Industrial Dust Collectors. What do they do?
Industrial dust collectors control, reduce, and remove potentially harmful dust and fumes from the air and the surrounding environment during manufacturing or construction processes to improve air quality and maintain the health and safety of workers.
Industrial dust collectors are used in a wide range of industries and commercial settings to meet workplace health, safety and environmental requirements.
Industrial dust collectors are designed to handle high-volume dust loads, and consist of a fan, filters, a filter-cleaning system, and a dust receptacle or dust discharge system.
Industrial Dust Collectors. What different types?
There are five main types of industrial dust collectors are:
- Inertial separators
- Fabric filters (bag houses)
- Wet scrubbers
- Electrostatic precipitators
- Unit collectors
Grydale Dust Collectors. Fabric Dust Collectors (Fabric Cartridge)
Dust unit collectors control contamination at its source. They are small and self-contained, consisting of a fan and dust collector. They are suitable for isolated, portable, or frequently moved dust-producing operations, such as bins and silos or remote belt-conveyor transfer points.
The key advantages of unit collectors include:
- Small space requirements.
- Collection of dust (for return to main material flow / processing, or recovery of dust product).
- Low initial cost.
There are two main types of unit collectors; Fabric Collectors that are normally used for fine dust, or Cyclone Collectors that are normally used for coarse dust. Grydale offer Fabric Dust Collector Units.
Fabric collectors are frequently used in minerals processing operations because they provide high collection efficiency and uninterrupted exhaust airflow between cleaning cycles.
The following points should be considered when selecting a unit collector:
- Air Volume
- Filtration Efficiency
- to be compliant with industry regulations.
- Operational Efficiency
- capable of managing dust loading without losing effectiveness
- able to operate for extended periods of time (e.g. full shift)
- able to regulate power consumption to deliver required air volume at minimal cost
- filter replacement timescales and costs
- Efficient Filter Cleaning
- Dust Discharge
- capable of discharging dust back into processing or collected for product recovery
- should not cause secondary dusting
- to be compliant with industry regulations
Industrial Dust Collectors. How to Choose?
Dust collectors vary widely in design, operation, effectiveness, space requirements, construction, and capital, operating, and maintenance costs. Each type has advantages and disadvantages. However, the selection of a dust collector should be based on the following general factors:
- Dust concentration and particle size – For minerals processing operations, the dust concentration can range from 0.1 to 5.0 grains (0.32 g) of dust per cubic foot of air (0.23 to 11.44 grams per cubic meter), and the particle size can vary from 0.5 to 100 micrometres (µm) in diameter.
- Degree of dust collection required – The degree of dust collection required depends on its potential as a health hazard or public nuisance, the plant location, the allowable emission rate, the nature of the dust, its salvage value, and so forth. The selection of a collector should be based on the efficiency required and should consider the need for high-efficiency, high-cost equipment, such as electrostatic precipitators; high-efficiency, moderate-cost equipment, such as baghouses or wet scrubbers; or lower cost, primary units, such as dry centrifugal collectors.
- Characteristics of airstream – The characteristics of the airstream can have a significant impact on collector selection. For example, cotton fabric filters cannot be used where air temperatures exceed 180 °F (82 °C). Also, condensation of steam or water vapor can blind bags. Various chemicals can attack fabric or metal and cause corrosion in wet scrubbers.
- Characteristics of dust – Moderate to heavy concentrations of many dusts (such as dust from silica sand or metal ores) can be abrasive to dry centrifugal collectors. Hygroscopic material can blind bag collectors. Sticky material can adhere to collector elements and plug passages. Some particle sizes and shapes may rule out certain types of fabric collectors. The combustible nature of many fine materials rules out the use of electrostatic precipitators.
- Methods of disposal – Methods of dust removal and disposal vary with the material, plant process, volume, and type of collector used. Collectors can unload continuously or in batches. Dry materials can create secondary dust problems during unloading and disposal that do not occur with wet collectors. Disposal of wet slurry or sludge can be an additional material-handling problem; sewer or water pollution problems can result if wastewater is not treated properly.
- Choosing the right size dust collector depends on airflow volume and air-to-cloth ratio that determine the efficiency of a system. Optimal dust collecting equipment increases employee retention and preserves equipment that helps lower maintenance and replacement costs.
- Choosing a too-large, undersized, or incapable dust collector can cause plenty of issues that impact performance and maintenance costs. Hence, the dust collector should be chosen in such a way that suits the company’s specific workplace.
- It must provide a safe and healthy work environment for the employees. Moreover, employee efficiency and production should not ignore.
Industrial Dust Collectors. How do they work?
Industrial Dust Collectors. What size?
Industrial Dust Collectors. Why are they required?
Market demand for dust control solutions is escalating globally and health and safety experts are focusing on increasing dust control regulations due to the potentially hazardous consequences on the health and safety of workers.
Dusts that can cause diseases when inhaled are found in a large number of industries and industrial processes. Hazardous dusts include but are not limited to: asbestos, crystalline silica, hard metals, aluminum, bagasse, fertilizer, cotton, hay, straw, and grains. Silicosis is the most common occupational lung disease worldwide and often referred to as the modern asbestos.
The risk of dust related diseases increases with increased exposure. Workplace Health and Safety (WHS) legislation now places strict requirements for the management of dust through Workplace Exposure Limits (WEL). Globally, the WEL for specific dust types do vary, but regulations are being periodically reviewed and updated to take into account current scientific evidence linking exposure to disease.
Industrial Dust Collectors. Revenue Generating.
Industrial dust collectors can also be used to recover valuable product that would otherwise be lost into the atmosphere. This can make the use of a dust collector cost neutral or a valuable addition to industrial processes. Dust can either be collected and re-introduced to processing or recovered and sold as a different product.