This blog covers a number of the design considerations to be made when selecting a Dust Extractor.
In order to ensure the effectiveness, efficiency, and safety of an air pollution control system, it is essential to take into account several key factors. These factors include:
Key Factors in Dust Extractor Design
Airflow is measured in either cubic metres per hour (m 3 /hr) or metres cubed per second ( m 3 /s) and must be high enough to capture and transport dust particles.
Filter materials should be specified to ensure they are correct for the dust type and application.
Filtration area should be calculated to ensure the filter give consistent
extraction without blocking.
Dust collection containers can be in the form of bags, bins, skips, 20 ft containers or a separate transfer system to a silo etc. Dust volumes and access should be considered.
Additional factors for consideration include noise, mobility, durability, and safety.
Different Styles Of Dust Extraction Systems
Reverse Air Filters
Reverse Air Filters (RAF) utilise controlled, intermittent reverse air flow to clean the filter media and are commonly used in industries where high volumes of dust and other airborne particles are generated. These use vertical hanging filter bags with the dusty air entering the hopper, where most of the heavy particles drop out, with the remaining dusty airflow flowing up the inside of the filter bag and the clean, filtered air leaving via the top of the baghouse. This type of extractor is popular for its efficiency, reliability, and low maintenance requirements.
Static Filter (T Series)
Static Filter (T Series) uses constant downflow to flush dust down into the collection hopper. These use vertical hanging filter bags with the dusty air entering the top of the filter, using the downward airflow to push the heavy particles into the hopper, with the remaining dusty airflow flowing through the filter bag and the clean ,filtered air leaving via the sides of the baghouse. Commonly used in the woodworking, they are installed in fixed locations within a facility and connected to the machines that generate the dust and debris by ductwork.
Pulse-Jet Filters (PJF)
Pulse-Jet Filters (PJF) use vertical hanging filter bags on support cages. They are cleaned by periodic bursts of compressed air (or pulses). These pulses dislodge dust and debris from inside the bags and cause it to fall into collection bins (or hoppers) below the unit. The dusty air enters the top of the dust chamber where downward airflow causes most of the heavy particles to drop to the hopper. The remaining dusty airflow flows through the filter bag, with the clean, filtered air leaving via the top of the baghouse. Often used in mining, cement production, power generation, and metalworking, this type of extractor is popular for its efficiency, reliability, and low maintenance requirements.
Pleated Element Filters
Pleated Element Filters (APMP): Often selected for their efficiency, compactness, and easy maintenance regimens. Pleated Element Dust Collectors consist of a series of filters (or elements) arranged in a vertical row. Dirty air is drawn into the collector through an inlet, and the filters capture the particles while allowing the filter air to pass through. The clean air is then discharged back into the workspace while the captured dust is collected in a hopper underneath the unit.
Modular Dust Collectors & Planning For Growth
Airtight’s RAF dust collector systems come in modular configurations, making them highly modular and flexible. These modular dust collection systems are designed with scalability in mind, easily accommodating changing production needs of customers. With the ability to add or remove filter modules as needed, they are an ideal solution for those who plan to grow their operations or have fluctuating production needs. This design also helps to reduce upfront costs and enables more efficient use of resources.
Maximizing Efficiency: Dust Extractor Design Features That Save Time and Money
When it comes to dust extractor design, the initial cost and ongoing maintenance can seem quite significant. However, there are several cost-saving features to look for that can help reduce these expenses over time. Cost-saving features to look for in industrial extractors include:
Variable Frequency Drives (VFD), can reduce energy costs by adjusting the speed of the motor to match the actual demand.
Ensure that your dust collection systems are properly designed, optimizing ductwork sizing and layout. This helps to reduce energy consumption and maintenance costs. Properly designed ducting systems can also help minimize resistance and pressure drop. This results in improved airflow, efficiency and reduced energy consumption. Additionally, optimized ductwork sizing and layout can decrease the likelihood of blockages, which can lead to reduced maintenance costs over time.
Airtight Autogates fitted to machines to close off when not in use reduces the overall airflow as required, saving power and wear and tear.
Remote monitoring and control capabilities, which can help identify problems early on, reduce downtime, and improve overall efficiency.
Preventive maintenance is essential to the efficiency and safety of a dust and fume control system. Customers can reduce downtime, prolong equipment lifespan, and ensure it’s operating at optimal efficiency by implementing on-going preventative maintenance or aftercare servicing.
Essential maintenance tasks include regular inspections of ductwork, filters and other dust extraction components to identify wear and tear or damage.
Regular cleaning to keep areas clear of dust and debris, inspecting and maintaining fans, motors and other mechanical components, checking seals and gaskets to ensure there are no leaks, and regularly monitoring the performance of the system (airflow, rate, pressure drop, and filter efficiency). Simply monitoring the pressure drop in you baghouse gives a good indication of the system status.
Airtight Systems: Over 2 Decades History of Quality Performance
Airtight’s RAF ( reverse Air filters) have a long and well proven history. Airtight installed the first system around Christmas of 1999. The original installation successfully ran for a year in an untested environment, demonstrating flawless performance, before launching the product that we know today. As of today, this original filter unit is still in service and has served three different customers over its lifespan.
Airtight’s experts bring an engineering approach to their installations and designs, resulting in excellent feedback on how to maximize their units. This advantage gives the company an edge over their competitors.
“Understanding what the customer wants, and also understanding how you’re going to achieve it, allows us to offer customers a real solution, not just a piece of equipment. Airtight’s deep understanding of their system’s design also allows them to ensure they run at optimum levels. Thereby, providing customers with even more effective solutions”.
Brett Borthwick, General Manager, Airtight NZ
The Power of Teamwork: How Airtight Achieves Customer Success
Airtight’s broad range of engineering experience and 20+ years of cross-industry knowledge fosters teamwork to address unique customer needs. Engineers refer specific challenges to the team for the necessary level of expertise to craft the optimal solutions.
Maximising Customer Success: Airtight Engineers’ Role in the Dust Extractor Design Process
Airtight’s engineering team possesses a broad range of expertise in designing effective dust and fume control systems. They can identify sources of dust and determine its specific characteristics, which is critical in designing an efficient extraction system. They can also determine the required airflow by considering the size of the workspace, number of dust sources, and type of dust. Based on the specific characteristics of the dust, they can select the appropriate filters to use. Additionally, the team possesses highly skilled expertise in optimizing ductwork for constant airflow and minimal pressure drops. They also ensure compliance with national, state, and local regulations and codes.