Simple Steps to Take Now to Boost the Performance of Your Dust Collection System
Simple Steps to Take Now to Boost the Performance of Your Dust Collection System
Those working in heavy industry already know how critical the safety of workers is. One key component of employee health and safety that can be overlooked is the ongoing performance of dust collection technologies. Once dust collection is put into place, it’s not often checked for performance unless there’s an interruption to production.
Simply having dust collection technologies isn’t enough. Making sure equipment is properly sized and balanced, and that each piece is properly maintained, are critical steps to preventing operational efficiencies or worker injuries.
Without proper upkeep, dust collection systems can underperform, giving dangerous airborne particles a chance to wreak havoc. Dust collection technologies give workers clean, breathable air and prevent diseases like silicosis. They contribute to the overall well-being of a job site by removing other respiratory hazards like fine powders from the air.
There are several immediate steps business leaders can take now to optimize the performance of their dust collection systems – without investing in an entirely new one.
Engineering Audits
One of the most important initial steps to take is scheduling an engineering audit. C&W DustTech experts are on-hand to examine your existing operations and determine on-site needs, including proper airflow and system sizing.
Several C&W team members are certified through MSHA, allowing them to conduct site visits at mines.
Once on-site, our team can determine dust type and particle size, production volume and material flow, plant layout and airflow patterns, and specified regulatory requirements. They’ll also examine your current dust collection methods and maintenance practices.
After the audit, findings are presented in a written report that clearly spells out next steps for your unique application.
Case in point: Uncovering hidden airflow imbalances
During a recent engineering audit, C&W experts were on-site at a copper mining facility, where they identified several production points where dust collection issues were apparent. Most notably, dust was visibly escaping the conveyor load zone.
While the mine had previously invested in a system that contained four pickup points along its conveyor, C&W’s engineering team found the system had not been properly balanced. This meant the dust was not being properly collected at one of the pickup points due to an imbalanced airflow, causing the dusting issues.
“Our job is to find what is working, what’s not working and what could work better,” said Steve Cook, Mining, Aggregates & Cement Manager at C&W DustTech.
The C&W team initially recommended that the mining company’s maintenance team drill holes into the ducting attached to the pickup points. This allowed C&W experts to use probes and determine airflow rates to correct the issue.
“There was zero airflow coming out of the first one, and then way too much out of the second one,” said Cook. “The system was not very balanced.”
C&W compiled these issues into a final engineering study, giving operators clear next steps to quickly solve their dust issues. The incremental steps did not necessitate the purchase of an entirely new dust collection system. Instead, small steps to improve performance were provided.
Optimizing your dust collection system
Optimizing dust collection system performance doesn’t always require a full replacement. An engineering study can identify targeted incremental upgrades, such as adjusting hood designs and locations, adding enclosures to a design, addressing air leaks and other improvements for balancing airflow.
These studies provide a clear roadmap for dust collection optimization, but companies don’t need to wait for a full report to start making improvements. There are several practical upgrades that can be implemented right away to optimize your dust containment without a full system upgrade.
Balancing dry and wet dust suppression methods
If you’re using wet suppression technologies at any production point within your operations, swapping them out with dry dust collection methods can improve resource and operational efficiency.
On average, dry dust collectors achieve up to 99.9% removal efficiency for fine particulate when properly designed, according to Processing Magazine. Wet suppression systems’ efficiency can vary widely. These traditional methods achieve approximately 70% dust control efficiency for large particles with low-energy designs, and between 95% and 99% with high-efficiency designs for very fine particles.
Implementing dry dust collection technologies, where appropriate, can boost dust collection efficiency when properly designed, and entire systems are typically easy to set up and integrate with existing conveyor technologies.
C&W’s newest dry dust collection system, the Belt Conveyor Transfer Point Dust Collector, is uniquely designed to help those working in heavy industry contain dust at conveyor transfer points. These production points are often when the most dust and fine particulate can escape.
Connect with one of our experts to learn more about our new conveyor dust collector.
Improve dust capture at the source
Dust collection system performance issues are often rooted in misalignment between system design and effective dust capture at the source. Ahead of an engineering audit, operators can often improve dust capture at the source by addressing visible escape points and making small adjustments to hood placement, airflow or enclosures.
A critical component of the dust collection process is the hood, which captures dust where it’s generated. Our engineers will ensure the shape and size of your hood is appropriate for the source of your dust, positioning hoods as close as possible to where dust is generated.
Operators can also reduce fugitive dust by identifying open transfer points or areas where dust is escaping and implementing simple enclosures or containment measures. Ductwork should also be evaluated to ensure it is properly sized and designed with minimal turns to support efficient airflow.
Improving dust collection at the source is the most effective way to control airborne dust before it spreads through a workspace. Taking these small steps now can save you clean-up time now – and the possibility of equipment downtime or operational inefficiencies.
Examine your current maintenance routine
A focus on equipment maintenance can make a noticeable difference in your dust collection efforts. Components including blowers, belts, bearings, fuses, valves, actuators, filters and air hoses are all easily replaceable. They should be monitored and replaced before they begin to noticeably fail.
These critical parts are under constant stress from sticky, abrasive dust. Replacing worn components is a simple way to get more mileage from your existing dust collection technologies.
It’s important to monitor your systems daily for any visible dust, unusual noises or apparent reduction in airflow. Set a consistent emptying schedule for your hoppers so dust does not back up into the collector and ultimately be released back into the air. Schedule periodic inspections and cleaning to prevent buildup across your operations.
Start optimizing your system today
If you’re evaluating the performance of your dust collection system, it’s important to remember that improvements aren’t an all-or-nothing investment. But it is critical to begin the process of assessing each piece of equipment to make sure it is operating properly. This protects not only the investment you made in the equipment itself, but the employees at your jobsite, your reputation as a business and your bottom line – equipment that is properly maintained won’t break down.
Partnering with an experienced dust collection expert like C&W DustTech can help you identify immediate incremental steps to take to ensure your system is operating efficiently and safely, without a full system replacement.
