3 common factory changes that might require dust collection system updates


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Do I Have to Monitor Stack Emissions From My Industrial Dust Collector?

Air Permit Compliance is Confusing

Often facilities have a difficult time identifying exactly what local, state and federal regulators require of them regarding their dust collection systems. This is not unreasonable as the myriad of overlapping environmental, and health and safety requirements that affect dust collection systems can be quite the twisted knot to untangle. And stack monitoring requirements are just one more confusing twist in the knot. Many wonder if these monitoring requirements apply to them since their dust collection system is relatively simple and small scale. 

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Advantages of Using Triboelectric Product Flow Monitoring with a Cyclone Dust Collector

Understanding What's Happening Inside Your Cyclone Dust Collector

Cyclone dust collectors find use in many industrial applications with high volumes of product flow. Unlike other types of dust collectors, such as fabric filter collectors, cyclones can handle very high dust levels without sacrificing efficiency or sustaining damage. This is precisely why cyclones are often used as prefilters, removing the majority of the material from the airstream before it enters into a final “polishing” unit, such as a baghouse or cartridge collector. In other applications, cyclones are used for particle sorting or bulk material transport. 

Even though cyclones do not have a high enough collection efficiency to be used by themselves, they do play a large role in many applications, for emissions as well as process applications. In process applications, many have asked if triboelectric monitoring can control product flows through the cyclone. The answer is yes!

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3 Tips to Eliminate Unplanned Downtime Due to Your Industrial Dust Collector

The Huge Cost of Unplanned Downtime

Recent survey of auto industry manufacturing executives shows stopped production costs an average $22,000 per minute. A similar study found that of the facilities that can calculate the cost of downtime, most under estimate it by 300% on average! With this in mind, consider that when an industrial dust collector goes down, it almost always takes its associated system(s) down with it. In fact, in many facilities dust collectors used for pollution control must operate at all times. Any malfunction results in a mandatory shutdown of the entire process and even the facility. With downtime costs running into the tens of thousands per minute in many cases, we can see that these costs far outweigh the average costs to maintain the dust collector properly.

When the cost of downtime / hour or shift is measured in the thousands, properly maintaining an industrial dust collector isn't expensive.

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Triboelectric Detection for Early Warning of Hopper Bridging in a Cyclone Dust Collector

Cyclone Dust Collector Bridging & Other Hassles

Triboelectric dust detection systems can be used effectively to monitor a cyclone dust collector just as well as a fabric filter collector. In the same way that triboelectric systems can monitor baghouses for collection efficiency, operational output and maintenance needs, so to can they monitor cyclone dust collectors. In this article we'll take a quick look at common applications for cyclone collectors and then dig into two common operating problems that triboelectric detectors can assist with. 

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How to improve collector efficiency for reclaiming precious metal dust

Not just scrap!

Reclamation of precious metals is big business. US Census Bureau data indicates that nearly 14,000 metric tons of precious metal scrap were exported from the U.S. in 2012 valued at $5.5 billion.

In precious metals reclamation applications, efficiency means the difference between profitability and bankruptcy. Many precious metal reclamation processes make careful use of industrial dust collection systems at multiple points along the process. In addition, many other industrial processes that make use of precious metals in their processes (e.g. platinum catalysts in refineries) often have secondary reclamation systems installed to reclaim as much of these materials as possible. In both cases, any improvement in collection efficiency can result in increased profits. 

Different Ways of Using Dust Collectors to Reclaim Precious Metals

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What is an air material separator under NFPA 654?

 Air material separators - critical for dust collection and recirculation

Despite the well know dangers associated with combustible dust hazards there exist few specific OSHA/MSHA regulations covering them outside of a handful of specific industries (e.g. grain elevators) on a national level. Rather, local jurisdictions normally base their regulations on the guidelines found in the National Fire Protection Agency standards that outline best practice for eliminating or controlling these hazards.

The most widely used NFPA standard for combustible dust is NFPA 654 - Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids.  This standard contains guidance that is applicable to most combustible dusts in general industry and is attracting new attention based on updates to the regulations around recirculating air from dust collectors and combustible dust monitoring.

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Understanding Triboelectric Terminology - PM 2.5 and PM 10

Many new dust collector operators and maintenance professionals are understandably baffled when confronted with a whole new emissions compliance terminology. After all, most of their work revolves around mechanical issues, and thus the terminology and methods used to calculate and measure emissions can seem intimidating. 

To take some of the mystery out of these terms we've pulled together explanations of a couple key terms to bridge the gap between the mechanical side and the compliance side of emissions monitoring and control.  The terminology can make even a seemingly simple topic like particle size seem unnecessarily complicated with terms like PM 2.5

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Should Multinationals Harmonize their Industrial Dust Collection Globally?

Multinational corporations with manufacturing facilities in multiple locations face unique knowledge management and regulatory compliance challenges. Harmonizing industrial dust collection technology across all facilities can result in significant savings in two basic areas.                                                                       

Direct Savings on Cost of Goods

Eliminating unnecessary variations allows companies to consolidate requirements and purchase higher quantities of fewer items.  This typically results in better pricing from vendors. In a simple world they would use dust collectors with the same style and sizing of bags. Realistically, one size filter will not work for every application across a large plant, let alone a series of plants, so a more practical goal is to minimize different styles and keep only a few variations. For example, avoid purchasing systems with different bag diameters of 6.25", 6", 5-7/8", etc. Rather, try to keep diameters the same and just vary the lengths, having a set size for your "short" and "long" units. 

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Should My Dust Collector Supplier Provide My Emissions Compliance?

Facilities get their dust collection systems from literally hundreds of different suppliers. These include the big name OEMs with several decades of experience specializing in baghouses, as well as many medium and small OEMs focusing on smaller systems or certain applications. In addition, some custom manufacturing companies and larger HVAC/ductwork firms may also manufacture dust collectors on a project basis. Finally, countless sales rep organizations and environmental consulting firms may resell units from other OEMs to their customers.

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