Dust Cleaning System for Foundry Industry
HQCC was founded in 1982, and it is a high-tech corporation which is specialized in research and develop of environmental protection technologies, manufacture environmental equipment, projects construction and consulting.
We are professionally manufacturing of de-dusting systems and their parts as bag filters, de-sulfuration equipment, pneumatic transportation equipment, dust handling equipment, mechanical air cooling equipment and components in all different types and specifications. All these products are used widely in industry fields such as metallurgy, power, machinery, foundry, cement, chemical, food, etc..
Our clients list includes a lots of large scale iron and steel enterprises such as Baosteel, Baotou Iron & Steel Group, Ma Anshan steel Company, Sanming Steel Company, Nanjing Steel Group, Xining Special Steel Company, Sha Steel company; and some foundry enterprises such as China Faw Group Corporation, Dongfeng Motor Group, Guangzhou Honda. We also export our products to Vietnam, Malaysia, Burma, Turkey, India, Indonesia, Japan, UAE, and Iran.
Why choose us?
Complete process system
Because of its long history, large output, wide distribution, high market reputation, a complete process system, has enjoyed a good reputation in the industry.
Stay true to the mission
We will do our best efforts to make more contributions to promoting the harmonious between human and the nature.
Quality team
Has established a unique design, manufacturing and construction team, can complete all kinds of system engineering design, production, installation.
Global service
International users radiate Vietnam, Malaysia, Myanmar, Italy, Turkey, Japan, Thailand, UAE, Iran, Russia, India...
Dust cleaning system for foundry industry are engineered and designed to filter airborne dust particles and debris that can cause damage to plant equipment, create a hazardous work environment, and negatively impact plant production.
Installation of a new dust collection system for your facility either by replacing an old unit or expanding your existing operation, can mean an improvement in plant maintenance, waste collection, an increase in product quality, and plant efficiency and production.
Benefits of Dust Cleaning System For Foundry Industry
Fire suppression
Whenever there is a concentration of dust and gas, there is always the potential for fire. By having a dust cleaning system for foundry industry, especially one with a spark arrestor, the concern for fire is significantly reduced. A dust collection system has dust constantly moving, which prevents it from collecting and becoming a hazard.
Explosion proofing
Prior to the development of dust collection systems, dust explosions, especially in woodworking shops, were very common. The problem was so prevalent that many shops had a wall open to the outside. Much like fire prevention, dust cleaning system for foundry industry keep air moving and circulating to prevent the possibility of dust collecting sufficiently to produce an explosion bubble.
Odor reduction
Air in a dust cleaning system for foundry industry is constantly circulating and being refreshed, which assists in keeping odorous contaminants out. Though dust collection systems may get confused with air conditioning, they have far more benefits. When polluted air is sent through filtration, it removes the contaminants and odors they create. Odor reduction is not common in all dust collection systems. Where odor is a concern, carbon-impregnated filters are used.
Respiratory Health
One of the major areas of concern for the Occupational Safety and Health Administration (OSHA), the National Institute for Occupational Health and Safety (NIOSH), and the Center for Disease Control (CDC) is the safety of the workspace for workers. Regarding dust and contaminants, they have specific requirements regarding the allowable percentage of particulates in a cubic foot of air. Violation of these standards can lead to a business being closed, which makes it essential to install an acceptable dust collection system.
Personal safety
Something that is rarely considered in an industrial environment is the cleanliness and quality of the floor. One of the benefits of a dust cleaning system for foundry industry is the removal of the need to constantly clean the floor. There may be slight accumulations during a workday, but a dust collection system significantly reduces the need to sweep the floor or dust off a workspace.
Worker morale
Psychological studies have proven, such as the Hawthorne Study, that a clean, well-lit work environment produces more productivity and improved worker morale. Workers who are not constantly confronted with offensive odors and unclean workspaces tend to enjoy their workday and are more productive. A dust cleaning system for foundry industry is an essential factor in producing the ideal conditions. In many ways, investing in a dust cleaning system for foundry industry can benefit the bottom line.
Types of Dust Cleaning System For Foundry Industry
Industrial dust collectors
Industrial dust collectors are devices used to minimize the presence of various pollutants in order to maintain a high standard of clean air in workshops, plants, manufacturing facilities, or any commercial or industrial space. Regulatory and insurance agencies require dust collectors to be used to maintain healthy work environments due to the potential hazards to worker health and concerns related to air quality. Regulations stipulate certain degrees of soundproofing be installed around dust collecting machines to further protect workers.
Cyclone dust collectors
Cyclone dust collectors are inertial separators that use centrifugal, or cyclonic, air movement within a hopper chamber to separate particles from the air. The heavier particles are thrown against the outer wall of the hopper and fall to the bottom into a collection chamber.
Inertial separators
Inertial separators use gravitational, centrifugal, and inertial forces to separate dust particles from a stream of gas. The three types of inertial separators are settling chambers, baffle chambers, and centrifugal collectors.
Baghouses
Baghouses, also known as bag filters or fabric filters, are a type of dust collector, which is any system or machine that draws dust out of the air into a filter or separator. In this same group are equipment like air scrubbers, electrostatic precipitators, wet scrubbers, unit collectors, and inertial separators. By removing contaminated air particles from the environment around them, baghouse and dust collecting systems like them improve air quality and worker health and safety.
Shaker dust collectors
Shaker dust collectors are a form of baghouse dust collector that are used when compressed air is not available to clean the filter bag. The filters for a shaker dust collector are hung from the top of the unit with the bottom of the filter attached to a tube. Mechanical shaking of the bags cleans the filters. During cleaning, it is necessary to take filters off line to be cleaned, which is the reason that shaker dust collectors have several filter bags such that one filter can be shut off from the system as it is cleaned while the other filters in the system can continue to filter the air.
Cartridge dust collectors
Cartridge dust collectors use pleated fabric filters that have more filtering surface area per cubic feet due to the pleated design that reduces the air to cloth ratio and the size of the dust collector. The filters for cartridge dust collectors come in various shapes including round, oval, square, or rectangular and have expanded metal mesh on the inside, outside, or both. Other forms of cartridge dust collector filters use fabric bands to maintain their shape. The materials for cartridge filters are a blend of polyester and cellulose covered in a nanofiber coating for filtration efficiency.
Dust control booths
Dust control booths make it possible to isolate and control dust from certain processes within a larger facility. They enclose the source of dust to prevent it from spreading. Referred to as walk-in booths or isolation booths, dust control booths offer an extra level of dust and contaminant collection that is located at the site where the dust is created. Dust control booths are commonly used for processes that are being completed by one worker and involve grinding, polishing, sanding, cutting, welding, and deburring operations.
Laser pack dust collectors
Thermal cutting processes, such as plasma cutting and laser cutting, produce fumes and flammable particulate matter that has to be carefully handled. Laser pack dust collectors are designed to remove the emissions created from thermal cutting processes. They are equipped with spark arrestors and spark discharge units to collect hot particles in a collection bin.
Components of Dust Cleaning System For Foundry Industry
Ductwork
The ductwork must be designed correctly for the collection system to function. The proper size of the ductwork will depend entirely on the airflow requirements, the number of machines in service, the length of ductwork necessary, the blower size, and the size of the particulates to remove.
Fan/blower
- This component pulls contaminated air into the system to be purified. There are two basic types, axial and centrifugal. An axial system has propellers, while the centrifugal system has wheels within a housing.
- This element will also require the proper adjustments. The first determination is the amount of air that must be moved. It’s also necessary to calculate the static pressure throughout the system, the temperatures, the amount of debris in the air, and the humidity.
Dust filter
- The dust filter is the purifying component of a dust collection system. The air is forced through the filter. The air-to-cloth ratio is the amount of air that passes through a square foot of the filter. A high-quality filter system will have a lower percentage.
- Filter fabrics can be customized for chemical resistance, withstand high temperatures, and abrasion resistance. Due to the variety of filter fabrics, it is recommended to contact a trusted manufacturer to find a suitable filter fabric for your facility.
How to Maintain Dust Cleaning System For Foundry Industry
Use the right parts
Make sure your dust collector system is using the right parts, from the blower, dust filter, a filter-cleaning system, dust receptacle or dust removal system, to cartridges and baghouse solenoids, fans and valves. Each part plays a role to ensure the collector is operating at design point. We recommend using factory recommended replacement parts and be leery of less expensive alternatives.
Is your hopper free of dust?
A duct collector’s hopper should never be used to store dust. The hopper is intended to funnel process dust to a storage bin. Dust accumulating in a hopper creates a potential fire or deflagration risk. Dust in your hopper will also clog the system and diminish the collector’s performance and prevent the pulse-cleaning from doing its job.
Check diaphragm valves
It’s smart to make checking your diaphragm valves a priority each year. Particularly when new baghouses or cartridges are installed, it is recommended to check the valves and ensure that all filters are cleaned properly from the beginning. Remember that it’s always cheaper to replace diaphragm valves that it is to buy new filters because of inadequate pulsing. (Remember to wear appropriate ear protection when testing pulse valves as the noise level can rise considerably.)
Regularly check your ductwork
The National Fire Protection Association requires protection for the ductwork and safety processes upstream of the dust collector. It’s smart to equip your ducting with a flow-activated isolation valve protecting downstream work areas from the propagation of flame and pressure through the inlet duct when deflagration occurs in a dust collector. If there is deflagration in a dust collector, the pressure will close the valve preventing the passage of flame and smoke to areas upstream from the valve. The valve latches shut and must be reopened manually. Some parts of the valve may be damaged, and a thorough inspection is required before the valve is back in service.
Make sure you’re using the correct air pressure in your dust collector
Compressed air pressure is crucial for the performance and longevity of a dust When compressed air is too low, filter cartridges are not properly cleaned which results in rapid downgrade and saturation. When air pressure is too high, filter cartridges are used up faster and need to be replaced more frequently, driving up cost and maintenance. It’s very important to always have your compressed air pressure within the limits of manufacturers recommendations. Your compressed air should be oil and water free, and the amount should be sufficient for all users performing simultaneous tasks.
Keep an eye on pressure drop
Increasing pressure drop (typically measured in inches of water column)across the dust collector affects the ability of the collection system to capture dust. As a safety measure, change filters when airflow reaches a differential pressure. New filters have the lowest pressure drop because of the inherent permeability of the media. As the bags develop dust, some particulate embeds itself into the filter media, which increases the pressure drop.
Create an inspection or maintenance program
Dust collectors have allowed companies to effectively capture airborne particulate which helps provide a healthy and clean work environment. To ensure a dust collector is working properly, periodic inspections and a maintenance program will go a long way toward keeping your dust collector functioning at a high level. Scheduled inspections on a daily, weekly, monthly, semi-annual and annual basis will keep your dust collector working efficiently and keep your maintenance costs down. Failing to routinely inspect and maintain your dust collector can hurt its performance, and continued neglect will lead to your dust collector not meeting EPA outlet emissions standards.
Inspect the filter media
To optimize your dust collector’s performance; you should inspect your filter media often. The filter is the most important part of a dust collector because it accumulates and supports dust cake. Dust cake is what provides high filtering efficiencies during operation. Regularly inspect the clean-air side of the dust collector for leaks and the bags for tears. If pressure drop within a dust collector becomes extremely high compared to normal, it may be caused by excessive dust cake or “blinding” of the filter bags.
Understand your needs
Before purchasing a dust cleaning system for foundry industry, it is essential to understand your specific requirements. Consider factors such as the type and volume of dust and fumes generated in your facility, the size of the area to be covered, and any regulatory requirements that need to be met. Conducting a thorough assessment of your needs will help you choose the most suitable collector for your application.
Types of dust collectors
There are several types of dust and fume collectors available, each with its own advantages and limitations. Common types include baghouse collectors, cartridge collectors, cyclone collectors, and electrostatic precipitators. There are pros and cons to each of these types of collectors. So, research online or ask an expert to help you determine which one is best suited to your needs.
Consider airflow and filtration efficiency
Airflow and filtration efficiency are critical factors to consider when selecting a dust collector. The collector must be able to handle the volume of air and contaminants produced in your facility while maintaining high filtration efficiency to ensure clean air output. Therefore, be sure to choose a collector with the appropriate airflow capacity and filtration efficiency for your application and facility.
Evaluate maintenance requirements
Regular maintenance is also essential for ensuring the optimal performance and longevity of your air filtration equipment. Consider factors such as filter replacement frequency, ease of access for maintenance tasks, and the availability of replacement parts when evaluating different dust collector options. Choosing a collector with minimal maintenance requirements can help minimize downtime and operating costs.
Energy efficiency
Energy consumption is another crucial consideration when selecting a dust and fume collector. Look for features such as variable frequency drives (VFDs) and optimized airflow designs. These can help reduce energy consumption and operating costs over time. Investing in an optimized, energy-efficient collector can lead to significant long-term savings.
Compliance with regulations
Ensure that the dust and fume collector you choose complies with relevant industry regulations and standards. This includes those set by organizations such as OSHA, NFPA, and the EPA. There may also be local authorities in your area with unique regulations. Compliance with these regulations is essential for maintaining a safe and healthy work environment and avoiding potential fines or penalties.
Budget considerations
Finally, consider your budget when planning and purchasing an dust cleaning system for foundry industry. It is important to weigh the upfront costs just as much as ongoing maintenance expenses and long-term operating costs of different collector options to find the most cost-effective solution for your facility.
Certifications
Our Factory
We are professionally manufacturing of de-dusting systems and their parts as bag filters, de-sulfuration equipment, pneumatic transportation equipment, dust handling equipment, mechanical air cooling equipment and components in all different types and specifications. All these products are used widely in industry fields such as metallurgy, power, machinery, foundry, cement, chemical, food, etc..
HQCC has two workshops which cover an area about 50.000m2 with advanced machineries to satisfy the productions in different requirements.
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