Selecting a Dust Collection System

By Thomas J. Vidmar

Many criteria must be considered when selecting and designing a dust collection system. Among these are dust characteristics, environmental conditions, and dust collection system performance requirements. With this information, the capabilities of various types of equipment can be matched to the application. The three basic types of dust collection systems available today are cyclones, bag-houses, and cartridges. Cyclones represent the oldest form of dust collection technology. They have no moving parts or replaceable filter elements. Instead, they separate dust particles by centrifugal force. Cyclones are most frequently used as product receivers, as pre-cleaners to high-efficiency fabric collectors, or as independent collectors for very coarse dusts. These systems are recommended for extremely high temperatures (500 F and higher), removal of extremely coarse particles, and as a prefilter/classifier to a cartridge or baghouse collector. They have the advantage of requiring very little maintenance. Baghouses have been in use for several decades and were the first dust collection systems to use fabric media to remove contaminants. Today's baghouses come in two predominant types - shaker and reversepulse cleaning. Baghouses are recommended for medium-to-high temperatures (200 to 550 F), hygroscopic or other "sticky" or fibrous dusts, medium efficiency applications, and extremely heavy dust-loading conditions if the required efficiency is not high. Cartridge filters are the newest technology in dust collection. These systems use rigid pleated cartridges in place of bags, and can therefore accommodate a large amount of filter surface area in a small package. Dust collects on the outside of the cartridges and is removed by reverse-pulse cleaning while the unit is in operation. Cartridges are recommended for dry, dusty environments, high efficiency applications with a high amount of fines (particles less than 1 micron), recirculation requirements, hazardous applications where the safe change-out is an advantage, tight space or headroom requirements, and low fan horsepower requirements. Media Selection The heart of any cartridge or baghouse collection system is the filtering medium. In cartridge collectors the medium is usually a non-woven fabric of cellulose and other synthetic fibers. The large amount of filtering surface allows a very low approach velocity. The denseness of the medium

FARR APC 3505 South Airport Road Jonesboro, AR 72401 Ph: 870-933-8048 filterman@farrapc.com

allows for a high degree of particulate arrestance. secondary filtering effect.

Dust buildup on the media surface provides a

Filter bags for baghouses are available in a variety of fabrics, most commonly needled polyester felt. The fabrics aid in applications where contaminant is fibrous, sticky or hot (up to 550 F). Because bags operate at a higher air-to-surface ratio than cartridges, they operate at a higher pressure drop and greater energy costs. Filter bags used for a high-velocity operation may experience fine dust bleed through the media and lowered efficiencies. Optimum face velocity is often used to determine the best hardware/software package for the required operation. In the dust collection industry, this face velocity is identified as air-to-surface ratio, expressed as cubic feet per minute air velocity per square foot of filter (cfm/sq ft.), or more simply feet per minute (ft/min.). For example, a 5760 cfm operation requirement is cleaned by a 16 cartridge dust collector, with each cartridge having 240 sq ft of media. The optimum face velocity, therefore, equals 5760 cfm divided by 16 cartridges divided by 240 sq ft/cartridge, which calculates to 1.5 ft. in. Baghouses are generally recommended for operation at an air-to-surface ratio of 6:1 or 8:1. Pleated cartridges, by contrast, contain much greater media surface area and therefore operate at much lower ratios, typically around 1.5:1 or 2:1. In general, the lower the air-to-surface-surface ratio, the more conservative the operation of equipment, whether a baghouse or cartridge type. When higher ratios are selected, the contaminant being collected will impact on the filtering surface at higher velocities. This may cause particulate to imbed in the media, resulting in ineffective cleaning cycles. Some cartridge designs use an outside perforated screen for column strength. If contaminant must pass through this screen before reaching the media, face velocity will increase even more. Each perforated hole creates a venturi effect which may erode the media permanently. This perforated screen may also impede back flushing. If space or funds are limited, one of the smaller collection systems with slightly higher air-to-surface ratios may be necessary, although such systems also result in shorter filter life and higher operational pressures. Conversely, if an installation is unattended or long service intervals are desired for other reasons, a larger collector with a lower ratio may be indicated. Although cyclones do not have a filtering medium, the design of the hardware is an important to its efficiency rating. The internal velocity is the pivotal element in determining a cyclone as a true centrifugal particulate separator. A high inlet velocity coupled with a high aspect ratio (height divided by circumference) will cause contaminant to be thrown to the outside of the airstream for collection. This efficiency comes at the cost of higher operational pressures. When a cyclone has a low aspect ratio it, often serves as no more than a dropout chamber operating at a low pressure drop but with poor efficiency.

FARR APC 3505 South Airport Road Jonesboro, AR 72401 Ph: 870-933-8048 filterman@farrapc.com

Before determining the type or size of dust collector to be installed, a thorough analysis of the system requirements is necessary. This analysis should include consideration of the dust characteristics, environmental conditions, and performance requirements. Answering the following questions will provide a good start. Dust Characteristics What is the type of material to be handled? How is the dust generated? Study the process that is generating the dust to determine its content. For example, if a lead-based paint is being sandblasted, the process will generate both sand and lead paint particles. How is the dust captured at the source? By considering how dust is captured or conveyed before it reaches the collector, it is possible to determine more accurately the percentage of fines that will have to be collected. What are the size and shape of the dust particles? Dust particle size (expressed in microns) has a critical bearing on the type and size of the system to be used. The smaller the particle size, the greater the need for a very efficient collector. Cartridge collectors offer the highest filtration efficiencies, with capability to capture particles as small as one micron or less. Cyclones, by contrast, offer a cost-effective way to collect coarse particles. Dust particle shape is also important in system selection. Spherical particles, which tend not to stick to each other, can be captured effectively with cartridge collectors. Highly fibrous or sticky particles, however, may require the use of a cyclone or specially treated bags. What are the other physical characteristics of the dust? Is the dust hygroscopic (likely to absorb moisture from the air)? Is it electro statically charged? Are there other physical characteristics that will cause the particles to adhere to each other? Also, what is the weight or density of the particulate to be collected? A light, spherical dust such as talcum may have the same particle size as much heavier lead oxide, but the two dusts will require collection systems with different air-to-cloth ratios because of their different densities. What chemical reactions must be taken into account? Will oxidation be occurring? Or will the dust be emitting hydrogen or another gas that could create an explosive hazard? Such chemical reactions must be considered, and plans must be made to deal with them safely, especially when the dust contains several types of particulate matter. What is the concentration of dust being generated? An industrial grit blasting process, or a foundry shakeout area, will generate a very high concentration of dust. By contrast, intermittent hand-grinding of metal may yield very light concentrations of contaminant. Dust concentration is a key factor in determining the type of service duty required of the dust collection system and in projecting bag or cartridge life. What is the concentration of dust at the collector inlet? Sometimes, plant engineers take dust samples from the floor and use it to evaluate collector requirements. This is not a recommended approach, however, because heavier particles tend to settle out on the floor. A far more accurate method is to sample dust at the anticipated location of the collector inlet.

FARR APC 3505 South Airport Road Jonesboro, AR 72401 Ph: 870-933-8048 filterman@farrapc.com

Environmental Conditions What is the temperature at the collector inlet? Temperature of the air moving through the collector will have an effect on the collector materials of construction. Measurement at the dust collector inlet location will best enable the user to assess the level of temperature resistance that the system requires. Will the collector be located inside or outside the plant? If the system is to be located outdoors, wind and other weather conditions are a concern. If it is to be located on the rooftop, size and weight of the collector become important factors. Headroom and other space limitations must be taken into account. If seismic forces are an issue, the system may need extra bracing or other support. Is there an explosive element to be considered? If explosive materials are contained in the dust particles, an explosive vent may be needed, and possibly a sprinkler or deluge system. Industry standards for proper vent sizes should be studied as well as fire and building codes. What are the electrical requirements of the system? These requirements should be investigated to assure that they can be met. Is an adequate supply of compressed air available? Reverse pulse cartridge or baghouse collectors use compressed air for filter cleaning. If the supply is low, there may not be enough pressure to clean the system properly. If the air supply is poorly regulated and pressure is too high, damage to the filtering media may result. Mao, the compressed air supply should be clean, dry, and oil free. Otherwise, it might compromise the steady-state condition of the media, reducing filtration efficiency and raising operating pressures across the media. System performance requirements What is the required level of filtration efficiency? Filtration efficiency is determined largely by the size, shape, and other characteristics of the dust. But other factors come into play as well. For example, if the air downstream of the collector is to be recirculated into the plant, higher filtering efficiency will be needed than if the system is vented outdoors. Or, if the goal is to reclaim particulate, the collector must be designed with the right efficiency to separate the reclaimable material. Can air be recirculated downstream of the collector? One reason for the growing use of cartridge collectors is their ability to capture very fine contaminants, and allow heated or cooled air to be recirculated back into the plant. Such systems should contain a safety monitoring filter in addition to the cartridges for contaminant removal. A recirculating dust collection system can often bring thousands of dollars in heating energy savings per year. What is the desired maintenance cycle i.e. filter change-out time and frequency)? Filter element life can vary so drastically that it is sometimes expressed in weeks and sometimes in years. Though a larger collector will cost more initially, it will yield longer bag/cartridge life and reduced maintenance costs an important point to consider in selecting the size of the system. Also, to evaluate the system's maintenance requirements accurately, operating time should be projected in terms of hours. A dust collector that operates around the clock may have design and service requirements different from a system that only handles an eight-hour shift.

FARR APC 3505 South Airport Road Jonesboro, AR 72401 Ph: 870-933-8048 filterman@farrapc.com

What are the potential safety hazards? Possible safety hazards to personnel must also be considered. For example, if the system is collecting a toxic dust, bags that are time-consuming to change and require considerable handling should be avoided. Rigid cartridges can be changed quickly from the outside, with no need for the worker to enter the collector. What is the effect of operating pressures on housings and fans? Will the system operate under negative or positive pressure and at what level? The operating pressures will determine the gauge of material needed to ensure adequate strength as well as fan horsepower requirements. A Class 3 fan may be needed for higher pressure systems, for example, while a Class 2 fan will suffice for lower pressures. Should filter elements be precoated? Sometimes it is desirable to coat the filter media with an inert dust such as calcium carbonate or diatomaceous earth before operation. This is a common method of increasing the initial efficiency of the collector. What other non-standard features should be included? Will a special finish or stainless steel construction be required? What is the number and location of inlets and outlets? Review special requirements carefully during the planning stages; it is much easier to design them into the system than to go back and make modifications later.
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FARR APC 3505 South Airport Road Jonesboro, AR 72401 Ph: 870-933-8048 filterman@farrapc.com