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Filtration and Vacuum Specialists since 1976

A Scientific Review of Dust Collection - Part 12

Future Trends In Dust Collecting

Reference material by: Scientific Dust Collectors

Because our newsletters are a service to our valued customers we have decided to share some important and educational information on Scientific Dust Collection. Over the next several months we will be focusing on the use of Dust Collectors. We felt that the extensive information and it's importance in the industry would be very useful in helping our customers make an informed decision on their needs for dust collectors in their businesses. Because the information is extensive we will be spreading it over several months.

By understanding both the collecting mechanisms and the related mathematics for explaining the phenomena, new equipment designs will continue to "break through" traditional limitations. Listed below are key future trends which will improve all aspects of dust collecting:
  • Greater collection efficiency and cleaning capability of all particle sizes, especially the finer particles two microns and smaller through the use of refined cleaning systems and better filter media options.
  • Higher air to cloth ratios that are beneficial for achieving high process air stream flow rates while reducing the number of bags or cartridges. The end user benefits from lower costs for purchasing the initial collector, less space occupied by the collector, and reduced yearly maintenance and replacement filter costs.
  • Specialized collector designs for welding fumes and other chemical dusts are growing and improving with the better cleaning systems and filter media options available..
  • User friendly designs of both collectors and controls are becoming more commonplace which include easier installation and removal of cartridges from the collector and more electrical options that are prewired at the factory.
  • Application specific devices are more available such as devices for reducing the moisture in the compressed air manifold, apparatus for freeing dust blockages in the hopper, and electric control options for customizing the timing of the cleaning cycle.
  • Specialized collector designs for low headroom and other difficult physical location configurations are becoming more commonplace.

Collecting Dust with Greater Efficiency

Scientific Dust Collectors is a leader in providing great dust collection efficiency for both baghouse and cartridge media design. For cartridge collectors, a patented downflow direction is used to redirect the inlet air around the cartridges and to the hopper below. By using a combination of inlet baffles, the process air stream is separated into multiple downward air streams that work together to minimize the frequent upward turbulent air flows inside the dirty air chamber where the cartridges are housed. For baghouses, a different approach is used which is accomplished by locating the process air inlet in the upper portion of the dirty air chamber. The process air stream does not flow directly onto the bags but rather enters the collector horizontally to the vertically mounted bags. As the process air enters into the bag zone, its velocity is reduced and the large particles of dust will simply drop to the hopper below.

In addition, a vertical perforated baffle is provided so that the inlet can distribute the dust laden air into the area where the bags are located. As the dust laden air is being pulled towards through the various bags, there is a continuous downward flow that allows the bags to capture the fine dust particles. Also, since the process air flow is downward, the cleaning air releases the finer particles into a downward air stream. Both the baghouse and cartridge collectors have a generous distance between each of the bags or cartridges which further assists in the cleaning and collection process by helping to prevent reentrainment of the dust particles.

Equally important to easily collect dust is the ability to clean the dust from the bag or cartridge media without driving the just removed dust into and through the neighboring bag or cartridge. Scientific Dust Collectors' approach is to maximize the air from the compressed air valve and corresponding purge tube by the use of a nozzle. Instead of achieving the 1030 feet per minute orifice velocity as found in many generic collectors, Scientific Dust Collectors' nozzle approaches 1750 feet per minute air velocity. The benefit from the higher speed comes with the greater amount of induced air into the mouth of the cartridge or bag.

It is important to note that the initial cleaning air velocity of 1750 feet per minute is momentary and is greatly reduced as it enters into the mouth of the cartridge or bag so that it will have the best cleaning effect on the filter media. The end result is less compressed air that is used per cubic foot per minute of process air stream compared to other collectors, and an ideal velocity control of the cleaning air when it reaches the filter media.

Higher Air to Cloth Ratios

The push towards higher air to cloth ratios has accelerated in recent years. The dust collectors of tomorrow will continue to strive towards having higher and higher air to cloth ratios. The benefits to the end user are both initial cost reductions for the purchase of the dust collectors and for the long term maintenance due to less filter media (cartridges or bags) and less compressed air cleaning valves. Also, more process air stream flow rates will be able to be utilized in smaller dust collectors which gives more flexibility to the end user.

Scientific Dust Collectors' designs are current and successful because of its use of advanced nozzle technology with induced air benefits in cleaning more filter media. In addition, a high inlet configuration for providing a natural "drop-out" zone and process air velocity reduction, and generous spacing between bags or cartridges in the dust collector results in less dust reentrainment. With the proper selection of filter media for the application, this total combination of design capabilities ensures success in capturing dust efficiently and with minimal costs.

Specialized Collector Designs for Welding Fumes and Other Chemical Dusts

Since the dust collection industry encompasses such a wide range of chemicals and substance mixtures, the use of specialized collector designs are expected. Dust collector manufacturers are continuously adapting their equipment to accommodate these special needs. For example, welding fumes contain a mixture of very small submicron and larger dust particles, moisture droplets, and hot sparks that need to be successfully treated in the process air stream, captured in the filter media, and then released to the hopper section.

Scientific Dust Collectors provides a fume dust collector that cools the hot sparks in a spark trap, provides filter media that is water repellent, and a downward process air stream flow environment that quickly captures the fine particles. Also, a cleaning air jet with nozzle technology is sized to properly clean the dust from the filter media and to allow the agglomerated dust to settle into the hopper or drawer below. The unit is user friendly in that the cartridges are easily installed by use of foot pedals so that no hand tools are needed.

Scientific Dust Collectors Products

Dust collecting technology and equipment is continually evolving and end users are demanding that the dust collectors be more user friendly to their specific needs and environments. Dust collectors can be located both indoors and outdoors. They can be located close to people or installed remotely on top of buildings or silos. When the collector is located indoors, headroom is usually limited. Therefore, Scientific Dust Collectors provides user friendly designs that give the end user choices on the type of collector that will best suit his space and budget.

With some size limitations as to the number of bags for some styles, four styles of baghouse are currently available from Scientific Dust Collectors as listed below:

  • Top Removal: Bags are removed and / or replaced from inside the walk-in upper bin area which is above the tube sheet. Also, changing the bags is contained inside the upper bin. The advantage is the bag changes are done from the clean side and inside the upper bin.
  • Top Railing Top: Provides the capability to have the bags removed / replaced through the roof of the collector. The advantage is less collector height than top removal style.
  • Bottom Removal: Bags are removed and / or replaced from inside the dirty air chamber where the bags are housed. The main advantages are a lower headroom height compared to top removal styles and a lower cost for the collector.
  • Horizontal Baghouse: Bags lay horizontally and are removed horizontally from the compressed air manifold end. Main advantage is low headroom.

For cartridge collectors, Scientific Dust Collectors offers two styles of collectors:
  • Vertical Style Cartridge Collector: Single vertical mounted cartridge. Main advantage is gravity aided cleaning of cartridge due to its vertical location.
  • Horizontal Style Collector: Horizontally and tandem mounted cartridge. Main advantage is ease of release of cartridge without entering the collector.

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