How to Choose the Right Industrial Dust Collector
Dust control is a major concern in most industrial settings. Governmental regulatory agencies such as the Occupational Safety and Health Administration (OSHA) and National Institute for Occupational Health and Safety (NIOSH) regulate and publish standards for air quality within production facilities.
Effective industrial dust collectors are a necessity for these operations to meet these standards and keep workers safe. There are many options for a system, including:
Baghouse
Baghouse industrial dust collectors are used in a variety of industries to filter a wide range of air particles, from fine wood and grain dust to heavy metal fumes. They’re known for their ability to handle a variety of temperatures, making them well-suited for many industrial processes.
One major advantage of baghouses is their lower operating and maintenance costs, compared to other types of dust collection systems like electrostatic precipitators. This is due in part to the fact that they don’t use bags that need to be replaced, and also because of their efficient cleaning mechanisms like pulse jet cleaning, which extends bag life and minimizes downtime for maintenance.
These systems can be customized based on specific application needs, with different air-to-cloth ratios and fabric constructions to choose from. The type of filter material and the system’s size and aeration are other factors that can affect the overall cost of a baghouse.
Once you’ve selected a baghouse, it’s important to know how to operate it properly, including how to perform the correct start-up procedure. This will optimize performance, help prevent initial blinding and extend the life of new filters. It’s also important to regularly monitor pressure drop, which will help you spot and address developing issues before they become more serious.
Cartridge
Cartridge dust collectors have filters that are pleated, cylindrically shaped and offer industrial dust collector more filter surface area in a smaller form factor than baghouse filters. They are commonly used in applications that have a light to moderate dust loading such as metalworking, shot blasting, welding fumes, sanding, powder coating and thermal spray operations.
Dirty air enters the dust collector through a baffled inlet, passes through the filters and is cleaned by short bursts of compressed air called pulses. The filtered clean air is then recirculated back inside the facility or vented to the outside environment.
Regular industrial dust collector filter change-outs allow the system to operate at optimum efficiency. This means less energy use, lower operational costs and a healthier working environment for your employees.
Unlike baghouses, cartridge-style dust collectors are generally easy to access for filter maintenance and cleaning, requiring the use of simple tools. They can be hung in either downflow or upflow styles, depending on the application and facility layout. Downflow models are usually easier to access for routine maintenance because they do not require the use of special tools or actual physical entry into the cavernous dirty air plenum (potential confined space entry).
They are typically built in a vertical orientation or stacked industrial dust collector side-by-side to fit areas with limited overhead space. They can be configured to meet NFPA, OSHA and other safety standards for your operation.
Cyclone
Whether you’re operating inside a massive factory or a small shop, your industrial processes will generate dangerous dust particles that must be removed before they escape into the atmosphere. The best way to do this is by using a cyclone dust collector. These machines create a curved flow of air in a high-speed, revolving motion. This forces larger dust particles to fall downwards through the cyclone walls, while the clean air is directed into the gas exit at the center of the machine.
When selecting a cyclone dust collector, it’s important to consider the size of your workspace and the type of materials you use. You should also choose a model with a remote control to save time and effort when starting and stopping the dust collection process.
The motor power of a cyclone dust collector is also an important factor to consider, as it dictates how powerful the unit will be. For example, a 1.5HP model will work well for small shops, while a 2HP model will be ideal for medium-sized ones. For large shops, a 3HP model will provide the necessary suction.
In addition to the motor power, it’s also important to select a model with a large collection bin capacity. This will help you avoid having to empty the collection drum frequently and will also save you money in the long run.
Thermal Spray
Thermal spraying, also known as metalizing, is a process that coats surfaces with heated materials. It is used to protect metals from corrosion, wear, and oxidation in industries such as aerospace, medical implants, gas turbines and automotive manufacturers. The process generates a fine dust called fume that is often toxic and can have adverse health effects for workers if inhaled.
This type of dust can be combustible and operations that generate or handle this dust need special mitigation efforts to minimize fire and explosion risks. Typically, effective collection and extraction systems are needed to mitigate the hazards of these fine particles.
These collection systems need to be specially designed for the specific spraying methods, materials and local conditions. This allows the system to maximize separation efficiency and minimize the collection of non-hazardous air.
It is important to note that even the best filtered industrial dust collector cannot completely eliminate all contaminant from your facility. Therefore, proper housekeeping is required to ensure that all areas are adequately ventilated.
To do this, avoid sweeping the area with a broom. It will disperse the contaminated dust into the air. Instead, a vacuum is recommended. In addition, employees should not eat, drink or smoke near toxic dusts. The use of protective gloves and masks are also encouraged in the work environment. Psychological studies show that a clean working environment improves morale and productivity. Additionally, it can prevent your business from being shut down due to violations of worker safety laws such as OSHA and NIOSH.