Chapter 4 Collecting and Disposing of Dust

After dust-filled air has been captured by a dry dust collection system, it must be separated, collected, and disposed of. The dust collector separates dust particles from the airstream and discharges cleaned air either into the atmosphere or back into the workplace.

What Is a Dust Collector?

Cleaning dust from the air is necessary tol
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Reduce employee exposure to dust Comply with health and air emission standards Reduce nuisance and dust exposure to neighbors R.ecover valuable products from the air

Necessity for Dust Collectors

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Five principal types of industrial dust collectors
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are-

Types of Dust Collectors

Inertial separators Fabric collectors Wet scrubbers Electrostatic Unit collectors precipitators

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Dust Control Handbook

Inertial separators separate dust from gas streams using a combination of forces, such as centrifugal, gravitational, and inertial. These forces move the dust to an area where the forces exerted by the gas stream are minimal. The separated dust is moved by gravity into a hopper, where it is temporarily stored.

The three primary types of inertial separators are. . .

Settling chambers Baffle chambers Centrifugal collectors

Neither settling chambers nor baffle chambers are commonly used in the minerals processing industry. However, their principles of operation are often incorporated into the design of more efficient dust collectors.

Settling Chambers
Gas inlet Gas outlet

A settling chamber consists of a large box installed in the ductwork. The sudden expansion of size at the chamber reduces the speed of the dust-filled airstream and heavier particles settle out. Settling chambers are simple in design and can be manufactured from almost any material. However, they are seldom used as primary dust collectors because of their large space requirements and low efficiency. A practical use is as precleaners for more efficient collectors.
Dame Chambers

Dust collection hoppers

Settling

Chamber

Baffle chambers use a fixed baffle plate that causes the conveying gas stream to make a sudden change of direction. J..arge-diameter particles do not follow the gas stream but continue into a dead air space and settle. Baffle chambers are used as precleaners for more efficient collectors.

Collecting and Disposing of Dust
Centrifugal Collectors

65

Centrifugal collectors use cyclonic action to separate dust particles from the gas stream. In a typical cyclone, the dusty gas stream enters at an angle and is The centrifugal force created by the spun rapidly. circular flow throws the dust particles toward the wall of the cyclone. After striking the wall, these particles fall into a hopper located underneath. The most common types of centrifugal, collectors in use today area

or inertial,

Single-cyclone Multiple-cyclone

separators separators

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Single-cyclone separators create a dual vortex to separate coarse from fine dust. The main vortex spirals downward and carries most of the coarser dust particles. The inner vortex, created near the bottom of the cyclone, spirals upward and carries finer dust particles. Multiple-cyclone separators, also known as multiclones, consist of a number of small-diameter cyclones, operating in parallel and having a common gas inlet and outlet, as shown in the figure. Vulticlones operate on the same principle as cyclones-creating a main downward vortex and an ascending inner vortex. Nrulticlones are more efficient than single cyclones because they are longer and smaller in diameter. The longer length provides longer residence time while the smaller diameter creates greater centrifugal force. These two factors result in better separation of dust particulates. The pressure drop of multiclone collectors is higher than that of single-cyclone separators.

Cyclone

Multiclone

Advantages and Disadvantages - Centrifugal Types Cyclones Advantages 0 Have no moving parts 0 Can be used as precleaners to remove coarser particulates and reduce load on more efficient dust collectors
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Collectors Disadvantages

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0 Have low collection efficiency respirable particulates
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Suffer decreased efficiency or gas density increases Are susceptible to erosion

if gas viscosity

Can be designed to remove a specific size range of particles

Have drastically reduced efficiency to reduction in airflow rate 0 Cannot process sticky dust

due

Multiclones

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Have no moving parts Are more efficient separators than single-cyclone

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Have low collection efficiency respirable particulates

for

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Are prone to plugging due to smaller diameter tubes Improper gas distribution may result in dirty gas bypassing several tubes Cannot process sticky dust For a given gas volume, occupy more space than sing&cyclone separators Normally have higher pressure drop than single-cyclone separators

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Have low pressure drop when used as a precleaner

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if elbow precedes inlet vane. Line high-efficiency cyclone with refractory or erosion-resistant material.Multiclones Symptom 0 Erosion l l Cause High concentrations of heavy. hard. small-diameter cyclone. 0 Insulate cyclone. clean gas outlet tubes. l Use corrosion-resistant material such as stainless steel or nickel alloy. . hard.Cyclones Symptom 0 Erosion l Cause High concentrations of heavy. 0 Corrosion l Moisture and condensation in cyclone l Keep gas stream temperature above dewpoint. 0 Insulate multiclone. Overloaded tubes 0 Loss of volume in tubes 0 Uneven pressure drop across tubes 0 Plugging in inlet vanes. Check for pluggage and leakage and unplug or seal the ductwork.Common Operating Problems and Solutions . Common Operating Problems and Solutions . Install a wear shield to protect tubes. Install turning vanes in elbow. l l 0 Clean cyclone routinely. l l l Reduced gas velocity in cyclone Check the direction of fan rotation. sharp-edged particles l l Solution Install large-diameter “roughing” cyclone upstream of high-efficiency. if rotation is wrong. Install vibrator to dislodge material. l hopper. Reduced efficiency or dirty gas stack Leakage in ductwork Leakage in multiclone Seal all sections of ductwork and multiclone to prevent leaks. reverse two of the three leads on motor. l Close all inspection ports and openings. and discharge hopper l l 0 Low gas velocity l Uneven flow distribution l Moisture condensation l Overfilling in discharge hopper l l l Install turning vanes in elbow inlet. sharp-edged particles Uneven gas flow and dust distribution l l l Solution Install cast iron tubes. l l l Dust buildup Reduced efficiency or dirty discharge stack l l Gas stream below dewpoint Very sticky material Leakage in ductwork of cyclone Maintain gas temperature above dewpoint. l Install bin-level indicator in collection l Empty hopper more frequently.

measure airflow by conducting a Pitot traverse across inlet to determine quantity and distribution of airflow. 2. block off rows of cyclone to maintain the necessary flow per cyclone. allow hot. dry air to pass through cyclone for a few minutes after process shutdown to avoid condensation. wear. 5. Conduct same startup procedures as cyclones. Turn on fan.68 Dust Control Handbook Startup/Shutdown Type Cyclones 1. 2. Check fan bearings. Check gaskets. Same as cyclones. Multiclones 1.Centrifugal Collectors Shutdown Startup Check fan rotation. Inspect dust discharge hopper to assure dust is removed. corrosion. and other visible signs of deterioration. Weekly Monthly Multiclones Daily Weekly Monthly . 3. Inspect individual cyclones and ducts for cracks caused by thermal expansion or normal wear. 2. Clean discharge hopper. Check fan motor current. If combustion process is used. and other openings for leakage. Check stack (if cyclone is only collector). 0 0 0 0 0 Check cyclone interior for erosion. Preventive Type Cyclones Procedures . 3. Record fan motor amperage. 4. 4. If flow is significantly less than desired. 3. At least once a month. Turn off exhaust fan. and improper gas and dust distribution. Maintenance 1. 4. Close inspection doors. Same as cyclones. Record pressure drop across multiclone. valves. Check pressure drop across cyclone. Check multiclone interior for erosion. Conduct same shutdown procedures as cyclones. and cyclone discharge. 1.Centrifugal Collectors Frequency Daily l Procedure 0 0 0 Record cyclone pressure drops. Allow exhaust fan to operate for a few minutes after process shutdown until cyclone is empty. Procedures . connections. corrosion. wear.

Electrostatic Forces - . The bags can be of woven or felted cotton.Collecting and Disposing of Dust 69 Commonly known as baghouses. Particles that do not cross the fluid streamlines come in contact with fibers because of the fiber size. increasing the probability of contact between the particles and collecting surfaces. synthetic. Interception - Brownian Movement - Submicron particles are diffused. Clean air ~ Baghouse Dust-laden gases enter the baghouse and pass through fabric bags that act as filters. The high efficiency of these collectors is dust cake formed on the surfaces of the fabric primarily provides a surface on particulates collect through the following anisms: Inertial Collection - How They Work due to the bags. The presence of an electrostatic charge on the particles and the filter can increase dust capture. They are one of the most efficient and costeffective types of dust collectors available and can achieve a collection efficiency of more than 99% for very fine particulates. or glass-fiber material in either a tube or envelope shape. fabric collectors use filtration to separate dust particulates from dusty gases. The which dust four mech- Dust particles strike the fibers placed perpendicular to the gas-flow direction instead of changing direction with the gas stream.

they are popular in the minerals processing industry. However.02 in. hence the space requirements are quite high. wg can interfere with cleaning. Walkways Tube sheet Dirty gas Collected solids Mechanical-Shaker Baghouse Shaker baghouses range in size from small. Air-to-Cloth The passed the bag. volume per Ratio: of unit gas area now of The air-to-cloth ratio for shaker baghouses is relatively low.70 Dust Control Handbook A combination of these mechanisms results in formation of the dust cake on the filter. the airflow can be diverted to other compartments. compartmentalized units. three common Tllfechanical shaker R everse air R everse jet Mechanical Shaker Shaker mechanism Clean gas In mechanical-shaker baghouses. the baghouse can be cleaned. In shaker baghcuses. . because of the simplicity of design. Types of Baghouses As classified by cleaning typesof baghouses are. which eventually increases the resistance to gas flow. Pressures as low as 0. . and the dust collects on the inside surface of the bags. there must be no positive pressure inside the bags during the shake cycle. when one compartment is being cleaned. Continuous processes use compartmentalized baghouses. method. Dirty gas enters the bottom of the baghouse and passes through the filter. Vibration produced by a motor-driven shaft and cam creates waves in the bags to shake off the dust cake. Cleaning a mechanical-shaker baghouse is accomplished by shaking the top horizontal bar from which the bags are suspended. . They can operate intermittently or continuously. The filter must be cleaned periodically. tubular filter bags are fastened onto a cell plate at the bottom of the baghouse and suspended from horizontal beams at the top. handshaker devices to large. Intermittent units can be used when processes operate on a batch basis-when a batch is completed.

This flexing of the bags breaks the dust cake.? Baffel plate Cdlacted solids Reverse-Jet Baghouse . Bags are cleaned by a short burst of compressed air injected through a common manifold over a row of bags.by a venturi nozzle mounted at the top of the bag. Compressad .1 s). Dirty gas flow normally enters the baghouse and passes through the bag from the inside. Dirty gas enters from the bottom of the baghouse and flows from outside to inside the bags. causing the dust cake to crack and fall into the hopper below. maintenance needs are somewhat greater. Reverse Jet Reverse-Air Baghouse Solenoid valve ~~~~ 6hee. the bags are fastened onto a cell plate at the bottom of the baghouse and suspended from an adjustable hanger frame at the top. which is fastened onto a cell plate at the top of the baghouse. individual bags are supported by a metal cage. however. ‘b air manifold In reverse-jet baghouses.bubble. t Diny gas -. and the compartment is returned to the main stream. partially. filtration is stopped in the compartment to be cleaned. At the end of the cleaning cycle. Before a cleaning cycle begins. traveling through the entire length of the bag and causing the bag surfaces to flex. Bags are cleaned by injecting clean air into the dust collector in a reverse direction. and the dust collects on the inside of the bags. rigid rings are sewn into the bags at intervals. and the dislodged dust falls into a storage hopper below. The compressed air is accelerated . However. The metal cage prevents collapse of the bag. Since the duration of the compressed-air burst is short (0. which pressurizes the The pressure makes the bags collapse compartment. Collscced solids Clean backwash si WI supPan Bag sup~onsd bv rings The flow of the dirty gas helps maintain the shape of the bag. it acts as a rapidly moving air. Reverse-air baghouses are compartmentalized to allow continuous operation. reverse airflow is discontinued. to prevent total collapse and fabric chafing during the cleaning cycle.Collecting and Disposing of Dust 71 Reverse Air In reverse-air baghouses. Space requirements for a reverse-air baghouse are comparable to those of a shaker baghouse. Clean gas Venturis .

Cartridge collectors are available in single use or continuous duty designs. Due to its pleated design. resulting in reduced air to media ratio. the cartridges are cleaned by the conventional pulse-jet cleaning system. and overall collector size. In the continuous duty design. Also. the total filtering surface area is greater than in a conventional bag of the same diameter. In single-use collectors. collectors provide more complete cleaning and reconditioning of bags than shaker or reverse-air cleaning continuous-cleaning feature methods. . pressure drop. Unlike baghouse collectors. so the space requirements are lower. Because of this continuous-cleaning feature. this type of collector employs perforated metal cartridges that contain a pleated. Cartridge Collectors Cartridge collectors are another commonly used type of dust collector. in which the filtering media is woven or felt bags.72 Dust Control Handbook Reverse-jet dust collectors can be operated continuously and cleaned without interruption of flow because the burst of compressed air is very small compared with the total volume of dusty air through the collector. the dirty cartridges are changed while the collector is off. The short cleaning cycle of reverse-jet collectors These reduces recirculation and redeposit of dust. reverse-jet dust collectors are usually not compartmentalized. nonwoven filtering media. the allows them to operate at higher air-to-cloth ratios.

3 . creating potential for exposure to toxic dust Can result in reduced cleaning efficiency if even a slight positive pressure exists inside bags Dave low air-to-cloth ratio (1 to 2 ft/min) Require frequent cleaning because of gentle cleaning action Pave no effective way to remove residual dust buildup Cleaning air must be filtered Require personnel to enter baghouse to replace bags.Advantages Types Mechanical-shaker baghouses and Disadvantages .Baghouses Disadvantages Have low air-to-cloth ratio (1. which can withstand intensified cleaning cycle to reduce residual dust buildup l Simple to operate 0 Have low pressure drop for equivalent collection efficiencies Reverse-air baghouses Have high collection efficiency for respirable dust _4re preferred for high temperatures due to gentle cleaning action Have low pressure drop for equivalent collection efficiencies Reverse-jet baghouses 0 0 0 0 0 0 0 0 0 Have high collection efficiency for respirable dust Can have high air-to-cloth ratio (6 to 10 ft/min) Have increased efficiency and minimal residual dust buildup due to aggressive cleaning action Can clean continuously Can use strong woven bags Have lower bag wear Have small size and fewer bags because of high air-to-cloth ratio Some designs allow bag changing without entering baghouse Have low pressure drop for equivalent collection efficiencies g 0 % g $ a” 3 l . which creates potential for toxic dust exposure Require use of dry compressed air IVay not be used readily in-high temperatures unless special fabrics are used Cannot be used if high moisture content or humidity levels are present in the exhaust gases Advantages 0 Have high collection efficiency for respirable dust 0 Can use strong woven bags.5 to 2 ft/min) Cannot be used in high temperatures Require large amounts of space Need large numbers of filter bags Consist of many moving parts and require frequent maintenance Personnel must enter baghouse to replace bags.

Install double bags. Speed up repressurizing fan. Add more compartments 0 8 High baghouse pressure drop or modules. Increase shaker speed. 0 (RJ) Increase pressure. 0 Bag cleaning mechanism not properly adjusted Shaking not strong enough (VS) Compartment isolation damper valves not operating properly (MS.Baghouses* Symptom l Cause 0 Baghouse undersized Solution Consult vendor. Check output on all terminals. Check for obstructions in piping. Check diaphragm. Check compressed-air dryer and clean it if necessary.Common Operating Problems and Solutions . Check to see if timer is indexing to all contacts. Clean for longer duration. Check damper valve seals. RA) Compressed air pressure too low Increase cleaning frequency. Check pilot valves. Check air supply of pneumatic 0 0 operators. Check linkage. Loosen bag tension. Check for leaks. Clean more vigorously. 0 Repressurizing pressure too low (RN 4 Pulsing valves failed (RJ) Bag tension too tight (RA) Eag tension too loose (nw Cleaning timer failure 0 *MS = RA = RJ = mechanical shaker reverse air reverse jet . Decrease duration and frequency. Check valve seals. Tighten bags.

Smooth out cloth under clamp end re-clamp. if possible. Check diaphragm and springs.Symptom 0 Cause Not capable of removing dust from bags 0 0 l 0 0 Solution Check for condensation on bags. Clean Check Check Check out pressure taps. Tie off leaking begs and replace them later. diaphragm in gauge. Reduce supply pressure. if possible. Allow more dust buildup on bags by cleaning less frequently. for proper fluid level in manometer. Reduce airflow. 0 Pulse too long 0 Pressure too high 0 Diaphragm valve failure . Caulk or weld seams. Use a precoeting on bags (MS. Check pilot valve. Clean rows of bags randomly instead of sequentially (R J). for Excessive reentrainment of dust 0 0 F mpty hopper continuously. 0 Incorrect pressure-drop reading 0 0 0 0 l Dirty discharge at stack 0 Bags leaking 0 0 0 Replace bags. Send dust sample end begs to manufacturer analysis. Dryclean or replace bags. hoses for leaks. Isolate leaking compartment or module. Check and tighten clamps. Reduce pulsing duration. Send beg in for permeability manufacturer. test and review with Bag clamps not sealing Failure of seals in joints at clean/dirty air connection Insufficient filter cake 0 l 0 0 0 0 Bags too porous Cleaning cycle too frequent 0 0 High compressed-air consumption (RJ) l 0 0 0 0 0 Reduce cleaning cycle. RA).

Replace dryer. Check pilot valves. Install aftercooler. 0 Compressed-air small Compressor supply line too 0 worn out 0 0 l Pulsing valves not working Timer failed preheating l Moisture in baghouse 0 Insufficient Run the system with hot air only before process gas flow is introduced. Preheat repressurizing air. condensation (RJ) l l . if possible. and diaphragms. Bypass dryer temporarily. Replace rings. springs. Ins tall dryer. Check for worn components. Raise gas temperature. Keep fan running for 5 to 10 min after process is shut down. Check compressed-air piping. Eliminate direct metal line through insulation. Lower dewpoint by keeping moisture out of system. l Repressurizing __air causing _ _. Check terminal outputs. 0 System not purged after shutdown Wall temperature below dewpoint l l l l l l Cold spots through insulation Water/moisture air (RJ) in compressed l l l l Check automatic drains. 0 Restrictions piping 0 in compressed-air dryer plugged l Compressed-air Replace dessicant in the dryer.Symptom l Cause l Solution too l & Reduced compressedair pressure (RJ) Compressed-air high consumption See previous solutions. Consult design. Use process gas as source of repressurizing air. Rebuild compressor or consult manufacturer. Insulate unit.

Remove dust continuously.Symptom l Cause l Solution See previous solutions. Slow down shaking mechanism. Rework or replace hoppers. Reduce pressure. bags wearing out 0 Baffle plate worn out 0 Too much dust 0 Cleaning cycle too frequent 0 Inlet air not properly baffled from bags Shaking too violent (MS) Repressurizing @Al pressure too high Pulsing pressure too high (RJ) Cages have barbs (RJ) . Install primary collector. Replace baffle plate. Material bridging in hopper Moisture in baghouse 0 Dust stored in hoppers 0 Hopper slope insufficient 0 Screw conveyor opening too small l High rate of bag failure. Consult vendor. Use a wide. Reduce pressure. Remove cages and smooth out barbs. Slow down cleaning. flared trough.

Measure baghouse temperature and check that it is high enough to prevent moisture condensation. even if baghouse is insulated. (Ensure that all compartments of shaker or reverse-air baghouses are open.Baghouses Shutdown 1. moist gases. 3.) Activate baghouse fan and dust-removal conveyor. 2.78 Dust Control Handbook Startup/Shutdown startup 1. For processes generating hot. Continue operation of dust-removal conveyor and cleaning of bags for 10 to 20 minutes to ensure good removal of collected dust. Procedures . preheat baghouse to prevent moisture condensation. .

l l l Weekly 0 0 0 Monthly Quarterly Annually Check fan belts. Check welds. Check compressed-air lines. Check compressed-air pressure. Check packing glands. Inspect baffle plate for wear. Check all moving parts in shaker mechanism. Check hoses and clamps. insulation. Check for unusual occurrences in process. Check accuracy of indicating equipment. Assure that dust is being removed from system. Observe stack (visually or with opacity meter). Check pressure-drop-indicating equipment for plugged lines.Baghouses Procedure Check pressure drop. Inspect and lubricate appropriate items. including line filters and dryers. Inspect fans for corrosion and material buildup. Spot-check for bag leaks. Inspect hopper for wear. Observe control panel indicators. Observe damper valves for proper seating. Operate damper valves. Inspect paint. Inspect housing for corrosion. listening for proper operation. Check duct for dust buildup. Inspect bags thoroughly. Inspect screw-conveyor bearings for lubrication. . Walk through system. Check gaskets on doors. Check that valves are opening and closing properly in bag-cleaning sequence. etc. Check drive belts for wear and tension. Spot-check bag tension. Check screw conveyor for wear or abrasion.Collecting and Disposing of Dust 79 Preventive Frequency Daily Maintenance Procedures . Verify accuracy of temperature-indicating equipment.

This is the principal mechanism in the collection of submicron dust particles.Regardless of the contact mechanism used. 0 Scptuation . condensation of moisture occurs on the dust particles. Gas-Liquid . as much liquid and dust as possible must be removed.When liquid droplets are scattered among dust particles.This is one of the most important factors affecting collection efficiency. hit the droplets. the larger dust particles will continue on in a straight path. the gas and liquid streams. the stream separates and flows around them. 0 Wet Scrubber Contact . the particles are deposited on the droplet surfaces by Brownian movement.80 Dust Control Handbook Wet Scrubbers _ Gas oullet Dust collectors that use liquid are commonly known as wet scrubbers. they settle into a collector. There is a large variety of wet scrubbers. As the agglomerates grow larger. This increase in particle size makes collection easier. Due to inertia. Interception . In these systems. or diffusion. dust particulates and water droplets combine to form agglomerates. Once contact is made. the scrubbing liquid (usually water) comes into contact with a gas stream The greater the contact of containing dust particles. all The gas-humidification process conditions fine particles to increase their size so they can be collected more easily.If a gas passing through a scrubber is cooled below the dewpoint. and become encapsulated.When water droplets placed in the path of a dust-laden gas stream. Condensation Nucleation .Finer particles moving within a gas stream do not hit droplets directly but brush against them and adhere to them. the higher the dust removal efficiency. Diffusion . The particle and droplet come into contact by four primary mechanisms: Gas-Liquid Inertial Impaction . have of three basic operations: 0 Gas-Humidification - WW?r spreyr however.

5 to 6) scrubbers (6 to 15) than 15) Strainer Liquid in Pipe Pipe Mist eliminator scrubbers (greater Due to the available.to high-energy fTigh-energy scrubbers (2. \\rater introduced from the top to wet the cyclone walls carries these particles away.to Medium-Energy Serubbers Wet cyclones use centrifugal force to spin the dust particles (similar to a cyclone). A drag chain system removes the sludge and deposits it into a dumpster or stockpile.Collecting and Disposing of Dust 81 The "cleaned" gases are normally passed through a mist eliminator (demister pads) to remove water droplets from the gas stream.5 to 2. Contaminated gas Liquid out Liquid in Wet Cyclone . .5) Low. examples of large number of commercial scrubbers is not possible to describe each individual However. Types of Scrubbers J. the following sections provide typical scrubbers in each category.to medium-energy !\"edium.1m. rrheir efficiency is poor-below 10 J. liquid in spray nozzles Dirty water is Gas inlet Gas distributor plate Water and sludge drain These scrubbers operate at pressure drops of 1 to 2 in. Spray- Tower Scrubber Clean gas Low. Spray nozzles Low-Energy Scrubbers In the simple. The dirty water from the scrubber system is either cleaned and discharged or recycled to the scrubber. they are capable of treating relatively high dust concentrations without becoming plugged. The wetted walls also prevent dust reentrainment. scrubber. However.1m particles. . drained at the bottom. it type here. water gauge and are approximately 70% efficient on 10 J. In both systems solid material settles on the bottom of the tank. Dust is removed from the scrubber in a clarification unit or a drag chain tank.. . \\Tet scrubbers may be categorized by pressure drop (in inches water gauge) as follows: . gravity-spray-tower droplets formed by liquid atomized fall through rising exhaust gases. and throw the particulates upon the collector's wetted walls..ow-energy scrubbers (0.

water.particles m and above. Cyclone separator Liquid in Venturi Dirty gas Injection points Liquid out . i. into fine droplets. saddles. These high-gas velocities immediately atomize the coarse water spray.000 ft/min.e.1. . diameter stainless steel wire and increasing gas velocity to more than 1. Cross-Flow Scrubber Gas with contaminants Scrubbing liquid inlet Packed section Three types of packed-bed scrubbers areCleaned gas entrainment separator Packing support plate Liquid out . The agglomeration process between particle and droplet continues in the diverging section of the ventiJri. such as coke.to High-Energy Scrubbers Packed-bed scrubbers consist of beds of packing elements. The dust-laden gases enter through the venturi and are accelerated to speeds between 12. using . or other manufactured elements.. Since efficiency of a venturi scrubber depends on pressure drop. broken rock. The large agglomerates formed in the venturi are then removed by an inertial separator. rings. These scrubbers have good collection efficiency for respirable dust. High energy and extreme turbulence promote collision between water droplets and dust particulates in the throat. and the collection efficiency 5 1. from 2 to 8 is good for Medium.800 ft/min.82 Dust Control Handbook Scrubbing liquid inlet Packed bed Cleaned gas Contaminated gas Liquid out Pressure drops for these collectors range in. Venturi scrubbers achieve very high collection efficiencies for respirable dust. H igbEnergy Scrubbers Scrubbing liquid in Packed section Gas with contaminants Liquid out Counter-Current-Flow Scrubber Clean gas Venturi scrubbers consist of a venturi-shaped inlet and a separator. .000 and 36. some manufacturers supply a variable-throat venturi to maintain pressure drop with varying gas flows.003 in. which is injected radially into the venturi throat. The packing breaks down the liquid flow into a high-surface-area film so that the dusty gas streams passing through the bed achieve maximum contact with the liquid film and become deposited on the surfaces of the packing elements. Cross-flow scrubbers Co-current flow scrubbers Counter-current flow scrubbers Co-Current-Flow Cleaned gas Scrubber Efficiency can be greatly increased by minimizing target size.

Collecting and Disposing of Dust 83 Advantages and Disadvantages Advan tapes l .Wet Scrubbers Disadvantages Have low capital costs and small space requirements Can treat high-temperature high-humidity gas streams and 0 0 Have high operating and maintenance Require corrosion-resistant with acidic gases Require a precleaner costs materials if used l 0 l for heavy dust loadings Are able to collect gases as well as particulates (especially %ticky” particulates) Have no secondary dust sources 0 0 0 0 Cause water pollution. require further water treatment Are susceptible to erosion at high velocities l Collect wet products Require freeze protection .

Replace nozzles or rebuild heads.84 Dust Control Handbook Common Operating Problems and Solutions . Increase the water bleed rate. Clean fan housing and blades regularly. or waste disposal area and supply clean water as makeup. Supply filtered scrubbing liquid. For vane-type demisters. Use wear-resistant orifice plates to reduce erosion on valve components. settling pond. Ensure that scrubber is installed vertically. Maintain liquid seal. and Wet/dry buildup l l l Dust buildup in fan Excessive fan vibration Liquid pump failure 0 l Worn valves Jammed valves Erosion of slurry piping l l Plugged nozzles l Ruildup on mist eliminators . spray the center and periphery intermittently to clean components. Maintain pumping velocity of 4 to 6 ft/s to minimize abrasion and prevent sedimentation settling. Change source of scrubbing liquid. For chevron-type demisters. Divert some of the recycle slurry to a thickener.Wet Scrubbers Problem l Solution Keep all areas dry or all areas flooded. Use inclined ducts to a liquid drain vessel. Provide continuous purge between valves and operating manifold to prevent material buildup. Install clean water spray at fan inlet. spray the water from above to clean the buildup.

liquid levels. 3. or other drain systems so slurry concentration can build slowly. When pump cavitation noise is heard. liquid flows. 6. 4. set valves to determine operating conditions for desired flow rates. . duct pressure drops. 2. Checkout Procedures . With recycle flow on.Wet Scrubbers Shutdown 1. 7. drain the system. bleeds. Install temporary strainers in pump suction line and begin liquid recycle. Start fans and pumps to check their rotation. Check final concentration as cross-check on bleed rate. 2. Open system manholes. 5. Open bleed to pond.Collecting and Disposing of Dust 85 Startup/Shutdown Prestart 1. and scrubber pressure drop. Startup 1. Start recycle pumps with liquid bleed closed. 4. Start liquid flow to all pump glands and fan sprays. 2. Fill largevolume basins from external sources. 3. 4. Record the valve positions as a future baseline. Shut down fan and fan spray. 5. Insulate scrubber from operation. Shut off makeup water and allow to bleed normally. thickener. 7. Shut down fan. Allow vessels to fill with liquid through normal level controls. Check gas saturation. Perform all recommended lubrications. Check insulation dampers and place scrubber in series with primary operation. 6. 5. 3. Allow liquid system to operate as long as possible to cool and reduce liquid slurry concentrations. Record all system pressure drops under clean conditions. turn off pump and pump gland water. and other drains. Leave inlet control damper closed for 2 min to allow fan to reach speed. Start fan and fan inlet spray. fan pressure drop. Disconnect pump suction piping and flush it with water from an external source. and remove temporary strainers.

Check ductwork for leakage and excessive flexing. Check vibration of fan for buildup or bleeds. transformer insulation. Measure temperature rise across motor. Check and repair wear zones in scrubbers. and ductwork. including contacts. Check bearings. if necessary. Check fan inlet and outlet pressure.Wet Scrubbers Procedure Check recycle flow. Use motor current readings to detect flow decreases. Lubricate damper drive mechanisms and bearings. Record inlet and saturation temperature of gas stream. Inspect fans on dirty applications for corrosion. drive mechanisms. and vibration. temperature rise. oil level. Check bleed flow. piping. Use fan current to indicate gas flow. Check pump discharge pressure. Verify proper operation of dampers and inspect for leakage. Verify accuracy of instruments and calibrate. and particulate buildup. abrasion. chain tension. Line or replace as necessary. Check pressure drop across mesh and baffle mist eliminators. Check liquid spray quantity and manifold pressure on mist eliminator automatic washdown. Clean electrical equipment. valves.86 Dust Control Handbook Preventive Prequency Daily Maintenance Procedures . Check wet/dry line areas for material buildup. Check scrubber pressure drop. Inspect orifice plates. Check slurry bleed concentration. oil temperature. and clarifier rakes. sprocket alignment. Check fan and pump bearings every 8 hours for oil level. Clean and dry pneumatic lines associated with monitoring instrumentation. Weekly Semiannually . and cooling fans. oil color. Clean by high-pressure spraying. if necessary. Clean. sprocket wear.

000 volts. The airborne particles receive a negative charge as they pass through the ionized field between the electrodes. The collected material on the electrodes is removed by rapping or vibrating the collecting electrodes either continuously or at a predetermined interval. An increase in the dust-particle migration velocity to the collecting electrodes increases efficiency. The four main components tators are. to impart lates in the gas stream a charge to particu- High voltage design discharge electrode (normally negative) 30. affect the efficiency of electro- Larger collection-surface areas and lower gasflow rates increase efficiency because of the increased time available for electrical activity to treat the dust particles. to provide high-voltage. These charged particles are then attracted to a grounded or posi ti vely charged electrode and adhere to it.Collecting and Disposing of Dust 87 Electrostatic precipitators use electrostatic separate dust particles from exhaust gases. Collecting plates are usually grounded. unidirectional current Ionizing section. Electrostatic Precipitator . . Cleaning a precipitator can usually be done without interrupting the airflow. of high-voltage. direct-current discharge are placed between grounded collecting forces to A number electrodes electrodes. Electrostatic Precipitators High tension support frame High voltage insulators Gas seal The contaminated gases flow through the passage formed by the discharge and collecting electrodes. . A means of removing A housing to enclose the collected the precipitator particulates zone The following factors static precipitators: . . The migration velocity can be increased by- Decreasing the gas viscosity Increasing the gas temperature Increasing the voltage field .000 to 75. Collecting plate Rapper Dishcharge electrodes Discharge wire weights of all electrostatic precipi- Dust hopper Power supply unit.

with a series of discharge electrodes spaced along the centerline of two adjacent plates. and the particles become charged and adhere to the collection plates. The collected dust is removed from the bottom of the cylinder. apart. Collected particles are usually removed by rapping the plates and deposited in bins or hoppers at the base of the precipitator. or extremely toxic materials.Single-stage precipitators combine an ionization and a collection step. Tubular precipitators are often used for mist or fog collection or for adhesive. Tubular Precipitators . Singldtage . parallel surfaces that are 8 to 12 in.Tubular precipitators consist of cylindrical collection electrodes with discharge electrodes located on the axis of the cylinder. sticky. The charged particles are collected on the grounded walls of the cylinder. radioactive.The majority of electrostatic Plate Precipitators precipitators installed are the plate type. The contaminated gases flow around the discharge electrode and up through the inside of the cylinders. They are commonly referred to as Cottrell Discharge electrode 0 Plate Tubular 0 Plate-Type Precipitator Precipitate stage . Pre-ionizing stage Tubular-Type Precipitator . The contaminated gases pass through the passage between the plates.88 Dust Control Handbook Types of Precipitators There are two main types of precipitators: 0 HigbVoltage. Particles are collected on flat.

including submicron-sized particles Usually collect dust by dry methods Have lower pressure drop and therefore lower operating costs Can operate at high temperatures 12000 F) and in colder climates (up to .Collecting and Disposing of Dust 89 Advantages and Disadvantages Advantages Have collection efficiencies in excess of 99% for all particulates.000. gas pressure.Electrostatic Precipitators Disadvantages Have high initial investment costs Do not respond well to process changes such as changes in gas temperature. dust loading. particulate size distribution. gaseous or chemical composition. gas flow rate. or electrical conductivity of the dust Have a risk of explosion when gas stream contains combustibles Produce ozone during gas ionization Require large space for high efficiency. and even larger space for dust with low or high resistivity characteristics Require special precautions to protect personnel from exposure to high-voltage Require highly skilled maintenance personnel Can remove acids and tars (sticky dust) as well as corrosive materials Allow increase in collection efficiency increasing precipitator size Require little power Can effectively handle relatively large gas flows (up to 2.OOOf@/min) by .

Advantages of unit collectors include small space requirements. Dust bin Cyclone Collector . The cleaning operation should be simple and should not increase the surrounding dust concentrat ion.normally used for fine dust Cyclone dust collectors normally used for coarse Fabric collectors are frequently used in minerals processing operations because they provide high collection efficiency and uninterrupted exhaust airflow between cleaning cycles. or frequently moved dust-producing operations.000 fta/mln. such as bins and silos or remote belt-conveyor transfer points. portable. and maintenance periods have been sacrificed. Cyclone collectors are used when coarser dust is generated. They are small and selfcontained. consisting of a fan and some form of dust collector. and low initial cost. or machining. The unit should have an automatic discharge or sufficient dust storage space to hold at least 1 week’s accumulation. their dust-holding and storage capacities. unit collectors control contamination at its source. However. with manual shaking or pulsejet cleaning . main types of unit collectors: with capacities There are two Unit Collector 0 0 Fabric collectors. servicing facilities. must all The unit should maintain its rated capacity while accumulating large amounts of dust between cleanings. ranging from 200 to 2. the return of collected dust to main material flow. A number of designs are available. They are suitable for isolated. 8 hours). The following points should selecting a unit collector: Fabric Collector Filter be considered comply with when Cleaning efficiency applicable regulations. as in woodworking. metal grinding. The unit should be capable of operating unattended for extended periods of time (for example.90 Dust Control Handbook Unit Collectors Unlike central collectors.

effectiveness.1 to 5. cotton fabric filters cannot be used where air temperatures exceed HO0 F. and so forth. For example. operating.Collecting and Disposing of Dust 91 l If renewable filters are used. Required . Each type I!owever. the dust concentration can range from 0. Dustremoval and servicing requirements are expensive for many unit collectors and are more likely to be neglected than those for a single. Also.5 to 100 pm. The selection of a collector should be based on the efficiency required and should consider the need for high-efficiency. and capital. they should not have to be replaced more than once a month.0 grains of dust per cubic feet of air. its salvage value. such as baghouses or wet scrubbers. condensation of steam or water vapor can blind bags. such as electrostatic precipitators. Various Concentration and Particle Size - 0 Degree of Dust Collection 0 . the has advantages and disadvantages. The unit should be quiet. the nature of the dust. such as dry centrifugal collectors. or lower cost. operation.The degree of dust collection required depends on its potential as a health hazard or public nuisance. high-efficiency. the allowable emission rate.The characteristics of the airstream can have a significant impact on collector selection. construction. high-cost equipment. Dust collectors vary widely in design. selection of a dust collector should be based on the following general factors: l Selectinga Duet Collector Dust For minerals processing operations. space requirements. and the particle size can vary from 0. large collector. Characteristics of Airstream . moderate-cost equipment. 0 0 Use of unit collectors may not be appropriate if the dust-producing operations are located in an area where central exhaust systems would be practical. and maintenance costs. The unit should be durable. the plant location. primary units.

Methods of Disposal . Collectors can unload continuously or in batches. Dry materials can create secondary dust problems during unloading and disposal that do not occur Disposal of wet slurry or with wet collectors. Sticky material can adhere blind bag collectors. sewer or water pollution problems can result if wastewater is not treated properly. and type of collector used. nature of many fine materials rules out the use of of electrostatic precipitators.The combustible types of fabric collectors. plant process. 0 Characteristics of Dust - Moderate to heavy concentrations of many dusts (such as dust from silica sand or metal ores) can be abrasive to dry Hygroscopic material can centrifugal collectors. 0 A comparison of various dust collector is included in the following table. volume. characteristics . Some particle sizes and shapes may rule out certain . to collector elements and plug passages.92 Dust Control Handbook chemicals can attack fabric or metal and cause corrosion in wet scrubbers.Methods of dust removal and disposal vary with the material. sludge can be an additional material-handling problem.

wg) 0.25 25 l-5 3-6 3-8 3-a 0.Comparison of Dust Collector Characteristics To Control Particulates Greater Than f pm) 20-40 Pressure Drop fin.to highenergy scrubber (e.75-1.50 550 14) 180 (3) Z’nlimited Cnlimited 256-756 Low-energy scrubber (e.. Does not include ducting.25 0. and power requirements.5 2. 550’ F based on glass-fiber bags.to mediumenergy scrubber (e..25 0.g. Cost based on collector section only. water. packed bed) High-energy scrubber (e. venturi) Precipitator (singleor double-stage) Notes: (1) (2) (3) (4) 1-5 6-15 5-10 Rone Large Unlimited 0. .oo Eased on standard construction..5 Humid Air Influence Kay cause condensation and plugging Vay cause condensation and plugging Vay make bag cleaning difficult IKay cause bag to blind 5 3-5 None Rone Space Requirements Large Vaximum Temperature (1) f F) 750 50-256 Device Cyclone nlulticlone 10-30 3-6 Vaderate 750 56-250 Shaker baghouse Reverse-air Reverse-jet baghouse baghouse 0..5-2. Actual costs may vary. Synthetic fabrics may be used to 275 ’ F.g.g.g. 180’ F based on cotton fabric.5-6 Large Moderate Large Large Moderate 180 (3) 3Oe-$2.25 15 and greater 0.5-2 0. centrifugal collector) Iedium. Cost figures should be used for comparison only.5 5-15 P!one Improves efficiency Moderate Large Unlimited 500 50041 . spray tower) Low.

Their straight. They have low space requirements. 0 Backward-Blade Fans - Backward Blades Backward-blade fans operate at higher tip speeds and thus are more efficient. They are usually used against low to moderate static pressures. The centrifugal force imparts static pressure to the air. There are three main types of centrifugal l fans: Radial-Blade Fans - Radial-blade fans are used for heavy dust loads. and they withstand considerable abrasion. These fans have medium tip speeds and medium noise factors. radial blades do not get clogged with material. Types of Fans There are two main kinds of industrial fans: 0 0 Centrifugal fans Axial-flow fans Fans Centrifugal L-___~~ / Radial Blades Centrifugal fans consist of a wheel or a rotor mounted on a shaft that rotates in a scroll-shaped housing. The diverging shape of the scroll also converts a portion of the velocity pressure into static pressure. makes a right-angle turn. Air enters at the eye of the rotor. and a low noise factor. low tip speeds. Although they are noisier than radialblade fans.94 Dust Control Handbook Fan and Motor The fan and motor system su plies mechanical energy to move contaminated air Prom the dust-producing source to a dust collector. l Forward-Curved-Blade Fans - Forward-Curved Blades These fans have curved blades that are tipped in the direction of rotation. these fans should be used after a dust collector. and is forced through the blades of the rotor by centrifugal force into the scroll-shaped housing. Since material may build up on the blades. backward-blade fans are commonly used for large-volume dust collection systems because of their higher efficiency. .

They are normally used for clean air only. These fans move the air parallel to the fan’s axis of rotation. Tube-Axial Fans . 0 Tube-Axial Fan 0 Vane-Axial Fan When selecting considered: 0 a fan.) Type of drive arrangement.Vane-axial fans are similar to tube-axial fans except air-straightening vanes are installed on the suction or discharge side of the rotor. Vane-Axial Fans . causing a helical flow pattern. wg. They are best suited for moving air containing substances such as condensable fumes or pigments. They are easily adapted to multistaging and can develop static pressures as high as 14 to 16 in. Propeller Fan The three main kinds of axial fans are0 Propeller Fans . a radial-blade fan should be used with fibrous material or heavy dust loads. wg. They are usually used for general ventilation or dilution ventilation and are good in developing up to 0. they are more efficient than propeller fans and can develop up to 3 to 4 in.Collecting and Disposing of Dust 95 Axial-Flow Fans Axial-flow fans are used in systems that have low resistance levels. wg. the following points should be Fan Selection Direct Driven 0 Volume required Pan static pressure Type of material to be handled through the fan (For example. Therefore.Tube-axial fans are similar to propeller fans except they are mounted in a tube or cylinder. The screw-like action of the propellers moves the air in a straight-through parallel path. and nonsparking construction must be used with explosive or inflammable materials. belt drive Space requirements such as direct drive or Belt Driven l 0 l Less space requirements Assure constant fan speed Fan speeds limited to available motor speeds Greater space requirements Fan speeds easily changed (a vital factor in many applications) l l 0 l 0 .5 in.These fans are used to move large quantities of air against very low static pressures.

This table is known as a multirating table. 0 .) Sufficient size to handle the required volume and pressure with minimum horsepower Need for special coatings or construction operating in corrosive atmospheres Ability of fan to accommodate total pressure while maintaining volume when small changes in the necessary air Need for an outlet damper to control airflow during cold starts (If necessary. volume) along the length of its characteristic curve. the point of rating can only be at the point at which the system resistance curve intersects the fan characteristic curve. the actual selection of fan size and speed is usually made from a rating table published by the fan manufacturer. sleeve bearings are suitable to 2500 l?. and it shows the complete range of capacities for a particular size of fan. 0 0 For a given pressure. when the fan is installed in a dust collection system.96 Dust Control Handbook Noise levels Operating temperature (For example. Points to Note: 0 The multirating table shows the range of pressures and speeds possible within the limits of the fan’s construction. the damper may be interlocked with the fan for a gradual start until steady-state conditions are reached. ball bearings to 5500 F. A particular fan may be available construction classes (identified through IV) relating to its capabilities in different as class I and limits. the highest mechanical efficiency is usually found in the middle third of the volume column. However.) Fan Rating Tables After the above information is collected. A fan operating at a given speed can have an infinite number of ratings (pressure and.

Check that the fan impeller is rotating in the proper direction-clockwise or counterclockwise. such as an elbow. Check for proper belt tension. No k. For example. or trapped. considered when installing the fan: Avoid installation of elbows or bends at the fan discharge.50 to 0. pressure loss. field installation creates airflow problems that reduce the The following points should be fan’s air delivery. the equation for brake horsepower. blade setting. for a 20% increase in exhaust volume in a system with 5 in.) 0 Pan ratings for volume and static pressure.65 for most centrifugal fans. or the system resistance. as described in the multirating tables.Collecting and Disposing of Dust 97 0 In a given system. For belt-driven fansLou . For a given system. and inside of housing for buildup of dirt. This rating can be changed only by changing the fan speed.foreign matter.ss Typical Fan Discharge Conditions . which will lower fan performance by increasing the system’s resistance. are based on the tests conducted under ideal conditions. For rapid estimates of probable exhaust volumes available for a given motor size. an increase in exhaust volume will result in increases in static and total pressures. or square duct. ft3/min total pressure. can be useful. mitred elbow. the new pressure loss will be 5 x (1. inches of water mechanical efficiency of fan (Operating points will be 0. impeller blades. Often. Avoid installing fittings that may cause nonuniform flow. obstructions.2 in.2012 = 7. Check the passages between inlets.05VP Lou = IVP Fan Installation LOSS = 1VP Check that the motor sheave and fan sheave are aligned properly. as illustrated. Brake Horsepower Equation bhp = cfm x TP 6356 x ME of fan 0 where: cfm TP ME = = = air volume. a fan at a fixed speed or at a fixed blade setting can have a single rating only.

are also generaland are motor is Wound-Rotor Motors - These motors known as slip-ring motors. but they are not airtight. . only integral-horsepower motors are discussed here. 0 and are These motors have a of a nonsynchronous. alternating-current motors and are. systems require motors with more than 1 hp. they should not be used where the air contains substances that might be harmful to the interior of the motor.98 Dust Control Handbook Electric Motors Electric motors are used to supply the necessary energy to drive the fan. Types of Motors The two most common types of integral-horsepower motors used in dust collection systems arel Squirrel-Cage Motors - constant speed induction type. alternating-current motors. These enclosures prevent free exchange of air between the inside and the outside. Fractionalhorsepower electric motors are normally single-phase. however.used when less Since most dust collection than 1 hp is required. Squirrel-cage and wound-rotor motors are further classified according to the type of enclosure they use to protect their interior windings. They are purpose or continuous-rated motors chiefly used when an adjustable-speed desired. They are normally classified in two groups: 0 Integrals Fractionals 0 electric motors are normally Integral-horsepower three-phase. These enclosures fall into two broad categories: 0 Open Totally enclosed 0 Dripproof and splash-proof motors are open motors. Totally enclosed motors are weather-protected with the windings enclosed. They provide varying degrees of protection.

440 volts). another kind of totally enclosed motor. but within the protective shield. temperature. These motors are the most commonly used motors in dust collection systems.e. They have an integral-cooling fan outside the enclosure. and frequency Environmental conditions under which motor would be operated (for example. such as line voltage (110. single-phase or three-phase alternating current. When selecting considered: a motor. the fan and drive elements) and power company restrictions on starting current Necessary overload protection Ability starts to supply adequate for the motor power under %olb’ . Both open and totally-enclosed motors are available in explosion-proof and dust-ignition-proof models to protect against explosion and fire in hazardous environments. 220. or open flames) Characteristics of the load (i. corrosive atmospheres.equired brake minute Characteristics of power supply. that directs air over the enclosure. humidity.Collecting and Disposing of Dust 99 fan-cooled (TEFC) motors are Totally enclosed. the following points should be horsepower and revolutions per Selection of Motor R..

Fan Troubleshooting Symptom Insufficient ftz/min airflow. or other obstructions near fan outlet . if possible Install turning vanes in elbow Redesign turning vanes Remove all obstructions Obstruction near fan outlet Sharp elbows near fan outlet Improperly designed turning vanes Projections. low Fan Probable Cause Chart Solution 5 Forward curved impeller installed backwards Fan running backwards Impeller not centered with inlet collar(s) Fan speed too low Elbows or other obstructions restricting airflow No . dampers. where possible Increase fan speed to overcome this pressure loss Remove obstruction or redesign ductwork near fan outlet Install a long radius elbow.straight duct at fan inlet Reinstall impeller Change fan rotation by reversing two of the three leads on the motor Make impeller and inlet collar(s) concentric yncrease fan speed by installing smaller diameter pulley Redesign ductwork Install turning vanes in elbow Remove obstructions in ductwork Install straight length of ductwork. at least 4 to 6 duct diameters long.

high fG/min Fan l Backward inclined impeller installed backwards (high horsepower) Fan speed too fast Install impeller as recommended by manufacturer Reduce fan speed Install larger diameter.Symptom Duct System l Probable Cause Solution Actual system more restrictive (more resistant to flow) than expected Dampers closed Leaks in supply ducts Decrease system’s resistance redesigning ductwork by l Open or adjust all dampers according to the design Repair all leaks in supply duct l Too much airflow. pulley on fan l Duct System l Oversized ductwork. high ftS/min Fan l Backward inclined impeller installed backwards (high horsepower) Fan speed too high Install impeller as recommended by manufacturer Reduce fan speed Install larger diameter pulley on fan l Duct System l System has less resistance than expected to flow l Reduce fan speed to obtain desired flow rate . less resistance Access door open Redesign ductwork or add restrictions to increase resistance Close all access and inspection doors l Low static pressure.

& Symptom Gas Density l Probable Cause Solution 3 Gas density lower than anticipated (due to high temperature gases or high altitudes) 0 Calculate gas flow rate at desired operating conditions by applying appropriate correction factors for high temperature or altitude conditions Low static pressure. low ftzlmin Duct System l Fan inlet and/or outlet conditions not same as tested 0 0 0 Increase fan speed Install smaller diameter pulley on fan Redesign ductwork Hi h static pressure. low ft f /min Duct System l l Obstructions in system l 0 0 Remove obstructions Redesign ductwork Install larger diameter ducts Duct system too restricted High horsepower 0 Backward inclined impeller installed backwards Fan speed too high l Install impeller as recommended by manufacturer Reduce fan speed Install larger diameter pulley on fan l l l Duct System l l Oversized ductwork Access door open l l Redesign ductwork Close all access/inspection doors .

. which will open gradually until fan comes to its operating speed Fan Selection l Fan not operating at efficient of rating point Redesign system Change fan Change motor Consult fan manufacturer Fan does not operate Electrical l l Blown fuses Electricity turned off Replace blown fuses Turn on electricity Check for proper voltage on fan Change motor to a larger size 0 Wrong voltage l Motor too small and overload protector has broken circuit Mechanical Broken belts Loose pulleys Impeller touching scroll l l l Replace belts Tighten or reinstall pulleys Reinstall impeller properly .Symptom Gas Density l Probable Cause Solution Calculated horsepower requirements based on light gas (e.. high temperature or high altitude) but actual gas is heavy (e.g.g. cold startup) Replace motor Install outlet damper.

If the material in the hopper has a bridging tendency. rappers. for wet dust collectors. or air jets should be used. Removing collector dust from dust can be accomplished the hopper of the dust Conveying the dust Storing the dust Treating the dust for final disposal Removing Dust from Hopper Collected dust must be removed from the hopper to prevent recirculation within the dust collector. dust can be returned to the product stream and sold. the collected dust must be disposed of properly. disposal of dust may become a problem.104 Dust Control Handbook Disposal of Collected Dust After dust-laden exhaust gases are cleaned. Conveying the Dust After the dust has been removed from the collector. Ideally. rotary air locks or tipping valves should be used to maintain a positive air seal. it must be transported to a central point for. equipment such as bin vibrators. 2. secondary dust problems may arise during unloading and disposal of collected dust. Since the material must be removed continuously (while the dust collector is operating). the disposal of wet slurry or sludge can be a problem. Proper disposal of collected in four steps: 1. when dry dust collectors are used. Conveying of dust can be accomplished by the following methods: l l Use of screw conveyors Use of air conveyors (pneumatic conveying) Use of air conveying) slides (low-pressure pneumatic 0 0 Use of pumps and piping systems to convey slurry Screw conveyors have been used with a great deal of success. trouble areas to be considered are . For example. However. if this is not possible. 4. 3. accumulation and ultimate disposal.

low-air-volume principle. Also. care must be taken in this method to prevent water-pollution. light dust. They operate on a high-velocity.Collecting and Disposing of Dust 105 maintenance access. Pneumatic conveyors are often selected to convey dry dust because they have few moving parts and can convey either horizontally or vertically. For wet dust collectors. a storage facility must be used to permit disposal in efficient quantities. Trouble areas include excessive wear and abrasion in the piping and high capital and operating costs. most collected materials have very fine components that may seal the pond and prevent percolation. Pumps and piping systems are used to convey the slurry to a settling pond. two settling ponds are usually needed. Por wet dust collectors. They work on the principle of air fluidization of dust particles and are useful for heavy horizontal conveying. However. Air slides are commonly used for nonabrasive. the disposal of fine dust requires great care to prevent recirculation by the wind. Elevated storage tanks or silos are normally used to permit loading of dry dust into enclosed trucks underneath. decanted and dried out during the dry season. inclined conveyors can be used to convey the slurry to a settling pond. After the material has been removed and transported from the dust collector. worn-out bearings and casings due to abrasive materials. and air leaks. the accumulation area is a settling pond. A settling pond may require considerSince the storage area can only be able space. Trouble areas include ability to maintain a certain downward slope and greater maintenance requirements. Storingthe Dust In most cases. Several final dust disposal methods commonly used are0 Treating the Dust for FinalDisposal Landfilling Recycling Pelletizing Byproduct utilization Backfilling mines and quarries 0 0 0 0 .

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