Bag Leak Detection Blog

Directly Measure Particle Velocity

Just like in dilute phase conveying systems, dust collection systems require the bulk materials stay entrained in the air stream.  This is accomplished when the air speed in the systems remains at or above the minimum conveying velocity for the product. If it dips below the minimum conveying velocity (also called transport velocity) the dust particles will begin to settle out of the air stream. Dust collector systems are engineered for certain parameters based on things like fan size, duct configuration, and filter media.  Once in operation, it is more common that the engineered conditions do not always match the reality of the process conditions.Directly measuring the particle velocity inside the dust laden duct can provide operations the means to understand and even optimize the performance of their dust collector system.

Problems Caused By Low Air Velocity In Dust Collection Systems

Do you monitor your dust collectors?

Baghouses and dust collectors have the reputation for being neglected or a source of constant maintenance problems. Some facilities have to monitor their dust collectors based on their local, state or federal reguations. Thrugh the years it has been common to simply monitor the differential pressure, or just visually inspect the outlet stacks. Triboelectric broken bag detectors and bag leak detection systems have been around for decades now. Let’s take a look at how a triboelectric dust collector monitoring system can bring benefits to your facility.

Multiple Demanding & Dusty Applications

Cement plants rely heavily on dust collection systems for various processes in their plants. From capturing emissions from their boilers and kilns, to conveying systems used to move cement and other bulk materials around, to silo bin vents. What benefits can triboelectric technology from Auburn Systems provide in all of these areas within a cement facility?  

Here two areas where implementation can simplify compliance and improve operations.

Use Opacity Monitoring with Triboelectric Particulate Monitoring

Planning Ahead to Minimize Downtime

Many industrial facilities work hard to plan scheduled downtime to conduct maintenance as needed throughout the year. In some, however, production and operational requirements preclude periodic shutdowns. And for others, shutting down the process, even partially is not practical due to the amount of time required to restart production. For these reasons many facilities plan yearly maintenance outages where major repairs, installations and other tasks can be done all at once.

Following a comprehensive PM plan throughout the year is an effective way to minimize downtime. Planning is the key to efficient shutdown maintenance that accomplishes all required goals and helps reduce unplanned downtime during the rest of the year. Plants with dust collection systems preparing for their yearly shutdowns can begin planning for the following tasks now to achieve the best results come shutdown time. 

Annual Preventative Dust Collector Maintenance Inspections

Differential Pressure - Not necessarily the best parameter for dust collector/baghouse monitoring

DP is the king of dust collector monitoring metrics. However, some users have come to think that it is the ONLY metric to monitor on an industrial dust collector. This certainly is not the case…especially as the size and complexity of the system increases. Here are 4 important areas for which differential pressure cannot provide adequate insight.  

Total Emissions Levels

Differential Pressure is a Critical Baghouse Performance Metric

Successfully operating your dust collector means carefully monitoring the differential pressure on each unit. Differential pressure is the principal operating metric used to monitor performance of a dust collector. 

Most modern collectors operate at peak collection efficiency between 2” - 6” of differential pressure. For this reason, many air permits (as well as operating documentation) specify a DP range for the collector "not to exceed" in order to achieve emissions compliance. This is combined with other performance considerations, such as rising or falling airflow throughout the system, to provide an operating view that is monitored in parallel with the emissions output readings. 

What to Do When DP is too High or too Low?

Direct and Indirect Dust Collector Performance Metrics

On smaller dust collection systems, differential pressure often is the only metric used by operators to monitor the performance and condition of the system. For smaller systems this often proves sufficient. However, as systems get larger and more complex, plants usually start including additional monitoring metrics into the mix with the goal of early warning and predictive monitoring to reduce down-time, prevent reportable incidents and manage the maintenance burden and costs. 

Predictive, Indicative & Alert Dust Collector Monitoring Metrics

Efficient but not Necessarily Easier

Many industrial facilities choose to recirculate air from a dust collector inside of their facility rather than exhaust it outside the building. However, doing so presents some engineering concerns that must be addressed, including attention to NFPA 654. Let’s consider 3 reasons why you might consider recirculating the air in your facility despite the potential complications.  

Climate Control Costs

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.