What is an Dust Collector System?

Industrial dust collectors are air pollution control equipment used in factories, plants, and warehouses to remove dust and other impurities from the air. They are essential for protecting workers’ health and safety, as well as for complying with environmental regulations.

Dust collectors work by drawing air through a filter. The filter captures the dust and other impurities, and the clean air is then discharged back into the environment. There are many different types of dust collectors, each designed for a specific application. Some of the most common types of dust collectors include:

• Baghouse dust collectors: These are the most common type of dust collector. They use a series of bags to filter the air.
• Cyclone dust collectors: These collectors use centrifugal force to separate the dust from the air.
• Wet scrubbers: These collectors use water to wash the dust out of the air.
• Electrostatic precipitators: These collectors use an electric field to attract the dust to plates.

Dust collectors are used in a wide variety of industries, including woodworking, agriculture, food processing, pharmaceutical, recycling, cement and rock products, metal fabrication, mining, and chemical processing. They are essential for maintaining a safe and healthy work environment, and for complying with environmental regulations.

Some additional details about dust collectors:

• They can be used to collect a variety of dusts, including sawdust, metal shavings, plastic fines, and chemical powders.
• They can be used to collect dust from both stationary and mobile sources.
• They can be used to collect dust from both large and small areas.
• They can be used to collect dust from both high- and low-pressure systems.
• They can be used to collect dust from both wet and dry environments.

Dust collectors are an important part of any industrial safety plan. They can help to protect workers’ health, prevent fires, and reduce pollution. If you are considering using a dust collector in your workplace, be sure to consult with a qualified professional to choose the right type of collector for your needs.

Industrial Dust Collector System Parts

• Dust Collector Hoods
• Dust Collection Ductwork
• Air Material Separators
• Explosion Protection Equipment
• Rotatory Air-Locks
• Rotary valves
• Motorized valves
• Pneumatic Valves
• Trickle valves
• Dust Collector Exhaust Fans

Components Examination of Dust Collection System  

Dust Collector Hoods / Industrial Dust Hood

Small modifications in dust collector hood designs usually produce big results mainly in performance and total cost of operation. Check:

• Blown, ripped, or broken filter media,
• Check if it has warped or cracked filter assembly,
• Test airflow speed to make sure they are getting the designed airflow.
• Inaccurate installation of a filter component,
• Do a visual investigation to make sure they haven’t been destroyed during the year.
• A separated bag filter or a mechanical breakdown of the tube sheet due to abrasion
• If a restricted damper is found by hood for balancing, make sure it is operating in the right position.

Dust Collection Ductwork

Ductwork is used to take the dirt & air from the gathering point to the collector. It must be sized correctly to create a “carrying velocity” to keep dust moving through. 

• Do an actual inspection to make sure no leaks have occurred.
• Calculate air velocity through ductwork to make sure intended airflow is accurate.
• Examine duct interiors to make sure dust isn’t growing up.

Air Material Separators in the dust collection system 

An air material Separator is a part that departs air used for moving from the element it conveys. It is a machine designed to divide the conveying air from the material being conveyed. To keep it working properly

• Examine the pressure drop across the separator to understand if it is within parameters.
• Scrutinize cleaning process to see if they are working properly Check the timing, valves opening, air pressure, etc. See the guidance and maintenance handbook.  Usually, monitoring the system will let you know if it is working correctly.
• Monitor recycled line weight and outlet in wet scrubbers.
• Visually inspect the vessel walls to be sure there are no cracks.

Explosion Protection Equipment

An explosion is a severe risk at many constructions, processing, and metalworking factories. It can even originate from a dust collection system that’s preserved incorrectly. A properly designed dust collector that manages combustible dust always holds an explosion protection system. The purpose of any type of explosion protection equipment is to restrain an explosion and reduce damage. 

• According to NFPA, it needs yearly inspection. Following the manufactures manual for the explosion protection equipment will preserve the tools and equipment as it was designed.
• Some explosion protection such as chemical suppression should be performed by industry qualified personnel.
• Visually inspect that the vent closure is on point and able to work as intended.

Dust Collector Rotary Airlock

An airlock separates the dust collector hopper from the outside while letting the collected dust to exit the system.  Usual airlocks are rotary valves, trickle valves, double dump valves, and knife gates.

Rotary valves

The main purpose of a rotary airlock valve is to give an air seal at the outflow opening of the dust collector hopper. Rotary airlock valves are usually installed between the hopper flow and a conveyor or release bin. To check if it is working properly: 

• You should check it to see they are still rotating
• The valve body and rotor blades on a rotary airlock valve require regular inspection for wear and replacement determination.
• Grease the parts regularly and examine temperature to make sure they aren’t overheating.
• On explosive applications, the rotor removal should be regulated to make sure it still stands with NFPA 69.

Pneumatic Valves

• To make sure the pneumatic valves in dust collector are working properly, follow steps:
• You need to test valves to make sure they are still working as meant.
• Measure Air pressure to be sure that it still follows the design parameters.

Motorized valves 

• To make it work properly, grease the parts regularly.
• Measure bearing temperature to be sure they aren’t overheating

Trickle valves

Trickle valves, also known as vacuum valves, are generally used in manufacturing dust collection applications to manage an airlock seal on a dust collector tank while providing bulk solid material to be automatically discharged. To maintain:

• Inspect the cover to know it is sealed. 
• During the process, verify that material is still flowing and the matter hasn’t bridged above it.

Instrumentation

The dust collection system consists of many parts and instruments. It has a huge list of components that help a dust collector to work properly. to make sure it works properly:

• Do separate examination for Level gages, pressure gages, VFDs, pH meters, zero speed switches, etc. It asks for a different maintenance procedure.
• Follow the handbook of the particular model for maintenance and review.

Dust Collector Exhaust Fans

Dust collection systems need an exhaust fan to stimulate ventilation air from the position of pick-up, through the ductwork and dust collector filter tools and from the exhaust stack. For maintenance

• The fan installation needs to be inspected to see there are no holes.
• The charge and amps should be regulated to make sure it is working at its planned condition.
• The parts need to be lubricated and temperature needs to be checked so they aren’t overheating.
• The fan’s wave should be reviewed along with monitoring to see if any unusual noise is arising from the fan.

Dust Collector System Maintenance Checklist

This is not an all-inclusive list but we have covered all major points when it comes to Dust Collector System Maintenance, You can make a Dust Collector System Maintenance Checklist based on the information listed in this article.

Each part of the industrial dust collection system is different, and each has its components and characteristics. But these simple plans can help you monitor and manage your dust collector’s heath, as well as limit shutdowns due to incompetence, increase filter life and prevent costly EPA fines. To increase efficiency and security, there is no backup for an on-site review by an expert. 

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