P84 (polymide) dust collector filter media displays excellent stability under dry high heat temperatures, has great filtration properties, and performs well even under elevated levels of moisture content. These are some of the reasons P84 is one of the more expensive filter medias used in pulse jet baghouse dust collectors. Industries that use P84 filter media range from waste to energy, power, and cement.
The stability of P84 filter media is a benefit to a wide variety of applications lime kilns, smelting, incinerators, coal fired boilers, and glass and ceramic industries. It can be utilized in operating conditions of a maximum 500 degrees Fahrenheit and offers a good resistance to mineral acids. If your baghouse is operating above 450 degrees Fahrenheit keep in mind that you may need to oversize the bag to account for the shrinkage that will occur at extreme temperatures. Media weight is typically available in 14, 16, and 18 ounces. Below are more of the characteristics of P84 filter media.
• PTFE Membrane
• Singe
• Glazed
PTFE Membrane: Applying a PTFE membrane will allow you to lengthen the life of your bag since the membrane acts as the filter cake. It would allow for very little dust to stick to the bag itself. As the dust stays on the surface of the membrane and does not get entrained into the fibers of the bag, this allows your filter to last twice as long. Other benefits include reduced wear and tear, savings on maintenance costs, reduced energy costs, and more.
Singe: A pre-treatment process that is achieved by passing the filter material over an open flame, removing any straggly surface fibers. The result is a uniform surface area that improves cake release.
Glazed: A pre-treatment process achieved by a high pressure pressing of the fiber at elevated temperatures. The fibers are fused to the body of the filter medium that improves mechanical stability.
To learn more about filter media, treatments, configurations, and air-to-cloth ratio download our filter bag eBook below.
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Fiberglass filter media has been a leading industry standard for air filtration and applications where high temperatures are prevalent. Fiberglass media consists of dense structure of fine fiberglass filaments, and is used in industries such as chemicals, minerals, and energy pipelines and utilities.
In most cases, fiberglass media is requested in 22 ounces. Also keep in mind that fiberglass media has a sensitive bag to cage fit. Below are some of its main characteristics.
• PTFE Membrane
• Silicone, Graphite, Teflon
• Acid Resistance
• Teflon B
PTFE Membrane: If you are working with acid elements, one of the main challenges you may encounter with fiberglass media is a shortened bag life. Acids will attack and corrode the glass filament, but one way to lengthen bag life would be to add a PTFE treatment.
A normal bag collects dust on the surface of the bag. This creates a build-up of dust referred to as the filter cake. When you add a PTFE membrane treatment to a bag, the membrane begins to act as the filter cake. It allows for very little dust to stick to the bag itself. The dust stays on the surface of the membrane and does not get entrained into the fibers of the bag, allowing you to lengthen the life of your filter. Other benefits include reduced wear and tear, savings on maintenance costs, reduced energy costs, and more. Some common applications are cement/lime kilns, incinerators, coal-fired boilers, furnaces, cupola, and silica/alloy.
Silicone, Graphite, Teflon: This protects glass filament from abrasion and can add a lubricity. While it provides limited protection against chemical attacks, it is best for non-acidic conditions.
Acid Resistance: Shields glass filament from acid attacks, and can also reduce abrasion.
Teflon B: Although this provides limited resistance to chemicals, it can offer enhanced fiber to fiber resistance.
For additional resources on filter bag media, construction, and air-to-cloth ratio you can access our filter bag eBook below. You can also watch our “Guide to Filter Media” video here.
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A combustible dust explosion is a serious hazard for a wide variety of industries including manufacturing, processing, metalworking, chemicals, and more. This hazard can materialize in many areas of a plant, but is more likely to occur at the dust collection system. Implementing proper explosion venting in your dust collection system can reduce your risk for a hazardous explosion.
The first step is to identify and determine if your facility has any combustible dust risks present. Click this link to learn more about combustible dust characteristics and the conditions for a dust explosion. If you have identified that your facility is at risk, you should evaluate your options for both prevention and protection.
There are multiple strategies for explosion venting, the best method for your facility will depend on a variety of factors. Start off by asking yourself these questions:
• What are the state and/or local regulations for fire safety and explosion venting?
• Is the dust collector setup inside or outside?
• What is the distance of the dust collector from the roof or walls?
• Is the dust collector or vent close to any other structures?
• What’s the cost?
Preventative Maintenance Plan: In conjunction with a protection strategy, every facility should implement a well-designed and operated preventative maintenance plan. A preventative maintenance plan for your dust collection system will help manage the levels of combustible dust. Following a maintenance plan for your baghouse, bin vent, or cartridge collector will help you address any concerns before they create a larger issue.
Explosion Vent or Panels: Explosion vents or panels are designed to rupture at a set pressure (PStat).
When a source of ignition meets a fuel source with sufficient oxygen present, an ignition will occur. As the ignition begins, the pressure inside of the vessel will increase rapidly. Depending on the material’s Kst value, the pressure rise may be slow or extremely rapid. As the ignition progresses, the internal pressure will meet the PStat rating of the explosion panel. The explosion panel will rupture, venting the ignition gasses. The explosion vent provides a relief avenue for the expanding gasses, but the pressure in the vessel will continue to rise until it reaches the Pred pressure. This is the maximum pressure of the ignition event when explosion vents are functioning, so this is usually the pressure rating the vessel is designed to withstand.
Explosion panels can be used with a short length of ducting to allow for interior use without flameless venting.
Although these vents do require replacement once a rupture occurs, they are simple, cost-efficient, and easy to install. Explosion vents are commonly used on baghouses and cartridge dust collectors.
Flameless Venting: Flameless venting can consist of a flame arrestor element, vent panel, and flanged housing. This method is designed to combine the techniques of explosion venting and flame arresting. A flame arrestor element can be installed over a standard explosion vent. When the vent ruptures, the burnt dust and flames enter the flame arrestor element. The element helps to contain the hazardous dust and flames and prevents it from exiting, where it could potentially ignite a secondary explosion or endanger employees. While flameless venting does stop flames from exiting the vessel, there will be extremely hot gasses exiting the flameless vent. When using flameless venting, make sure to pay close attention to the vents proximity to personnel areas. If possible, always aim flameless vents away from regularly occupied areas.
Explosion Latch: Explosion latches work under the same principle as the explosion panels, but they are not single use. When using explosion latches, there will be a network of small, hinged doors along the walls of the baghouse dirty air plenum. The doors have special latches that are designed to release at a set pressure (Pstat), which can be reset if opened. Explosion latches are a more cost effective option, compared to explosion panels, for large a baghouse when a large quantity of vent area is required.
No Return Valve: Protecting the dust collector from over-pressure is essential, but it is equally important to stop an deflagration propagation back to the operator space. To prevent this, a No Return Valve is needed in the inlet duct. This valve is a weighted damper that is held open by the air flow during normal operation, allowing air and dust to pass through to the dust collector. In the event that deflagration occurs in the dust collector, the pressure propagation through the duct work will close the No Return Valve. This prevents the deflagration from reaching any process equipment and also limits the risk of secondary explosions.
Abort Gate: Abort gates are high speed dampers that contain a spring assisted blade and is typically held in place by an electromagnet. They are used to minimize the risk of an explosion by diverting flame, spark, or debris from entering a facility through a return air system. They are activated by a spark detection system that is placed far enough upstream, which would allow time for the gate to be activated. A mechanical barrier will redirect process air to a safe area.
If the baghouse exhaust duct is not being returned to the plant space, an abort gate is not necessary since any deflagration through the clean air duct would remain outdoors. If the exhaust gasses are being returned indoors, an abort gate is required.
Spark Detection & Extinguishing System: This method uses infrared sensors, typically located on the ductwork, to detect sparks or burning material in the ductwork upstream. Before it can travel further downstream and become an ignition source inside the dust collector the extinguishing assembly is activated, and a minimal amount of water is released to eliminate the hazard.
Secondary Event Protection: All of the methods described previously are excellent options for managing primary explosions, but one of the most catastrophic outcomes of a combustible dust explosion is an un-controlled secondary explosion. A secondary explosion occurs when ambient dust outside of the dust collection system is ignited. In many cases, there is a layer of dust on all horizontal surfaces brought on by inadequate dust collection and containment.
When a primary explosion happens, there may be a pressure wave that propagates through the plant. This will “kick up” the layer of ambient dust. If the explosion is not contained in the dust collection system using the methods previously outlined, this ambient dust in the air could come in contact with the primary explosion flame front. This results in an uncontrolled explosion in an occupied space.
To minimize the risk of secondary explosions, the first step should always be to expect perfect performance from your dust collection system. It is not acceptable to have a dust collection system that does not function properly. It is also highly suggested to limit the amount of horizontal surfaces in your plant that cannot be regularly cleaned. Drop ceilings and in-accessible equipment are great examples of places that are rarely cleaned and dust tends to accumulate.
There are many explosion venting strategies that may fit your unique application or facility. It is always recommended to consult your local or state building codes and regulations before choosing your explosion venting strategy. Some areas will have specific regulations for fire safety and environmental safety, and you want to ensure you are meeting those guidelines. To learn more about which option may be right for your facility contact us today to speak with an engineer.
Download our dust collector purchasing guide below to learn other variables you should consider when planning for a new dust collection system.
Performing maintenance or troubleshooting inside your baghouse can be dangerous. Here are some basic baghouse entry procedures you can implement to minimize accidents and hazards.
Power Down & Lock Out
Before you begin any maintenance or troubleshooting on your dust collection system, your first and most important step is to power down and lockout any machinery. Securing your baghouse for personnel entry can include locking down your rotary valve, locking your blower, or sealing off any adjacent baghouse compartments.
Also, make sure to shut off the compressed air supply to the pulse jet cleaning system and allow the system to cycle until the pressure is relieved before entering the baghouse. Taking these initial steps provides a safe working environment and will ensure that accidents are minimized.
Safety in a Confined Space
The inside of your dust collection system is almost always defined as a “confined space”. No matter the application, it’s best to ensure you have safety guidelines in place whenever entry into your baghouse needs to occur. Here are some of the general safety precautions you can take.
Designate an additional crew member as a watchman. They should be present at the entrance point to ensure safety procedures are being followed and can immediately assist should any complications occur.
Communication
It’s important to let your team know what work is being done, where, and at what time. This allows others to re-schedule any work that could impede on safe entry into your baghouse.
Combustible Dust
If you are working with combustible dust, make sure the dust levels inside of your system are well below being explosive. All hot work, like welding, should be performed well outside of the perimeter of your baghouse. If hot work must be done inside the baghouse, thoroughly purge the space with clean air until dust is no longer present.
Emergency Plan
A total shut down and lock out of your baghouse will minimize safety hazards, but you shouldn’t hesitate to formulate a retrieval plan should an emergency occur while employees are in inside the confined space.
PPE Personal Protective Equipment
OSHA requirements for protective gear will vary based on your application. Basic protection can include a hard hat, safety glasses, gloves, and a face mask. Before entry into your baghouse system, make sure that your crew is supplied with and compliant in wearing safety gear required for your application. You can find additional information on OSHA’s website about personal protection equipment hazards and solutions https://www.osha.gov/SLTC/personalprotectiveequipment/hazards_solutions.html
Polyester is a widely available and relatively low cost filter bag media that offers great dimensional stability. This makes polyester filter media one of the most common types of filter media used in baghouse dust collection systems. Poly is used in a wide variety of industries such as food processing, manufacturing, woodworking, metalworking, and more.
Polyester’s maximum continuous operating temperature is 275 degrees Fahrenheit and has good overall qualities to resist abrasion and performs well with dry temperatures. You can see polyester available in 12, 14, and most commonly 16 ounces. Below are the common characteristics of polyester media.
There are a variety of treatments available for polyester. Finishes can include:
• PTFE membrane
• Hydro-oleophobic coating
• Acrylic,
• Anti-static (epitropic)
Pre-treatment processes can range from:
• Singe
• Glazed
• Calendered
PTFE membrane: Can double the life of a standard filter bag, reduce wear and tear, reduce maintenance costs, reduce energy costs, and more.
Hydro- Oleophobic: Aids in filtration and adds resistance to water and oils.
Acrylic: Can help improve cake release and filtration efficiency in certain applications.
Anti-Static (epitropic): Helps ground the filter bag.
Singe: This removes straggly fibers which provides a uniform surface area and improved dust cake release.
Glazed: Fibers are fused to the body of the filter medium, which improves mechanical stability.
Calendered: This process flattens and smooths the filter medium. This can increase surface life, dimensional stability, and provides a more uniform fabric surface.
To learn more about filter bag media, construction, treatments and finishes, and air-to-cloth ratio you can download our filter bag eBook below. You can also watch our “Guide to Filter Media” video here.
Looking to find your filter? Simply follow the link below, submit your filter bag information, and get a quote within 24 hours.
Do you have a new dust collection project? One of the first, and most important questions to ask is, what’s the right dust collector for my application? Reliable dust collectors are critical for the optimal operation of most industrial and manufacturing facilities. Choosing the right dust collector can ensure high air quality. Without an appropriate dust collector, particles can clog up your equipment, contaminate products, reduce overall operational efficiency, and put worker health at risk.
There are three standard dust collector designs: baghouse, cartridge, and bin vents. The best design for your needs is dependent on specific aspects of your dust collection process. This can include the following:
The three most common dust collectors are baghouses, cartridges, and bin vents. Each type exhibits different characteristics.
The most widely used style of dust collector is a baghouse. They are usually larger than other types of dust collectors and well suited for high volume and high temperature applications.
Baghouses use fabric bags to capture dust particles in the gas or the air moving through the system. When contaminated air pulls through the filters, it catches the dust and clean air is expelled.
Instead of fabric bags, cartridge dust collectors use a filter made of pleated media. Spun-bond polyester, nanofiber, and an 80/20 substrate are the most common filter medias on cartridge filters. Treatments like PTFE, fire retardant, and water or oil resistant coatings can also be available.
Cartridge dust collectors house it’s filters in a sealed chamber, and this is where dirty air pulls through the cartridges. It then traps the dust, thereby allowing clean air to be expelled. The pleated surface of a cartridge filter provides efficient filtration because there is more surface area available. This makes it optimal for filtering fine particles and fumes. Cartridge dust collectors are also compact and can be installed in confined spaces.
Silos and other large containers typically have bin vents installed on top. Their purpose is to vent displaced air during loading. A pneumatic or compressed air system propels material into the silo or container. Afterwards, the bin vent filters the displaced air as it flows out of the container while it keeps an airtight seal. A bin vent ultimately prevents dusting and loss of product during the loading process.
Depending on the needs of your application, each type of dust collector offers unique benefits.
An extensive range of industries use dust collectors. Their use is dependent on the particular needs of an application.
When you choose the right dust collector for your application it plays a part in the efficiency of your facility. If you would like to learn more about dust collector designs, you can download our “Dust Collector Purchasing Guide” eBook or watch this video “How Much Does a Dust Collector Cost?”. If you would like to speak to an equipment specialist, click here to contact our experts or request a quote.
Certain sectors of the industrial workforce produce large amounts of dust and other particulates. Understanding how dust affects human health is vital to keeping employees and the surrounding community healthy and comfortable, yet many people don’t understand the long-term repercussions of particulate matter (PM). Repeat exposure to dust has a number of health risks, but to mitigate these issues, companies use dust collectors.
Dust collectors are filtration devices that remove particulate from a flowing air stream. They improve air quality, eliminate potential fire hazards, and keep dust from negatively affecting the product quality and producing a musty odor. When companies use a filtration device, they also prevent dust from accumulating on machinery, which helps the equipment operate efficiently.
Industries that commonly utilize dust collectors include:
Dust particles with diameters of 10 micrometers or less are easy to inhale. At this small size, particles infiltrate deep into the lungs and bloodstream, which could cause a broad range of symptoms.
The short-term effects of dust inhalation can include:
Serious long-term impacts of dust inhalation can include:
Dust in the workplace significantly impacts employees and could become dangerous or even fatal over time. It’s tied to more sick day requests and lost productivity.
Studies show it also affects the world at large. Fine dust particulates contribute to air pollution and reduce the air quality for everyone in the vicinity. They can travel through HVAC systems and seep into nearby homes and businesses, even when their doors and windows are closed. In areas with high PM levels, children are more likely to experience developmental delays or impairments and chronic illness, according to the World Health Organization (WHO).
Regulating bodies such as OSHA and NFPA produce guidelines to protect the community and employees from dust inhalation. The industrial workforce use specially designed dust collector equipment to comply with these regulations and keep people safe.
It’s challenging to filter out fine pieces of dust and debris, but engineering advancements make it possible to remove particulates as small as 0.1 micrometers. These state-of-the-art systems use polytetrafluoroethylene (PTFE) membranes, which reduce the pore size of the filter material to allow for more effective diffusion.
At U.S. Air Filtration, we offer three dust collectors:
When choosing a dust collector, facility size and volume of dust are two major factors to consider. For high volumes of particulate filtration, a large system will be necessary. Smaller facilities may prefer a compact collector that are portable and can be scaled up.
At U.S. Air Filtration, we have over 50 years of experience designing high-quality dust collection solutions. To learn more about creating a healthy work environment with dust containment systems, download a Dust Collector Purchasing Guide today, watch our video “Understanding Dust Properties”, or “How Much Does a Dust Collector Cost?”. You can also contact us or request a quote for assistance choosing the best dust collector for your facility.
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