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.
The best method of dust removal from your hopper is dependent on some of the following components:
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
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 (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.
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?
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
Constantly cleaned so there is minimal dust build up in the dust collector
Requires dry compressed air
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
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.
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.
How are you collecting your dust?
What is the size of your duct being used to collect the dust?
What is the cubic feet of your work environment?
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 well maintained dust collector ensures your system is performing at peak efficiency. It’s also critical to minimizing unscheduled plant downtime and the wear and tear of your dust collector parts. As part of a regular preventative maintenance program, customers can also request a visit from bonded and insured technicians to perform either a dust collector inspection. An inspection typically includes an analysis of your dust collector and its most vital parts, a written report, and recommended corrective actions to solve any issues. An inspection may also include an exam of the following:
Overall status of dust collector(s)
Compressed air system for leaks
Air Shut off valve is sealed and is properly working
Repair or replace damaged solenoids, valves, or diaphragm kits
Any other repairs or troubleshooting needed on a baghouse – for example, vibration issues with a system after a filter change
Dust Collector Inspection and Service Questions
If you are looking for an inspection or service from a supplier, here are some of the most common questions asked before receiving a formal proposal and costs.
What type of service or troubleshooting are you requesting?
Where will the service take place?
What type of dust are you filtering? Is it hazardous? Is special safety equipment required?
Are there any current issues with your filters?
Is there any special training or background checks needed before entering a facility?
When would you like to have the service performed? What are the permitted service hours (evening or day work, weekends only, etc.)?
For more information on inspections or services for your dust collector, you can contact a USAF account manager at 888-221-0312 or also email [email protected] Also included below is a link to our comprehensive dust collector maintenance eBook that can be downloaded.
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.
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.
To start add 0.5” Second
Add the filter resistance of the collector. This will be the maximum recommended differential pressure from a dirty set of filters.
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.
• Industrial Dust Collection buyers place high importance on customer experience when making purchasing decisions
• Customer experience is defined by the interactions a buyer has with a company before, during and after a sale.
• There are five things industrial buyers value most in their purchasing experience: Product knowledge, Responsiveness, Service, Relationship, and Educational Resources
If you were to ask most people what’s most important to them when making a purchase historically it’s come down to three things – price, quality, and service. But as buyers have become more savvy and have less time to spend on purchasing, customers now place equal if not more importance on customer experience when making dust collection purchasing decisions. In fact, 86% of buyers are willing to pay more for agreat customer experience. And a recent Walker study found that by the end of 2020, customer experience will overtake price and product as the key brand differentiator.
Customer experience is defined by the interactions a buyer has with a company before, during and after making a purchase.
What makes a good customer experience when purchasing dust collector parts
We recently sent a survey to our customers to understand what they currently value when making purchasing decisions and to learn where there may be gaps and opportunities for improvement.
By understanding our buyer’s perspective it helps us build an experience tailored to the different needs and wants of our customer.
We’ve organized our findings into five core components that customers valued most:
Top 5 Key Components to a Customer Service Experience
Expertise and Product Knowledge
Educational Resources and Tools
Dust Collection Expertise and Product Knowledge
Expertise and product knowledge were voted as the most valued component in a dust collection customer service experience. Dust collection needs vary significantly even within the same industrial application. Today buyers value sales reps who function first as product experts who understand their specific dust collection challenges. Finding the right dust collection products that will optimize performance requires vast technical knowledge on a filters, valves, troubleshooting, dust collection engineering and more. When a sales rep delivers and establishes their expertise, this evokes trust and assurance to the customer that their buying journey and partnership will be successful.
“I had a very good conversation with internal sales, Mark. Sharing technical knowledge and information is always helpful!” – Customer Testimonial
Leveraging Technology to Improve Responsiveness
Responsiveness is critical to industrial dust collection customers in order to keep their system running at peak performance. A customer may need dust collector parts for an upcoming inspection, an unexpected explosion, or replacements for broken or underperforming parts. To help solve issues before they turn into more disruptive maintenance problems, it’s vital to get a response back to the customer promptly.
To improve response time, companies can leverage technology in innovative ways that cater to the customer.
For example, at USAF our sales reps can be reached through multiple channels including direct phone line, email, online quote request, online chat, email nurturing and marketing automation, or via the main line where a live person will answer and direct your call immediately. Investing in several channel options allows USAF to communicate with customers quickly, using their preferred communication method.
Further, as more of the buyers journey moves online, and as more buyers now prefer online communication over phone and face to face contact, particularly in response to COVID-19, companies need to adapt by investing in technology that will streamline the buyers journey by moving more customer interactions online. This could include any or all of the following solutions:
Chatbot Artificial Intelligence
Marketing Automation & Email/SMS nurturing
Content marketing – Includes videos, blogs, eBooks, case studies
“The products I purchase are specialized and by me contacting Patty and her quick response back to me works for our relationship and I wouldn’t change it. She does a fabulous job!” – Customer Testimonial
Customers face so many choices when it comes to where they purchase dust collector parts. One key component to the dust collection customer experience is service. Great service isn’t about being short-sighted and merely searching for the next opportunity, instead it’s about prioritizing solving customer problems and focusing on long term wins.
Today’s industrial buyers expect a service experience that combines one on one human connection with the efficiency that technology brings. An example of this could include the following touchpoints that combine technology with personal outreach:
Regular phone call check ins by sales rep before, during and after a sale to help the customer identify the right product and confirm successful delivery.
Email nurturing that includes how to advice and relevant educational information on dust collection.
E-Commerce product catalog for direct online sales
Post-sale shipping and tracking notifications by email or text
Post-sale customer satisfaction survey by email
While technology has changed the way we do business in critical ways, particularly through e-commerce, the need for human connection will never go away. Companies who can master this hybrid model by finding the right balance of human vs. technology touchpoints will be the most successful in the future.
“I think you’re already doing a great job. Bonnie is always fast to respond to my emails (always within an hour, often within minutes). On top of that she calls me periodically just to check up. She is a true professional and you should consider her a major asset to your company. Without her being my sales person I cannot guarantee that I would be even purchasing from you, there are local guys that I could buy from but I keep coming back to USAF because the service is so good.” – Jake Z.
The main goal of establishing a relationship between the customer and their sales rep is to create a consistent experience across all touchpoints in the dust collection journey. The sales rep is the direct connection from the company to the customer, and to ensure the process is as smooth and positive as possible the sales rep should be a customer’s first go-to contact for orders, questions, or issues.
Have you ever called a customer service line for a large retail or phone company? You often find yourself frustrated at being bounced around through several different departments before you even speak to the right person. A direct sales rep for a company keeps an eye on the customer’s entire journey to ensure their experience is positive and to also help mitigate any issues that may cause a bigger problem down the road.
“Bonnie was incredibly kind, helpful, and persistent (in a good way) with our last order” – Thomas J.
Educational Dust Collection Resources and Tools
Expertise, product knowledge, responsiveness, service, and a relationship are all important to the dust collection customer service experience. Providing additional educational resources and tools throughout the purchasing journey is crucial to building trust and long term partnerships. Examples of successful educational resources can include:
eBooks that provide in depth analysis on a key topic such as dust collection design
Regular blog posts that answer common questions customers ask
3D animated product demo videos
Instructional maintenance videos – includes installation, assembly, how-to and troubleshooting advice
Engineering drawings of products
Detailed spec sheets
Project case studies
Here are the most popular dust collection resources USAF has complied over the years that are most valued by our customers.
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.
The Top 5 Benefits of a Dust Collection System
Meet Compliance Regulations and Standards
Improve Product Quality
Enhance Health and Safety Standards
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.
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.
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
Combustible Dust at the Right Concentration Level
Do you work in an industry with combustible dust? Some of the industries that are susceptible are:
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.
Baghouse dust collectors are highly efficient systems used in industrial applications that remove dirt, dust, and debris from the air. Baghouses improve worker health and safety, protect the mechanics of industrial equipment, and maintain compliance with environmental and workplace safety regulations.
Proper baghouse system design, installation, and maintenance are critical for minimizing plant downtime and maximizing system efficiency and longevity. Important design considerations, such as the airflow and square footage required for your system, will depend on your facility’s workspace and dust collection needs. Once a system is designed and installed, performing regular maintenance is vital for keeping it operating as efficiently as possible. Here, we address some of the most commonly asked questions about these critical systems.
Why do you need to install a baghouse dust collector system?
The primary reason for installing a baghouse dust collector system is to improve air quality by removing potentially harmful airborne particles, gas fumes, and other contaminants generated during manufacturing processes. Depending on the industry and the types of debris being produced, installing a dust collection system may be required in order to comply with air emission guidelines or workplace safety standards. OSHA, for example, requires industrial plants to meet certain indoor air quality standards to prevent dust-related health issues. Before designing a baghouse dust collector system, it is important to research what types of safety and air quality regulations might be applicable to your facility.
Baghouse dust collection systems may also be installed to upgrade, improve, or enhance a facility’s existing dust control strategies. Regardless of your specific reasons for installation, it is important to implement a preventative maintenance program in order to prevent future problems and keep the system operating at optimal efficiency. General steps may include:
Making sure the system operates within acceptable levels by monitoring differential pressure, timing controls for pulse valves, compressed air pressure, etc.
Regularly emptying drums and hoppers to prevent dust build-up
Frequently inspecting valves, hoses, gaskets, filters, and other components and replacing them when necessary
What type of particulate are you looking to filter?
The type of dust being generated in your facility will influence the type of dust collector that should be used. Common types of industrial dust include:
Wood dust. Fine wood particles generated during woodworking processes can linger in the air, causing health issues for workers.
Pharmaceutical dust. The manufacturing of drugs, vitamins, and minerals generates fine powders that can be highly toxic if inhaled.
Food particulates. High levels of dust can be created during the processing of spices, flour, sugar, cornstarch, grains, and other dry food products.
Metalworking dust. Metalworking processes can create a harmful mixture of fumes and fine dust ranging from 0.01 micrometer to 1 millimeter in diameter.
Particle size will help you determine the number of filters required and the best type of filter media for your system. While standard filters are usually sufficient for collecting moderate-to-large particles, pleated filters may be necessary to effectively capture very fine particles and fumes. It is also important to select a filter with the appropriate air-to-cloth ratio as this will influence the system’s ability to adequately protect workers from dust and contaminants.
Low filtration efficiency will expose workers to more particles and can increase the risk of explosions. In some cases, coating the filters with a porous particulate layer, known as a precoating, can enhance filtration and improve baghouse system performance.
What size of baghouse dust collector system do you need?
Baghouses tend to be larger than other dust collector systems and are typically used for high-volume and high-temperature applications. These systems employ cylindrical fabric filter bags to capture and separate dust particles from the air. The three most common baghouse designs are:
Pulse jet. Pulse jet baghouses are self-cleaning filtration systems that use pulses of compressed air to clean the bags. Cleaning occurs while the system is online.
Reverse air. Reverse air baghouses feature a compartmentalized design that allows for the cleaning of individual sections without shutting the entire system down.
Shaker baghouses clean bags by mechanically shaking the dust out of them. These are simple to operate and have a low initial investment cost. However, cleaning is performed while the system is offline.
With their versatile and universal design, baghouses can meet a wide variety of industrial dust collection requirements. Common applications range from food production, pharmaceutical manufacturing, woodworking, and metalworking to energy utilities, chemicals, mining, and more. For optimal performance, your baghouse dust collector should be sized and designed to accommodate your facility’s air purification requirements as well as any spatial restrictions. Design considerations should include:
One of the most important decisions when designing a baghouse system includes selecting the right filter media. There are a wide range of filter medias available to accommodate a variety of dust characteristics. Temperature, dust properties such as moisture and abrasion will determine which filter media will provide the best performance and efficiency at your operation. Here is an overview of the most common filter medias available.
Polyester – Polyester’s maximum continuous operating temperature is 275 degrees Fahrenheit and has good overall qualities to resist abrasion and performs well with dry temperatures.
P84 – The stability of P84 filter media is a benefit to a wide variety of applications lime kilns, smelting, incinerators, coal fired boilers, and glass and ceramic industries. It can be utilized in operating conditions of a maximum 500 degrees Fahrenheit and offers a good resistance to mineral acids.
PTFE/Teflon – Generally used for severe environments operating at high temperatures. Industries that use PTFE filter media range from cement, steel foundries, and energy.
Fiberglass – Fiberglass filter media has been a leading industry standard for air filtration and applications where high temperatures are prevalent.
Baghouses are custom designed for each unique application and often require advanced engineering to integrate the baghouse system into the overall plant operation. As such, baghouse units typically start at $50,000 to $1 million or more.
To get the best value from your dust collector, it is important to size the system appropriately during the design phase. This will ensure the system captures dust efficiently while reducing energy consumption.
How do you remove dust collected by the baghouse system?
Knowing how to properly dispose of dust once it enters the baghouse system’s hopper is essential for preventing airflow blockages, fire hazards, and other issues. The most common dust removal strategies are:
Enclosed box. Dust is funneled into an enclosed box under the hopper that is emptied once capacity is reached.
Drum/bag. Dust is collected into a detachable drum or bag, allowing for convenient disposal.
Rotary valve. Rotary valves allow materials to be manually or automatically moved from the collector to a disposal drum or bin.
Screw conveyor. In large baghouse systems, screw conveyors remove dust by transporting it from the collector to a disposal area.
Most baghouse systems employ rotary valves or screw conveyers for automatic removal of dust.
Baghouses have automated cleaning options with control panels that can be programmed to clean the bags anytime the differential pressure reaches an upper threshold. This enables an ongoing cycle of cleaning that occurs automatically during dust collector operation.
Filters, filter media, and other baghouse components should also be inspected at regular intervals and replaced when necessary. Routine inspections are an essential part of preventing future problems and maintaining optimal efficiency.
How do you enter a baghouse dust collection system for further cleaning?
When entering the baghouse system for cleaning or maintenance, the following measures should be implemented to ensure employee safety:
Secure the system by powering down and shutting off valves, blowers, compressed air, etc.
Communicate the details of the operation to all employees
Wear the appropriate personal protective equipment (PPE)
Have additional crew available to assist if needed
Thoroughly purge the system of combustible dust before performing any hot work (welding, grinding, etc.)
Establish an emergency plan for escape/retrieval
Baghouse Dust Collector Systems from U.S. Air Filtration
Baghouse dust collection systems provide a versatile and efficient solution for capturing particles that are released into the air during industrial activities. At U.S. Air Filtration, we design and manufacture baghouse dust collection systems to accommodate a range of operating conditions and filtration needs. Our solutions are expertly designed and constructed to optimize your facility’s productivity while minimizing maintenance and energy costs.
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.
What Regulations Are Applicable to Dust Collectors?
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.
How Does the Project Scope Affect the Ideal Type of 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 high–temperature 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.
What Are the Key Components of an Industrial Pulse Jet Dust Collector?
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
Baghouse vs. Bin Vent vs. Cartridge Dust Collectors
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.
The Industrial Dust Collector Design Process
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.
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
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