Dust Extraction System

A dust collection system is an air quality improvement system used in various industries to improve breathable air quality and safety by removing particulate matter from the air and environment. Envirocon complete line of Dust Collector system & its equipment’s offers an effective and efficient method for filtration of air-bone dust generated by plant. The system cleans air by forcing it through a series of airtight filters. Once the air is cleaned, it is expelled outside or recirculated, after it has achieved the proper emission’s standards. Systems to collect dust must then be designed, installed and operated properly. Such systems are typically referred to as Dust Aspiration Systems, Dust Collection Systems or Dust collectors. System designing is done by variety of means, depending on the application and the dust being handled. It can also be as complex as an electrostatic precipitator, a multistage baghouse, or a chemically treated wet scrubber or stripping tower or single stage or multi-stage cyclone.

Envirocon proprietary dust collection systems have helped process plants with pollution control boards regulation by controlling in plant & environment pollution. In addition to this, these systems help to reduce occupational hazard.

Dust collection systems work on the basic formula of capture, convey and collect.

First, the dust must be captured or extracted. This is accomplished with devices such as capture hoods to catch dust at its source of origin. Air with dust, generated during process or at storage silo, receiving bin, mixer, dryer, Belt conveyor, Screen etc get’s sucked by suction hoods. Many times, the machine producing the dust will have a port to which a duct can be directly attached. Centrifugal fan used to create necessary air flow & suction pressure

Second, the dust must be conveyed. This is done via a ducting system, properly sized and manifold to maintain a consistent minimum air velocity required to keep the dust in suspension for conveyance to the collection device dust collector ( BAG FILTER, CYCLONE ETC). A duct of the wrong size can lead to material settling in the duct system and clogging it.

Finally, the dust is collected. Dirty air containing particles of dust enters the collector through the ductwork.

The air hits a set of baffles, which are angled pieces of metal that slow it down. As a result, this keeps the dust from hitting the filters at full speed.

Then the air enters what we call the dirty air plenum. This just means the side of the collector where the air is dirty. The air travels through the filter bag, which retains the dust particles on surface of the filter bag, and the clean air passes out through bags to atmosphere.

Collected dust on filter bag are discharge by Pulsejet cleaning method into the dust collector hopper. At the bottom of this space, collected dust drops out into a drum or hopper.

Four main types of industrial dust collectors are:

• Bag Filters
• Cyclone Separator
• Wet scrubbers
• Electrostatic precipitators

1 Bag Filters

A baghouse, also known as a baghouse filter, bag filter, or fabric filter is an air pollution control device and dust collector that removes particulates or gas released from commercial processes out of the air. They are used for dry separation of dust particles or for the extraction of useful dust from streams air. Usually contamination at the outlet after the cleaning process is not more than 10 mg/m3, while the purity of air after the process filtration reaches 99.99%. Envirocon proven capabilities in Dust Control System for design and manufacturing of 1000 M3/Hr to 2,00,000 M3/Hr gas volume, successful installation of Dust Collection System for high temperature, Dust Collection System for Boiler Flue gas cleaning etc.

These filters are widely used in various industries production, such as:

• Power plants, steel mills, pharmaceutical producers, food manufacturers, chemical producers and other industrial companies often use baghouses to control emission of air pollutant.
• Removal of dust from transport companies, for example, in cement industry;
• Processing of ferrous and non-metallic materials, for example, in foundry;
• Removing the dust from the kettle settings, in biomass burning;
• As a filter product for mills, for example, for a coal.

2 Cyclone Separator

A cyclone is centrifugal separator where the particles are swung as a result of their mass by the centrifugal force to the outside. Entering air is automatically forced a rapidly spinning double vortex movement, so-called "double-vortex". Centrifugal cyclonic collectors use cyclonic action to separate dust particles from the gas stream. In a typical cyclone, the dust gas stream enters at an angle and is spun rapidly. The centrifugal force created by the circular flow throws the dust particles toward the wall of the cyclone. After striking the wall, these particles fall into a hopper located underneath. Salient features of Cyclonic Separator.

• Simple construction
• No moving components
• Lower maintenance
• Constant pressure drop
• Pressure: up to 700 PSI
• Temperature: Unto: 1200 Deg C
• MOC: MS, SS304, Alloy Steel, etc.

The most common types of centrifugal, or inertial, collectors in use today are:

• Single Cyclone Seperator
• Multicyclone Seperator

• LOWER OPERATING COSTS - It reduces maintenance expenses, increase equipment life and lead to reduced energy costs by recirculating clean air within the workplace.
• REDUCES RISKS - It improves safety and cleanliness in the workplace, thus reducing your health and fire risks. When the air is filled with dirt, dust, debris, chemicals or gasses, it can affect the lungs of anyone who breathes this air in. With a dust collector, these contaminants are removed from the air, cleaning the air and improving the safety of everyone inside.
• INCREASED PRODUCTIVITY - It contributes to increased productivity by reducing equipment downtime, workers' sick days and on-the-job injuries. When dirt, dust and debris collect on equipment, it can make its way inside, interfering with the mechanics of the equipment. This can lead to slower machines and broken equipment. Compromised machinery constantly needs attention and repairs. Dust collectors remove this risk, allowing your machinery to work at optimal performance.
• THEY LEAD TO BETTER PRODUCT QUALITY - With dust in the air, it can collect on products throughout the manufacturing process. This can negatively impact the quality of the finished product. Dust collectors, however, significantly reduce the dust, smoke and fumes in the air, keeping them away from finished products and thus improving their quality and increasing customer satisfaction.
• THEY HELP YOU MEET COMPLIANCE REGULATIONS- There are numerous laws and regulations in place for workplace safety. Some of these regulations are related to the environment and the quality of the air. Poor air quality can cost you heavily, not just in fines, but by creating potential hazards that can damage your factory or affect your employees. Factory dust collectors help you to comply with governmental regulations as well as keeping everyone (and everything) inside the building safe.
• THEY HELP TO ENSURE HAPPIER EMPLOYEES - When the air quality is bad, employees suffer. As a result, they become unhappy and start to look for employment elsewhere. Unsatisfied employees don’t work well, and high employee turnover can prove costly. Keeping the air clean and healthy with a factory dust collector improves the morale of your employees, allowing you to retain great, happy people in the workplace.