Industrial working environments that produce harmful dust particles and fumes that can pollute the air are required to have a dust collection system to ensure that the air quality is maintained at safe levels, protecting the health and safety of workers and the environment.
Unlike other types of dust control equipment like industrial vacuums and portable dust collectors that target specific areas of dust generation, a dust collection system is designed to cover an entire facility by filtering out large volumes of dust that can linger in the workspace atmosphere.
Understanding how each different type of dust collection system works can help industrial operations find the best solution to meeting the dust management requirements of their specific facility and activity.
There are four main types of dust collection systems:
Cartridge Dust Collectors
Suitable for general-purpose industrial dust removal, cartridge dust collectors make use of a series of pleated cartridges to filter out dust pollutants from the air. As air is pushed through the cartridge filters, carried dust and fume particles that are unable to pass through the filter become trapped on the surface, allowing the air the passes through to be cleaner and free of pollutants.
The fabric of the pleated cartridges is typically made from a composite of polyester and cellulose material and may feature nanofiber coating to aid in the release of trapped dust during cleaning. Cleaning of the cartridge filters will be necessary over time as more dust accumulates on the filter — too much dust material can reduce the efficiency of the air filtering as air becomes more difficult to pass through.
Most cartridge dust collectors feature a pulse jet cleaning process to automate the removal of accumulated dust. Compressed air is blasted on the filters to dislodge and remove the dust particles, ensuring continuous filtration efficiency.
The versatility of cartridge dust collectors in filtering out most types of dust makes it suitable for industrial applications such as welding, grinding, sanding, woodworking, pharmaceutical manufacturing, food processing, and chemical handling.
Baghouse Collection Systems
Baghouse collection systems operate in a similar process to cartridge dust collectors, taking in large amounts of air constantly and passing it through a filter to remove dust particulates. Instead of pleated cartridges as filter material, a baghouse collection system features the use of long cylindrical bags made from woven filter fabric.
The use of filter bags instead of cartridges provides baghouse collection systems with a significantly higher dust capacity due to the larger surface area of collection on the filter material. The filter bags are cleaned in the same way as cartridge dust collectors with pulse air blasting to remove dust from the filter bags.
Baghouse collection systems best used in industrial applications where there is a high volume of dust generation including cement production, power plants, steel mills, and grain handling.
Cyclone Separator Systems
Cyclone separator systems are effective solutions for industrial dust removal, designed to separate dust and particulate matter from the air using centrifugal force. As contaminated air enters the cyclone chamber, it is rapidly spun around, causing heavier dust and fume particles to be flung outward toward the walls of the chamber. These particles then fall into a collection bin at the bottom, while the cleaner air exits through the top of the cyclone.
Cyclone separators feature robust construction from durable metals to ensure they can withstand harsh industrial environments. These systems are particularly efficient at handling large volumes of coarse and heavy dust particles, which makes them suitable for applications where dust loads are high and particles are relatively large.
Unlike dust collectors that make use of filters, cyclone separators do not need regular cleaning or replacement, leading to significantly reduced maintenance efforts and costs, as there is no need to deal with filter clogging or downtime associated with filter replacement.
Cyclone separator systems are particularly beneficial in environments where dust and particulate matter in the air are coarse, such as boiler emission control, cement plants, lime kilns, asphalt plants, milling and grinding operations.
Wet Scrubbers
Wet scrubbers utilise a liquid, typically water, to capture and remove dust particles from the air. As air containing dust and pollutants is funnelled into the scrubber, a fine spray of water or other liquid is applied. The particles are trapped by the water droplets, forming a slurry that is then collected and removed from the system. This method allows wet scrubbers to efficiently capture a wide range of particulates, including fine dust, fumes, and gases.
Wet scrubbers are especially effective in environments with high levels of dust and where combustible dust is a concern, as the liquid medium helps to reduce the risk of fire and explosions. Additionally, the liquid used in wet scrubbers can often be recycled, enhancing the system’s cost-effectiveness and sustainability.
Wet scrubbers are best used in industrial applications with high dust and gas emissions, such as chemical processing plants, metal smelting operations, power plants, and incinerators.
Searose Environmental specialises in dust collection and extraction systems in Brisbane and Sydney across a wide range of industrial applications from woodworking to mining and metal work. Our services include installation, repair, and maintenance work for dust collection systems, as well as expert advice for determining the best environmental control equipment for compliance and a safe workplace.