When industrial dust collection products are integrated into complete systems they remove industrial contaminants from polluted air streams prior to atmospheric discharge. When feasible, they allow the return of cleaned air back into the manufacturing facility.
The type of industrial dust collector you need, as well as the final system design, depends on many factors. These include the collected particulates’ physical and chemical compositions, process exhaust conditions, local and federal regulations, and others.
“At SysTech Design, we select and market components that adhere to best practices, maximize efficiency, constructed for longevity, and are in compliance to published Standards and Codes.” – John Conley 1986
Industrial Dust Collection System Benefits
Benefits of an effective industrial dust collection systems include:
- Employees are protected from the harmful effects of pollution with an effective industrial dust collection system.
- Industrial dust collectors keep facilities compliant with health and air emission regulations.
- Use of industrial dust collection systems protects the environment from pollutants from manufacturing processes.
There are two key areas we focus on when reviewing a new system layout. First, the geometry and chemistry of particulate in the air stream which determines the way we configure and select components. Clean air system flow control components such as multibladed dampers on the “dirty side” can no longer be used as they would gum up or fail prematurely. The second key factor is keeping particulate in suspension after it is collected and effectively conveying it to the filtration device. Should equipment slowly fail or breakdown, particulate settling in the duct creates potential duct collapse, leaks in the duct, fire and explosion potential, additional static pressure loses with increases in fan horsepower, fan wheel abrasion, and imbalance.
Our systems approach is divided into two categories:
Ducted Pollution Control Systems – These systems are often termed central systems meaning the pollution control device or dust collector is located away from the process collection point and a duct system conveys the material to the air cleaning device. It is critical when evaluating systems that all the components included are of equal quality and value. The major components would include the dust or mist collector, capture hood (s), conveying duct, flex connector (s), fan damper, and HEPA filter assemblies. Also, duct layout, start-up and commissioning services, and controls need to be closely evaluated.
Self-Contained Dust Collectors – Self-contained dust collectors are a “complete” system by design, in that they include all the items included in a ducted system, but without the duct. These would include smaller cartridge and envelope bag collectors, portable dust collectors, downdraft benches, downdraft tables, portable equipment, and environmental control booths.
SysTech has developed quite a few systems since 1985. We configure industrial dust and fume collection systems using quality components and the proper materials of construction. Examples are:
Dust, fume and mist collection system design is about:
- Maintaining airflow thru system to minimize particulate and material deposition
- Minimizing noise levels from components
- Minimizing the pressure loses thru the system with proper duct and fitting configuration
- Minimizing horsepower requirements
- Maximizing capture with hoods with correct airflow
- Maintaining the integrity of duct and components by selection of proper materials of construction
Dust Collectors – Dust collector designs are available to handle most dust encountered. Whether bags, cartridges, pleated bags, blanket media or box filters, maximizing collection efficiency with filter media longevity is the goal. Understanding of the materials being collected, before equipment selection, will ensure these criteria are met.
Industrial Dampers and Louvers – Industrial dampers may be used to adjust airflow on the clean air side of the pollution control device. Materials of construction will vary depending upon airstream constituents.
Industrial Duct Systems – Industrial duct systems are sized and constructed for the materials being conveyed. Duct, elbows and fitting options include carbon steel, galvanized steel, stainless steel, FRP, and PVC as options.
Flexible Connectors – Duct connected to a fan or blower requires a flex connector for vibration isolation. If noise is an issue, these connectors can be fitted with acoustic treatment to prevent breakout noise from the fan.
Industrial Exhausters – An industrial exhauster conveys the dust or mist with the maximum efficiency while meeting the design performance requirements. Materials of construction vary to match the material conveyed and the airstream chemistry.
Fan Silencers – Fan silencers are selected to attenuate noise from either the fan inlet or discharge, which may or may not be ducted back into the facility. Silencers on the fan inlet prevent noise radiating back thru the collection system into the plant.
Electrical Controls – Electrical Control packages are offered to monitor fan motor speed, dust collector pulse cleaning, and explosion protection devices along with standard start-stop switches and disconnects.
They are many air cleaning technologies available for dust and mist filtration. Selection is based on the characteristics of the particulate or mist such as chemistry or abrasiveness, temperature, amount of material collected, explosivity of the materials, amount of maintenance the client can assign to the air cleaner, and location of the air cleaner in the facility. The major dust collector technology options would include:
Cartridge dust collectors are the preferred means for dust collection because of their initial efficiency, minimal space envelope and ease of maintenance. That said, baghouses are still required in those process areas where material loadings and material characteristics require their use. When cartridge style units are implemented, Donaldson® Torit® advanced technology cartridge dust collectors and filtration media provide effective solutions for managing a variety of industrial dust control issues including toxic, explosive and potent compounds. Both their Downflo® Evolution (DFE) Collector and Downflo® Oval (DFO) Dust Collector set the standard for cartridge dust collection.
- Powered by patented Ultra-Web® nanofiber filtration technology
- Provide cleaner air with up to 25% more filtration capacity than other collectors
- Dust collection filters last up to two times longer
- Provide significant cost savings and optimal service
Donaldson® filtration research and development has led to cartridge dust collectors that solve most industrial dust and particulate challenges in a variety of facilities such as:
- Food Processing
- Metal Working
Accidental atmospheric release of and worker exposure to potent compounds is a major concern in the pharmaceutical industry. Pharmaceutical materials containment is of utmost importance. Donaldson® Torit® Downflo® has set containment standards for pharmaceutical dust containment systems with:
- Filters and contains dusts of low, intermediate, and potent toxicity
- Potent compound surrogate tested
- Features triple-sealed Bag-In/Bag-Out (BIBO) components at the filters
- Includes integrated HEPA BIBO chamber under negative pressure
- Variety of clean-change dust discharge options such as a continuous liner
Dust collector applications and collection systems rely on a dust collector with filter media that has high efficiency particulate removal with long filter life. Donaldson® Torit® with their Power Core® dust collector designs, couples Ultra-Web® filter media in unique pack symmetry with an enhanced filter cleaning system to address that need. The filtration media in each pack, is configured in a corrugated flute structure allowing a straight through airflow. A 60% reduction in filter size is gained over cylindrical cartridge filters. This is the recognized next generation in dust collector design. The filter packs significantly reduce the collector “box” size, change-out maintenance time/costs and operation costs. The only thing not reduced is the interval between filter replacements.
Advancing technological has always been a Donaldson Company trademark. The Donaldson® Downflo® Evolution (DFE) dust collector series advances a new design package with fewer filters and a smaller footprint. It has an enhanced MaxPulse™ filter element cleaning system, triagonal shaped filter cartridges and their proven Ultra-Web® filter media. The DFE was designed to enhance filter cleaning, improve filtration capacity, increase filter life and reduce compressed air usage. This evolution is just another example of Donaldson’s commitment to provide the best dust collector design on the market.
Where required, the baghouse is the acceptable means to control those dusts loadings made up of agglomerative or fibrous materials, concrete, limestone and various melt shop applications to name a few. The available of numerous filter bag materials allows effective filtration efficiency over a wide span of process dust applications. Donaldson® Torit® line of baghouse dust collectors features the Torit® RF Baghouse dust collectors, developed to handle large air volume and heavy dust loading encountered in process applications such as:
- Food Processing
The RF dust collector design as well as other Donaldson baghouse models, have multiple filter media options based on particulate capture efficiency and airstream conditions. Need more airflow out of an existing collector? Consider the retrofit advantages using our pleated filter media.
The Donaldson Torit DCE® Dalamatic® Dust Collector is an auto reverse jet dust collector suitable for continuous process applications that have high product loads. They are available in stand-a-lone units or as insertables into process streams. Available with Dura-Life Filter Media resulting in surface loading, high filtration efficiency and 2 to 3 times normal bag life.
- Contiguous filtration of high dust concentrations
- Compressed air cleaning system
- Stand-alone or insertable configurations
- Downward airflow to minimizes re-entrainment
- Modular design means future capacity
- Horizontal bag removal
- Food contact Compliant configuration if using optional Helix Tubes
Silos and large hoppers require exhaust air filtration for pneumatic loading or dumping of materials. These applications where primarily bag style units until the evolution of cartridge filter technology. Easier to maintain and smaller packages allow the cartridge unit to have distinct advantages. Donaldson® Torit® manufactures silo or bin vent dust collectors specifically designed for collecting and cleaning dusts from silos, bins, bag dump stations, conveyor transfer points, etc. Because applications vary widely, optional features are numerous. They can be fan powered or unpowered, filters can be reconditioned or cleaned with compressed air pulse cleaning or a mechanical shaker, and filters can be cartridges, filter packs, pleated filter bags, envelope bags or socks. Important considerations for equipment selection include filtration efficiency, maintenance requirements and time required to replace filter media. Before selecting a dust control system, dust characteristics including explosion hazard must be evaluated.
Dust collection can be achieved at individual workplaces or stations using downdraft tables and benches having integrated fans and filtration systems. These tables can also be connected to a much larger dust collection system where a central dust collector is stationed remotely. The DualDraw line of downdraft tables accommodate a wide variety of industrial jobs that generate particulate including sanding, gluing, deburring, grinding, welding and more. Patented DualDraw downdraft tables:
- Provide symmetrical airflow across the total work surface
- Built to order benches mandate an operator clean breathing zone
DualDraw downdraft tables also feature vented backs, adjustable side panels and are fully self-contained, requiring no duct work.
This special Dual-Draw portable down draft table is used to protect the operator from air-born dust while grinding and sanding composite helicopter parts. Here the downdraft table is undergoing airflow testing at DualDraw prior to shipment to the customer.
Read more about Downdraft Tables and Benches here.
Knowing that when handling metals known to be explosive, DualDraw manufactures a wet dust collector that effectively and safely captures combustible metals such as magnesium, titanium and aluminum.
DualDraw offers wet dust collectors to collect combustible metal dusts such as magnesium, titanium, or aluminum.
They are available as downdraft tables, walk-in filtration rooms or as self-contained scrubbers that can be used for ambient collection or ducted to any existing tables or hoods.
DualDraw products for combustible dust collection are compliant with NFPA and OSHA standards.
Particulate collector applications and collection systems that handle “sticky” dusts in saturated airstreams are difficult to address with either a dry or wet collector. Handling those dusts that are not dry nor wet, spawned the Ultra High-Efficiency (UHF®) System was specifically designed for those applications. The UHF filters out smoke and sticky oily emissions using a rolling bed of designed filtration media, capturing particulate down to sub-micron in size at a low pressure drop and horsepower requirement. Finding solutions to these applications mandates that the UHF option be evaluated before proceeding with your equipment selection.
SysTech supplied side access filter housings feature the most complete line of containment systems with industrial HEPA filters. Find solutions for any application with a wide variety of choices such as:
- Materials of construction
- Indoor or outdoor
- Temperature rating
- Air flow capacity
HEPA filters are factory tested to meet necessary regulatory requirements for applications in hospitals, biotechnology, biomedical, laboratories, food processing, pharmaceutical, semiconductor fabrication, and more. A Bag-In Bag-Out (BIBO) option is available for applications where containment is required. SysTech Design will recomend the best Industrial Air Filtration System solution for you.
We represent the most trusted manufacturers and offer a full selection of products to meet most industrial air system applications.
American Warming & Ventilating
As a proven engineering and manufacturing company of louvers and dampers, American Warming and Ventilating is a leader in the air control industry. With a focus on customer satisfaction and quality products, American Warming and Ventilating has become the trusted name for industrial air systems control.
Fans and blowers used integral to and in conjunction with dust collectors have been an OEM staple of Cincinnati Fan for many years. As a manufacturer specializing in dust collector fans, they have a significant history of successfully applied products.
Donaldson Company – TORIT®
Donaldson Torit is an established name in the dust and fume collection marketplace. Their innovative designs for both dust and fume collection devices and enhanced filtration media are at the forefront of air pollution control equipment manufacturer. They offer complementary components for collection and conveyance of pollution air streams including complete room enclosures, fume exhaust arms, vacuum receivers and Easy Duct™, a clamp together duct system that allows changes in duct layout at asignificantly reduced installation cost.
DualDraw manufactures downdraft tables and benches in custom design configurations to capture dusts at its source. These self-contained dust collectors offer a multitude of advantages for isolated dust and fume collection conditions.
If you’re in need of a single piece of equipment or a complete dust collection system, SysTech is readily available to help you develop an air quality control plan you can live with. We offer the most technologically advanced systems and solutions from the leading manufacturers of filtration technology. Are you considering replacing your industrial dust collector or updating your duct system? Consider SysTech’s solutions for low-maintenance and long-equipment-life.