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Author:
Michael Klepik, Chief Executive Officer
Michael Klepik, Chief Executive Officer
Industrial air purification systems effectively clean the atmosphere in the workspace and ensure compliance with maximum allowable concentration limits in the workshop as well as with environmental requirements in general.
Purpose and Applications of the Systems
Industrial and commercial fans, blowers, and air purification equipment are used across a wide range of industries. In the chemical industry, they capture corrosive gases, explosive dust, and solvent vapors; in pharmaceuticals, they provide protection against toxic active pharmaceutical ingredients (APIs) and cross-contamination; in metallurgy and the production of construction materials, they address high concentrations of fibrogenic and silicosis hazardous dust.
Industrial air purification equipment removes oil mist and welding fumes in metalworking; controls allergens and explosive organic dust in the food industry; captures volatile organic compounds (VOCs) in the paint, varnish, and printing industries; ensures explosion safety in woodworking; and maintains required air quality in electronics manufacturing.
Industrial air purification equipment removes oil mist and welding fumes in metalworking; controls allergens and explosive organic dust in the food industry; captures volatile organic compounds (VOCs) in the paint, varnish, and printing industries; ensures explosion safety in woodworking; and maintains required air quality in electronics manufacturing.
Three air purification units by Torch-Air installed at a client’s chemical production facility
Expert Commentary by Michael Klepik: Selection and Application of Air Purification Equipment
Comparison of Methods
There are various industrial air purification methods, and the choice of a specific one depends on the type of pollutant (particulate matter, gases, or aerosols), particle size, and industry requirements for safety, cleanliness, explosion protection, and cost effectiveness. Those same inputs go into a data sheet before any gas cleaning equipment is quoted, together with temperature, dew point, and corrosivity.
Dry methods are a universal solution for capturing solids of any size, including toxic active pharmaceutical ingredients (APIs), allergens in the food industry, and fibrogenic dust in the production of building materials. They provide dry product collection and achieve efficiencies of up to 99.99% when using HEPA/ULPA filters.
Wet cleaning is indispensable in the chemical and metallurgical industries, where simultaneous removal of aggressive gases, cooling of high-temperature streams, and neutralization of explosive dusts are required. However, it is associated with the generation of liquid waste and higher operating costs.
Dry methods are a universal solution for capturing solids of any size, including toxic active pharmaceutical ingredients (APIs), allergens in the food industry, and fibrogenic dust in the production of building materials. They provide dry product collection and achieve efficiencies of up to 99.99% when using HEPA/ULPA filters.
Wet cleaning is indispensable in the chemical and metallurgical industries, where simultaneous removal of aggressive gases, cooling of high-temperature streams, and neutralization of explosive dusts are required. However, it is associated with the generation of liquid waste and higher operating costs.
Dry and wet air purification units by Torch-Air. A completed R&D project
Adsorption systems are the method of choice for the paint, varnish, printing, and chemical industries, where the main pollutants are volatile organic compounds (VOCs) and solvent vapors. They require mandatory pre-cleaning to remove solid particles and prevent clogging of the sorbent. In some industries, combined systems are used: for example, in the pharmaceutical industry, dry HEPA filtration is supplemented with carbon adsorbers to capture solvent vapors after drying, while in the chemical industry, scrubbers can be combined with adsorption post-treatment to meet stringent environmental standards.
Comparison of Wet and Dry Purification Methods
The table shows the best industrial air purification approach for each specific case.
Overview of Typical Industrial Units
Today, the following industrial air purification systems for sale are available:
- Bag filters – dust laden flow passes through fabric or synthetic materials that trap the solids;
- Wet Scrubbers – contaminated flow is exposed to a liquid that captures dust and gaseous impurities;
- Adsorber – a layer of sorbent retains molecules of gaseous impurities;
- Oil mist collector – use a combination of mechanical filters to trap oil particles;
- Industrial portable dust collectors – local unit that can be moved from one location to another, each equipped with a filter unit.
Cost of Industrial Air Purification
The cost of industrial air purification consists of capital expenditures (CAPEX) and operating expenditures (OPEX). Scrubbers represent the largest cost across both types of expenditure, as they have a more complex design, require a foundation and significant floor space, and are characterized by high power consumption, fluid replacement, and wastewater disposal.
Portable units and small oil mist collectors are the cheapest in terms of capital expenditure. They lack complex automation components, utilize commercially available filters that require no custom design, and are easy to install.
The cheapest types of industrial air purification systems in terms of operating costs are bag filters (for high dust loads) and oil mist collectors (with oil return). Bag filters can last up to 2–5 years without replacement, and the cost of replacing a set of bags is 5–15% of the equipment's CAPEX, which is significantly lower than the cost of replacing cartridges. Additionally, they have moderate energy consumption, produce dry waste that is easy to dispose of, and are simple to maintain. Oil mist collectors partially offset operating costs by returning oil to the process. They are also characterized by low energy consumption and ease of maintenance.
Portable units and small oil mist collectors are the cheapest in terms of capital expenditure. They lack complex automation components, utilize commercially available filters that require no custom design, and are easy to install.
The cheapest types of industrial air purification systems in terms of operating costs are bag filters (for high dust loads) and oil mist collectors (with oil return). Bag filters can last up to 2–5 years without replacement, and the cost of replacing a set of bags is 5–15% of the equipment's CAPEX, which is significantly lower than the cost of replacing cartridges. Additionally, they have moderate energy consumption, produce dry waste that is easy to dispose of, and are simple to maintain. Oil mist collectors partially offset operating costs by returning oil to the process. They are also characterized by low energy consumption and ease of maintenance.
Diagram of a Real Air Purification Unit
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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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