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How Do Industrial Dust Collectors Work?
You can think of dust collection equipment as a big vacuum cleaner that's designed to suck up large amounts of dust at high speeds. Industrial dust collectors work the same way household vacuum cleaners do. The main difference is that instead of using bags to collect the dust, industrial dust collection systems use a series of filters and a huge fan to suck up and blow away the dust.
Filters can be either wet or dry. They all function the same way by forcing the fast-moving airstream to make a 90-degree turn, bringing it in contact with filter media that allows only particles smaller than a specific size to pass through. The tiny particles are captured while the air is returned to its original direction.
Another type of filter used in industrial dust collectors is the cyclone filter. The principle behind these filters is the same as the regular one, but instead of using a straight 90-degree turn, it uses centrifugal force to repel particles away from the airstream. This allows for better collection efficiency and a reduced pressure drop in the system.
Different Types of Industrial Dust Collection Systems
Industrial dust collection systems are divided into different types:
Baghouse Dust Collector:
A baghouse or cartridge filter is an industrial dust collection machine that uses large amounts of cloth bags to separate the dust from the airstream. The air is forced to travel through a series of filters where centrifugal force pushes the fine particles into hoppers while the clean air is returned to the system. These types of industrial dust collectors are commonly used in mining, metal fabrication, and manufacturing, where a high level of separation is required, which makes cyclone filters a less viable option. They're also well-known for their relatively cheap initial cost and low operational costs.
Cartridge Dust Collectors:
Similar to Baghouse dust collection systems, cartridge dust collectors also rely on cloth bags or cartridges. Still, instead of using a cyclone filter to separate the dust from the airstream, it uses specially designed cartridges with internal micro-fibers that capture even the tiniest particles. This type of system is good at separating small particles, and it's well known for its high collection efficiency and low-pressure drop.
Wet/Dry Drum Dust Collector:
A wet dust collector, also known as a wet scrubber or belt scrubber, is an industrial dust collection system that uses water to separate the dust from the airstream. The fast-moving airstream comes into contact with a series of nozzles that are used to atomize the water, creating tiny droplets, which are then propelled towards the dust particles, causing them to attach to the liquid. This not only allows for a better separation but also minimizes dust re-suspension once it's been collected.
Action Booth Collectors:
An action booth is an industrial dust collector that uses a series of inlets that are placed at different angles in order to capture the dust particles. It works by allowing the fast-moving airstream to come into contact with several inlet openings, which forces it to make a 90-degree turn and bring it into contact with filter media before redirecting the airflow back into the environment. These industrial dust collectors are commonly used in applications that produce a lot of fine dust because their design allows for greater capture efficiency when compared to other types.
LaserPack Units:
A laser pack dust collector is an industrial dust collection system that uses a series of inlets with overlapping sections, which forces the airstream to make several 90 degree turns in order to ensure proper separation. The use of multi-angled channels allows for extremely high efficiency when it comes to capturing fine particles, making them excellent at collecting dust that other industrial dust collectors have a hard time collecting.
Cyclone Dust Collector:
A cyclone dust collector, also known as a cyclone filter, is an industrial dust collection system that uses centrifugal forces to separate the dust particles from the airstream. This type of industrial dust collector works by drawing in the contaminated airstream through the inlet and causing it to spin inside a conical chamber which creates centrifugal force. The dust particles are forced to the outside of the cylindrical wall while the clean air continues through the center and is expelled back into the environment.
Shaker Dust Collectors:
A shaker dust collector uses a series of dust-laden air streams to separate the fine particles from the larger ones, which allows for increased operational efficiency and lower maintenance costs. These industrial dust collectors are more effective at collecting the fine dust particles that come from metal fabrication and sheet metal applications since they're able to remove over 90% of the dust in the airstream.
Pulse Jet Dust Collectors:
A pulse jet dust collector is a commercial dust collection system that uses a series of compression and decompression chambers to separate the fine particles from the larger ones in an extremely efficient manner. This type of dust collector works by drawing in the contaminated airstream through the inlet and causing it to compress and repeatedly expand inside a closed loop. During this process, the dust particles are forced to the outside of the chamber wall while the clean airstream continues through and is ejected back into the environment.
Benefits of Using Industrial Dust Collectors
Industrial dust collection systems provide two major benefits: health and safety.
First off, most industrial production processes create a lot of dust particles that can be hazardous to workers if inhaled. Without proper dust extraction equipment in place, employees run the risk of breathing in harmful dust particles, which can lead to serious respiratory issues like asthma, hypersensitivity pneumonitis, chronic bronchitis, and even lung cancer. Fortunately, industrial dust collection systems are capable of taking up fine metallic fines that would otherwise get into the airstream and cause serious health problems for personnel.
Another major benefit is increased production efficiency. Since industrial dust collection systems can remove up to 90% of fine dust particles from the airstream, companies can avoid production delays due to clogging, which has a direct effect on output. Furthermore, these industrial dust collectors are capable of prolonging equipment life and reducing absenteeism due to illness.
If your company is using an industrial dust collection system, you should know that they not only keep workers safe but also increase the overall efficiency of your operations.
How can Metal Ready assist you?
Metal Ready is a manufacturer of industrial dust collection systems offering both stand-alone and custom installation solutions. Our team will work with you through the entire design, manufacture, and installation process to ensure that your system meets or exceeds your expectations. We've gained knowledge on designing, building, and installing industrial dust extraction units that keep workers safe while helping companies achieve higher levels of production. Some of the dust collection systems we have to offer include:
- metalworking dust extractors
- woodworking dust extractors
- industrial pleated filters
- fume collectors for welding fumes
- cartridge dust collectors
For more information on industrial dust collection systems and how to select a dust collector for your facility, fill out this form or give us a call today!
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