Many of us have seen the large funnel shaped mass of metal sitting outside of a manufacturing facility, school or processing plant. These are cyclone dust collectors and they come in many shapes and sizes. If you are curious how they work or are wondering which one will be the right one for your process, read on.
HOW THEY WORK
Cyclone dust collectors filter dust by utilizing centrifugal, buoyant and drag force. When dust laden air enters the cyclone at a controlled speed, the heaver dust particles are forced to the outside of the cyclone wall. This friction allows the dust particles to drop to the bottom of the cyclone into a collection device. The spinning air creates a secondary vortex in the middle of the cyclone that that exhausts the clean air out the top. Cyclones operate at various efficiencies depending on factors such as height to width ratio, water pressure drop, cfm and inlet type.
Most cyclone collectors never operate at peak efficiency. In order to reach maximum efficiency, all the factors mentioned above need to measured precisely and the cyclone manufactured to the specifications based on those measurements. If designing a new system, these measurements can be estimated closely with a knowledgeable engineer and precise measurements of duct length runs and sizes. However, the expense of manufacturing a custom cyclone collector to match these measurements is cost prohibitive. Instead, purchasers should look for a cyclone that shows efficiency based on CFM to water pressure drop and choose the appropriate cyclone for their application.
Efficient cyclones are capable of filtering 90% of particulate down to 15 microns. Options for collecting more particulate may consist of adding an additional cyclone in a series increasing the efficiency an additional 90%, making the total efficiency 99% down to 15 microns. If smaller particulate size is the issue for additional filtration, a bag house filtration system can added to a single cyclone or after the secondary cyclone.
THE INVOLUTE INLET
The involute inlet is an important part of any cyclone dust collection system. The involute initiates the cyclonic action of the dust laden air when entering the dust collector. This allows the clean air vortex to exhaust without the disruption of particulate entering the cyclone. Without this feature, dust laden air would enter the cyclone directly into the exhaust vortex removing much of the efficiency.
DO YOUR HOMEWORK
If you are in the market for a cyclone dust collector, there are some steps you can take to insure you obtain the efficiency that you require for your application. Know your CFM requirement. This is calculated by knowing how much airflow you require at each pickup point within your system. This can be a single pickup point or several. Know your water pressure drop. This is calculated by understanding how much force it will take to move the air at the CFM you require. If these calculations are beyond your knowledge, make sure to hire an engineer who is knowledgeable in dust collection or a dust collector manufacturer that has the engineering experience and willingness to assist you in making these important calculations.
One of the latest trends in down draft benches is the addition of return air flow, also called air-makup. The idea is that re-directing the exhaust air back toward the bench will force more particulate down toward the filers, thus increasing the amount of dust that can be collected. There are several reasons why this is a bad idea.
Standard filters used in these systems are capable of filtering up to 99% of dust down to 1/2 micron, which is excellent. However, the 1% of dust that makes it through the filter is typically dispersed throughout the ambient environment to expose workers to safe levels of the dust. By redirecting the exhaust air back at the worker, the contaminated air is concentrated around the worker at the table. Additionally, this is air with the most dangerous dust. At 1/2 micron or less, the dust is easily ingested by the worker and is easily absorbed by the body.
The best scenario for airflow at the work deck is to pull ambient air into the system. The less disruption to this airflow the more efficient the equipment will be in capturing dust. The disruption caused by the return air flow blowing can create “eddys” (just like in a river) around the worker and/or the material being processed on the bench. This again can lead to the worker being exposed to higher dust levels.
It turns out that return air flow is an add on expense that just doesn’t make sense. It sounds like a nice option and it allows manufactures to under power the equipment to achieve a higher FPM (feet per minute) at the deck. Visit www.proventilation.com to see our full line of quality down draft benches.
High Efficiency Cyclone Dust Collectors
Using a special high-efficiency design, the Tornado TXE is capable of approximately 90% collection efficiency down to 15-20 micron particles.
TXEs arranged in-series on a single platform are capable of approximately 99% collection efficiency down to 15-20 micron particles. Tornado TXE high efficiency cyclones are some of the most maintenance free dust collectors available. With no moving parts other than the motor and no filters to replace, they will provide years of low-maintenance, reliable service.
For applications involving particulate below 15 microns, optional after-filter assemblies are also available. Polyester Felt Bags provide standard efficiencies of 96% down to 5 micron. Alternate filtration media can also be used to further increase particle collection efficiency—including HEPA for 99.97% to .3 micron.
Our Involute Inlet
Centrifugal force causes heavier dust particles to move outward toward the cyclone wall. Friction and gravity then force the dust to fall into a receiver. Cleaned air spirals up the center vortex of the cyclone and exits at the top.
It is extremely important that the vortex that forms in the center of the cyclone and exits the exhaust is not contaminated by particulate entering the cyclone. The ProVent TORNADO TXE prevents this by initiating centrifugal force in the inlet forcing particulate to the outside of the cyclone prior to entering the cyclone. This is known in the industry as an involute inlet and makes ProVent dust collectors the most efficient in the industry.
Tornado TXE and TXEF are the best designed, built and efficient cyclone dust collectors on the market.
Cyclones can be utilized on a number of different applications. Volume (CFM), pressure (wg), and velocity (FPM) all impact performance. ProVent can help you make the proper selection based on your specific application.
Contact your ProVent agent today!
ProVent will be happy to assist in the precise sizing of your fan assembly. There are many factors other than CFM that will deter-mine the equipment size and fan package that will be needed to meet your performance requirements. Instead of offering standard units that may be “close” to meeting your system requirements, we size our equipment taking into account particle size, static pressure loss throughout the system and efficiency needs.
The ProVent TXE is designed for your application to meet your needs. We do not provide standard designs which may require oversizing equipment to meet your CFM requirements.
Many manufacturing and processing facilities have operations that expose their employees to dangerous levels of airborne contaminants. The installation of proper process ventilation systems can save companies from the hassle of dealing with OSHA citations.
Industrial ventilation is necessary to ensure clean air standards are met for the health and safety of industrial and manufacturing employees. This is of particular importance for industries involving toxic chemicals, flammable vapors and debris, welding fumes, solvent vapors, oil mists, and unwanted affluent of all kinds. Industrial ventilation typically involves installing systems to supply and exhaust ventilation to control emissions, exposure, and chemical dangers in the workplace environment. Installing ventilation systems, such as downdraft benches, oil mist collectors, and dust collection booths are much easier and cost effective for industrial companies than some of the alternatives such as process changes and chemical or material substitutions or eliminations. When employees are exposed to dangerous levels of chemicals, dust, flammable vapors, and other air contaminants, OSHA requires that the employers take steps to reduce exposure to safer levels.
The design and troubleshooting of industrial ventilation systems should be handled by a qualified ventilation engineer or companies specializing in the field through an onsite inspection of a company’s process ventilation needs. An inspection such as this can save a company thousands of dollars by preventing improper equipment selection and system design by staff in a hurry to bring their facility up to OSHA standards.
Some industries require very specialized ventilation systems. Oil mist collectors are required for industries that have airborne process oil and coolant from industrial machining operations such as vehicle and vehicle parts manufacturing. Oil mist collectors are particularly easy to fit into existing operations. Another more specialized type of ventilation system are a down draft bench systems which are self-contained ventilated workstations. These are particularly useful for hand grinding, sanding, and deburring operations. Down draft bench systems are also excellent choices for mixing and weighing operations, as well as, sparking operations or combustible metal processing and fiberglass finishing operations. When the process requires a larger area, dust collection booths are more appropriate. These are also useful for grinding, deburring, sanding, and polishing operations.
Many industrial ventilation manufacturers and installers offer jobsite consultations to determine the best ventilation equipment and systems are best for a particular facility. These engineers can help decide if a company should choose equipment such as oil mist collectors, down draft benches, or dust collection booths are best for their type of facility.
See www.proventilation.com for more information on industrial ventilation systems and oil mist collectors, down draft benches, and dust collection booths.
The Wet-Type dust collection market has been steadily growing over the past ten years for several reasons. Companies’ awareness of NFPA Guidelines has increased over this time period and they now realize that wet-type dust collection is a worthy and often necessary investment for their operation. The risk of a fire and the consequences which include significant production down time, employee injury or even death makes wet-type dust collection necessary in certain applications.
NFPA 484 is the Standard for Combustible Metals. This standard applies to the production, processing, finishing, handling, recycling, storage, and use of all metals and alloys that are in a form that is capable of combustion or explosion, as well as to operations where metal or metal alloys are subjected to processing or finishing operations that produce combustible powder or dust. (www.nfpa.org/484). If your process involves aluminum, titanium, magnesium, zirconium, tantalum, and/or niobium, NFPA 484 pertains to you. In most instances a wet type dust collection system is preferred for rendering these combustible materials inert. There are no expensive filters to replace, no chemical isolation systems to re-charge. While dry filtration systems become less effective as their filters load with dust, orifice impingement wet systems do not.
The cost of outfitting dry filtration systems with appropriate passive and active controls to comply with NFPA requirements has become prohibitively expensive. Passive controls involve special explosion vents and ducting to control pressure and to direct and extinguish flames. Active controls involve pressure/flame detection, and chemical isolation and extinguishing systems. These systems need to be regularly checked and re-charged, adding further to the cost of a dry filtration system. Wet collectors simply do not require these systems because the combustion hazard is removed immediately when the process material enters the water scrub.
There are two main types of wet-type dust collectors. The orifice / impingement design and the internal / venturi design. The O/I design utilizes a large cone-shaped orifice and an impingement plate that resides inside and on top of the cone. This creates an extremely efficient “scrub”. The scrub is where the dust entering the collector is mixed with water and sinks to the bottom of the collector and is the most important part of removing particulate. The process works best when the water surface to air ratio is highest within the scrub, thus making the most water to particulate contact. The O/I design does this most efficiently by removing 95% particulate down to 3 micron with just 3” wg of pressure drop. Additionally, by utilizing a wide opening in the cone, the O/I design will never clog.
A contributing factor increasing demand for wet-type dust collection is the increased use of materials suited for wet-type dust collection in products being manufactured. Aluminum and Titanium are the two most common metals where processes that create dust need to be rendered inert in a wet-type collection system. From aerospace to golf clubs, these metals are turning up in our products more often.
Other emerging markets for wet collection include food processing and pharmaceutical industries. Wet dust collection systems are used very effectively when process dust is water soluble and biodegradable. The wet system effectively captures dust where it is thoroughly scrubbed out of the air, dissolves, then simply drains away. There is no combustion hazard. There no exposure to workers by contaminated filters and little down time wasted by filter changes. Processing this way is less expensive and reduces a company’s environmental impact by avoiding costly trips to the land-fill with dirty filters. We have seen a move in this direction just in the past year. More and more companies are beginning to see that these simple advantages add up to significant savings and public relations advantages over time.
Currently, about half of the wet-type dust collectors we manufacture are stainless steel. Companies in the food processing industry are finding uses for wet-type dust collection and require the sanitary benefits of stainless steel for their applications. Stainless steel also increases the life of the dust collector approximately 70% making it an attractive option for companies willing to spend a little more money now and reap the benefits later.
Looking forward, companies are increasingly utilizing wet-type dust collection for unique applications that, we as a manufacturer, never considered. Recently a company had a process that created dust with a sticky residue. They were constantly replacing cartridge filters in their very large dry collection system. The ductwork required frequent cleaning and production needed to be halted during these maintenance operations. The process dust tested to be soluble and biodegradable and they are in the process of replacing a large dry cartridge dust collection system with a wet-type dust collection system. This solution will save the company hundreds of thousands of dollars in maintenance and production down-time in the coming years.
Wet-type dust collectors have been around since the late 1930’s. However, with today’s highly technical processes and materials, the benefits of wet-type dust collection is just beginning to be realized. Configurations such as piped systems, booth systems and down draft bench systems has allowed wet-type dust collection to be available for a wide range of processes. This, together with the small footprint requirements, elimination of expensive ductwork, and low maintenance requirements will continue to make wet-type dust collection more popular than ever in the coming years.
James K. Will,
Senior Sales Engineer
Harbor Springs, Michigan, USA
If there is too much dust in the workplace, it can cause many problems and the most serious is the short and long term health problems. Not only does dust make the place all messy and dusty, but also means you and your employees are breathing in harmful particles. The problems usually start off by allergic reactions and can turn into major respiratory problems. Also, a large amount of dust at work interrupts machinery and causes several malfunctions, which can result in a costly experience for you. However, the solution to your problems are dust collection booths.
What They Are
Dust collection booths are ideal pieces of equipment for workplaces that produce both a small and large amount of dust. They are perfect systems for those who wish to have a healthier and safer work environment. A dust collection booth is directly setup inside the workplace and controls the dust.
What They Offer
Dust collection booths offer a high level of control for dust, pollutants and dangerous particles that can be harmful to both the equipment and employees. With one of these systems in place, all pollutants are removed from the workplace, which results in cleaner air both inside and out.
A dust booth works perfectly well with dangerous materials, especially if a wet filter dust collection system is included. A dust booth is designed to work with dusts that are potentially explosive and provides a safe collection of the materials, as well as clean air that is OSHA and NFPA approved.
There is a huge variety of dust booths and these include the wet-type dust collection model, flood curtain booths, and the environmental work cell. The environmental booth is specifically for projects that involve sanding, finishing operations, chemical mixing, welding, and grinding of tools. A flood curtain booth suits projects like deburring, hand sanding, media blasting, and metal spraying. Lastly, the wet-type booths are designed for dangerous materials.
When selecting the dust booth for your workplace, it is important you consider the materials you work with. Speaking to an expert prior to choosing the final system is recommended, and ensures you make the right choice.
Working with metal and wood results in the release of harmful dust particles into the atmosphere, which is dangerous to the workers’ health. Continuous exposure to these particles means your employees will be breathing in the dust, which can lead to both short and long term health problems. In order to maintain the health and safety of your employees in the workplace, downdraft tables must be in place. They are made to solve the problem and controldust by cleaning the air, and give you a healthier and safer work environment.
What They Do
Downdraft tables give workstations a built-in ventilation system that is intended to catch and filter fumes, smoke, and dust. The air that gets filtered is driven back into the environment, which eliminates energy loss and any need for costly in-house exhaust systems.
Downdraft tables are highly efficient in controlling dust from buffing and sanding, which is caused in woodworking places. Metal workers can also benefit from a downdraft table, as their work can result in the production of large amounts of highly toxic dust. These systems are also a must for workstations dealing with composites, welding and plastics.
A downdraft table is made from high quality materials, which helps it to resist a multitude of tasks. You will find they come in numerous types, which includes portable cartridge, cartridge, wet, stationary tables, and walk-around ventilated. The one you choose highly depends on the materials that you work with.
Because of the huge variety in types and sizes, you will always find the ideal ventilation that is suitable for your workplace. This ventilation system can increase both yours and employees’ health, as it will limit the exposure to the harmful dust particles and offer you cleaner and purer air to breathe in.
A downdraft table is a multipurpose way to protect employees and easily meets the safety standards set forth by industries. You will be provided with a reliable and safe workstation, which you employees can safely work in.
Speaking to someone who specializes in industrial air collection will always help with selecting the setup that will work best for your industry.
Factories that produce heavy dust particles require a dust collector system in place, so employees can breathe in clean and pure air at all times. Also, with one of these systems in place, machinery functions well and lasts longer. Dust collection booths also help limit dust into a closed area and safely trap it inside a closed space for easy removal. When it comes to dust collection booths, there are many available, and the most common ones are listed below.
Flood curtain booth
These are used mainly when working with metal spraying, media blasting and hand sanding. They require the use of water, which is stored in a tank in order to flood a stainless steel vertical wall, where the procedure affluent is absorbed. Flood curtain booths can use roof and wall panels to trap extra dust and they can also contain illumination for the booth.
Environmental Work Cells
These are used in numerous working conditions, which include welding, sanding, chemical mixing, powder coating and grinding. They are made from 12-gauge all linked construction that is high quality. Environmental work cells incorporate pleated cellulose cartridge filters with high efficiency fan assemblages, and feature dust drawers; these are easy to access from inside the booth.
Wet-Type Dust Collection
The last of the dust collection booths is the wet-type dust collection. This requires a formation of blowers to power dust particles and pollutants against a series of water walls. The water walls wet the airborne pollutants and trap them away from workers and machinery. These are mostly used for sanding operations, deburring, and grinding. They are made from solid-fused heavy sheet steel and come in the availability of numerous sizes.
A dust collection booth is used to capture particles and other pollutants that can affect workers’ health in the workplace. Another thing that can be affected by the continuous dust is the machinery in the workplace, as the constant exposure of dust means it eventually builds-up and causes malfunctions in the equipment, which means more repairs. This device saves companies and industries a lot of money, as they don’t have to repair machinery often and because the worker’s health is better, they will also perform efficiently. Save the health of your employees and your expensive equipment with this ventilation system.
Downdraft benches allow a more comfortable practice with collection of dust in your factory or office. They have many other advantages apart from just taking care of all the dust and these are listed below.
Downdraft benches feature special filters that let you clean up dust from almost any type of work setting. They are well-known for this feature and the whole process is a breeze, one you know how.
How It Works
A downdraft bench system filters out the air within your work or office space and returns the cleaned air into the floor. This means you will always be free from hazardous particles and dust, which are both dangerous for health. Downdraft benches also save a lot of power, which is a brilliant factor to help you cut down on energy costs.
How Downdraft Systems Benefit Employees
Once this system enters an office, it increases employees’ work performance, which is due to the much healthier environment they will be working in. Employees become more efficient workers, as they can breathe in air that is both pure and clean, which has a healthy effect and lessens absent rates.
However, there’s more! As well as benefiting employees, this system also benefits machinery as it is less likely to rust, dust and stop functioning. Machinery also needs taking care of and if you have well-functioning machinery, this results in little wear and tear and fewer repair costs.
Overall, a downdraft bench system decreases working costs and increases profit by helping your workers perform better. You are also saved on power costs and the whole procedure is hands free. This means it requires less manual effort.
The durable system is made of stainless steel, which is the kind that doesn’t rust. Before creating these tools, the material used was both tried and tested. With the help of this system, you can easily clean fumes and dust from your work setting and reduce the risk these particles can have on the health. These systems are a must for all industries and are really helpful tools, which should not be overlooked.
Pollution is a common factor in today’s environment and it is vital to find a system that will help to maintain cleanliness and hygiene. Not only will a system like this help us in personal activities, but will also do the society a huge favor. The only way to achieve this goal of maintaining a pollution-free and environmentally friendly environment is with downdraft benches.
Downdraft benches are specifically designed workstations or tables with ventilation that enables them to filter out the contaminants and return clean air to the environment, including your workspace. Downdraft benches come in various sizes, which allows you to browse through a variety of options and choices before you select the final one. These systems can be used on various applications, and can even clean up building or fused materials that have been wasted or used.
One of the first things that will change is the quality of air that is breathed in by you and your employees. This workstation also increases efficiency of both your industry employees and machinery. If the air is cleaner, your employees will be breathing in pure air, which results in better performance, less illnesses; therefore, less absence rates. Also, the machinery in your business will stay well-maintained as the excess dust will be sucked up by the downdraft bench, which results in less wear and tear of theequipment.
The filtration system in a downdraft bench saves energy, which means you will never face a heavy electricity bill because of this system. Also, if the contaminants are filtered away from any machinery in your industry, they will not be clogged and will function well and last longer.
The downdraft tables will not only clean your work environment, but also raise the effectiveness of your machinery. The majority of these tables work on filters that are easily maintained, and these also don’t need replacing so soon. Again, this will save you money.
To sum it all up, these downdraft tables have many advantages, which will always improve the health and safety of you, your employees and your equipment.