Category Archive: Dust Collection Design

Baghouse Dust Removal Options

Why Baghouse Dust Removal Matters

The right baghouse dust removal method can help minimize problems that arise due to dust build up in your hopper.

A hopper is designed to be temporary storage for your discharge. What happens if you have excessive dust build up in your hopper? This can result in your air flow being blocked off and would cause a loss of suction throughout the dust collection system.  This can also become a hazard because it’s more opportunity for combustible dusts to create a dangerous explosion. The right dust removal method for your application can help you avoid these issues.

Key Components

The best method of dust removal from your hopper is dependent on some of the following components:

  • What’s your Dust Collector Type? Baghouse or Cartridge Dust Collector?
  • What are the characteristics of your dust? For example, hazardous or non-hazardous?
  • What are the loading rates of your dust?

Baghouse Dust Removal Methods

James Hardie Dust Collection System

Enclosed Box

A simple pipe system funneling dust into an enclosed box, placed underneath your hopper, is one dust removal option. Your maintenance team would be required to monitor and empty the box once capacity has been reached. Prompt removal of dust build up in your enclosed box helps prevent backup or an overflow of the box itself. Non hazardous dust and light dust loads typically use enclosed boxes.

 

Drum or Bag

A removable drum or bag can be a simple and easy solution to collecting and disposing dust. Once a drum or bag fills up, maintenance simply removes it by hand or forklift. Once empty, the drum or bag can then be put back into its place. This is ideal for non toxic dusts that you can easily handle.

Rotary Valves for Baghouses

Rotary Valve

Rotary valves (also known as airlocks, rotary feeders, or airlock feeders) help transition material from a dust collector to a drum or bin. It seals a pressurized system against loss of air and pressure. This minimizes product loss during processing. Dust collection, pneumatic conveying, mixing, weighing, feeding, and blending use rotary valves. Larger baghouse systems with over 10,000 CFM  can also use rotary valves.

Screw Conveyor for Baghouse Dust Collectors

Large baghouses with heavy dust loads typically use screw conveyors. The screw conveyer would transport dust away from the collector, then send it to a designated disposal area. This is ideal for hazardous or reused materials.  Agriculture, mining, foundries, wood production, and chemicals are applications that use screw conveyors.

Would you like to learn more about design considerations for a new dust collection system? For more information, download our dust collector purchasing guide.

Dust Collection Design Considerations 7

Different Baghouse Styles: Advantages and Disadvantages

When it comes down to finding the right dust collection system, there are a few different baghouse styles to choose from. So how do you know which one is best for you?

Baghouse Styles

Before we dig into the differences between some of the baghouse styles, you need to consider your dust properties and air-to-cloth ratio.  Baghouses are ideally suited for large volume applications with airflow exceeding 1,000 CFM or when high temperature applications are above 375 degrees.  In these environments, a baghouse will handle and most efficiently filter your dust laden air. 

There are three main baghouses styles (e.g. shaker, reverse, and pulse-jet)  that are commonly used in most industrial processing and manufacturing applications.  Here’s a brief overview on the pros and cons of each to help guide you in identifying the right option for your work environment.

Pulse Jet Baghouse 

Pros:    Cons:
Constantly cleaned so there is minimal dust build up in the dust collector   Requires dry compressed air
Space Efficient   Cannot be used when there is humidity of high moisture content present
Requires fewer bags   Cannot handle high temperatures (unless you use special filter media
     

Reverse Air Baghouse 

Pros:  Cons:
Can handle high temperatures Needs to be cleaned often
Gentle cleaning which allows for longer bag life Residual dust build up is hard to remove
Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse Low air-to-cloth ratio
   

Shaker Baghouse 

Pros:     Cons:
Very simple to operate     Cannot handle high temperatures
Low initial investment cost     Not space efficient (takes up a large area)
Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse     Energy and time sensitive 

What Volume Dust Collector do I need?

Do you have a new dust collector project in the works and need help determining the volume? Our introduction to dust collector volume can help with that.

Baghouse Dust Collector

The Right Volume

The most important consideration to factor into a new dust collector is making sure the airflow or volume of the dust collector is efficient at capturing dust and is right for your application.

For instance, if the volume of your system is too low then your system will not filter dust as efficiently. As a result, your production, air quality and life of your collector can be shortened.  Similarly, if it is too high then your energy consumption costs can be higher and you could disrupt the process of your application. 

Measurement of Volume

You measure volume in cubic feet per minute or otherwise known as CFM.  CFM is a measurement of airflow related to air conditioning, heating and ventilation environments. In dust collector applications CFM measures the amount of air per minute that can be moved from a space.  

Work environments vary dramatically from one another based on several variables. Even very similar environments can require vastly different volumes. To determine the right capabilities for a new dust collector, here are some variables to consider carefully.

  1. How are you collecting your dust?
  2. What is the size of your duct being used to collect the dust?
  3. What is the cubic feet of your work environment?
  4. Calculating volume for new installations.

Do you need more detailed information? Download our full guide to dust collector volume below. In addition, it comes with a chart that can be helpful for your new dust collector project.

 A Guide to Dust Collector Volume

Do you have more questions or need some help? Our equipment specialists are also available at 888-221-0312.

Related Resources:

Video: Air to Cloth Ratio

Video: How Much Does a Dust Collector Cost?

How to Get the Right Dust Collector for your Application

How To Get the Right Air to Cloth Ratio for Your Dust Collector

Video Option: Air-to-Cloth Ratio

Dust collector air to cloth ratio is a critical measure to ensure your system is performing efficiently. 

How to get the right air to cloth ratio

 

What is Air-to-Cloth Ratio?

Air-to-Cloth ratio (a.k.a. Air-to-Media) is defined as a measurement of the amount of air passing through one square foot of filter media.

Watch Video: Air-to-Cloth Ratio

Air to Cloth Ratio

Which is better, Lower or Higher Air-to-Cloth Ratio?

Generally the lower your air-to-cloth ratio, the more effective your system is at removing dust from your work environment.

If you operate on a higher air-to-cloth ratio, one of the common issues you will encounter is a decrease in suction. This happens because there is too much dust to capture with an insufficient amount of filter media. The filter cake on your bag eventually builds up too quickly. As a result, your air velocity and suction decreases. From there it’s a domino effect and your plant air quality decreases, filters clog quicker, and valve life expectancy is impacted. So, you’ll be performing change-outs more frequently which will cost both time and money.

How to Calculate Air-to-Cloth Ratio

To calculate air-to-cloth ratio, take the amount of airflow (CFM) and divide that by the amount of filter area within your dust collector. 

For example, if you’re calculating for a cartridge collector, a typical range would be a 4:1 air to cloth ratio.  Keep in mind that environments with a large ventilation area and more pick up points require a system with a higher CFM to provide adequate suction.  Would you like to know which air to cloth ratio may be right for your project? If so, download our air to cloth guide which provides the recommended ratio for a wide variety of applications.

Why is right Air-to-Cloth ratio important?

What are the negative effects of improper Air-to-Cloth ratio?

  • Poor venting, therefore causing damage to equipment
  • Incur high pressure drops 
  • Impacts your air velocity
  • Excessive use of compressed air

Related Resources:

Filter Bag Media Quiz

Video: Guide to Fan Sizing

How to Get the Right Dust Collector for your Application

What Volume Dust Collector do I need?

Guide to Dust Collector Fan Sizing

Video Option: Guide to Fan Sizing

Dust Collector Fan Sizing

Industrial fans are used in dust collection systems to push dust-laden air through the filters. Fans can either force a draft (push air) or induce a draft (suck air) through the dust collector. Industrial fans are an essential component to a dust collection system so it’s important to choose the right size fan to make sure you have adequate suction to remove dust from the work environment.

Today we will be helping you size your dust collector fan with this 5-step process. Dust collector fan sizing includes consideration of the following variables.

• Airflow or Cubic Feet Per Minute, commonly known as CFM
• Static Pressure
• Environment & Location
• Power Requirements
• Size & Type of Dust Collector

Airflow or CFM

The first variable you want to consider with dust collector fan sizing is your airflow volume or CFM. CFM stands for cubic feet per minute and measures the amount of air per minute that can be moved from a space. If your CFM is unknown, you can use your pickup points and duct sizing to get started instead.

Static Pressure

The second variable you want to consider is your static pressure. This is defined as the pressure created by a fan or some other source to move air through a ventilation system.

Environment & Location

Next, take a look at your environment and location. Location, temperature, altitude, humidity, and area classification can all affect the size and type of fan that is right for your dust collection system.

  • Location – If you are in a humid location this will affect the paint finish of your fan and the fan design.
  • Temperature, Altitude, Humidity – When designing a fan these are all variables used to size the right fan wheel. This will ensure you are moving the right amount of air with the right amount of static pressure.
  • Environment & Area Classification – Make sure to find out if your environment includes any hazardous area classifications. Area classification is also important to ensure your fan meets the classification requirements.

Power Requirements

A 3-phase fan is commonly used in dust collection applications. You will also need to consider the power requirements of the country in which the fan will be operating. Different countries have different standards.

Size and Type of your Dust Collection System

Lastly, the fan you choose is determined by the size and type of your dust collection system. There are multiple models which handle different volumes.

A top mount or collector mounted fan is typically used on cartridge collectors that handle a range of 1,500-10,000 CFM. Whereas ground mounted models are used on Baghouses and multi-module cartridge collectors where high volumes are required. Typically, up to 290,000 CFM.

If you need help sizing your fan, you can contact one of our equipment specialists at 888-221-0312, email [email protected] or request a consultation here.

Dust Collection Resources

Looking for additional resources on dust collection systems? Get a free download of our Dust Collector Purchasing eBook below. It’s a comprehensive guide organized into key topics such as dust properties, volume, air to cloth ratio, dust collector styles, and more.

The Importance of Static Pressure for Your Dust Collector

Static Pressure and Your Dust Collection System

Static pressure is the pressure created by a fan or other source to move air through a ventilation system and plays a critical role in the design and performance of pulse jet baghouse dust collection systems. Today we are discussing the importance of static pressure, what it is, how it’s measured, and how to calculate it.

What is Static Pressure?

Static pressure is used to determine the fan size you’ll need for your dust collection system. If the fan you choose for your system cannot handle the static pressure, air will not be able to move properly through the system and your dust collector will not be able to remove dust effectively.

How Static Pressure is Measured

Like differential pressure, static pressure is measured in inches of water and sometimes will be called water column. The abbreviation for this unit is usually seen as “w.c.” and can also be seen as “w.g.”

How to Calculate Static Pressure

To calculate required static pressure, sum the following components of a dust collector system.

  1. To start add 0.5” Second
  2. Add the filter resistance of the collector. This will be the maximum recommended differential pressure from a dirty set of filters.
  3. In most cases you can use 6” for a baghouse and 5” for a cartridge collector. Then add 1” If an outlet duct exists in the system.
  4. Fourth, add the friction loss in the duct system coming to the dust collector. For simple runs of 100’ or less, you can use 6” as a rule of thumb.

Please keep in mind these are general guidelines and there are many other variables to consider to make sure your system is engineered safely for your unique work environment to achieve peak performance.

To get specific help for your application, contact one of our equipment specialists at 888-221-0312, email [email protected] or request a consultation below.

Dust Collector Project Consultation

Dust Collection Resources

In search of additional dust collection resources to help you? Get a free download of our Dust Collector Purchasing eBook below. It’s a full guide organized into key topics such as dust properties, volume, air to cloth ratio, dust collector styles, and more.

Dust Collector Purchasing eBook

Video: Guide to Fan Sizing

Video: Air to Cloth Ratio

Video: How Much Does a Dust Collector Cost?

 

 

5 Ways a Dust Collection System Improves Plant Efficiency and Saves Money

Why you may need a new dust collection system for your application and how a new system can improve operations.

What is a Dust Collection System?

Dust collection systems are engineered and designed to filter airborne dust particles and debris that can cause damage to plant equipment, create a hazardous work environment, and negatively impact plant production.

Installation of a new dust collection system for your facility either by replacing an old unit or expanding your existing operation, can mean an improvement in plant maintenance, waste collection, an increase in product quality, and plant efficiency and production. A new dust collection project can be a long process. Let’s start by exploring the top 5 benefits of a dust collection system.

Baghouse

The Top 5 Benefits of a Dust Collection System

  1. Meet Compliance Regulations and Standards
  2. Boost Productivity
  3. Improve Product Quality
  4. Enhance Health and Safety Standards
  5. Preserve Quality of Equipment

Meeting Compliance Regulations and Standards

Many industrial industries in the U.S. must comply with strict air pollution control standards . These standards can be set by the Environmental Protection Agency (EPA), National Fire Protection Agency (NFPA), OSHA, or local governing entities such as the AQMD in California.

All agencies require industrial facilities to maintain and meet air quality standards to ensure a safe and clean environment for their plant, employees, and the surrounding community. To get started on what air permits may be needed for your specific application and location, check out our guide on dust collector air permits.

The risks of non-compliance are health and safety risks to employees, explosions, failed inspections, and fines from agencies such as the EPA. All companies, large or small, are susceptible to these risks. Cemex, one of the largest producers of cement in the U.S. was fined by the EPA for $1.4 million in 2011 for exposing people to sulfur dioxide and nitrogen oxide emissions. Cemex was also ordered to install pollution controls at its Ohio cement plant as part of the settlement.

Enhance Production

An accumulation of dust particles and debris on industrial equipment can interfere with overall plant performance. A dust collection system can collect these dust particles before they can interfere and compromise the health and performance of your manufacturing equipment. When your dust collection system is not performing well either due to extended wear and tear, or because your dust collector is undersized and overextended, your entire operation is at risk. Maintenance issues that go unchecked can result in an unexpected plant shut down that can close down operations for days, weeks or more. It may be difficult to know if your unit is undersized, overextended, or too old. In these cases, consult with a dust collection engineering firm and request an engineering study. By doing so you’ll get recommendations that can minimize the risk of inefficient and poorly working equipment as well as frequent and costly maintenance.

Improve Product Quality

For many manufacturing facilities, dust in the air can mean dust on their products. Dust can settle and accumulate on products during the manufacturing process. This has a negative impact on the quality and consistency of finished goods. A dust collector will reduce and effectively capture these dust particles, allowing for product quality to improve and maintain consistency.

Enhance Health and Safety Standards

Inhalation of hazardous dust affects human health and a dust collection system is vital to removing these hazards and to keep employees safe. Industries like woodworking, chemicals, iron casting, asphalt, etc. operate facilities that continuously emit hazardous contaminants, debris, gasses, and chemicals. If the hazardous dust particles and debris aren’t removed, employees inhale this polluted air and are at risk for both short-term and long-term health issues. A dust collection system can minimize this hazard. To get a better understanding of the long and short term health risks check out this guide on the health impact of dust collection systems.

Dust Collection Safety

Another serious risk for the company is the possibility of a fire or explosion due to an accumulation of combustible dust. There are only four conditions needed for an explosion to occur:

4 Conditions That Create an Explosion

  • Oxygen
  • Enclosed Space
  • Ignition Source
  • Combustible Dust at the Right Concentration Level

Do you work in an industry with combustible dust? Some of the industries that are susceptible are:

Agriculture (grain, flour, sugar, etc.)
• Wood
Metals (aluminum, zinc bronze, etc.)
• Rubber
Chemicals (coal, sulphur, etc.)
• Pharmaceuticals
• Pesticides
• Plastics
• And More

Learn how you can prevent a dust collector explosion with these resources we’ve gathered together here.

Preserve the Quality and Prolong the Life of Equipment

When dust particles and debris are created inside a manufacturing facility the contaminated dust settles onto other surfaces such as computer systems and manufacturing equipment. A buildup of dust can be harmful and result in malfunctioning equipment. This can also create unnecessary, frequent, and costly maintenance in order to keep harmful dust and debris from accumulating. With a dust collector system purifying and collecting dust particles, the chances of excessive dust build-up is minimized.

To find out if you may benefit from an engineering study at your facility, contact a US Air Filtration engineer today. If you’re looking for additional resources on dust collection systems and the buying journey, download our free Dust Collector Purchasing Guide that touches on key topics like dust properties, volume, air-to-cloth-ratio, dust collector styles, low maintenance design features, and more.

Video: How Much Does a Dust Collector Cost?

Dust Collection Lead Times and Shipping During the Holidays

Dust Collection Lead Times

There are many variables that impact dust collection lead times, particularly during a pandemic.  Whether you are returning to work, ramping up production, or are planning a change-out during  this holiday season, consider the following factors that can have an impact on your lead times.

  • Media Availability: Specialty or rare media is usually not in-stock and may need to be sourced or fabricated. Examples include media such as PPS, P84, PTFE on PTFE, Fiberglass, Basalt, and Aramid (depending on seasonal availability and media weight requested), etc.
  • Custom Features: Dust collector parts with features, dimensions, or accessories that are not common. This can include oval shaped cages, uncommon weights for filter media (e.g. Aramid 16 oz.), and more.
  • Production Schedule: Dust collector change-outs and maintenance are often seasonal depending on factors such as location and industry. Production schedules can get backed up when an influx of orders are received around the same time. For example, change-outs in the Northeast region of the U.S. are commonly scheduled in the spring or fall season. This is because a large percentage of customers want to avoid conducting change-outs in the extreme temperatures of summer and winter months.
  • Holidays: Holidays can impact everything from production to shipping. If you have a scheduled change-out during a long holiday weekend, it is best to cushion in additional time to receive and inspect your order.

If you are returning to work after a long hiatus, we have created a return to work dust collection start-up guide and a dust collector maintenance eBook that you can download below to help get your dust collection system started safely.

Return to Work Guide

Dust Collector Maintenance eBook

Dust Collection Shipping

Shipping will continue to change and evolve, especially during the holiday season. We want to help you get what you need, when you need it. We also want to be as transparent as possible and provide the most up to date changes regarding dust collection lead times and shipping. The standard procedures and guarantees that you may have been used to with shipping, may have been modified. Below are some of the top changes that directly affect a large portion of businesses.

UPS

  1. Changes to the UPS Service Guarantee: Effective March 26, 2020 and until further notice, the UPS Service Guarantee is suspended for all shipments from any origin to any destination. Commitment times for some services have also changed.
  2. Is UPS slowing down delivery service? The majority of UPS services continue with the same expected delivery timeframes customers have come to expect. While UPS has suspended their Service Guarantee, they are committed to providing timely and reliable service.

For more details and answers to some of your other questions, we highly recommend checking the UPS website for the latest changes and service alerts: UPS Notices and Service Alerts

Fedex

  1. Changes to Fedex Money Back Guarantee: Earlier this year and until further notice, FedEx suspended money-back guarantee for all FedEx Express, FedEx Ground, FedEx Freight and FedEx Office services.
  2. Do I need to sign for my package? Until further notice, Fedex has suspended Signature Required for most shipments.

For more details and answers to some of your other questions, we highly recommend checking the Fedex website for the latest changes and news: Fedex Notices and Alerts

Freight Carriers

This year multiple freight carriers have minimized their workforce or altered their protocols as businesses slowly ramp up production or remain closed in response to COVID-19. Many carriers adapted quickly and implemented safety measures for their remaining staff to maintain continuity of shipping services. As freight carriers navigate through ever-evolving changes and face the upcoming holiday season, you may experience a delay in general delivery times.

To get more detailed information about a specific carrier, please check their website directly for the latest updates or changes.

Warehouse Management

Should businesses’ and warehouses ramp up holiday hours, we want to help you avoid costly delays or complications. Implementing a comprehensive receiving process is one way to eliminate added time or delays to your dust collector start-up or change-out.

To get a comprehensive receiving check list, access and download our guide below.

Download My Free Receiving Check List

Once the receiving process is complete, and as soon as you are able to, you can access our filter bag check list below. The check list will help guide you through the process of verifying product count, fit, and what to do should you encounter any issues.

Download My Free Filter Bag Check List

Industrial Dust Collection System Design Considerations

Table of Contents

Dust collection systems are key to maintaining appropriate conditions for employees and equipment in industrial workspaces. Dust collectors are designed and constructed to filter airborne dust and debris that can cause injury or illness to employees, damage or degrade equipment, and negatively impact plant production. In light of this important function, it is essential to choose the right dust collection system to maintain a clean, productive, and compliant work environment. Below is an overview of some of the considerations to keep in mind when designing and selecting a dust collector system.

Dust Collection Design Considerations 1

What Regulations Are Applicable to Dust Collectors?

bag house and enclosure

Certain industrial operations—e.g., chemical manufacturing, food processing, and metalworking/woodworking—generate significant amounts of airborne dust and debris. As these compounds can negatively affect human health, numerous federal, state, and local regulatory organizations—e.g., the Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA), and National Fire Protection Association (NFPA)—impose strict guidelines aimed toward preventing employees and passersby from exposure. One key method industry professionals employ to comply with regulations is integrating dust collector equipment in their facility to minimize dust accumulation.

In addition to choosing the right dust collector for a facility, plants are required to attain the right permits. Air permits are legal documents provided by a local or state agency to businesses that generate above a certain level of air pollution. Air quality permits indicate the air emission guidelines—e.g., air pollution limitations, control equipment requirements, and filtration efficiencies—to which the business must comply. These guidelines may vary by municipality, country, or state.  Factors that impact air permitting requirements include plant size, application, industry, and equipment employed. As such, it is essential to communicate with the governing body closest to the facility’s location to acquire the most relevant information.

Dust Collection Design Considerations 2

How Does the Project Scope Affect the Ideal Type of Dust Collector?

chemical dust collector

The dust collection expectations of a facility significantly influence the type of dust collector that should be employed. Some of the factors to keep in mind when choosing a dust collector design include:

Type of material. The following dust properties influence which dust collection method is most effective:

  • Size (small or large)
  • Bulk density (loose or compact)
  • Composition (acidic or basic)
  • Temperature (room temperature or elevated)
  • Moisture level (low or high)

For example, baghouse dust collectors are suitable for sticky and hightemperature dust, while cartridge dust collectors are more appropriate for finer dust particles. If the dust is highly explosive or flammable, a spark detection system, explosion vent, or sprinkler vent may be necessary.

  • Daily dust disposal quantities. Estimated dust disposal volume and frequency helps determine which discharge method is most convenient. For example, bin vent and cartridge collectors are suitable for lower volumes of dust, while baghouse dust collectors are better suited for large volumes of dust greater than 55 gallons per day.
  • Air velocity (in FPM). The velocity requirements in a dust collector depend on the weight of dust particulate; the heavier the dust, the greater the speed required to convey dust particulate through the dust collection system.
  • Air-to-cloth ratio. also referred to as the air-to-media ratio—is the amount of air that passes through one square foot of filter media. While a lower air-to-cloth ratio is generally indicative of better filtration efficiency, optimal ratio depends on the particular dust collection system and the facility.

Dust Collection Design Considerations 3

What Are the Key Components of an Industrial Pulse Jet Dust Collector?

5 most commonly replaced dust collector parts

Dust collector systems are generally tailored to accommodate specific workspace and air purification needs. Although the exact components vary from system to system, all dust collectors consist of the following elements:

  • A blower to facilitate the movement of air through the system
  • A ductwork system to contain the dust-laden air as it moves through the system
  • A filter to capture dust
  • A filter cleaning system and discharge mechanism for dust removal
  • A dust receptacle to temporarily store the dust
  • A dust removal system to dispose of the collected dust
  • A control panel to automate each cleaning cycle

Dust Collection Design Considerations 4

Baghouse vs. Bin Vent vs. Cartridge Dust Collectors

Baghouse FAQ

As indicated above, dust collectors share many of the same basic components. However, the design and construction of these elements may vary depending on the type of dust collector. The most commonly used dust collection system for dry dust collection utilizes pulse jet technology.  Three of the most common pulse jet dust collector designs are:

  • Baghouse dust collectors: These dust collectors are large, making them ideal for use in high-volume and high-temperature dust collection applications. Baghouses rely on fabric bags to capture dust and other particles as they move through the system. Once the dust-laden air is filtered, clean air is expelled from the system.  Baghouses can accommodate airflow volumes up to one million CFM or more.
  • Bin vent dust collectors: These dust collectors are generally used to vent air during loading operations for silos and other similarly sized containers. Bin vents rely on the natural upward movement of dust and debris during loading to filter dust particulate and prevent dust from escaping the container.
  • Cartridge dust collectors: Cartridge dust collectors operate similarly to baghouse dust collectors, except they utilize cartridge filters made from pleated filter media instead of fabric bags. Their pleated filter design and finer filter media allow for better filtration of smaller dust particulates. Additionally, as they are generally more compact than baghouses, they are better suited for use in confined spaces and smaller dust loads.

Dust Collection Design Considerations 5

The Industrial Dust Collector Design Process

Dust Collection Design

When planning the design and construction of a dust collection system, it is important to have a clear understanding of how the system should perform within the facility. As indicated above, some of the factors to keep in mind include dust type, dust collection volume, air velocity, and air-to-cloth ratio. These considerations, among others, influence how the system should be designed and constructed.

Three of the design elements affected by these factors are:

  • Dust collector ductwork serves as a transportation network for the dust-laden air within the dust collector. Ductwork size and complexity depend on the size and complexity of the system, while diameter depends on the type of dust generated and its expected volume and velocity. During the design and construction of this system element, limiting the complexity (i.e., using straight lines and minimal curved or transitional elements) and size helps ensure better system efficiency.
  • Dust removal mechanism. The ideal dust removal mechanism depends on the type of dust collector employed, the type of dust being collected, and the dust loading rate. The main mechanisms utilized include:
    • Enclosed box (i.e., a pipe system funnels dust into an enclosed box),
    • Drum or bag (i.e., the drum or bag is removed, emptied, and replaced once it is full),
    • Rotary valve (i.e., the valve allows dust to flow from the dust collector into a drum or bin)
    • Screw conveyor (i.e., a screw conveyor carries collected dust from the system to a designated storage/disposal area).
  • Explosion venting. If the dust collected by a dust collection system is combustible, appropriate measures—such as integrating explosion vents or panels, flameless venting, or spark detection and extinguishing systems—should be implemented to minimize the risk of explosion and fire outbreaks.

Dust Collection Design Considerations 6

How Much Does a Dust Collection System Cost?

Dust collectors vary in size, ranging from the compact units used in small, residential or hobby workshops to the large-scale systems designed for industrial facilities. Smaller units—accommodating airflows up to 1,000 cubic feet per minute (CFM)—generally cost between $100 to $5,000, and are suited for small, residential shops, while larger units—handling airflows between 2,000 to 10,000 CFM—cost between $10,000 to $80,000, depending on the unit size, filter media, and fan size. Custom dust collection systems for highly specific or unique applications range between $50,000 to $1 million, depending on the system requirements.

Some of the main factors that influence the cost of a dust collection system are:

  • Dust type: what is/are the dust’s composition, properties, particle size, combustibility, temperature, moisture level, etc.?
  • Dust load: how much dust must be removed from the air?
  • Filter media: what filter media is used in the system?
  • Air-to-cloth ratio: how much air should pass through the filter media?
  • Fan size: what fan size is integrated into the system?
  • Material handling and conveying: what material handling/conveying elements are integrated into the system to ensure efficient and effective dust removal?
  • Paints, coatings, or unit insulation: does the system require specialized paints, coatings, or insulation to ensure its durability?
  • Electric controls or accessories: what electrical controls and accessories are necessary for proper system function?

Dust Collector Maintenance Considerations

dust collector design features for easy maintenance

Once a dust collector system is designed, constructed, and installed in a facility, it is essential to implement an adequate maintenance program to ensure it continues to provide effective and efficient performance throughout its service life. Below we outline some of the typical steps in a maintenance program.

  • Verify the system operates within acceptable ranges (e.g., air pressure to solenoid valves, timing controls for pulse valves, compartment differential pressure, etc.)
  • Check the condition of the filter media, fan bearings, damper valves, door seals and gaskets, and other system components and repair/replace them if necessary
  • Empty the dust in the hopper if necessary

It is important to employ the proper safety measures to protect against injury during any maintenance operation. For example, when performing maintenance inside of a baghouse dust collector:

  • Ensure the unit is powered and locked down
  • Employ the proper personal protective equipment (PPE)
  • Designate a lookout
  • Communicate the specifications of the operation (what, where, when, etc.) to all other employees
  • Verify combustible dust inside of the system is within safe levels
  • Formulate an emergency escape/retrieval plan

For additional maintenance tips, check out U.S. Air Filtration’s Dust Collector Maintenance Checklist.

Dust Collection Design Considerations 7

Industrial Dust Collector Systems From U.S. Air Filtration

Dust Collection Systems

For over 40 years, U.S. Air Filtration, Inc. has designed and manufactured standard and custom dust collection systems for customers around the world. We provide baghouse dust collectors, bin vent dust collectors, and cartridge dust collectors. To learn more about our design and manufacturing capabilities, check out our design services page or dust collector purchasing guide. For further assistance designing or selecting a dust collector for your facility, contact us or request a quote today to schedule an engineering consultation.

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What Dust Collector is Right For My Application?

Do you have a new dust collection project? One of the first, and most important questions to ask is, what’s the right dust collector for my application? Reliable dust collectors are critical for the optimal operation of most industrial and manufacturing facilities. Choosing the right dust collector can ensure high air quality. Without an appropriate dust collector, particles can clog up your equipment, contaminate products, reduce overall operational efficiency, and put worker health at risk.

There are three standard dust collector designs: baghouse, cartridge, and bin vents. The best design for your needs is dependent on specific aspects of your dust collection process. This can include the following:

  • What is the type of dust you are filtering?
  • Do you know your expected dust volume?
  • Do you have size restrictions for the dust collector?
  • Are there emissions requirements you need to follow?
  • What’s the temperature of the surrounding environment?

3 Main Types of Dust Collectors

The three most common dust collectors are baghouses, cartridges, and bin vents. Each type exhibits different characteristics.

Baghouse Dust Collectors

The most widely used style of dust collector is a baghouse. They are usually larger than other types of dust collectors and well suited for high volume and high temperature applications.

Baghouses use fabric bags to capture dust particles in the gas or the air moving through the system. When contaminated air pulls through the filters, it catches the dust and clean air is expelled.

Cartridge Dust Collectors

Instead of fabric bags, cartridge dust collectors use a filter made of pleated media. Spun-bond polyester, nanofiber, and an 80/20 substrate are the most common filter medias on cartridge filters. Treatments like PTFE, fire retardant, and water or oil resistant coatings can also be available.

Cartridge dust collectors house it’s filters in a sealed chamber, and this is where dirty air pulls through the cartridges. It then traps the dust, thereby allowing clean air to be expelled. The pleated surface of a cartridge filter provides efficient filtration because there is more surface area available. This makes it optimal for filtering fine particles and fumes. Cartridge dust collectors are also compact and can be installed in confined spaces.

Bin Vent Dust Collectors

Silos and other large containers typically have bin vents installed on top. Their purpose is to vent displaced air during loading. A pneumatic or compressed air system propels material into the silo or container. Afterwards, the bin vent filters the displaced air as it flows out of the container while it keeps an airtight seal. A bin vent ultimately prevents dusting and loss of product during the loading process.

Advantages of Dust Collectors

Depending on the needs of your application, each type of dust collector offers unique benefits.

  • Baghouse dust collectors: Baghouses offer filtration of large to moderate sized particles. This is ideal for use in manufacturing and industrial settings that filter a large amount of material on a regular basis.
  • Cartridge dust collectors: Cartridge collectors are ideal for applications that require the filtration of smaller particles on a reduced scale. The pleated construction and versatile media of cartridge filters allows them to easily adapt to specific applications. In addition, they are smaller than their baghouse counterparts and can be easily installed in confined spaces.
  • Bin vent dust collectors: Bin vents are great for bins or containers that need to filter the air being expelled from the top. They are compact and their filters can be also be easily changed.

Dust Collector Applications

An extensive range of industries use dust collectors. Their use is dependent on the particular needs of an application.

  • Baghouse filters: For use in high volume and high temperature applications such as lumber milling, automotive manufacturing, mining applications, and foundries.
  • Cartridge filters: Useful for applications with fine particles and fumes such as welding, laser cutting, wood processing, agriculture, and fiberglass processing.
  • Bin vent filters: Specialized and highly valuable for silos, storage containers, and other high dust and material holding applications.

Dust Collectors from U.S. Air Filtration

When you choose the right dust collector for your application it plays a part in the efficiency of your facility. If you would like to learn more about dust collector designs, you can download our “Dust Collector Purchasing Guide” eBook or watch this video “How Much Does a Dust Collector Cost?”. If you would like to speak to an equipment specialist, click here to contact our experts or request a quote.