PROJECT REPORT PHARMACEUTICAL DUST EXTRACTOR(PDE)

Presented By: (Students Name) PRATIK PANCHAL KETAN PANCHAL (Semester) 8th 8th (Permanent Roll No.) 06ME26 06ME25

Guided By: Prof. DHAVAL. M. PATEL DEPARTMENT OF MECHANICAL ENGG. U. V. PATEL COLLEGE OF ENGINEERING, GANPAT UNIVERSITY, GANPAT VIDYANAGAR, KHERVA-382 711, DIST. MEHSANA

CERTIFICATE
THIS TO CERTIFY THAT SHRI: PANCHAL KETAN B
ROLL NO. :06 ME 25 OF 8TH MECHANICAL CLASS HAS SATISFACTORILY COMPLETED THE PROJECT ON PHARMACEUTICAL DUST EXTRACTOR WITHIN FOUR WALLS OF U.V.PATEL COLLEGE OF ENGINEERING,KHERVA.

SIGN :

DATE:

CERTIFICATE
THIS TO CERTIFY THAT
SHRI: PANCHAL PRATIK H ROLL NO. :06 ME 26 OF 8TH MECHANICAL CLASS HAS SATISFACTORILY COMPLETED THE PROJECT ON PHARMACEUTICAL DUST EXTRACTOR WITHIN FOUR WALLS OF U.V.PATEL COLLEGE OF ENGINEERING,KHERVA.

SIGN:

DATE :

ABSTRACT
The trend among pharmaceutical companies to develop selective drugs of high potency has pushed the industry to consider the potential of each hazardous ingredient to become airborne.Dustiness issues are not unique to the pharmaceutical industry, but are relevant to any industry where powdered materials are mixed, transferred and handled. Interest in dustiness is also driven by concerns for worker health, the potential for plant explosions and the prevention of product loss. Unlike other industries, the pharmaceutical industry is limited by the milligram quantity of powdered material available for testing during product development. These needs have led to the development of a bench-top dustiness tester that requires only 10 mg of powder and fully contains the generated aerosol. The powder is dispersed within a 5.7 liter glass chamber that contains a respirable mass sampler and a closed-face sampler to quantify the respirable and total dust that are generated with a given energy input. The tester distinguished differences in dustiness levels of five different powders. Finer powders were dustier, and the respirable dust percentage was always less than that for total dust. Four testers have been built and evaluated using pharmaceutical grade lactose. Dustiness measurements determined using all four testers were comparable. The pharmaceutical industry uses surrogates such as lactose to represent active compounds in tests that estimate the dust concentration likely to occur in a new manufacturing operation. Differences between the dustiness of the active compound and its surrogate challenge the relevance of the surrogate tests to represent true exposures in the workplace. The tester can determine the dustiness of both the active compound and its surrogate, and the resultant ratio can help to interpret dust concentrations from surrogate tests. Further, dustiness information may allow the pharmaceutical researcher to select powder formulations that present low airborne concentrations in the workplace

INDEX
SR NO. Abstract List Of Figure List Of Table Executive Summery 1 1.1 2 3 4 5 6 7 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 10 Introduction Concept Of Dust Collector Objectives Of Dust collection Working Principle Scope Of Project Salient Features Types Of PDE Main Parts Of PDE Function Of Main Parts Of PDE Intake Manifold Dust Collecting Hopper Rotor & Motor Blower Filtration Bag Stapper Caster wheel Technical specification CONTENTS PAGE NO. iv vii viii 9 10 10 11 11 11 12 13 15 16 16 16 16 17 17 17 17 18

11 11.1 12 12.1 12.2 12.3 13 14 15 16 17 18

Design Description Rotor Specification Calculation Suction Capacity Filtration Area Dust Storage Capacity Choice Of Dust Collector Application Advantages Limits Conclusion References

19 19 25 26 26 26 27 28 29 29 29 30

LIST OF FIGURE
SR NO. 6.1 6.2 7.1 8.1 8.4 11.1 11.2 11.3 11.4 11.5 NAME OF FIGURE Vertical Blower PDE Horizontal Blower PDE Overview of PDE Intake Manifold Filtration Bag Rotor Filtration Plate Storage Drawer Blower Body Of PDE PAGE NO 12 13 14 15 16 19 20 21 22 23

LIST OF TABLE
SR NO 2.1 9.1 9.2 13.1 NAME OF TABLE Objectives of Dust Collector Recommended Spares for 300 CFM Dust Collector Recommended Spares for 150 CFM Dust Collector Factors affecting on choice of Dust Collector PAGE NO. 11 18 18 27

EXECUTIVE SUMMERY
Dust extraction system is used for many industries like as: Asphalt industry The dust-bearing exhaust gases are fed into the dust collector at a temperature of 100 170. The separation of coarser particles is carried out in a pre-separator (separation > 90m) and a skimmer (separation > 63m). The exhaust gases enter the filters crude gas chamber from above via the crude gas hood and then flow through the filter bags into the clean gas chamber. The achieved residual dust content lies well below the prescribed limiting value. The separated dust (sand and fine fillers) is fed back into the mixing process by discharge elements and screw conveyors. A main radial fan blows the purified gases out into the atmosphere via a chimney stack. Cement industry
Cement manufacturing, handling,storage and distribution involve processes that require dust control.

Quarry and minerals industry

Dantherm has long experience in providing centralised dust extraction installarions and individual units for mineral handling and processing, from aggregates to clay preparation for brick and ceramics manufacture. Tough reverse jet and reverse air filter units, with generous pre-separation sections and hard grade ducting can handle heavy abrasive dust loads efficiently and with minimal maintenance requirements. Crushing, screeniing, conveying, storage and outloading may be handled by a single centralised dust extraction plant if required.

Pharmaceutical industry
Pharmaceutical dust extractor machine is extremely useful in controlling the dust generated during the compression of tablets. These equipments are used to remove excess powder from compressed tablets. These Dust Extractor Machine is not only ensure a dust free end product for use but also health and safety of people coming in contact with pharmaceutical processing machines. Extracting hazardous dust at the point of origination and conveying them to the correctly designed filtration system is necessary to protect both personnel as well as the plant. These Dust Extractor Machine successfully capture dust with the air stream and convey it to the dust collector.

1. Introduction Pharmaceutical dust extractor is a machine collecting dust(powder) which is explosed by tablet press machine. Dust extractor vary widely in design, operation, effectiveness, space

requirements, construction, and capital, operating, and maintenance costs. Each type has advantages and disadvantages. Dust collection technology is taken lightly by the production or maintenance engineers of a manufacturing plant and they try to fabricate a simplistic collector, which, unfortunately, never works. It is not uncommon for us to deal with such customers who have either tried their own hands or have taken the services of a back-yard fabricator for this purpose and have burnt their fingers. A poorly designed/manufactured dust collector might cost less to begin with, but it might cost a lot over a short/medium term and may achieve absolutely nothing. Manufacturer, supplier and exporter of Pharma Machines including dust extractor machine for collecting loose powder or dust from the polishing chamber. Our dust extractor unit is used to control the flying dust that is automatically generated during the compression of tablets. It is also used for various stages of cleaning operations when coupled with tabletting machine and automatic capsule filling machine. Controlling dust hazards and cross contamination at tablet compression, reducing mechanical strain and balanced air blowing system are some of the ideal features of our dust extraction machine. 1.1 Concept of dust Collector
In simple words - A suction hood is placed near the source point. This suction hood is connected to the dust collector which sucks in air and the dust comes along with it. This dust is separated from the carrier air and the clean air is allowed to escape, either within the premises or

outside.

10

2. Objectives of Dust Collection There can be several objectives of collecting dust, some of the important reasons can be following: Protection of the operator Protection of the production equipment from the dust Protection of the job from the effects of dust Protection of quality of environment in a premises Recovery of the expensive materials
Table2.1-Objectives of Dust Collection

3. Working Principle Pharmaceutical dust extractor machine is extremely useful in controlling the dust generated during the compression of tablets. These equipments are used to remove excess powder from compressed tablets. These Dust Extractor Machine is not only ensure a dust free end product for use but also health and safety of people coming in contact with pharmaceutical processing machines. Extracting hazardous dust at the point of origination and conveying them to the correctly designed filtration system is necessary to protect both personnel as well as the plant. These Dust Extractor Machine successfully capture dust with the air stream and convey it to the dust collector. 4. Scope of Project Design and fabrication of PDE. Selection & Implementation of major components Motor, Rotor, Blower, etc Integration of all other engineering details

11

5. Salient Features Dust Extractor Machine is provided with stainless steel 304/ 316 contact parts In this Dust Extractor Machine, Blower fan is dynamically balanced and the unit is with castor wheels. Overcome dust hazards as well as cross contamination at tablet compression. Minimizes mechanical strain, excessive wear of tableting machine-resulting in minimum machine break-downs and punch wears. All inlet manifolds and dust collection tray are of S.S. Four inlet manifolds facilitate to connect Tablet Machine and the De-dusting units. Machine in fitted with the castor wheels for easy mobility.

12

6. Types of PDE

Fig 6.1- Vertical Blower PDE

13

Fig 6.2-Horizontal Blower PDE

14

7. Main Parts of PDE Manifold Dust collecting hopper Filtration bag Rotor & Motor Blower Stapper Caster Wheel

Fig 7.1-Overview of PDE

15

8. Function of main parts of PDE 8.1 Intake manifold

Fig 8.1-Intke Manifold

Intake manifold is the main part of the PDE. Normally in the PDE there are four no. of manifold are used. For that two big flexible pipes are used. One end of the both pipes is attached to the both of the intake manifold and the other end is attached to the tablet press where we have to suck the dust powder. 8.2 Dust collecting hopper Dust collecting hopper is used to collect the dust which is sucking by the blower also collect the small dust which is stappered by stapper through the filtration bag.Dust storage capacity of the Dust collecting Hopper is about 0.0040 m3. 8.3 Rotor & Motor Roter is heart part of pharmaceutical dust extractor, by rotating rotor at high speed the air is sucked,the roter is provided with 12 number of blade each having angle of 20

degree.the inner & outer diameter of roter are 120mm &210mm respectively .moter is used having power of 0.5hp & 2800rpm. 8.4 Blower Blower is used for the suction purpose. The main function of the blower is to suck the dust powder from the tablet press through the intake manifold. Blower is designed according to required suction capacity.For this project the suction capacity of the blower is 240 CFM(cubic feet per minute) or 7.178 m3/m.

16

8.5 Filtration Bag

Fig 8.4-Filtration Bag

Filtration bag is used to filter the big dust particle of the powder. Some of the small Dust particle is stick with the filtration bag and there after with the help of stapper all the particle which is sticked to the filtration bag is collecting at the dost collecting hopper. 8.6 Stapper Stapper is used to collect the remaining small particle of the dust powder. Stapper is shake off the all small dust particle which is sticked on the filtration bag and collect it to the dust collecting hopper. 8.7 Castor Wheel Castor Wheel is provided at the bottom of the machine to make the machine movable.with help of caster wheel machine is easly trantsport by dragging,without lifting machine.

17

9. General Specification RECOMMENDED SPARES FOR 300 CFM DUST EXTRACTOR MODEL 300 CFM STD/GMP
SR NO PART NO MS MB NAME OF THE PART 1 2 3 4 5 * X-9/7 * B B B B B POLYPROPYLENE BAG TENSION SPRING U" RIBBON - 1/4" 3MTR 3/8" THREAD BACKLITE KNOBS ELE.OVER LOAD RELAY 2.5 TO 4 Table-9.1 * Minimum Spares to be kept in stock REQ. QTY 4 4 1 6 1

RECOMMENDED SPARES FOR 150 CFM DUST EXTRACTOR MODEL 150 CFM STD/GMP
SR NO PART NO MS MB NAME OF THE PART 1 2 3 4 5 * X-9/7 * B POLYPROPYLENE BAG B TENSION SPRING B U" RIBBON - 1/4" 2MTR B 1/4" THREAD BACKLITE KNOBS B ELE.OVER LOAD RELAY 2.5 TO 4 Table-9.2 * Minimum Spares to be kept in stock REQ. QTY 4 4 1 6 1

18

10. Technical Specification Suction Capacity ( 430.69 m3/ hr.) Filtration Area (0.4396 m2) Dust Storage Capacity (0.0043 m3) Inlet Connection 1 Nos. of Dia (38.1mm) Power 0.5 HP / 2800 RPM / 3 Phase / 440 V / 50 Hz Overall Dimensions 315 (L) X 315 (W) X 450 (H) (in mm) 11. Design Description 11.1 Rotor Specification Inlet Diameter(D1)=120 mm Outlet Diameter (D2)=200 mm Speed of Rotor(N)=2800 rpm Velocity of vanes=u1(m/s) Velocity of air=V(m/s) Vane angle( )=20 degree Width of vane(B)=50 mm

19

Fig 11.1-Rotor

20

Fig 11.2-Filtration Plate

21

Fig 11.3-Storage Drawer(Dust Collecting Hopper)

22

Fig 11.4-Blower

23

Fig 11.5-Body of the PDE

24

12. Calculation 12.1 Suction Capacity(Q) =

D1N

60 Velocity of vanes(u1) = 0.120 2800 60

u1 =17.58 m/s

Now

=20
Velocity of air(V) = u1tan V =17.58 tan =17.58*tan20 V=6.39 m/s Now

Q = v D1 B =3.14*6.39*0.120*0.05
=430.69 m3/hr =7.178 m3/m Q=240 CFM

12.2 Filtration Area Dia of Filter Hole=100 mm Length of Filter bag=350 mm n=No. of hole Filtration Area= Dl n =3.14*0.100*0.350*4 =0.4396 m2 12.3 Dust Storage Capacity Cs=Length(l)*Width(w)*Height(h) =285mm*275mm =4310625 mm3

25

13. Choice of a Dust Collector

Dust collectors vary widely in design, operation, effectiveness, space requirements, construction, and capital, operating, and maintenance costs. Each type has advantages and disadvantages. However, the selection of a dust collector should be based on the following general factors: Dust concentration and particle size - For minerals processing operations, the dust concentration can range from 0.1 to 5.0 grains (0.32 g) of dust per cubic feet of air (0.23 to 11.44 grams per standard cubic meter), and the particle size can vary from 0.5 to 100 m. Degree of dust collection required - The degree of dust collection required depends on its potential as a health hazard or public nuisance, the plant location, the allowable emission rate, the nature of the dust, its salvage value, and so forth. The selection of a collector should be based on the efficiency required and should consider the need for highefficiency, high-cost equipment, such as electrostatic precipitators; high-efficiency, moderate-cost equipment, such as baghouses or wet scrubbers; or lower cost, primary units, such as dry centrifugal collectors. Characteristics of airstream - The characteristics of the airstream can have a significant impact on collector selection. For example, cotton fabric filters cannot be used where air temperatures exceed 180 F (82C). Also, condensation of steam or water vapor can blind bags. Various chemicals can attach fabric or metal and cause corrosion in wet scrubbers. Characteristics of dust - Moderate to heavy concentrations of many dusts (such as dust from silica sand or metal ores) can be abrasive to dry centrifugal collectors. Hygroscopic material can blind bag collectors. Sticky material can adhere to collector elements and plug passages. Some particle sizes and shapes may rule out certain types of fabric collectors. The combustible nature of many fine materials rules out the use of electrostatic precipitators. Methods of disposal - Methods of dust removal and disposal vary with the material, plant process, volume, and type of collector used. Collectors can unload continuously or in batches. Dry materials can create secondary dust problems during unloading and disposal that do not occur with wet collectors. Disposal of wet slurry or sludge can be an 26

additional material-handling problem; sewer or water pollution problems can result if wastewater is not treated properly.
The choice of the dust collector has to be made on the basis of following factors:

a. The process or the activity from where the dust is being generated b. The type of material being process, e.g. steel, graphite, plastic, rubber, etc. c. Nature of the dust being generated - its particle size population, temperature, shape of the particles, and other properties; like whether it is hygroscopic, toxic, inflammable, free-flowing or sticky, etc. d. Quantum of dust : The peak quantity of dust generated per minute e. Location of the dust collector with respect to the production equipment f. Whether a suction hood is already installed, and, if not, what are the parameters which are going to affect the design of the suction hood, like size of the source point, no. of source points, other working/moving components in the vicinity of the job, loading/unloading of the job, etc. g. What kind of dust disposal system will meet the requirements of the system - whether a batch disposal or continuous disposal will be required.
Table-13.1

27

14. Application:

To Remove powder from tableting machine. To remove sticked powder from tablet in de-dust machine. To remove powder from multi-mill machine. At the out put of the granulator. Similar concept is also utilized in Asphalt industry This concept is used even in Quarry and minerals industry,cement industy.

28

15. Advantages

Modular design provides optimum field flexibility and short manufacturing lead time - have it your way fast Heavy duty carbon steel construction for long life. Due to the filtration bag small Dust also can be collect Available in standard unitary type models & custom based specially designed models for PDE All the units are designed & manufactured as per GEP & GMP Available in Single skin/Double skin & MS/SS construction.

16. Limits

Cant be use in heavy Duty application. Noise produced due to the rotor & motor.

17. Conclusion

It is the responsibility of the system designer to ensure that there are adequate air flows and velocities in the system and that the selection of duct components and fan equipment has been optimized

29

18. References Web Reference

www.wikipedia.org www.danthermfiltration.co.uk www.camfilfarrapc.com

www.farrapc.com

www.milkeninstitute.org www.techflow.net www.cm1981.in www.cadmech.in www.fluidpack.in www.nfsrps.com www.cimaindustries.com www.bapihvac.com

Books Reference

Fluid mechanics and Hydraulic Machines by R K Bansal.

30