Wednesday, October 26, 2016
Are you looking for some dust collection tips and guidelines to ensure your dust collector performs efficiently? Then you have landed on the perfect page.
Let’s explore the world of dust collection system. Read on to learn some expert tips and advice on how you can keep your dust collectors functioning efficiently.
What are the major components of your dust collection system
A dust collection system has five major components namely:
- Collection hood
- Dust collector
- Material handling or discharge equipment
One of the best dust collection tips we can give to ensure the efficiency of your dust collector, is for you to take extra care of these components. This entails monitoring the following:
- Mechanical operations
- Differential pressure
- Hopper levels
- Number of cleaning cycles
Here are some tips so you can ensure the efficiency of these components.
Dust collection tips and guidelines for your collection hoods
Collection hoods are the entrance to your dust collector system. Ensure it is working efficiently by checking the following:
See if there is an adequate airflow circulating inside your collection hood. Note however that there are differences between measuring the inlet (return) and outlet (supply) flow. Thus it is always best to work with an expert dust collection maintenance team. Call us at 1800 786 642 for assistance.
Capture and duct velocity
Capture velocity is the speed of air at the hood opening. This overcomes opposing air currents and captures dust to flow into the hood. Duct velocity, on the other hand, is the speed of air inside the ductwork.
An efficient collection hood should have a duct velocity equal to or slightly greater than the minimum air velocity required to move dust particles in the air stream. It must have a flow pattern and capture velocity sufficient to control dusting without collecting excessive dust.
What happens if capture velocity is too high?
If the capture velocity is too high at the collection hood, excessive particulate will get into the dust collector towards the filters. The filters then will be subjected to heavier than designed dust loading. This will wear out the filters fast and will require more cleaning energy.
How to ensure your dust collection hood is functioning efficiently?
Here are some tips on how you can ensure the efficiency of your dust collection hood:
- All the collection hoods are designed and located properly.
- The area around the collection hood is enclosed to prevent excessive outside air being pulled in the system.
- The hood area is large enough to maintain capture velocities of 200ft per min - 250 fpm.
- Blast gates are installed to achieve system balance.
- Necessary adjustments at each hood are applied to ensure proper capture velocity.
Dust collection tips and guidelines for ductwork (dust highway)
The ductwork is the highway of your dust collection system. To ensure it works efficiently you need to check the following:
For most applications, the proper dust velocity is between 3500 and 4000 fpm. If it goes lower than 3500 fpm then dust will fall out in the airstream. If it goes higher than 4000 fpm then it will result to duct abrasion, especially in the duct branches and elbows. Schedule a consultation with our team of experts, today. Call us at 1800 786 642.
The size of your ductwork heavily influences the result of your dust collection system.
Ductwork that is sized too small results to a high velocity rate in the duct. This increase speeds up the wear and tear of the ducts.
How will you know if the ductwork is too small?
Plants with small ductwork have holes and patches. Due to this, some plant owners think patching these ducts is the best solution. Little do they know that properly designing the ductwork is a more efficient approach in solving this problem.
Ductwork that is too large results to very low velocities. This produces dust fall-out and build-up in the duct which creates maintenance problems. The dust build-up reduces the cross sectional area of the duct which affects the overall airflow and air velocities of the collection hoods.
Uneven loading of ductworks causes abrasion to the filters. In extreme cases, it even results to wear through the dust collector hopper walls.
What is the ideal length of these ductworks?
Ductwork into the dust collector should have a straight run of at least eight diameters. This ensures the air and dust loading to the dust collector is evenly distributed over the whole dust collector.
I have shorter ductwork. What should I do?
Several factors have to be considered before adding vent hoods and ductwork. This includes answering the following questions:
Can the system handle the additional air requirement?
Do I have to resize the ductwork in order to maintain the proper velocity based on the airflow increase?
Adding and installing ductworks seem to be the easy fix. But without the right design and planning, you may soon find yourself needing to use turning vanes just to ensure the even distribution of dust and air. Thus it is better to correctly design the ductwork to avoid additional workload to your maintenance department. Talk to us if you want to redesign your dust collection system's ductwork.
Dust collection tips for the actual dust collector
These are the following key points you need to consider with your dust collector:
Air to cloth ratio
The relationship between the amount of air flowing through the dust collector and the total amount of media is based on the following factors:
- Dust loading
- Dust particle size
- Dust weight
Talk to us for your dust collector maintenance needs.
This refers to the velocity at the bottom of the filter bags. If this is too high, the capture dust will not fall effectively into the filter bags. Thus many dust collection manufacturers recommend a velocity of less than 300 fpm (1.5 m/sec).
How to fix an excessively high can velocity?
There are two ways of fixing an excessively high can velocity.
Increase the house size of the dust collector
High can velocity results in higher than desired differential pressure and cleaning cycles. This results to filter bag abrasion caused by too much airflow through the dust collector housing. To fix this, you can look at increasing the house size of the dust collector or reduce the airflow.
Use of shorter pleated filters and regular filter replacement
Regular replacement of filter bags improves bag cleaning whilst the use of cages with shorter pleated filters greatly improves its efficiency. It lowers the velocity below the bags thus reducing corrosion. However, this should only be done on a case per case basis depending on the recommendation of an expert dust collection maintenance team.
Consistent differential pressure yields consistent airflow and velocities throughout the system. At an average, dust collector systems operate very well between 5 in. and 6 in. WC (127 and 132 mm). Thus adjusting the cleaning controls to differential pressure is a simple and inexpensive way of ensuring the efficiency of your systems.
Dust collection tips and guidelines for the fan (the engine)
The fan is the engine that supplies energy to the dust collector system. Thus it is very important to ensure it functions efficiently.
Size of your dust collection fan (engine)
The size of your fan dictates the amount of air volume of your dust collection system. If your fan is undersized then it cannot produce your desired air volume. It is forced to deliver more air volume than needed. This puts unnecessary stress to the whole system resulting to more frequent maintenance problems.
Talk to us if you feel your dust collection fan's size does not fit your requirements. We can design a more efficient system for you.
Dust collection tips and guidelines for handling equipment
Hoppers filled with dust create a circulating dust load. This results to:
- Raised differential pressure
- Shortened filter life
- Increased need for filter cleaning
To prevent this from happening, air locks need to be placed at the bottom of each hopper. This prevents dust to flow back through the hopper.
It is important to check all of your dust collection components when experiencing airflow or dusting problems.
Do not settle for a quick fix in one area. Investigate all five components to properly evaluate your system's condition.
Understand and strictly follow the guidelines provided by your dust collection manufacture. Create and implement a reliable dust collection system. Most importantly talk to an expert dust collection maintenance team that are skilled and experienced to perform all the necessary repairs for you.
Call us today at 1800 786 642 for your dust collection maintenance and filter replacement needs. Otherwise follow our LinkedIn
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