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  1. Dust Collection Start-up Guide

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    To download a free PDF version of this Dust Collection Start-Up Guide simply click this link here.

    As factories and industrial plants resume production after a shut-down period, employers are faced with the responsibility of minimizing work hazards by instituting best practices and safety measures. This is where a dust collection start-up guide will help.

    Starting up your dust collection system the right way will make sure your equipment is operating properly while also protecting the safety of your workplace and workforce. The steps in this dust collection start-up guide will also ensure your system is in good working order so you don’t have to worry about an unexpected shutdown.

    To streamline your start up process and make it as hassle-free as possible, we’ve prepared a comprehensive checklist and action item notebook. These resources can help you address any issues promptly. Our guide is broken out into four sections:

    1. Best Practices for Dust Collection Start-Up
    2. Dust Collector Start-up Checklist
    3. Action Item Checklist
    4. Maintenance Questions to Consider

    Dust Collection System

    Part 1: Best Practices for Dust Collection Start-Up

    Power Down & Lock Out

    Before you begin start-up, maintenance or troubleshooting on your dust collection system, your first and most important step is to power down and lockout any machinery. Securing your baghouse for personnel entry can include locking down your rotary valve, locking your blower, or sealing off any adjacent baghouse compartments. Taking these initial steps provides a safe working environment and will
    ensure that accidents are minimal.

    Additional Watchman & Communication Plan

    Designate an additional crew member as a watchman. They should be present to ensure safety procedures are being followed and can immediately assist should any complications occur. It’s important to let your team know what work is being done, where, and at what time. This allows others to re-schedule any work that could impede on a safe start-up of your dust collection system.

    Combustible Dust

    If you are working with combustible dust, make sure the dust levels inside of your system are well below being explosive. Perform all hot work, like welding, well outside of the perimeter of your dust collector.

    Emergency Plan

    A total shut down and lock out of your dust collector will minimize safety hazards, but you shouldn’t hesitate to formulate a retrieval plan should an emergency occur.

    PPE (Personal Protective Equipment)

    OSHA requirements for protective gear will vary based on your application. Basic protection can include a hard hat, safety glasses, gloves, and a face mask. Before start-up or entry into your baghouse system, make sure that your crew is supplied with and compliant in wearing safety gear required for your application.

    Learn more about Baghouse Entry Procedures

    Part 2: Dust Collection Start-up Guide Checklist

    You can print,  electronically download the PDF, or  access the dust collection start-up guide on your phone or mobile device by clicking below.

    Click here to complete the checklist online

    Dust Collection Start-up Guide Checklist

    VISUAL INSPECTION

    • Power down and lock out your dust collection system with lock in place before proceeding further.
    • Inspect hopper to ensure the discharge, including screw and rotary valve (if applicable) are free
      of debris.
    • Check the interior of your collector for signs of moisture. Is condensation inside the unit?
    • Perform visual inspection of filters. Filter should be as clean as possible with minimal
      dust cake. Dust cake should be dry, not sticky or caked on.
    • Check your cleaning system.
      • If you have a pulse jet unit – check your pulse cleaning system.
      • If you have a pulse jet unit – turn on header and listen for air leaks coming from your valves.
      • If you have a shaker unit – check your motor assembly.
      • If you have a reverse air unit – check to ensure bags are taut.

    FAN INSPECTION

    • Make sure your fan is securely bolted to your unit.
    • Check to make sure the fan is sealed.
    • Check tension on all belts and drives
    • Check belts and chains for signs of wear, including cracking and stretch.

    For more detailed instructions download our Fan Maintenance Guide here>

    SYSTEM START-UP INSPECTION

    • Start up your system by powering on your control panel and your fan.
    • Check fan for excess vibration.
    • Check your controller to ensure all valves are running.
    • Check your differential pressure to make sure pressure is within limitsDust Collection Start-Up Guide Differential Pressure Chart
    • If your differential pressure is in the blue range noted above, perform a leak detection test.

    Part 3: Maintenance Action Item Checklist

    Record maintenance issues you’ve encountered during your start-up inspection that require attention below. Note the issue, part type, part number and quantity impacted. Download a PDF copy here.

    Part 4: Time Saving Maintenance Questions to Consider

    1. To eliminate unexpected plant shutdowns due to baghouse issues should you consider a spare set of filters and diaphragm repair kits
    2. Do you have an ongoing maintenance schedule in place? Download our standard maintenance checklist if you need one.
    3. Do you need to adjust your preventative maintenance schedule? If COVID-19 has altered your production and maintenance schedule, consider what you need to adjust going forward.
    4. Do you have the specs for each of your dust collector parts listed in one central location? If not, here is a sample spec template for Filter Bags and Cartridge Filters. Having this ready can help your dust collection supplier get you the right parts quickly, affordably and accurately.

    For more complimentary dust collection maintenance resources, visit our blog with over 50 articles on dust collection design and maintenance. You’ll find additional help on the following topics and more.

    About U.S. Air Filtration, Inc.

    OUR COMPANY
    U.S. Air Filtration was established in 1987 to serve the needs of industries requiring air pollution control systems. We aim to meet and exceed United States EPA standards for air quality. Over the years, we have worked on projects ranging from $20,000 to over $3 million. Our Founder, Engineering and Sales Personnel has been active in the industry for over 30+ years.

    OUR MISSION
    To help our customers achieve peak production by providing exceptional service, products and expertise in air pollution control.

    OUR VALUES
    Our values are the foundation for our actions as leaders, colleagues, employees and citizens. At U.S. Air Filtration, our values incorporate our conduct towards our customers, our suppliers, our fellow employees, and the general public.

    US Air Filtration Core Values

    U.S. Air Filtration Customer Service

     

  2. Guide to Calculating Dust Collection CFM

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    CFM is a measurement of airflow related to air conditioning, heating and ventilation environments. In dust collection applications CFM measures the amount of air per minute that can be moved from a space.

    If you’re not familiar with how to calculate dust collection CFM, the process can be intimidating. In this article we will help you understand our approach to calculating CFM requirements for you. Along with the questions you should be asking your dust collection engineering firm to identify the optimal solution for your plant.

    Dust Collector Purchasing Guide

    Dust Collection CFM Questions to Consider

    • Where is your dust being created?
    • Are you using taps or hoods at the points of dust creation?
    • What type of dust are you working with?
    • What are your dust characteristics?

    One of the first questions we ask is, “Where is your dust being created?” This allows us to understand where your pick-up points are, and how many of those need to factor in when calculating your CFM.

    Methods of Dust Collection

    How Much Does a Dust Collector Cost

    Once we understand where the dust is being created, then the next question becomes, “What’s the best way to collect the dust at that dust creation point?” Three common methods are:

    1. Tap
    2. Hood
    3. Articulating Arm

    Many facilities include source taps at every machine. If there are no taps, then a hood or a smaller pickup point can be added. For example, a hood can be added above a table to capture dust if there is a need to constantly maneuver around the table.

    If there is movement happening around the machine in different ways (e.g., leaning over a machine) then there may be a need for an articulating arm. An articulating arm allows a way for the hood or pick up duct to be as close as possible to the actual creation of the dust. As U.S. Air Filtration helps you calculate the right CFM, we will work together with you to gather these details machine by machine.

    What’s Needed to Calculate CFM?

    You may not know the CFM you need, but here are the things you can provide that will allow us to help solve that for you.

    • How close can we get to the machine?
      • For example, if the machine has a six-inch tap, then we would know that would require a six-inch duct. Generally, when the machine is designed, your pickup points are also designed with the intention to efficiently capture dust.
    • Blueprint of your facility or a roughly drawn layout
      • This helps us understand the distances between the machines, walls, and where the dust collection system will be placed.
    • Photos of your machines. This helps us identify if you are using taps or hoods.
      •  Tap
        • If there are no taps, how are people using the machine?
        • Is the machine stationary?
        • Does someone need access 360 degrees around the machine?
      •  Hood
        • If there are no hoods, what is the size of the machine or table that’s creating dust? This helps us properly size a hood and with those dimensions we can look at velocity at the hood.

    Then, depending on the weight of the dust, we get a better understanding of the specific velocity needed to move the dust and the duct size that’s required. These two factors together can help us get to the right CFM for your dust collection project.

    Dust Collection Source Capture versus Room Capture

    Dust Collection CFM

    In the case of a grinding application, you may do all your grinding in one room and want to ventilate the entire room itself.

    While the initial calculations and process to ventilate one room may seem easier, it’s not necessarily the best in terms of cost. Our recommendation is to get as close as you can get to the source of the dust, which allows you to move less air. This can mean a smaller system, which can lower the price tag of your project while also capturing dust more efficiently.

    For an everyday example, let’s say you have dust all over your kitchen floor and you don’t want to vacuum every square inch of it. Then your option would be to try and suck the dust up through a hood. That requires you to pull a large amount of air very quickly, which in turn requires much greater force from the fan to capture the dust. In contrast to that, if you have a vacuum and a hose, then you can pick up everything closely using a very small amount of air and suction requirements.

    While it may be tempting to “just ventilate the room”, keep in mind that every CFM comes with a price tag. Moving 100,000 CFM versus 10,000 CFM is going to be more costly. The details that go into calculating your CFM may be cumbersome at first, but it will save you from spending a considerable sum of money in the long run.

    Negative Impacts of Miscalculating CFM

    The Dangers of an Undersized Dust Collector

    When designing a dust collection system, it’s best to err on the high side of CFM rather than the lower side. It’s very difficult is to make a dust collection system larger once it’s in place. It’s much easier, if necessary, to damper the fan down or add a smaller fan.

    Correcting for a larger than needed dust collection system involves adding more filter media. Upfront costs are slightly higher, but your system will work well, and you’ll be able to remove dust out of the way as you intended. The reverse isn’t true. If your system is too small, it’s very difficult to add filter media. Getting the dust out of your facility will always be an uphill battle. So, to reiterate when in doubt error on the high side.

    • If you underestimate CFM, you won’t capture the dust that you need to capture.
    • The system will not work the way it was designed. Therefore, you will spend a large sum of money on maintenance expenses due to increased wear and tear..
    • If you overestimate CFM, the dust collection system will work just fine, but long term you will pay 20%-30% more for a system.

    Advantages of Working with USAF

    U.S. Air Filtration Dust Collection Engineering

    One of the advantages of working with U.S. Air Filtration is that we have a team of engineers with over 40 years dust collection experience who can gather the details you provide and calculate the numbers to get you to the right CFM.

    Calculating CFM and designing a system is a complex engineering process.  We do all the leg work for you, so you don’t have to.

    If you would like to speak to an engineer about your specific project, contact us at 888-221-0312 or email [email protected]

  3. Dust Collector Purchasing Guide

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    Download the free PDF version of this Dust Collector Purchasing Guide here.

    Our dust collector purchasing guide will help you identify the right dust collection system that will perform safely, efficiently, and reliably for many years to come. Identifying the right components and needs for your next dust collector can be an overwhelming process. Factors to consider include:

    5 Things to Consider When Purchasing a Dust Collector

    1. Dust Properties – Learn the dust properties you need to be aware of to help you find the right filter media and type of dust collector.
    2. Volume – Understand key variables for measuring volume or airflow requirements in your work environment in order to size your collector properly.
    3. Air-to-Cloth Ratio – Learn why air to cloth ratio is important and how to find the right air-to-cloth ratio for your operation.
    4. Dust Collector Styles – Learn about three most common dust collectors, their advantages and disadvantages.
    5. Low Maintenance Design Features – Learn important dust collector design features that will help you save time and money in long term maintenance expenses.

    At the end of this dust collector purchasing guide, there are also additional resources that provide more details about combustible dust considerations and on demand cleaning.

    Dust Collector Dust Properties

    Dust Properties and Your Work Environment

    Do you know your dust? Consider your dust properties and characteristics of your work environment carefully to identify the best dust collection solution.

    Dust Properties to Consider:

    • Size – What is the size of the dust particles being filtered; fine or large?
    • Density – Is the dust low in density like wood dust or heavy in density like fine steel dust?
    • Chemistry – Will you be filtering any abrasive dust? Corrosive dust?
    • Temperature – Are you operating in a high heat environment? What is the operating or maximum temperature at your facility?
    • Moisture – Is moisture or oil present in the dust?

    Knowing your dust properties is the first step to help you determine the type of dust collector that is best suited for your unique application.

    Your Work Environment

    The next step to finding the right dust collection solution is to consider your space constraints, emissions requirements and temperature of your airstream.

    Space Constraints

    Dust collectors vary in height, width and depth depending on the application and the amount of dust being captured. Take note of any height or space restrictions in the work environment and take measurements of the space allotted for your collector along with the space available around the collector. Many dust collectors are top load which means you will need to allow space above the collector to replace and service the collector from the top of the unit.

    Emissions Requirements

    Depending on your application, your dust collector may require a permit with specific emissions requirements. These emissions requirements vary by state and are expressed as an efficiency percentage for cartridge collectors or an emission limit (e.g. lbs/hr or gr/dscf) for baghouses.

    Temperature of the Environment

    The temperature of the airstream will determine what type of filter media is required and will affect fan size. Temperatures greater than 260 degrees will require special filter media and changes to the dust collector fan. If the unit will be outside in a cold/extreme climate you will need to consider insulating the unit as well.

    Dust Collector Volume

    Understanding Volume or Airflow Requirements

    Calculating Your Airflow

    After considering your dust properties, the next step in dust collector purchasing is our airflow or volume requirements. Calculating your airflow correctly is critical to the long term health of your collector so your system will be efficient at capturing dust.

    Why is Volume Important?

    If the volume of the system is too low, your system will not capture the dust effectively which can impact production and air quality. If the volume of your system is too high, your energy consumption costs will be higher and you may disrupt the process of your application.

    How is Volume (Cubic Feet Per Minute) Measured?

    Dust collector volume is measured in cubic feet per minute or CFM. CFM is a measurement of airflow especially related to air conditioning, heating and ventilation environments like those requiring dust collection. In dust collector applications CFM measures the amount of air per minute that can be moved from a space.

    Variables to Consider

    Work environments vary dramatically from one another based on several variables, and even very similar environments can require vastly different volume. To determine the right volume capabilities for your new dust collector, consider some of the following variables carefully.

    • How are you collecting dust?
    • What is the size of the duct being used to collect the dust?
    • Cubic feet of the work environment

    Dust Collector Air to Cloth Ratio

    Air-to-Cloth-Ratio

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

    What is Air-to-Cloth Ratio?

    Air-to-cloth ratio, also known as air-to-media, is defined as a measurement of the amount of air passing through one square foot of filler media. Generally the lower your air-to-cloth ratio, the more effectively your system removes dust from the work environment. If you are operating at a higher air-to-cloth ratio, one of the common issues you may encounter is a decrease in suction. This is because a large amount of dust laden air is filtered by an insufficient amount of filter media. The dust cake on the bag builds up too quickly; resulting in a decrease in air flow through the filters and suction at pickup points.

    How to Select or Calculate Air-to-Cloth Ratio

    If you’re sizing a new cartridge collector system and know what type of dust will be filtered and the air volume needed to properly ventilate the area or pickup points. Our Air-to-Cloth Guide below is a good place to start. The guide gives you a general recommendation on the air-to-cloth ratio for several different applications. To find the dust collector suited to your dust and air volume requirements simply:

    1. Divide air volume of system by air-to-cloth ratio to get the total amount of filter area needed into the system.
    2. Divide the total filter area by the filter area per filter to determine how many filters are needed in the dust collector.
    3. Find the dust collector model that best fits your application by number of filters
      and type of dust collector.

    To calculate air-to-cloth ratio in your existing system, calculate the volume of air (CFM) and divide that number by the total filter area within your dust collector. For example, a sixteen filter cartridge collector pulling 7,000 CFM would have a 3.65:1 airto-cloth ratio (7000 CFM / 16 filters x 120 ft2 per filter). Or in the case of a baghouse, a hundred filter baghouse pulling 10,000 CFM would have a 6.37:1 air-to-cloth ratio (10,000 CFM / 100 filters x 15.70 ft2 per filter). Environments with a large ventilation area or more pick up points require a higher air volume (CFM) to provide adequate suction which means more filter media to keep a similar air-to-cloth ratio.

    Air to Media Chart

    Why is selecting the right Air-to-Cloth ratio important?

    • Extends filter life
    • Minimizes your operating costs
    • Meets air quality goals and requirements
    • Allows your dust collection system to perform at peak efficiency

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

    • Poor venting which causes damage to equipment
    • High pressure drops in differential pressure
    • Impacts your air velocity
    • Excessive use of compressed air

    Dangers of an Undersized Dust Collector

    Choosing a collector that is too small can cost you in long term maintenance costs. Some of the biggest problems we see people run into with an inappropriately sized dust collector are:

    • Consistently clogged filters (reduced filter life)
    • Increased downtime
    • Higher maintenance and energy costs
    • Decreased efficiency
    • Increased compressed air consumption

    To avoid the dangers of an undersized dust collector consider both CFM and air-to-cloth ratio carefully when designing your new unit.

    Baghouse Styles

    Dust Collector Styles

    Baghouse Styles

    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 several types or styles of baghouses available. Once you understand your dust properties, volume, and air-to-cloth ratio, you can determine the right baghouse style for your facility. Here is a summary of the pros and cons of the three most common baghouse styles: pulse jet baghouse, reverse air, or shaker style.

    Pulse Jet Baghouse

    ProsCons
    Bags cleaned continuously while unit is in operationRequires compressed air
    Easy to maintain, low maintenance costNot ideal for high moisture applications (+20%)
    Flexible Sizing and ConfigurationRequires filter cages

    Reverse Air Baghouse

    ProsCons
    Low maintenanceNeeds to be cleaned often
    Gentle cleaning which allows for longer bag lifeResidual dust build up is hard to remove
    Units are typically compartmentalized into sections which allows them to be maintained without shutting down the entire baghouseFilter bags are expensive compared to Pulse Jet bags
    Bags are typically custom made and not available in stock for quick shipment

    Shaker Baghouse

    ProsCons
    Very simple to operateLimited filter media options
    Low initial investment costNot space efficient (takes up a large area)
    Filters cleaned via shaker mechanismNot suited for high dust loads
    Bags are typically custom made and not available in stock for quick shipment

    What’s the Right Type of Pulse Jet Dust Collector?

    The three most common pulse jet dust collection systems are baghouses, cartridge collectors, and bin vents. Below is an overview of each type of pulse jet system and common applications for each:

    Baghouses

    Baghouses are typically the largest of the three types of dust collectors. They are well suited for large volume and high temperature applications. Baghouses are perform well for applications with high dust loads of more one 55 gallon a drum per day. The most common applications that use baghouses include:

    • Wood
    • Mining
    • Asphalt
    • Foundries
    • Cement

    Cartridge Collector

    Cartridge Dust Collectors are compact and very modular in design. These are best suited for applications with the following characteristics:

    • Moderate or low dust (collecting less than one 55 gallon drum per day)
    • High efficiency filtration requirements
    • Space restraints or small footprint requirements
    • Possibility of future plant expansion

    The most common applications for cartridge collectors include:

    • Welding
    • Grinding
    • Laser/Plasma Cutting
    • Bulk Powder Processing

    Listed here is a baghouse and cartridge collector comparison chart to help you determine which option may be best suited for your application.

    Baghouse and Cartridge Collector Comparison Chart

    FeatureBaghouseCartridge Collector
    Airflow Range (in CFM)1,000+ CFM500+ CFM
    Dust Loading Per DayMore than 55 gallon drumLess than 55 gallon drum
    TemperatureUp to 500°FUp to 180° F
    Design Features20-30 feet tall Pulse jet cleaning Reverse airflow cleaning (part that removes larger particles)7-12 feet tall More compact for applications where space is limited Higher efficiencies
    Common ApplicationsWood · Metalworking · Mining · Foundries · Tile · Drywall · Fiberboard ManufacturingWelding · Plasma Cutting · Grinding · Bulk Powder Processing · Paint Booths
    Type of Filter MediaWoven or feltPleated, non-woven

    Bin Vent

    Bin vents are usually used in applications where you are moving product from one location to another. Like a cartridge collector, bin vents are also compact, and designed for easy change-outs. They are designed to efficiently vent silos and tanks while minimizing product loss. Bin vents are frequently used in the following applications:

    • Cement
    • Agriculture
    • Tank Loading
    • Conveyor Belt

    Dust Collection Design Features

    Low Maintenance Design Features

    To avoid the hassle of excessive and costly change-outs and maintenance consider important dust collector design features that will help you lower your long term maintenance and energy costs.

    Listed below are some of the easy maintenance design features your dust collector should include.

    Dust Collector Design Features for Easy Maintenance

    • On-demand cleaning for reliable performance and
      reduced wear and tear
    • Modular design with low profile options for easy
      expansion and access
    • Filter change-outs performed outside or clean air side of
      the collector
    • No special tools or equipment required to perform
      change-outs
    • Quick removal access filter covers
    • Change-outs performed in 30 minutes or less
    • Standard filter sizes to ensure product availability and competitive prices
    • Multiple filter options for a variety of applications

    Dust Collector Additional Resources

    Additional Resources for Dust Collector Purchasing

    How to Prevent a Dust Collector Explosion

    If you are dealing with combustible dust, you’ll need to implement a preventive maintenance plan, which will help you avoid a serious dust collector emergency.

    What is combustible dust?

    Combustible dust can be defined as any fine material that has the ability to catch fire and explode when it’s mixed with the proper concentration of air.

    When can combustible dust create an explosion?

    When the right conditions are in place, combustible dust can become hazardous and create an
    explosion. Dust can collect on multiple surfaces in a facility (e.g. ducts, crevices, dust collectors, equipment, etc.), and once this buildup of dust mixes with the right conditions, it only takes a small ignition source to create a significant explosion. There are even scenarios in which combustible dust can self-ignite. This usually results from static that builds up as the particulates rub against one another.

    Who does it affect?

    Combustible dust effects a wide variety of industries such agriculture, metalworking, mining, chemicals, plastics, pharmaceuticals, etc. Industries that are susceptible to combustible dust are regulated by OSHA standards and NFPA guidelines.

    How can I prevent a dust collector fire?

    Now that you know what conditions required for combustible dust, when it can happen, and who it effects, how do you limit or prevent a serious explosion from happening? Your best plan of action is going to include steps that are proactive instead of reactive. Here are the proactive steps you can take:

    • OSHA Standards: Ensure you are meeting OSHA’s set of standards regarding
      combustible dust. Industries that are susceptible to combustible dust are regulated
      by OSHA standards when you implement OSHA’s set of standards, you are
      creating a safe working environment, avoiding property and economic loss from an
      explosion, and avoiding regulatory fines.
    • NFPA Guidelines: Make sure you are meeting codes outlined by the NFPA
      (National Fire Protection Agency). The NFPA publishes a list of guidelines that will
      help you minimize injury or death from combustible dust. The following codes are
      related to the most combustible types of dust (e.g. sugar, wood, fine aluminum):

      • 664, Standard for the Prevention of Fires and Explosions in Wood Processing and
        Woodworking Facilities
      • 484, Standard for Combustible Metals
      • 61, Standard for the Prevention of Fires and Dust Explosions in Agricultural and
        Food Processing Facilities
    • Preventative Maintenance Plan: Properly maintain your facility and dust collector
      to help prevent a buildup of dust. Clean up any excess dust build up on your dust
      collector, other equipment, vents, and filters.
    • Explosion Vents: Installing an explosion vent on your dust collector is one strategy
      that can minimize damage to your equipment and harm to employees should an
      explosion happen. The purpose is to relieve pressure in the dust collector caused
      by an explosion. Once the activation pressure is exceeded the vent(s) open safely
      relieving pressure.
    • Explosion Latches: Latches operate under the same concept as explosion vents.
      Latches provide venting in the event of an internal explosion.

    Dust Collector Purchasing Summary

    Selecting and pricing out a dust collection system involves careful consideration of each of the variables outlined above. Proper attention to these items is critical to ensuring your dust collector performs efficiently for many years to come and creates a clean, safe work environment for plant operators. Each dust collection application is unique, and it is possible that applications with very similar product characteristics or volume requirements may require a system that is vastly different due to the number of variables to consider. To help you engineer and select the correct system for your facility, consult with a dust collection engineering and manufacturing company with extensive experience designing systems for diverse applications.

    If you have further questions unique to your application or would like to speak with an engineer, give us a call at 888-221-0312 or email [email protected]

    Dust Collector Sizing Quiz

    Would you like to get a price range and a recommended cartridge collector? Simply complete this dust collector sizing calculator  and you’ll immediately receive an email with your recommended unit along with a price range for the unit.  A dedicated account manager will also contact you within 24 hours to assist in finding the right solution.

    Cartridge Dust Collector Sizing Quiz

  4. Air Pollution Control & Managing Industrial Dust

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    Disclaimer: The contents of this industrial dust blog are intended to be general safety guidelines. All businesses will still need to refer to OSHA, NFPA, and local ordinances required for their business.

    Industrial Dust Guide

    Dust builds up in your home may simply be a nuisance you take care of while spring cleaning. But in the workplace, dust can become a serious hazard if not properly handled. To get a better understanding of the negative effects of dust in the workplace we will provide a brief overview what industrial dust is, how industrial dust is created , potential dangers you should plan for, and the benefits of a properly engineered dust collection system.

    Industrial Dust Guide

    What is Industrial Dust & How is it Created?

    Dust consists of small particles of dry matter that build-up on hard surfaces such as floors, tools, industrial equipment, ducts, etc. Industrial dust can generate more frequently than household dust. This is because it generates from the daily from the manufacturing or production process. For example, a small woodworking shop could generate dust from activities like sawing, grinding, or cutting. Industrial dust can even break out during processing. Another example, in an agricultural facility process dust can come from sugar, flour, grains, etc.

    Common Types of Industrial Dust

    • Wood – Activities like sanding, high speed cutting, low speed cutting, paning etc. can create dust which is both explosive and fire prone.
    • Food Particulate– Certain food particulate can be explosive, abrasive and fire prone. This can encompass a wide variety of particulate such as flour, grains (corn, rice), soybeans, and more.
    • Cement & Concrete – This dust is abrasive but considered to be less explosive and prone to fire.
    • Paper Products – Dust created from paper products can be both explosive and fire prone.
    • Paint Powder – Paint pigments can be highly explosive
    • Pharmaceuticals – Pharmaceutical dust like dry powder and coating are both explosive and fire prone.
    • Plastic, Chemicals, Stone, Minerals , Metal etc.

    Is Industrial Dust Dangerous?

    The build-up of combustible dust is serious hazard in the workplace. Airborne dust presents a safety hazard to employees. Many types of industrial dust may contain carcinogenic properties that would require removal to keep employees safe, healthy, and to comply with government regulations.
    Airborne dust may also be highly flammable, and safeguards must be implemented to prevent the risk of a dust explosion.

    Conditions for a Dust Explosion

    • Oxygen
    • Enclosed space
    • Ignition source
    • Combustible dust at the right concentration level

    When you are working in an industry that operates with combustible dust, explosions and fires are a constant threat. If you are taking the right steps to ensure a safe working environment you are more likely to avoid a fire or explosion that would cost you the safety of your employees, thousands of dollars in lost production, and regulatory fines. Combustible dust can present itself in a variety of applications. Below are just some of the types of industries that work with combustible dust.

    Common Examples of Combustible Industrial Dust

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

    There are no short cuts to minimizing dust hazards and ensuring the safety of your employees. But understanding if you are working with combustible dust is the first step in prevention.

    Regulation of Air Pollution Control

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

    OSHA regulates industries that are susceptible to combustible dust. When implementing OSHA’s set of standards, you are creating a safe working environment, avoiding property and economic loss from an explosion, avoiding regulatory fines. To learn more about OSHA’s safety standards for combustible dust, visit their guide here.

    The NFPA (National Fire Protection Agency) is another agency that publishes a list of guidelines to help minimize injury or death from combustible dust. The following codes are related to the most combustible types of dust (e.g., sugar, wood, fine aluminum):

    • 664, Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities
    • 484, Standard for Combustible Metals
    • 61, Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities

    How a Properly Engineered Dust Collection System Supports Air Pollution Control

    5 Benefits of a Dust Collection System

    Dust collection systems are engineered and designed to filter airborne industrial dust particles and debris that can cause damage to plant equipment, create a hazardous work environment, and negatively impact plant production. The top 5 benefits of a dust collection system are:

    1. Meet Compliance Regulations and Standards – 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.
    2. Boost Productivity – 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.
    3. Improve Product Quality – 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.
    4. 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.
    5. Preserve the Quality of Equipment – As dust particles and debris are created inside a manufacturing facility, the contaminated dust will settle onto other surfaces such as computer systems and manufacturing equipment. This dust buildup can be harmful and result in malfunctioning equipment. It can also create unnecessary, frequent, and costly maintenance to keep dust and debris from accumulating. With a dust collector system purifying and collecting dust particles, the chances of excessive dust build-up is minimal.

    In addition to adding a dust collection system to your plant, you can also consider some of these dust removal options and explosion venting strategies.

    Baghouse Dust Removal Options

    • Enclosed Box – A simple pipe system funneling dust into an enclosed box, placed underneath your hopper, is one dust removal option.
    • Drum or Bag – A removable drum or bag can be a simple and easy solution to collecting and disposing dust.
    • 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.
    • 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.

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

    Explosion Venting Strategies

    Common Venting Strategies

    •Preventative Maintenance Plan: In conjunction with a protection strategy, every facility should implement a well-designed and operated preventative maintenance plan. Perform regular checks on the health of your dust collection system to prevent more serious issues.

    •Explosion Vent or Panels: Explosion vents or panels are designed to rupture at a set pressure (PStat). When a source of ignition meets a fuel source with sufficient oxygen present, an ignition will occur. As the ignition begins, the pressure inside of the vessel will increase rapidly. Depending on the material’s Kst value, the pressure rise may be slow or extremely rapid. As the ignition progresses, the internal pressure will meet the PStat rating of the explosion panel. The explosion panel will rupture, venting the ignition gasses. The explosion vent provides a relief avenue for the expanding gasses, but the pressure in the vessel will continue to rise until it reaches the Pred pressure. This is the maximum pressure of the ignition event when explosion vents are functioning, so this is usually the pressure rating the vessel is designed to withstand.

    You can use explosion panels with a short length of ducting to allow for interior use without flameless venting. They do require replacement once a rupture occurs, but they are simple, cost-efficient, and easy to install. Explosion vents are typically useful on baghouses and cartridge dust collectors.

    • Explosion Latch: Explosion latches work under the same principle as the explosion panels, but they are not single use. This is a more cost-effective option (versus explosion panels) when you have  a large baghouse or large quantity of vent area.

    Additional Venting Strategies

    • Flameless Venting: Flameless venting can consist of a flame arrestor element, vent panel, and flanged housing. This combines the techniques of explosion venting and flame arresting. You can also install a flame arrestor element over a standard explosion vent. When the vent ruptures, the burnt dust and flames enter the flame arrestor element. The element helps to contain the hazardous dust and flames and prevents it from exiting, where it could potentially ignite a secondary explosion or endanger employees. While flameless venting does stop flames from exiting the vessel, there will be extremely hot gasses exiting the flameless vent. When using flameless venting, make sure to pay close attention to the vents proximity to personnel areas. If possible, always aim flameless vents away from regularly occupied areas.

    • No Return Valve: Protecting the dust collector from over-pressure is essential, but it is equally important to stop a deflagration propagation back to the operator space. To prevent this, a No Return Valve is needed in the inlet duct. This valve is a weighted damper that is held open by the air flow during normal operation, allowing air and dust to pass through to the dust collector. In the event that deflagration occurs in the dust collector, the pressure propagation through the duct work will close the No Return Valve. This prevents the deflagration from reaching any process equipment and also limits the risk of secondary explosions.

    • Abort Gate: Abort gates are high speed dampers that contain a spring assisted blade and is typically held in place by an electromagnet. Their purpose is to minimize the risk of an explosion by diverting flame, spark, or debris from entering a facility through a return air system.

    • Spark Detection & Extinguishing System: This method uses infrared sensors, typically located on the ductwork, to detect sparks or burning material in the ductwork upstream.

    Secondary Event Protection

    All the methods described previously are excellent options for managing primary explosions, but one of the most catastrophic outcomes of a combustible dust explosion is an un-controlled secondary explosion.

    When a primary explosion happens, there may be a pressure wave that propagates through the plant. This will “kick up” the layer of ambient dust. If the explosion is not contained in the dust collection system using the methods previously outlined, this ambient dust in the air could come in contact with the primary explosion flame front. This results in an uncontrolled explosion in an occupied space.

    To minimize the risk of secondary explosions, the first step should always be to expect perfect performance from your dust collection system. It is not acceptable to have a dust collection system that does not function properly. Another suggestion is to limit the amount of horizontal surfaces in your plant that cannot be regularly cleaned. Drop ceilings and in-accessible equipment are great examples of this.

    There are many strategies that may fit your unique application or facility. We recommend to consult your local or state building codes and regulations before choosing your explosion venting strategy. Some areas will have specific regulations for fire safety and environmental safety, and you want to ensure you are meeting those guidelines. Here are some questions to consider before implementing an explosion venting strategy.

    Questions to Consider

    At U.S. Air Filtration, we have been eliminating the hazards of industrial dust for 35 years.
    To learn more about how you can manage industrial dust at your facility contact us at 888-221-0312 or [email protected] to speak with an engineer

  5. What Volume Dust Collector do I need?

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    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

  6. Dust Collector Inspection and Service

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    Dust Collection Systems

    22 Point Inspection

    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:

    1.  Overall status of dust collector(s)
    2. Compressed air system for leaks
    3. Regulator pressure
    4. Air Shut off valve is sealed and is properly working
    5. Solenoids firing properly
    6. Diaphragm Valves firing properly
    7.  Couplings are sealed
    8. Magnehelic is working properly
    9. Fan Vibration readings
    10. Bearing Temperatures
    11. And more

    Dust Collector Service

    Different from an inspection, a service on a dust collector system includes bonded and insured technicians performing a change out or corrective actions. This can include the following:

    1. Changing filters
    2.  Seal minor air leaks
    3. Repair or replace damaged solenoids, valves, or diaphragm kits
    4. Any other repairs or troubleshooting needed on a baghouse – for example, vibration issues with a system after a filter change

    USAF Dust Collector Warehouse

    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.

    1. What type of service or troubleshooting are you requesting?
    2. Where will the service take place?
    3. What type of dust are you filtering? Is it hazardous? Is special safety equipment required?
    4. Are there any current issues with your filters?
    5. Is there any special training or background checks needed before entering a facility?
    6. 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.

  7. The Importance of Static Pressure for Your Dust Collector

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    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?

     

     

  8. Dust Collection: How to Create a World Class Customer Experience

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    Dust Collection Customer Experience Summary:

    • 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 a great 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

    1. Expertise and Product Knowledge
    2. Responsiveness
    3. Service
    4. Relationship
    5. Educational Resources and Tools

     

    Dust Collection Purchasing Survey Graphic 1

    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
    • Call Center
    • 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

     

    Dust Collection Purchasing Survey Graphic 2

    Service

    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.

    Relationship

    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.

    Dust Collection Resources:

  9. 5 Ways a Dust Collection System Improves Plant Efficiency and Saves Money

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    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?

  10. Industrial Dust Collection System Design Considerations

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    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.

    For maintenance, troubleshooting and other resources, watch our video “How Much Does a Dust Collector Cost?”, subscribe to our YouTube channel, follow us on Twitter, and like us on Facebook & LinkedIn.