Professional Documents
Culture Documents
BIOE7200 Project DesignanalysisofDustcollectionsystem
BIOE7200 Project DesignanalysisofDustcollectionsystem
net/publication/338541015
CITATIONS READS
3 45,902
1 author:
Zaman Bhuiyan
University of Manitoba
20 PUBLICATIONS 5 CITATIONS
SEE PROFILE
All content following this page was uploaded by Zaman Bhuiyan on 12 January 2020.
BIOE 7200
Zaman Bhuiyan
ST # 7820341
University of Manitoba
Abstract : Most of the manufacturing industry faces significant challenges in the control of dust
to ensure continued sustainable operation and to meet emissions regulations and goals. The
methods for controlling dust emissions can either lie in the prevention of dust emissions or in the
removal of dust once it has become airborne. Though the concept for dust collection system seems
simple, many things can go wrong if don’t pay careful attention to the design details. Dust control
systems involve multiple engineering decisions, including the efficient use of available space, the
length of duct runs, the ease of returning collected dust to the process, the necessary electrical
requirements, and the selection of optimal filter and control equipment. Further, key decisions
must be made about whether a centralized or multiple system are best for the circumstances.
Critical engineering decisions involve defining the problem, selecting the best equipment for each
job and designing the best dust collection system for the needs of an operation. Well-designed dust
collection systems need to consider not only the dust as a potential contaminant, but also the
attributes of the dust capturing system. There are four key components in a dust collection system
is very important like exhaust hood, ductwork, dust collector and the air mover/fan. This project
helps to understand as a design guide which provides information that will help to achieve
optimum performance and energy efficiency in commercial dust collection systems by properly
selecting and sizing of exhaust hoods, duct, dust collector and air blower or fan. A well-designed
dust collection system has multiple benefits resulting in a dust-free environment that increases
productivity, comply with emission regulations, and improve industry employee morale. This
paper also illustrates design analysis and best selection of a dust collection system for various kind
of manufacturing industry who are facing dust emission and unable to control as well as can also
Keywords : Dust collector, exhaust hood, duct work, air mover, fan, plugging, buildup & design.
1|Page
Introduction: Dust collection involves the removal or collection of solid particles from a flowing
air stream to eliminate nuisance dust for safety and health considerations. Even installing a dust
control system does not promise complete prevention of dust emission but a well-designed system
can protect and gets other benefits such as preventing or reducing the risk of a dust explosion or
fire, reducing the likelihood of accidents, reducing cleanup and maintenance costs, reducing
equipment wear and assuring continuous compliance with existing health regulations. Dust
collection systems use ventilation principles to capture the dust-filled airstream and carry it away from
the source through ductwork to the collector. The selection of a dust control system is based on the
desired air quality and existing regulations. Dust collection systems can provide reliable and efficient
control over a long period. The dust collection system also is known as the local exhaust ventilation
system is one of the most effective ways to reduce dust emissions (Bhuiyan and Khan 2012). A typical
• A fan and motor to provide the necessary exhaust volume and energy.
Fig.1 : Illustration of components for a dust collection system (Andrew et al. 2012)
2|Page
Every single component plays a vital role in the proper operation of a dust collection system and
poor performance of one component can reduce the effectiveness of the other components. So, it’s
required very careful design and selection of each component to get a perfect dust collection
system.
Methodology :
Design Consideration : Designing a proper dust collection system can be broken down into six
key considerations (Jenike and Johanson 2018). These six considerations are:
1) Conveying velocity.
4) Plugging.
Conveying velocity: Sufficient conveying velocity is very important to pick up the dust from the
pickup hoods and transport the material through dust collector for separation from the air stream.
If systems is not work properly & effectively convey the dust, then it’s not possible to collect the
dust particles, which are sticky, have high moisture content, are heavy or oddly shaped, or are very
fine can present conveying difficulties in the dust collection system (Jenike and Johanson 2018).
Balance by design There are two main approaches which are, the balance by design method and
the blast gate method. In the balance by design method, the duct size and layout are engineered to
balance the airflow in the system’s branches, pickups, and trunk based on static pressure loss
through each section. If each branch has a similar static pressure loss, then the airflow, and thus
velocity, through each branch will be equal. This method doesn’t use blast gates to manually adjust
3|Page
airflow at each branch, in contrast to the alternative balancing method. The balance by design
method is the preferred method to ensure adequate conveying velocity in each portion of the
system because the method uses more information to provide a more detailed approach to system
design. When using the balance by design method, the path of greatest airflow resistance is first
determined through a static pressure loss calculation. This can be done through basic engineering
calculations for airflow resistance through pickup hoods, ductwork branches, and trunk lines
Air Mover : The selection process of an air mover is simple once the system has been determined.
Generally, fan or positive movement rotary blower are typically used to provide the suction force
for the dust collection system. Performance curves of an air mover provides the operating ranges
which demonstrate the air mover under specified conditions such as system resistance air
Avoid plugging : Dust collection system plugging may causes by itself in many forms, such as in
the duct, hopper, or filter. The root causes of plugging in a system can be include, such as poor
duct layout, Overfeeding the dust collection line, Leaks, Buildup and Hopper design (Jenike and
Johanson 2018).
Dust collector : The dust collector performance can either make or break the entire dust collection
system. On one hand, a properly performing dust collector will efficiently filter the particles from
the airstream, clean itself, discharge the solids into a hopper, and allow proper airflow through its
filter media, thereby maintaining proper conveying velocities in the system and stable fan
operation. On the other hand, poor dust collector performance can allow particles to bypass
through the filter, clogging and plugging, and substantially reduced airflow, rendering dust pickup
4|Page
Combustible dust hazards: About 50% of dust explosions occur in dust collectors and its
estimates that at least 7 out of 10 dusts can be combustible. Many dusts can burn rapidly either in
a flash fire or explosion scenario (Andrew et al. 2012). A dust explosion requires five key
ingredients:
• Combustible dust (sugar, plastic, wood, metals, and most carbon-containing dusts)
oxidant.
.1 Design Fundamentals: Design fundamentals are related to basic concept of fluid flow and
how they may be applied to air pollution control and collection systems.
.1.1 The Bernoulli Equation : The flow of fluids in any hood, duct, pipe or other enclosure is
governed by a single relationship of the Bernoulli equation. Preferably, the Bernoulli equation
states that the total mechanical energy of an element of flowing fluid is constant throughout the
system (Vatavuk 1995). This includes its potential energy, kinetic energy, and pressure energy
Where v = specific volume of fluid (ft3/lbm), p = static pressure gauge (lbf/ft2), z = height of fluid
above some reference point (ft), u = fluid velocity through duct, hood, etc. (ft/sec), g = gravitational
fan, etc. (ft-lbf/lbm), F = energy lost due to friction (ft-lbf/lbm) (Vatavuk 1995).
5|Page
.1.2. Static, Velocity, and Total Pressure : Air traveling through a duct is acted on
simultaneously by two kinds of pressure, Static pressure (SP) and Velocity pressure(VP). Both
static pressure and velocity pressure are components of a third kind of pressure which is total
pressure and total pressure (TP) also known as the “impact pressure”, which will at any point
within a duct, hood, etc. TP = SP + VP ,Where, SP = (cf)vp and VP = (cf)u2/2gc . Static pressure
(SP) is a force that compresses or expands the air. It is used to overcome the frictional resistance
of ductwork, as well as the resistance of such obstructions as coils, filters, dust collectors, and
elbows. Velocity pressure (VP) is the pressure required to accelerate the air from rest to a velocity.
It exists only when air is in motion, always acts in the direction of air flow and is always positive
.2 Design of Exhaust Hoods : The design of an exhaust hood requires complete process or
operation so that the most effective hood or enclosure can be installed. The successful design of
an exhaust hood depends on the rate of air velocity, location of the hood and shape of the hood
(Hollenbeck 2015).
.2.1 Rate of Air velocity: Most of bulk solids will require significant air velocity in the
ductwork to convey the material in full suspension, usually an air velocity of about 4,000 fpm
(67ft/s or about 45 mph). In some cases, it may not only be dust that is conveyed, as a additional
material like fumes or vapors may be included in the material stream. As shown in Table 1 from
the American Conference of Governmental Industrial Hygienists (ACGIH), there are a wide range
of minimum duct design velocities, which are based on the material conditions. In Appendix B,
there are different types hood design & air flow rates are available (Andrew et al. 2012).
6|Page
Nature of
Examples Design Velocity
Contaminant
Any desired velocity (economic optimum
Vapors, gases, smoke All vapors, gases, and smoke
velocity usually 1000-2000 fpm)
Fumes Welding 2000-2500
Very fine light dust Cotton lint, wood flour, litho powder 2500-3000
Fine rubber dust, Bakelite molding powder dust,
Dry dusts & powders jute lint, cotton dust, shavings (light), soap dust, 3000-4000
leather shavings
Grinding dust, buffing lint (dry) wool jute dust
(shaker waste), coffee beans, shoe dust, granite
Average industrial dust, silica flour, general material handling, brick
3500-4000
dust cutting, clay dust, foundry (general), limestone
dust, packaging and weighing asbestos dust in
textile industries
Sawdust (heavy and wet), metal turnings, foundry
tumbling barrels and shake-out, sand blast dust,
Heavy dusts 4000-4500
wood blocks, hog waste, brass turnings, cast iron
boring dust, lead dust
Lead dusts with small chips, moist cement dust,
Heavy or moist asbestos chunks from transit pipe cutting 4500 and up (≈ 75 ft/s or 23 m/s )
machines, buffing lint (sticky) quick-lime dust
Table 1 : Range of minimum duct design velocities (Jenike and Johanson 2018)
There are two issues that need to be considered when determining the rate of airflow to a hood, air
Air induction is based on the concept that material falling through air imparts momentum to the
surrounding air .Due to this energy transfer, a stream of air always travels with the falling material.
For example, a chute feeding sand to an elevator will drag air into the elevator (Wang et al. 2014).
The following air induction equation can be used to estimate exhaust volumes for hoods based on
material feed rate, height of free fall, size, and feed open area:
where Q = air quantity, cubic feet per minute; AU = enclosure upstream open area, square feet;
R = rate of material flow, tons per hour; S = height of material fall, feet; and D = average material
source and then pull this dust into the exhaust hood. The capture velocity must be powerful enough
to overcome all the opposing factors and air currents in the surrounding area. After this capture
velocity is determined, the exhaust volume for the hood can be calculated. The following "Dalla
Valle" equation is used to determine the exhaust volume needed for a basic free-standing hood
where Q = the rate of air exhausted, cubic feet per minute; Vx = the required air velocity at the
most remote point of contaminant dispersion, feet per minute; X = distance in feet from the face
of the hood to the most remote point of contaminant dispersion; and Ah = the area of hood opening,
square feet.
.2.2 Shape of the Exhaust Hood : Sizable pressure losses may occur if the shape or the exhaust
hood is not designed properly. These pressure losses are due to the mutual conversion of static and
velocity pressures. When dust is captured and pulled into a hood from a dust source, the hood
converts static pressure to velocity pressure and hood entry losses (Zhao et al. 2013). Hood entry
8|Page
where He = hood entry loss, K = loss coefficient; VP = velocity pressure in the duct, and SPh =
absolute static pressure about 5 duct diameters down the duct from the hood (Zhao et al. 2013).
The hood entry loss coefficients for three different types of hoods commonly which listed
below in the Fig.3 . The first case shows three different hood types: circular, square, and rectangular
with plain openings. The second case shows loss coefficients with flanged openings, and the last case
shows a bell mouth inlet for just a circular duct. This figure demonstrates the significant improvement
in the design, and thus the lowering of the hood entry loss coefficient, with each improvement in the
hood type (Zhao et al. 2013). Appendix A & Appendix D provide more data about hood entry loss
coefficient.
Fig. 3: Hood entry loss coefficients for different hood types (Andrew et al. 2012)
9|Page
.2.3 Location of the Exhaust Hood : The location of the exhaust hood is important to achieving
the maximum dust capture efficiency at minimum exhaust volumes. When the control-velocity
approach is used, the location of the hood is critical because exhaust volume varies in relation to
the location and size of the exhaust hood. The location of the exhaust hood is not as critical when
the air-induction approach is used. The air-induction approach requires the hood to be located as
far from the material impact point as possible to-prevent capturing coarse dust particles, which
• Reduce unnecessary transport or coarse dust through ductwork and thus reduce dust
velocity approach requires the hood to be located as close to the source as possible to (Zhao et al.
2013)-
.3 Fan : are a critical feature in the design of ventilation systems for dust control. They are used
to move the air through the ventilation system, whether to create an exhausting or blowing
ventilation system. There are two basic types of fans, axial-flow fans and centrifugal fans. There
are also other fan designs that use or combine the concepts of axial or centrifugal flow; these are
axial-centrifugal fans and roof ventilators. Again, the selection of the fan type is based upon the
10 | P a g e
requirements of the ventilation system design. In Appendix G – there different types of duct design
Fig.5: Typical centrifugal fan (Andrew et al. 2012) Fig.6: Axial centrifugal fan (Andrew et al. 2012)
.4 Ductwork Design : Ductwork design includes the selection of duct sizes based on the velocity
necessary to carry the dust to the collector without settling in the duct. From this information, pressure
losses in the duct and exhaust air volumes can be calculated and used to determine the size and type of
11 | P a g e
fan, as well as the speed and size of motor (Jenike and Johanson 2018). Before detailed design of the
• Type, size, and speed of the bulk material handling or processing equipment used.
• Exhaust hood and exhaust volumes required for each piece of equipment, each transfer
• Each branch and section of the main duct identified either by number or letter.
• Provides proper air distribution in all branches to maintain designed capture velocities
• Minimizes pressure losses, wear, and abrasion of ductwork thus reducing operating costs
Also, the primary ductwork sizing variable are length, diameter, and wall thickness need to be
.4.1 Length: The length of ductwork needed with an air pollution control system depends on such
factors as the distance of the source from the control device and the number of directional changes
required. Without having specific knowledge of the source layout, it is impossible to determine
this length accurately. It could range from 20 to 2,000 feet or more (Vatavuk 1995).
.4.2 Diameter: Circular duct is preferred over rectangular, oval, or other duct shapes (Vatavuk
1995). For circular ducts, the cross-sectional area, Ad, is given by:
12 | P a g e
Where, Ad = cross-sectional area of duct (ft2), Dd = duct diameter (ft)
The duct cross-sectional area is the quotient of the volumetric flow rate (Q) and the duct transport
velocity (ut):
As Q is usually known, the key variable in above equation is the duct transport velocity. The value
of this variable must be chosen carefully. If the ut selected is too low, the duct will be oversized
and, more importantly, the velocity will not be high enough to convey any particulate matter in the
.4.3. Wall thickness: The wall thickness of a duct depends on several factors like internal
pressure, diameter, material of fabrication, and other structural parameters (Vatavuk 1995).
The root causes of plugging in a system can be happen for following reason & should be careful
.4.4 Poor duct layout : There are many instances where the conveying velocity was correctly
selected and the fan and motor operated as required, but the dust didn’t convey effectively through
the duct. This is generally the result of too many elbows being placed near one another in the
system and poor branch to-trunk layouts, as shown in Figures 7a and 7b. As demonstrated in
13 | P a g e
Fig.7-a)Poor duct layout with a 90-degree entry Fig.7-b)Buildup inside the duct
ACGIH, the branch entries to the trunk line, as well as throughout the duct layout, are important,
and 90-degree entries should be avoided (Jenike and Johanson 2018). In Fig. 8, various branch
entry layouts are shown, labeled with how acceptable each is from a sound design perspective.
Furthermore, the duct diameter should be expanding along its run to the dust collector to maintain
the minimum conveying velocity, a factor that’s changing with the cumulative airflow gain caused
by an increase.
Fig. 8: Duct entry layouts and configurations to avoid (Jenike and Johanson 2018)
14 | P a g e
Fig.9: Duct layout showing expansion in diameter along length (Jenike and Johanson 2018)
in pipe diameter. An example of this principle is shown in Fig. 9, where it’s appropriate branch
entries and an increasing duct diameter (Jenike and Johanson 2018). In Appendix E & Appendix F
there are more details in principle of duct design and elbows design and placement.
.4.5. Overfeeding the line: Overfeeding of a dust collection system can present problems because
the additional material in the conveyor airstream increases system resistance, which then reduces
airflow and velocity. Some designers will use a dust collection system as a part of a material
recycling loop, for which the system usually wasn’t originally designed to do. As a result, heavy
solids loading in the line, often erratically introduced to the system, degrades system performance.
If a feeder, such as a rotary airlock valve or screw feeder, can be used to modulate the solids
flowrate into the duct, then this can be a simple improvement to regulate the feed rate and prevent
.4.6. Leaks: Leaks in a dust collection system can “rob the system” of conveying energy and
cause material settlement and buildup (Fig.10) as well as the systems of dust collection
performance will degrade. Leaks can occur at duct or pipeline couplings, diverters, elbows where
holes have formed, blast gates, and in dust collector housings. Leaks can be tested via use of talcum
15 | P a g e
powder, helium tracing, or non combustible smoke around suspected leak points (Jenike and
Johanson 2018).
.4.7. Buildup: The slow growth or increase of dust inside duct is called build-up. The buildup
problem was a result of temperature-induced softening of the resin, allowing the material to fuse
to the pipeline’s interior. This created increased friction and reduced the pipeline’s diameter, which
both significantly increased the system’s resistance to air and solids throughput. Buildup in the
ductwork can be addressed by various methods, including periodic manual cleaning; “pigging,”
whereby a semirigid projectile with flexible ribs and brushes is sent through the ductwork or dry
ice chips are used, where the scouring action cleans the duct and the dry ice evaporates, leaving
no trace. At a minimum, the ducts should be inspected quarterly to ensure buildup isn’t affecting
the system performance or leaving residual combustible dust or other solids that can allow dust
.4.8. Hopper design: An often-overlooked issue with dust collection system operation is the
plugging of the collected material in the hopper attached to the filter-receiver. The following are
possible problems that can arise when material builds up (Industrial Ventilation Manual 1998):
16 | P a g e
.4.8.1 Bridging: A no-flow condition in which material forms a stable, arch-shaped obstruction
.5 Dust collector : There are many types of dust collectors, including cyclones, baghouses, and
cartridge collectors. A cyclone, as shown in Fig.11, uses inertial effects to separate the solids from
the airstream, while a baghouse, shown in Fig.12, and a cartridge collector, as shown in Fig.13,
use some form of physical filter media, like cloth, synthetic fabrics, or even sintered metal to
capture the dust or solids; filter media is then cleaned by various methods, with filter replacement
Fig.11: Cyclone dust collector (Jenike and Johanson 2018) Fig. 12: Baghouse dust collector (Jenike and
Johanson 2018)
17 | P a g e
Fig.13: Cartridge collector with dust filter canisters (Jenike and Johanson 2018).
A cyclone dust collector is highly effective for separating large particles such as wood chips and
can be useful with separating streams with hot and abrasive bulk solids because there are no
moving parts or filters to damage but using of cyclones are limited to separate the fine particles;
for example, using a cyclone for an air-dust mixture with a 5-micron average particle size may not
be highly practical because the particles are too light, making centrifugal forces ineffective to
separate the particles from the airflow. In Contrast, a baghouse or cartridge collector with a
physical filter media where collection efficiencies can approach 99.99% with some technologies
18 | P a g e
There are many factors to need to be consider before selecting the dust collector , like -
temperature, moisture, particle size, airstream chemistry, air-to-cloth ratio, combustibility, particle
abrasiveness, and mechanical factors (for example cleaning and installation). In the above Table 2
provides a simple summary of filter media types considering many factors (Jenike and Johanson
2018). In Appendix C- there are different types dry dust collector for more understanding.
Baghouses and cartridge collectors must have enough filter area to clean the dust-laden air.
An important parameter for determining the size of the dust collector is called the air-to-cloth ratio,
which uses the collector’s air volume flow-rate (cfm or m3/min) per filtration area (square feet or
.6 Combustible dust hazards : Excellent guidance are available in NFPA standards to prevent
and protect against the combustible dust hazards. It’s recommended to review the NFPA standard
on the Fundamentals of Combustible Dust and then industry and design-specific NFPA standards,
including NFPA 664 (wood); NFPA 61 (food and agriculture); NFPA 484 (metals); and NFPA 68
(explosion venting). Note that NFPA standards are adopted by OSHA as consensus standards and
can be mandated by an authority having jurisdiction (AHJ), such as a plant owner, insurance
provider, fire chief, or building inspector. There are many methods to protect equipment and
process through explosion containment, isolation, suppression, and venting. NFPA 69 provides
Conclusion & Recommendations : Dust collection system functions best within an overall air
quality control strategy that may include many other components. Since dust collection systems
themselves consist of multiple parts that can vary widely, they tend to be more prone to
19 | P a g e
customization and upgrading than other industrial apparatuses. Therefore, when considering dust
1. What type of dust will remove by this system ? The type of dust collector and filtration
media required largely depends on the type of substance being removed. Example,
synthetic cellulose filters work best for removing dry dust. “Spun-bond” filters,
2. How much dust can this system remove, and how fast can it remove it? An effective
dust collector needs to move sizable amounts of air at reasonably fast rates. Air velocity
is usually measured in feet per minute (fpm) while air volume is usually measured in
3. Different dust sources (i.e. different machines) usually have published, minimum cfm
requirements for effective dust removal.(For example, the most powerful woodworking
tools require dust collection systems with 1000-cfm capabilities to effectively remove
wood chips.)
4. Factors such as duct size and static pressure affect a dust collector’s moving
capabilities. (Static pressure refers to the surface or directional friction that moving air
requirements of dust sources before investing in dust collection systems (Buczaj and
Buczaj 2012).
5. Will a central or portable dust collection system work best? Central dust collection
systems work best then require a great amount of vacuum power to clean contaminated
air in environment as well as require an out of the way location to conserve valuable
20 | P a g e
central space and if portable dust collection systems work best then need to prioritize
affordability and simplicity over power requirements (Kleinman and Marley 2005).
6. How many escape/weak points does this dust collection system possess? Because of
their multifaceted nature, even the best dust collection systems cannot always perform
at 100% efficiency. In such cases, it may be worth installing a secondary auxiliary dust
collection system.
7. Does it require to recirculate the air back inside? Recirculating air through dust
regulations can make it cumbersome and costly to emit contaminated air outside a work
environment and into the atmosphere. By recirculating air back inside work
References:
Andrew, C., O. Andrew, S. Joseph, and C. Jay F. 2012. Dust Control Handbook for Industrial
Bhuiyan, M. Y., and A. I. Khan. 2012. Analysis of design and purchase decision of central dust
Buczaj, M., and A. Buczaj. 2012. The use of labview environment for the building of the grain
21 | P a g e
Hollenbeck, P. 2015. The a-curve position from an aaberg exhaust hood. Ventilation 2015 -
Industrial Ventilation Manual. 1998. ACGIH: Industrial Ventilation Manual. Vol. 552.
Jenike, E. M., and Johanson. 2018. SIX KEY CONSIDERATIONS FOR PROPER DUST
Johnson, G. 2008. Designing your dust system collection to meet NFPA Standards- Part 1. PBE.
Kleinman, J., and D. Marley. 2005. Savings estimates for dust collection system controls:
Strategies used and lessons learned. Proceedings ACEEE Summer Study on Energy
Pansare, S., S. Pokharkar, K. Pawar, T. Khandve, and S. Patil. 2016. Review on Multicyclone
Vatavuk, W. M. 1995. Generic Equipment and Devices Chapter 1 Hoods , Ductwork and Stacks.
Book.
Wang, Y., Y. Yang, Y. Wei, J. Liu, and Y. Li. 2014. Experimental investigation on the flow
89–99. doi:10.1080/14733315.2014.11684039.
Zhao, Y., A. Li, P. Tao, and R. Gao. 2013. The impact of various hood shapes, and side panel
and exhaust duct arrangements, on the performance of typical Chinese style cooking hoods.
22 | P a g e
Appendix A : Hood Entry losses
23 | P a g e
Appendix B : Hood types and Air flow rate
24 | P a g e
Appendix C : Dry type dust collectors
25 | P a g e
Appendix D : Hood entry loss Coefficient
26 | P a g e
Appendix E : Principles of Duct Design Elbows
27 | P a g e
Appendix F : Principle of Duct Design
28 | P a g e
Appendix G : Principle of Duct design Fan inlets
29 | P a g e