How Cost Affects the Selection of an Industrial Dust Collection System
Industrial dust collection systems provide a safe working environment, and while upfront costs are high, they offer substantial savings through health and safety benefits, regulatory compliance, and increased operational efficiency. Understanding the various factors that affect cost can help you make a more informed purchase decision.
A blower or fan pulls the contaminated air through ductwork and into the system for filtration. The type of filter media determines initial startup and long-term maintenance costs.
Baghouse
Baghouse dust collectors are ideal for industrial facilities that produce high volumes of airborne particles and gas fumes. These units are typically located indoors, where they can save energy by recirculating cleaned air back into the facility. They can also help meet indoor air quality standards set by governmental agencies like OSHA.
A baghouse dust collection system consists of a series of filters, or bags, that are used to trap harmful particulate matter and gases during manufacturing processes. They are able to achieve high filtration efficiencies, ranging from 99.9% to 99.999%, and are capable industrial dust collection system of handling large air volumes. They are commonly used for capturing airborne particulate matter in a range of industries, including metalworking, pharmaceuticals, and chemical processing.
When dirty air enters a baghouse unit, it first passes through a baffle that knocks larger particles into a collection hopper below the filters. Then, the air is pulled up through the filter media and blown off of its surface by bursts of compressed air. The caked particles fall off the filters into a storage hopper below, and the clean air is released through an exhaust duct.
The performance of a baghouse system depends on the size of its filter, its particle sizing, and its air-to-cloth ratio. The type of cleaning method is also important. Some systems use a mechanical shaker, while others, such as the Mac Process MCF PowerSaver, employ an automatic pulse cleaning method that limits the amount of air compressor used in the cleaning process.
Cartridge-style
Cartridge-style dust collectors have a fan mounted on the top of their housing. They move contaminated air into a cartridge-shaped filtering system that holds wire-reinforced pleated polyester fiber filters. The cartridges are closed on one end, and the other is open for clean exhaust. An alternating sequence of compressed air blows back through the cartridges and dislodges built-up dust, which drops to the hopper below. Then, the cleaner air is expelled through a vent on the roof of the dust collection system.
Regular industrial dust collection filter change-outs ensure that your equipment works at peak efficiency. Filters that are full of dirt restrict airflow, which increases energy consumption and decreases system effectiveness. Regular maintenance also extends the life of the filter by ensuring that the filter pleats are not clogged with dust, which can result in gasket leaks and decreased performance.
Industrial dust collectors are sized to meet the needs of specific applications. They must be able to handle the required volume of airflow (in cubic feet per minute, or CFM). To get an accurate idea of how much your system will need to perform at maximum efficiency, talk to an experienced manufacturer.
Choosing the wrong type of dust collection system can leave your facility out of compliance with workplace safety standards. To avoid costly mistakes, speak with a reputable company that offers comprehensive product lines for all types of processing equipment.
Electrostatic precipitator
An electrostatic precipitator applies separation forces directly to dust-laden gases, making it much more efficient than baghouses or venturi scrubbers. It is also more cost-effective than wet collection systems, such as sprays or irrigation. In addition, it is highly effective for content that holds a lot of moisture or combustible particles. This system can also operate at higher temperatures than other types of particulate control equipment, which reduces operating costs.
ESPs are typically designed with a linear discharge electrode (cathode) and a platey dust-collecting electrode (anode). When dc high voltage is applied between the electrodes, the gas is ionized, causing electrons to flow towards the anode. This process is known as corona discharge. The ions then carry away a negative charge, which attracts them to a collection plate. The accumulated particles are then shaken off by mechanical rappers and fall into a collection hopper at the bottom of the device.
The ESP’s main features are its long electric field length, high power supply device efficiency, low discharge intensity and low corona inception voltage (CIV). In addition, the system can withstand severe working conditions, such as abrasion, erosion and corrosion. Its structural integrity is characterized by its framed discharge electrode and the SIII type dust collecting electrode with superior cross-sectional strength. In addition, it is able to eliminate the center vibration bearing problem, which often occurs in conventional devices.
Coating
Whether your work involves powder coating or some other form of industrial finishing, dust collection systems are an absolute necessity. The finishing process creates airborne particulate that can cause a range of problems, including respiratory issues and skin irritation, and can compromise worker safety. It also can impact quality and efficiency.
One of the main reasons to invest in a dust collection system is to meet local or state regulations, such as the Occupational Health and Safety Administration (OSHA) and the National Institute industrial dust collection equipment for Occupational Safety and Health (NIOSH). These organizations have specific standards regarding the allowable percentage of particulates in a cubic foot of air, and if these are violated, your business could be closed.
In addition to keeping workers healthy and safe, a well-designed dust collection system can improve productivity. Psychological studies, such as the Hawthorne Study, have shown that a clean and tidy workplace results in more productive employees. A dust collection system significantly reduces the need to sweep or dust, allowing workers to focus on the task at hand.
A cartridge dust collection system can be an excellent option for industrial processes that generate combustible and toxic dusts, helping facilities comply with major regulatory bodies like the Occupational Safety Health Administration, National Fire Protection Association, and EPA. It is also ideal for reducing airborne contaminants from grinding, milling, crushing, mixing and blending, drying and screening, and weighing and batching.