and abrasiveness will all impact your facility’s needs in terms of size, system type, and extra equipment to purchase.