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Author:
Anna Frank, Equipment Selection Expert
Anna Frank, Equipment Selection Expert
To ensure a comfortable work environment and meet required environmental standards, industrial enterprises are implementing specialized dust arrest systems.
Types of Dust Arresters
Dust arresters can be classified into the following types:
Baghouses - contaminated air passes through fabric bags, where particles are captured on the external surface via sieving and surface filtration. Cleaning is typically performed automatically using pulse-jet systems that inject compressed air into the bags. These systems require stable process conditions, particularly control of the dew point to prevent moisture condensation, which could cause clogging.
Baghouses - contaminated air passes through fabric bags, where particles are captured on the external surface via sieving and surface filtration. Cleaning is typically performed automatically using pulse-jet systems that inject compressed air into the bags. These systems require stable process conditions, particularly control of the dew point to prevent moisture condensation, which could cause clogging.
Blizzard BIG Pulse Jet Baghouse
Wet scrubbers - remove particulate matter by forcing the dust-laden gas stream to pass through a mist of water or chemical solution, where particles are captured through inertial impaction and diffusion. A significant operational constraint is the need to maintain gas temperatures above freezing to prevent ice formation, alongside the requirement for water treatment infrastructure to handle the resulting slurry.
Wet Scrubber Dust Collector
Cartridge dust collectors - utilize pleated filter media, usually made of cellulose, polyester, or composite materials, providing a larger filtration surface area in a compact housing. Filtration occurs as particles are trapped on the surface or within the depth of the media, depending on its structure. For regeneration, high-pressure pulse-jet cleaning is employed, where short bursts of compressed air release the solids layer into the collection bin without interrupting the airflow.
Comparison of Baghouse and Cartridge Filters
Adsorbers and dry scrubbers - powdered reagents are injected into the flue gas stream, where they chemically react with and neutralize acidic pollutants like SO₂ and HCl. This method is particularly suitable when water usage must be minimized or when the waste must remain in dry form for disposal.
Oil mist collectors - designed to capture aerosolized oil particles generated in machining operations by using a multi-stage process that often includes mechanical filtration and coalescence. To ensure effective separation and prevent re-entrainment, the design limits the face velocity through the filter media, typically within the range of 1–3 m/s.
Choosing the Right Unit
Equipment selection should account for contaminants type, particle size distribution, volume, and the specific room and process characteristics. The selection process involves: first, gathering all relevant parameters and defining filtration quality requirements; second, identifying any constraints (e.g., waste disposal capabilities) to rule out unsuitable options; and finally, conducting a techno-economic comparison of viable solutions to determine the optimal choice.
Safety Considerations
When mixed with oxygen, fine particles can ignite from a single spark. Any fine solids are potentially explosive, regardless of its chemical composition, with higher concentrations creating a greater risk. Since the blast wave can propagate at supersonic speeds, reducing contaminants concentration through collection is critical. However, the dust collection system itself can present an explosion hazard.
Overview Cyclone Spark
To mitigate this, the primary line of defense is a spark arrestor installed upstream of the filter, designed to prevent ignition sources from entering the system. The equipment is also fitted with internal pressure and temperature sensors. These sensors instantly send a signal to the control unit, triggering cylinders that release an explosion suppressant as a secondary protective measure. Other system safety measures are also employed.
The primary standards governing codes for dust collector spark detection and arrest are NFPA 69 and NFPA 654. A key mandate within these standards is that sensors must detect smoldering particles before they enter the collector, with the suppression system activating within milliseconds. Additionally, a rapid-isolation valve must be triggered to prevent the explosion from propagating through the ductwork.
The primary standards governing codes for dust collector spark detection and arrest are NFPA 69 and NFPA 654. A key mandate within these standards is that sensors must detect smoldering particles before they enter the collector, with the suppression system activating within milliseconds. Additionally, a rapid-isolation valve must be triggered to prevent the explosion from propagating through the ductwork.
What Is Combustible Dust and How To Manage It
Overview of Dust-Arresting Compounds
Dry reagents and wet cleaning solutions are used as dust-arresting compounds in scrubbers.
Dry reagents
The most common dry reagent is calcium hydroxide. It neutralizes acidic gases such as SO₂, SO₃, HCl, and HF, with the reactions resulting in the formation of sulfites/sulfates or calcium chloride.
Sodium bicarbonate is also highly efficient in neutralizing acidic gases. When heated, it decomposes to form active Na₂CO₃ and CO₂, which increases the available surface area for the reaction.
Calcium oxide is less commonly used, as it requires hydration within the system. Activated carbon, while not a reagent in the classical sense, is added to mixtures to co-capture dioxins, furans, and heavy metal vapors (e.g., mercury) through adsorption.
Sodium bicarbonate is also highly efficient in neutralizing acidic gases. When heated, it decomposes to form active Na₂CO₃ and CO₂, which increases the available surface area for the reaction.
Calcium oxide is less commonly used, as it requires hydration within the system. Activated carbon, while not a reagent in the classical sense, is added to mixtures to co-capture dioxins, furans, and heavy metal vapors (e.g., mercury) through adsorption.
Wet cleaning solutions
Pure water is the most frequently used solution in wet scrubbers. It effectively captures water-soluble gases (HCl, HF, NH₃) and particles through the mechanisms of inertial impaction and diffusion.
Alkaline solutions are added to increase neutralization efficiency. Sodium hydroxide is highly effective but requires careful handling. An inexpensive calcium hydroxide suspension (lime slurry) is also used, though it tends to form deposits. Sodium carbonate is considered a milder alkali.
Alkaline solutions are added to increase neutralization efficiency. Sodium hydroxide is highly effective but requires careful handling. An inexpensive calcium hydroxide suspension (lime slurry) is also used, though it tends to form deposits. Sodium carbonate is considered a milder alkali.
How to Test Dust Weight Arrestance
To verify the reliability and efficiency of the selected system, both laboratory analyses and field measurements are conducted, supported by dust arrestance calculations. The standard testing procedure includes a visual inspection of the housing for leaks and the filters for damage, measurement of key operating parameters (airflow rate, pressure drop across the filter), and air sampling upstream and downstream of the filter to determine the actual collection efficiency via dust weight arrestance. Following the dust weight arrestance test, specialists compare the results with the original design specifications. If the outcome does not show high dust arrestance, the root causes of the performance shortfall are investigated.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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