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Home / Case Studies / Dust Collector for Abrasive Dust and Tumbler Screening Machine Equipment
R&D Project: Dust Collector for Abrasive Dust and Tumbler Screening Machine Equipment
Category: Completed R&D Projects
Client
Our client is a leading manufacturer in the chemical and materials sector, specializing in high-quality polymers and composite materials used across various industries, including automotive, aerospace, and construction. Founded over 25 years ago, the company has grown into a major global player, known for its innovative solutions and commitment to sustainable development.
Headquartered in Houston, Texas, our client operates multiple manufacturing facilities worldwide, with a strong presence in North America, Europe, and Asia. The company employs over 5,000 people globally and maintains a robust research and development division focused on creating new materials and enhancing existing products.
Its product range includes a wide selection of polymers, high-performance fibers, and engineered composites, designed to meet stringent industry standards and customer specifications. Their products are essential components in high-tech manufacturing.
Headquartered in Houston, Texas, our client operates multiple manufacturing facilities worldwide, with a strong presence in North America, Europe, and Asia. The company employs over 5,000 people globally and maintains a robust research and development division focused on creating new materials and enhancing existing products.
Its product range includes a wide selection of polymers, high-performance fibers, and engineered composites, designed to meet stringent industry standards and customer specifications. Their products are essential components in high-tech manufacturing.
Production Process
Our client uses a GKM drum-type screening machine in its production process to ensure the highest quality of powdered and granulated materials. This machine plays a key role in classifying and separating product fractions during manufacturing, thereby improving efficiency and the quality of the final products. Its ability to prevent mesh clogging and maintain continuous operation is crucial for meeting the company's high performance requirements.
Problem
The air filtration system lacks sufficient performance, leading to rapid wear of filter elements and abrasive wear of the existing dust collector housing. Additionally, due to the system’s inefficiency, there are constant complaints from OSHA and factory workers.
Task
The client requires an efficient dust collection system to address the inadequate performance of their existing setup. The new solution must:
- Handle highly abrasive polymer and composite dust.
- Improve air filtration efficiency and reduce maintenance costs.
- Support an airflow of approximately 750–1000 m³/h at 10–12 m/s.
- Fit within specific dimensional constraints (1000 mm x 1000 mm x 2000 mm).
- Include a standalone filter unit near the production floor.
Current system component
A single dust collector that fails to provide effective filtration.
Temperature
Ambient
Gas/Dust:
Fine particulate dust generated during the grinding of polymer and composite materials:
- Less than 10 microns (µm) — 20%
- 10 to 100 µm — 50%
- 100 to 500 µm — 20%
- More than 500 µm — 10%
Average density
Approximately 0.9 g/cm³ (depending on the polymer type and filler content).
Initial Data
Equipment Description for the New Dust Collector Acquisition
Particularly with fine materials, it is crucial to prevent the screen mesh from clogging to ensure continuous operation. Several highly effective screen cleaners are available for this purpose. Its modular design allows for various configuration options. The product may be screened 2 to 3 additional times to enhance yield and efficiency. Alternatives include integrated control screens or reverse screening, where the finest particles are separated first, followed by larger fractions.
Tumbler Screening Machine
Client Communication
Client:
Good day.
We have a production line where all equipment is aspirated by a single system. The material is highly abrasive. To improve the quality of the final product, we decided to additionally aspirate the discharge from the oscillating screen.
A problem has arisen: the material aspirated from the discharge is penetrating the filter bags despite the baffle plate installed in the filter. We plan to separate these aspiration systems and require a small standalone filter for the screen, which can be installed next to the equipment on the production floor.
Do you have ready-made solutions for small filtration units? Please consider the possibility of supplying a separate filter and provide a commercial offer. The equipment drawing is attached. I will do my best to answer any questions.
Best regards, Chief Mechanic
We have a production line where all equipment is aspirated by a single system. The material is highly abrasive. To improve the quality of the final product, we decided to additionally aspirate the discharge from the oscillating screen.
A problem has arisen: the material aspirated from the discharge is penetrating the filter bags despite the baffle plate installed in the filter. We plan to separate these aspiration systems and require a small standalone filter for the screen, which can be installed next to the equipment on the production floor.
Do you have ready-made solutions for small filtration units? Please consider the possibility of supplying a separate filter and provide a commercial offer. The equipment drawing is attached. I will do my best to answer any questions.
Best regards, Chief Mechanic
Equipment Drawing
Engineer Torch-Air:
Good afternoon, we need to understand the required air volume for the filtration system.
Client:
Essentially, we need to aspirate a volume of 0.8 m³ at a speed of no less than 10 m/s. We are open to considering a system with a frequency converter to adjust the airspeed based on laboratory analysis.
Best regards,
Chief Mechanic
Best regards,
Chief Mechanic
Engineer Torch-Air:
Good afternoon,
A cyclone is likely a suitable preliminary solution, and the filtration speed needs to be reduced. It may also be necessary to install internal protection (lining) inside the cyclone or filter to minimize abrasive wear. The inlet, where the highest wear occurs, definitely requires protection.
Regarding performance, volume and speed are not sufficient parameters—we need surface area and speed in this case.
A cyclone is likely a suitable preliminary solution, and the filtration speed needs to be reduced. It may also be necessary to install internal protection (lining) inside the cyclone or filter to minimize abrasive wear. The inlet, where the highest wear occurs, definitely requires protection.
Regarding performance, volume and speed are not sufficient parameters—we need surface area and speed in this case.
Client:
In our case, the aspiration hose is additionally attached to the discharge. The diameter is 200 mm. This means we are aspirating material that has already passed through the screen, extracting dust from it to prevent further grinding.
Can we consider 10 m/s as the average speed and include a frequency converter? This would allow us to adjust the speed if necessary. On average, our system operates at 10-12 m/s.
Best regards,
Chief Mechanic
Can we consider 10 m/s as the average speed and include a frequency converter? This would allow us to adjust the speed if necessary. On average, our system operates at 10-12 m/s.
Best regards,
Chief Mechanic
The connection point of the aspiration hose.
Here’s how it looks in real life.
Client:
The actual speed measurement was taken, 6.4 m/s.
Engineer Torch-Air:
So, the capacity is 750 m³/h. Are there any other limitations regarding length, width, or height?
Client:
It would be ideal for us to have a length of 1000 mm, width of 1000 mm, and height of 2000 mm. A built-in fan would be acceptable.
Engineer Torch-Air:
Can you provide a schematic showing where the air intake should be and where the dust should be collected? The dust can either be collected in a container or discharged through a rotary valve.
Client:
We plan to place it in this location, after removing the sieve rack. The size there will actually be a bit larger than I mentioned earlier.
The discharge will be connected to the pipe indicated by the arrow. The discharge is planned to be through a rotary feeder.
The air intake is planned from the marked pipe, and the duct will be routed along the ceiling.
What if we use a small bag filter instead of a cyclone, with a protective plate for the bags?
The discharge will be connected to the pipe indicated by the arrow. The discharge is planned to be through a rotary feeder.
The air intake is planned from the marked pipe, and the duct will be routed along the ceiling.
What if we use a small bag filter instead of a cyclone, with a protective plate for the bags?
Engineer Torch-Air:
Yes, we can offer the Blizzard cyclone baghouse with internal lining and additional metal plates at the dust inlet of the dust collector. These metal layers are bolted and can be replaced with new ones when worn out. I’m attaching the drawing.
- Airflow capacity: up to 1000 m³/h
- Filtration area: 190 sqft (17.6 m²)
- Maximum temperature: 160°C
- Incoming dust concentration: maximum 60 g/m³
- Outgoing dust concentration: 10 mg/m³
Blizzard Baghouse
Blizzard Baghouse Photo
Proposed Solutions
BLIZZARD CYCLONE BAGHOUSE
- Combines a bag filter and a cyclone for enhanced efficiency.
- Internal lining with replaceable metal plates to minimize abrasive wear.
- Handles dust concentrations up to 60 g/m³, reducing clogging and extending filter life.
- Alternative to a cyclone, designed to prevent filter bag damage.
- Compact design suitable for installation near the screen discharge.
- Integration of a frequency converter to fine-tune aspiration speed.
- Ensures optimal dust extraction based on real-time performance data.
- Each solution enhances dust collection efficiency while ensuring durability and compliance with regulatory standards.
Conclusion
The client independently installed our baghouse, which combines two types of dust collectors—a bag filter and a cyclone. This dust collector has been in operation for about three years, during which only consumable materials have been replaced.
By separating aspiration flows, the client has reduced dust and abrasive loads on their dust collectors, leading to more efficient resource utilization and improved air filtration performance.
Our client remains at the forefront of the materials science industry, continuously expanding the capabilities and applications of polymers and composites. Strategic investments in technologies, such as the GKM drum-type machine and advanced air filtration equipment, not only uphold their reputation for quality and innovation but also strengthen their competitive advantage in the global market.
By separating aspiration flows, the client has reduced dust and abrasive loads on their dust collectors, leading to more efficient resource utilization and improved air filtration performance.
Our client remains at the forefront of the materials science industry, continuously expanding the capabilities and applications of polymers and composites. Strategic investments in technologies, such as the GKM drum-type machine and advanced air filtration equipment, not only uphold their reputation for quality and innovation but also strengthen their competitive advantage in the global market.
Best Baghouse Solutions for Abrasive Dust
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
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