Different Types of Industrial Dust Collectors
Industrial operations generate fine dust and fumes that require filtration. The right filtration system keeps workers safe and protects facilities from costly equipment failure.
Several types of industrial dust collectors are available to handle different plant processes. Choosing the best one depends on the nature of the pollutant, its concentration and size, and whether it’s hazardous or explosive.
Electrostatic Precipitators
As the name implies, electrostatic precipitators use an electric charge to grab dust particles from a gas stream. The resulting flakes are then collected and deposited in a hopper for subsequent removal. ESPs are highly effective at controlling particle pollution and are particularly well suited for applications involving combusting coal, oil or natural gas. They also work with a variety of gas temperatures and flow rates.
The most common type of ESP is a plate-wire precipitator, which consists of parallel metal plates and wire electrodes charged to high voltages (20,000 to 100,000 volts). As particulate-laden gases pass between the discharge and collection electrodes, the particles acquire a negative charge from the corona effect. As the particulates move toward the positive collector plates, they are precipitated from the gases in a process similar to that Industrial dust collector of a static dryer. The collected flakes are then cleaned by rapping the collector plates and in some cases with water sprays.
Compared to baghouse systems, ESPs have relatively low operating costs. However, they have a higher capital cost than other systems and can be subject to fluctuations in the gas stream that can reduce their performance. Additionally, the operation of ESPs can result in ozone emissions, which are harmful to humans with breathing conditions such as asthma. Ozone is also a carcinogen.
Baghouse Systems
Baghouse systems are popular among industrial users because they are highly effective at capturing and containing particulate matter in the air, allowing for a safe working environment. They can be customized for nearly any application and are often required by state OSHA regulations for facilities that run processes that produce heavy smoke, dust and other fumes.
A typical baghouse system consists of filter bags suspended inside a casing or housing that is vented to the atmosphere through fans on the outside of the unit. Dirty or polluted air is drawn in through ducts and blown through the filters, collecting solid particles on the bag’s surface until a “dust cake” forms. The filter is then cleaned, and clean air is discharged through the vents. Baghouses can be designed to discharge the dust cake on-line or offline, depending on the application and the ability to handle the pressure differential between the filtered and unfiltered air streams.
Choosing the right type of baghouse system depends on the particle size, airflow, and maintenance requirements of the process. For example, pleated filters offer higher efficiency than standard filter media and may be required for very fine particles and high-temperature applications. Pulse jet baghouse systems use pulses of compressed air to break up the dust cake and increase filtration efficiency. Some systems also use sonic horns to help dislodge the dust cake and reduce cleaning times.
Pulse Jet Systems
Pulse jet systems provide an excellent solution to industrial dust collection, particularly in areas where air quality is a major concern. They are highly versatile, and can be adapted to Industrial dust collector manufacturer meet the particular requirements of any production or manufacturing facility.
These systems are characterized by a Venturi valve inside the bag cage, which releases bursts of compressed air every few seconds to remove caked-on particles from the filter bags. This eliminates the need for downtime to clean bags and provides a continuous flow of product while dust is removed from the system.
The pulsing of the compressed air is also effective in keeping particle density low, allowing for longer filters without needing to replace them as frequently. The pulsing also helps with the energy costs of the system as a result of lower compressor air consumption to keep the air pressure in the system high.
The pulsing frequency of the compressed air is controlled by a timer board. However, it is essential that the maintenance team be familiar with how to adjust the pulsing frequencies of each unit. This includes daily (or at least once per shift) looking and listening to each unit while it is online to ensure that the pulsing frequency, sounds, and differential pressure is appropriate. This along with weekly, monthly, and yearly maintenance checks will help the plant to conserve compressed air as well as improve the efficiency of each pulse jet.
Other Options
There are many different ways to collect fugitive dust, and each one has its benefits and disadvantages. The most important factor when determining which method to use is the rate at which the material being collected is being produced. This will allow the industrial dust collector to be sized appropriately and avoid costly over expenditures.
One popular method is the cyclone dust collector. This type of system uses centrifugal force to separate dust particles from air within a cyclone-shaped chamber. They are highly efficient and can reach efficiencies above 99.9 percent. They are a great option for sticky and oily dust types.
Other options for industrial dust collection include baghouse systems, wet scrubbers and media filter-based collectors. The type of system used is based on the size of the facility and the materials being processed. The size and shape of the hood, fan horsepower and ducting diameter are also important in determining the proper type of dust collector to purchase.
It is recommended that all industrial dust collector machines be fitted with variable frequency drives (VFDs). This allows the machine to operate at a lower amperage and reduce electrical costs. They also help to regulate the fan speed according to filter conditions and process airflow requirements. VFDs also aid in extending the life of the fan by preventing abrasion and overheating.
