Case Study – Dust Collection Optimization in Gypsum Manufacturing

Background

A major gypsum manufacturer in Houston sought the expertise of Baghouse.com to address some challenges in their processing facility. Gypsum powder, a crucial material in construction, undergoes crushing, grinding, and other processes during its production.

Scope of Work

Gypsum manufacturing, especially in drywall production, contributed to environmental concerns due to particulate emissions and energy-intensive processes.

Baghouse.com provided and installed a new baghouse system equipped with a fan and optimized ductwork. The goal was to efficiently capture and control dust emissions throughout the 5 gypsum processing stages (crushing, screening, grinding, calcination, storage and transportation).

The design incorporated a closed circulation system with negative pressure, ensuring that the air path remained enclosed. To address the increase in air volume due to water content in raw materials and evaporation during grinding, a regulated air volume system was integrated.

Outcome

The implementation of a new baghouse system reduced particulate emissions during the grinding and processing stages, and greatly reduced energy costs.

Conclusion

Baghouse.com‘s tailored solution optimized dust collection for our client in Houston. This case study showcases the effectiveness of advanced dust collection strategies in mitigating environmental impact and enhancing the sustainability of manufacturing processes in the gypsum industry.

Would you like to know how a thorough technical inspection by Baghouse.com could improve the efficiency of your operations? Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andy Biancotti

Chemical and Pharmaceutical Manufacturing

Case Study – Dust Collection Enhancement in Chemical Manufacturing at Teknor Apex

Background

Teknor Apex, a leading player in the chemical manufacturing industry, faced challenges associated with airborne dust and chemical fumes, posing risks to air quality, worker health, and plant safety. Baghouse.com collaborated with them to address these challenges through the implementation of an advanced dust collection system.

Scope of Work

Everyday processes such as mixing, conveying, and blending generated hazardous airborne dust, creating potential fire and explosion hazards. Additionally, compliance standards for worker exposure limits, environmental regulations, and combustible dust standards demanded a comprehensive solution.

Understanding the unique dust issues related to chemical processes, we designed a system with high-efficiency primary and secondary cartridge filters. To prevent the dispersion of chemical fumes and dust, hoods and extraction arms were incorporated into their machinery to capture contaminants at their origin, minimizing their spread within the plant.

Considering the combustible nature of their dusts, NFPA-compliant safety components were integrated into the system, such as an explosion isolation valve, explosion vents, and an explosion-rated rotary valve to enhance plant safety.

Outcome

The source capture strategy not only enhanced efficiency but also minimized energy consumption, resulting in operational cost savings. NFPA-compliant safety measures provided Teknor Apex with robust protection against fire and explosion hazards, ensuring a safer working environment.

Conclusion

Baghouse.com‘s expertise in dust collection systems played a pivotal role in transforming Teknor Apex’s thermoplastics manufacturing facility. By addressing airborne dust hazards at their source and incorporating advanced safety features, the implemented system not only met compliance requirements but contributed to their overall operational efficiency.

Would you like to know how a thorough technical inspection and a system report by Baghouse.com could improve the efficiency of your operations? Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andy Biancotti

Woodworking

Case Study – Dust Collection System Upgrade for Gibson Guitars

Background

Gibson Guitars, a renowned name in the music industry, faced a critical need to upgrade the dust collection systems in their Bozeman, Montana, and Nashville, Tennessee manufacturing plants. The existing systems were outdated, with operational inefficiencies and lacked compliance with combustible dust safety regulations outlined by NFPA.

Scope of Work - Nashville, TN Plant

Having recently come under new management, Gibson Guitars embarked on a multiyear project to upgrade its dust collection systems at both its Nashville, Tennessee and Bozeman, Montana plants. The goal was to increase efficiency, reduce downtime, and improve the safety and environmental aspects of their systems.

First, Baghouse.com was contacted and asked to conduct a thorough audit of the existing dust collection systems at the Gibson USA plant in Nashville TN, in particular an outdated plenum pulse envelope baghouse that was in desperate need of replacement. The unit had suffered from years of neglect and was in poor physical condition, with large holes on the roof and sides of the unit. Additionally, the system had only partial protection against combustible dust hazards, which the plant wanted to address.

Taking into account their unique needs, we designed a complete dust collection system to meet the current production needs as well as providing for future growth. This included the installation of a new pulse jet style baghouse, a larger system fan, upgraded ductwork, and the integration of NFPA-required combustible dust safety equipment. To ensure compliance with NFPA regulations, explosion vents and an explosion isolation valve were strategically installed. Additionally, explosion-rated equipment, such as rotary valves, replaced non-compliant elements in the discharge system.

Scope of Work at Bozeman, MT plant

The situation at the Bozeman, Montana plant was somewhat different. This plant, which produces all of Gibson’s acoustic guitars, had an existing system that worked well, but that was far too small to account for increased production projections. The expansion of the facility was to take place in two stages: First, a new building was to be built while the existing building and production machines were to keep running. Once the new building was up, the layout of production machines would be completely reworked between the two buildings. Additionally, Gibson asked that the new system be designed and installed in such a way so as to not disrupt existing production and that the changeover be done with little to no downtime. The new system would also need to be able to transition into its expanded role once the facility expansion project was completed in several years.

With these challenging requirements, Baghouse.com set about engineering, supplying, and installing a new dust collection system that: (1) would provide for the current production needs, (2) be capable of nearly 3x capacity when the plant expansion was completed, (3) could be installed without disrupting production, and (4) meet or exceed existing best practice for combustible dust applications.

The solution proved to be a much larger multiple compartment pulse jet baghouse capable of handling 75,000 CFM+. The module (i.e. multiple compartment) style was used to provide additional redundancy and minimize downtime when conducting maintenance. Additionally, the system was outfitted with several protection devices to resolve combustible dust hazards such as high speed abort gates, spark detection, NFPA compliant rotary airlocks and explosion venting.

Importantly, during the design stage we proposed locating the new collector and fan adjacent to the existing baghouse so that it could be installed and brought online without decommissioning the existing system. When the switchover was to take place, we were able to simply extend the existing main trunk of the ductwork over to the new collector and connect the new return air ducting into the building through an enlarged wall penetration.

Eventually, once the new plant layout has been completed, a new, larger interior ductwork system will be installed and reconnected to utilize the full capacity of the new baghouse.

Thew system provides sufficient performance for the existing plant layout and stands ready to handle the estimated 3x increase in demand that will be needed once the plant’s expansion project is completed.

Conclusion

The upgraded dust collection systems led to improved operational efficiency, reducing downtime caused by maintenance issues and gained long-term reliability, reducing the need for frequent repairs and replacements.

Baghouse.com‘s expertise in dust collection systems proved instrumental in providing Gibson Guitars with a reliable, compliant, and efficient solution. These projects not only addressed immediate challenges but also positioned these woodworking facilities to handle the demand placed on them by Gibson’s sustained growth. Additionally, Baghouse.com’s ability to offer complete turnkey solutions allowed for the development of a comprehensive plan covering the collector, system fan, ductwork, combustible dust safety and installation processes so as to minimize production downtime during the changeovers.

We feel privileged to have been able to work with such a great company and to be part of their legacy as they continue to evolve to meet the needs of the 21st century musician.

Would you like to know how a thorough technical inspection and a system report by Baghouse.com could improve the efficiency of your operations?

Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andy Biancotti

Automotive and Aerospace Manufacturing

Case Study – Combustible Dust Safety in Aerospace Manufacturing

Background

An aerospace manufacturing client approached Baghouse.com looking for assistance in aligning with Dust Hazard Analysis (DHA) recommendations, which had identified non-compliance with NFPA guidelines for combustible dust hazards.

Scope of Work

Dust Hazard Analysis (DHA) Compliance

Baghouse.com conducted a thorough assessment of the existing dust collectors and equipment and compared the findings to NFPA guidelines for combustible dust hazards.
The DHA report highlighted critical gaps that needed urgent attention to ensure compliance and mitigate the risk of combustible dust incidents.

System Consolidation and Upgrade

One of the many small old baghouses that were replaced
by one bigger, more efficient unit

In response to the DHA findings, Baghouse.com proposed consolidating pickups from several older baghouses into a single, more efficient unit.

The baghouse underwent a major refurbishment, including the installation of new cartridge filters, pulse valves, solenoids, and updated hardware to meet industry standards.

NFPA-Compliant Safety Measures

Explosion isolation valve installed to meet safety requirements

Heavy gauge ductwork was strategically installed between the baghouse and the explosion isolation valve to meet the safety requirements outlined by NFPA.

To enhance safety measures, Baghouse.com incorporated NFPA-compliant explosion vents and an explosion isolation valve.

Heavy gauge ductwork was strategically installed between the baghouse and the explosion isolation valve to meet the safety requirements outlined by NFPA.

Specialized Equipment Installation

The installation of explosion-rated vents aimed to minimize the risk of dust-related incidents and ensure the safety of the environment.

Newly installed explosion vents

A crucial aspect of the upgrade involved replacing the non-compliant flex hose discharge with an explosion-rated rotary valve.

The installation of explosion-rated components aimed to minimize the risk of dust-related incidents and ensure the safety of the environment.

Outcome

This aerospace manufacturing facility achieved full compliance with NFPA guidelines for combustible dust hazards thanks to Baghouse.com tailored approach.

Conclusion

Baghouse.com expertise in dust collection systems and commitment to safety provided a seamless transition for this client. By addressing DHA recommendations and implementing NFPA-compliant upgrades, the project not only met regulatory requirements but also significantly improved the safety and efficiency of the dust collection processes.

Would you like to hear how a technical inspection and a system report by Baghouse.com could improve your operations?

Talk now with one of our baghouse experts for more information.

December 13, 2023/by Andy Biancotti

Mining and Quarrying

Case Study – Dust Collection in the Mining Industry

Background

Baghouse.com personnel performing an inspection that involved a meticulous examination of baghouses, collectors, fans, airlocks, conveyors, ductwork, pickups, and auxiliary equipment.

Baghouse.com partnered with a large mining company to improve their dust collection systems across multiple facilities across the US. We conducted system inspections and provide personalized training sessions for the maintenance, operations, and engineering teams.

Scope of Work

System Inspection:

Baghouse.com started the project with an in-depth review of the existing dust collection systems at various mining facilities.
The inspection involved a meticulous examination of baghouses, collectors, fans, airlocks, conveyors, ductwork, pickups, and auxiliary equipment.
Various parameters, including airflow, velocity, and pressure readings, were measured for a comprehensive evaluation.

Training Classes:

Following the inspection, Baghouse.com conducted half-day training classes tailored to the specific needs of maintenance, operations, and engineering staff.
The training aimed to empower the teams with the knowledge and skills necessary to operate and maintain the dust collection systems efficiently.
Key topics covered included best practices in system maintenance, identifying performance issues, and optimizing equipment for prolonged life.

Outcome

The mining company gained a clear understanding of the existing issues and opportunities for improvement within their dust collection systems.
The training sessions equipped the teams with practical knowledge, fostering a proactive approach to system maintenance and operation.
Baghouse.com implemented follow-up improvement projects based on the inspection report, ensuring sustained efficiency and compliance with industry health and safety standards.

Conclusion

Baghouse.com collaboration with the mining company exemplifies the significance of dust collection system inspections and training in the mining industry. By addressing existing challenges and empowering teams with relevant knowledge, the project not only optimized their performance but also laid the foundation for sustained operational excellence.

Would you like to hear how an inspection and training could have a positive impact on your operations?

Talk now with one of our baghouse experts for more information.

December 13, 2023/by Andy Biancotti

Dust Collector Maintenance

5 Benefits of a Well-Maintained Dust Collection System

In the world of industrial operations, maintaining your dust collectors in top condition can consume lots of time and resources. But investing in regular maintenance yields many advantages for productivity, product quality, employee health, compliance with safety standards, and equipment longevity:

1. Boost Productivity

Excessive dust accumulation inside your facilities or on industrial equipment poses a silent threat to productivity. If your dust collection system is underperforming due to prolonged wear and tear or if your dust collector is inadequate or undersized, it poses a significant risk to your entire operation. Filter leaks and other maintenance issues that go unchecked could lead to an unexpected plant shutdown, disrupting operations for days to weeks or more.

Filter leaks and other maintenance issues that go unchecked could lead to an unexpected plant shutdown, disrupting operations for days to weeks or more.

Additionally, even minor maintenance issues can have unseen impacts on your operations. Take for example a dust collection duct that slowly accumulates dust build-up. The airflow at dust pickups slowly reduces over time and fugitive dust slowly increases, costing more and more time spent on housekeeping and cleanup. Alternatively, addressing the issue with regular duct inspection and cleanouts will keep your workforce productively working on shipping product.

2. Increase Product Quality

For many manufacturing facilities, dust in the air can mean dust on their products. A robust dust collection system acts as a guardian, efficiently capturing and eliminating dust particles from the air. This not only enhances the quality of finished goods but also ensures consistency in production.

Any maintenance issue with your dust collector, fan, ductwork, cleaning system, or controls ultimately results in more unwanted dust in your facility, increasing the risk of dust on and in your products.

3. Enhance Health & Safety Standards

Industries dealing with hazardous materials emit contaminants that may pose serious health risks to employees. Inhalation of these particles can lead to both short-term and long-term health issues. For example, silica dust may expose workers to silicosis, and wood processing may expose workers to carcinogenic dust.

Maintenance Baghouse.com personnel performing an inspection at a plant

A well-maintained dust collection system plays a critical role in removing hazardous dust, safeguarding the comfort and long-term health of your workforce. Additionally, it mitigates the risk of fire or explosion, especially in industries susceptible to combustible dust.

4 Requirements for a Combustible Dust Explosion

— Oxygen
— Enclosed space (ductwork or a baghouse)
— Ignition source (spark or smoldering dust)
— Combustible dust dispersed at the right concentration level

4. Preserve Equipment

Manufacturing machinery is a substantial investment, and its lifespan can be significantly shortened by the accumulation of dust and debris. Dust settling on sensitive surfaces (such as computers, control boards, mechanical parts, etc.) can lead to malfunctions, resulting in frequent and costly maintenance.

A proactive approach to dust collection not only ensures the longevity of your equipment but also reduces the need for extensive and unplanned repairs.

5. Enhance Production Through Strategic Maintenance

Unlike reactive or routine maintenance, which focuses on fixing issues as they arise, strategic maintenance (also known as “planned maintenance” or “total preventive maintenance or TPM”) involves a thoughtful, long-term perspective. The first step in implementing strategic maintenance at your facility is to plan periodic inspections following a maintenance checklist tailored to your specific system.

If you have any questions or challenges specific to your industry, consult with a dust collection expert such as Baghouse.com for a comprehensive inspection to assess the efficiency and suitability of your current system. Call us now! Our experts can provide you with customized recommendations to minimize inefficiencies, ensuring your equipment works optimally and reducing maintenance costs.

In conclusion, the benefits of a well-maintained dust collection system extend far beyond mere compliance. It’s a multifaceted strategy that safeguards your investments, secures employee health, and improves your production efficiency.

Frequently Asked Maintenance Questions

How can I know if the filters are working correctly?

The main signs to know if your filters are in good condition or if they need to be replaced are whether they can be cleaned effectively or not by the baghouse, or if they start leaking. Click here to read more about filter service life.

How often should I do a filter changeout?

Baghouse filters have an average service life of 1-3 years in most applications. Some can go beyond that without major increases in emissions, while others may last less than a year in more difficult applications. The two main reasons to replace baghouse filters at the end of their life are (1) because blinded filters will begin to have higher and higher emissions (even if there are no holes) and (2) old filters have higher differential pressure (i.e. pressure drop), which decreases the airflow through the system, causing cascading effects of reduced dust collection at pickup point (fugitive dust emissions) and dust buildup in the ductwork.

Can we delegate the filter changeout to our in-house maintenance department?

Of course you can! But you want to make sure they are properly qualified for the task. With dust collection training from Baghouse.com, your maintenance technicians, maintenance planners, engineers, operators and reliability staff will be able to keep your systems running at maximum efficiency, troubleshoot any problems that may arise, and optimize the systems to meet the demands of production.

Read the article: Why Use Experienced Baghouse Technicians for Your Next Filter Replacement

Dust collection expert conducting a class

Training class tailored to maintenance, engineering and safety personnel

Can I outsource the baghouse filter changeout?

The answer is yes! However, you have to be careful who you outsource this vital task to. Inexperienced contractors often get in over their heads after accepting a contract to replace filters, only later discovering the complexity of the task. A rushed or improper installation can cause problems later due to early filter failure in some cases costing millions of dollars to replace.

Can you recommend someone for a system inspection?

Our experts can visit your facilities and perform a thorough inspection of all your baghouses. They will provide you with a comprehensive report of the things that could improve. Additionally, with a highly trained field service team, and decades of experience, you can trust Baghouse.com to do the filter service with minimal downtime.

Contact Us to Speak to One of Our Baghouse Experts.

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

November 28, 2023/by Andy Biancotti

Purchasing Supplies Tips

Purchasing a Dust Collector: 6 Factors to Keep in Mind

If you’re in the market for a dust collector, whether it’s a new purchase or an upgrade for your facility, it’s essential to make an informed decision. A dust collector is a crucial component for maintaining air quality and safety compliance in various industries.

To ensure you get the right dust collector for your specific needs, consider these six key factors:

1. Dust Control Requirements

Different processes generate various types of dust, from wood chips to welding fumes or grain dust. It’s vital to not only recognize the type of dust you generate but also how your processes create it. How much dust is generated by the process? Is this dust hazardous or does it require special handling? Are there regulatory standards for air quality that you need to meet?

In response to these challenges, two primary dust collection systems have proven effective: baghouse-style dust collectors and bin vents. These systems offer reliable solutions for grain dust control, each with its unique advantages.

2. Customization Options

Dust collectors are not one-size-fits-all solutions. The space constraints of your facility may require customizations in terms of height, footprint, or additional features like discharge devices, monitoring equipment, or fire and explosion mitigation tools.

Other common custom features include:

Rotary airlocks, screw conveyers, or other special dust discharge equipment
Special construction materials like stainless steel for food applications
Customer controls including integrated motor starters, timer boards, differential pressure gauges, or outputs to connect to control systems
Special sizing for very light dusts or restricted spaces

3. Complete System Design

The type of dust and your operational needs will determine the most suitable dust collector. In the cases where dust is hard to collect due to being too fine or sticky, you should obtain a dust collector that is equipped to capture it effectively. Another instance could be if your industry demands complying to food-grade standards.

Additionally, different dust collector styles are more suited than others for certain applications. Generally, cartridge collectors work best for light dust loads and fine dusts at lower temps, but perform poorly with heavy dust loading, irregularly-shaped dusts, or sticky dusts. Baghouses on the other hand, are able to work in a wide range of applications. Many companies will only offer you a single style and try to convince you it can do more with less so it appears to be the cheapest bid, regardless of how well it will perform later.

Finally, if your dust is hazardous or explosive, it’s crucial to obtain a specialized system (collector, ductwork and safety devices) designed to comply with NFPA regulations.

4. Installation Simplification

The ease of installation depends on the size of the dust collector and its location. Smaller collectors located close to the dust source may eliminate the need for extensive ductwork, simplifying installation. Understanding your processes, localizing dust collection, and minimizing collector size can streamline installation. It is critical to work with an expert in dust collection systems who can foresee potential installation issues and address them early on to ensure a smooth install.

5. Long-Term Value for Your Investment

Your investment in a dust collector goes beyond the initial purchase. Think about the operational costs for the entire lifecycle of the system. Factors like replacement filters, downtime due to maintenance, and energy consumption need to be analyzed closely. Evaluating collector style, location, and design can help you make a cost-effective choice. Watch video: Intro Guide to Sizing and Designing Your Baghouse

6. Post-Purchase Support

Baghouse.com is an original equipment manufacturer with extensive experience in design, installation, and parts supply. This makes us stand apart from others in the industry who simply resell catalog components. Our extensive experience enables us to provide tailored solutions, designed to meet every industry need. From design to installation and ongoing support, choosing us means opting for a partner invested in the success and longevity of your dust collection system.

In conclusion, investing in the right dust collector will significantly contribute to a safer and more efficient workplace. Making a well-informed decision ensures that your dust collector not only meets your current needs but also serves you for years to come. It’s an investment in both your facility’s air quality and the longevity of your operations.

Frequently Asked Questions

How do I know if this dust collector will work for my application?

When talking about dust collection, it’s rarely a “it works or it doesn’t” scenario; rather, it spans a spectrum from highly effective to very poor performance. While some smaller/cheaper systems may “work” for an application, that’s not the whole story.

A well-designed system, with the right collector size and style, operates efficiently, maintains low operating costs, and captures all target dust without compromising safety or emitting pollutants. However, poorly functioning systems may fail to capture all dust generated by a process, leading to compromised product quality, frequent filter blinding, high maintenance costs, safety hazards, and/or emissions that risk exceeding air permit limits. At Baghouse.com, we help you choose the right system, ensuring not just functionality, but the best performance.

Different companies recommended different kinds of dust collectors, with an ample range of prices. What should I consider when choosing my supplier?

It’s not uncommon for companies to try to convince their clients that a one-size-fits-all approach is best when it comes to dust collectors, either because it’s the only style they manufacture or because they aim to provide the lowest bid. However, at Baghouse.com we offer multiple kinds of dust collectors and we prioritize recommending what works best for your application rather than trying to be the lowest bid without regard for how it works. We ensure that you not only get a dust collector but the right one that aligns perfectly with your operations.

Who can I contact if I have technical issues with my dust collector?

Whether you need parts, filters or a system inspection to improve the efficiency of your dust collectors, the experts at Baghouse.com can simplify the maintenance process by providing you with the knowledge and supplies needed that will save you lots of downtime, money, as well as headaches!

Contact Us to Speak to One of Our Baghouse Experts.

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

November 14, 2023/by Andy Biancotti

Agriculture, Dust Collection 101, Food Processing

Grain Dust Collection Systems Overview

Grain dust collection is a paramount concern within the grain and seed industry, given the frequent occurrence of grain dust fires and explosions. So prevalent is this issue that OSHA has established its own combustible dust rule specific to agricultural dust. Failures in grain dust control not only compromise workplace safety but tragically result in injuries and fatalities.

The Varied Nature of Grain and Seed Dust

Grain and seed dust come in diverse sizes and textures, making effective control of dust a multifaceted challenge.

The grain dust can range from abrasive and sticky to fine and volatile. Moreover, grain processing facilities encompass a multitude of machines and processes, all of which require meticulous dust control to comply with OSHA and NFPA standards.

Processes within the grain and seed industry that are particularly prone to generating problematic dust include:

Conveyor belts and transport systems
Bucket elevators
Transfer points
Hammer mills
Bins and silos
Blenders and mixers
Truck and rail loading and unloading

In response to these challenges, two primary dust collection systems have proven effective: baghouse-style dust collectors and bin vents. These systems offer reliable solutions for grain dust control, each with its unique advantages.

Recommended Equipment for Grain Dust Control

Baghouse Dust Collectors: Unlike cartridge collectors which are very efficient but require uniform dust grain size, light loading, and a narrow range of dust types, a baghouse is a robust collector that can operate with a larger selection of filter media, and generally suffers from fewer problems with varying grain size and loading. A suction-side fan is typical, with a network of ductwork connecting the central dust collector to pickup points on conveyer belts, silos, transfer and loadout points, and other dust sources.
Bin Vents: A bin vent is a specialty piece of dust collection equipment designed for silos and storage bins. As product is loaded into a silo, via pneumatic transfer, gravity chute, etc., pressure is created in the enclosure. A bin vent is used to allow this pressure to vent to the outside air without spewing dust into the air. Bin vents may have a fan to generate negative pressure, or they may operate as a passive vent with no fan. In either case, they are filters that operate according to the same principals as a baghouse or other dust collector.

Possible Additional Equipment

- Cyclone separator
- Chemical isolation system
- Spark trap
- Explosion proof discharge drum kit or rotary airlock
- Abort Gate
- Explosion Venting
- Explosion Isolation Valve
- Airlock

Grain dust, due to its extreme combustibility, presents a substantial fire and explosion risk across all grain-handling applications. Dust control measures are vital in preventing accidents that can lead to injuries, facility damage, and even fatalities. Fires within grain processing facilities have been known to inflict significant harm on structures and equipment.

Given the inherent risks, it is essential to consider a highly effective grain dust collection system as a mandatory component of any grain and seed processing facility. Safety standards unequivocally dictate that all systems must be safeguarded against fire and explosion hazards. This is not an area where cost-cutting is prudent; investing in a properly designed system is an imperative step towards a safer, more secure working environment.

Contact Us to Speak to One of Our Baghouse Experts.

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

November 6, 2023/by Andy Biancotti

Baghouse Accessories

How to Select the Right Dust Collector Rotary Valve

Dust collector rotary valves, also known as rotary airlocks or rotary feeders, are essential components in many industrial processes that involve the handling of bulk materials and are very commonly used in dust collection systems. These valves play a crucial role in controlling the flow of material, preventing air and pressure loss, and ensuring minimal product loss during processing. Selecting the right dust collector rotary valve is of utmost importance to maintain system efficiency, safety, and product integrity. In this article, we’ll delve into the different types of rotary valves and the key considerations for selecting the right one for your specific application.

Understanding Rotary Valves

Rotary valves are mechanical devices that facilitate the transition of materials from pressurized environments, such as dust collectors, to unpressurized points, like storage bins or drums. They come in various types, sizes, and materials to suit different industrial applications.

Types of Rotary Valves

Drop-Through Rotary Valve: In drop-through valves, product feeds into an inlet at the top, typically from a gravity-fed hopper, and exits through an outlet below. These valves are often used in applications where the primary function is to maintain air pressure differentials.
Convey Through (Blowing Seals) Rotary Valves: In convey-through valves, product enters the inlet and is directly fed into a pneumatic convey line connected to ports on the bottom sides of the housing end covers. These are more suitable for applications where height limitations exist, and the valve feeds a pneumatic conveyor directly.

Choosing the Right Rotary Valve

Selecting the right rotary valve depends on several critical factors:

1. Application Type:

Airlocks: Used in applications where maintaining pressure differentials is crucial. They allow material to flow between different pressure zones and are commonly found in cyclone and baghouse outlets.
Feeders: These valves control the rate at which material flows through the valve by metering the bulk powder material’s flow. They are suitable for low-pressure or gravity-fed applications, such as filling packaging machines.
Airlock Feeders: Combining the functions of airlocks and feeders, these valves are versatile and can be used for feeding pneumatic conveyors or moving products in and out of pressure and vacuum receivers.

2. Materials of Construction:

The choice of materials for the housing, rotor, drive, and accessories is crucial to match the requirements of your product and the operating environment. For example, some applications may require stainless steel for its resistance to chemicals, while others may need cast iron or chrome-plated cast iron for durability.

Adjustable rotors allow for tips to be adjusted to account for wear, and flex tip rotors are designed to maintain an airtight seal while preventing material jams. These are just a couple examples of the type of material and design options available.

Sanitary rotary valve components

3. Ease of Cleaning:

For applications where frequent cleaning is necessary, choose a rotary valve designed for easy disassembly. Look for valves that facilitate access to product contact surfaces for cleaning. Hygienic applications should ensure the valve’s surface finish, seals, and construction meet regulatory standards.

Typically, open end rotors are easier to clean and maintain. These are often used with lighter or finer materials, to minimize the risk of material becoming trapped in the space between the endplates and rotor disc.

4. Explosion Protection:

In environments where explosion isolation is required, make sure the valve design complies with standards like NFPA to ensure safety in case of an explosion.

NFPA compliant rotary valve

5. Pressure:

The pressure of your conveying system is a key determinant of the required valve durability. Dilute phase pneumatic conveying systems typically operate between 4 and 8 PSI, while dense phase systems operate over 15 PSI. Valves for high-pressure or vacuum applications need to be designed to withstand the conditions, possibly requiring additional venting systems to prevent air leakage.

6. Temperature:

Consider the operating temperature, as extreme heat or cold can impact the choice of materials, rotor design, and airlock capabilities of the valve. Ensure the selected valve can withstand the temperature conditions of your application.

Selecting the right dust collector rotary valve is a critical decision for maintaining the efficiency and safety of your industrial processes.

By considering the type of valve, materials of construction, ease of cleaning, explosion protection, pressure, and temperature, you can make an informed choice that ensures optimal performance, minimal product loss, and a safe working environment. Collaborating with experts in this field such as Baghouse.com can be invaluable in making the right selection for your specific application.

Contact Us to Speak to One of Our Baghouse Experts.

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

November 3, 2023/by Andy Biancotti

Dust Collector Maintenance

Your Guide to the Dust Collection Maintenance Checklist

Routine maintenance is critical to ensure your dust collection system operates efficiently.

An essential first step in establishing an effective maintenance plan is the creation of a dust collector maintenance checklist. This checklist, tailored to your specific system, helps facility managers and maintenance staff perform periodic inspections as needed. In this article, we’ll explore the importance of a dust collector maintenance checklist, why you need one, and what to include in it.

Why Do You Need a Dust Collector Maintenance Checklist?

Your maintenance checklist should cover the entire system.

Baghouse system designs such as shaker, reverse-air, plenum-pulse-jet, and pulse-jet each require a checklist specific to their design. Regular inspections should be scheduled at various intervals, including daily, weekly, monthly, quarterly, semi-annually, or annually. By adhering to this routine, your dust collection system will continue to operate efficiently for years.

Neglecting regular dust collector maintenance can result in sluggish system performance, leading to costly repairs for both the dust collector and equipment affected by dust buildup. Repairs cause system downtime and production loss. Furthermore, an improperly functioning system can pose health risks to everyone in the vicinity, including workers, managers, owners, and visitors.

Signs That Your Dust Collector Needs Maintenance

Your DP gage can indicate when filters are blinded and require changing.

General indicators that a dust collector requires maintenance include:

✧ Abnormal drops or spikes in differential pressure, which may signal a filter failure
✧ Visible particulate emissions could indicate a seal failure or a torn filter bag
✧ Visual rust or holes in the system can indicate material erosion or environmental corrosion
✧ Unusual sounds from your pulse valves may indicate an issue with diaphragms or your compressed air source

All of these problems are easily preventable with regular maintenance.

What Your Checklist Should Include

Below is a list of dust collector maintenance items and when to check them, depending on the system’s design:

Daily Checklist

✅ Check differential pressure.
✅ Observe exhaust stack (or check emissions monitoring system).
✅ Operate damper valves.
✅ Confirm that dust is being removed from system via dust discharge system.
✅ Confirm cleaning system is operating correctly and set to the correct cleaning sequence.
✅ Check compressed-air lines, including line filters and dryers.
✅ Verify accuracy of temperature-indicating equipment.

Monthly Checklist

✅ Inspect fans for corrosion and material buildup.
✅ Check drive belts for wear and tension. 
✅ Inspect and lubricate appropriate items. 
✅ Spot check for bag leaks.
✅ Check hoses and clamps. 
✅ Check accuracy of indicating equipment.
✅ Inspect housing for corrosion.
✅ Walk through system, listening for proper operation.
✅ Check for unusual occurrences in process.
✅ Observe control panel indicators.
✅ Check compressed-air pressure.
✅ Check differential pressure-indicating equipment for plugged lines.
✅ Blow out any dust from differential pressure lines and verify gauges are in good condition and not fouled.

Quarterly Checklist

✅ Inspect baffle plate for wear.
✅ Inspect bags thoroughly.
✅ Check duct for dust buildup.
✅ Observe damper valves for proper seating.
✅ Check gaskets on doors.
✅ Inspect paint, insulation, etc.
✅ Check screw conveyor for wear or abrasion.
✅ Check that valves are opening and closing properly in bag-cleaning sequence.

Annual Checklist

✅ Check fan belts. 
✅ Check welds. 
✅ Inspect hopper for wear (see full list in Appendix)
✅ Evaluate filter performance (DP, emissions, failed bags, etc.) and schedule filter changeout as needed.
✅ Ensure the plant has one full set of filters on hand for emergencies. IF possible/necessary, also stock one full set of cages or a small number of spare cages for maintenance use.

A well-structured plan that includes a dust collector maintenance checklist benefits operators significantly. It ensures that routine maintenance is systematically scheduled and performed, leading to efficient, long-lasting dust collection systems and lower cost of ownership overall. By following the checklist at specific intervals and marking off completed tasks, you can help preserve your dust collector’s efficiency and longevity and avoid major surprises.