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HYDRAULIC FRACTURING SILICA EXPOSURE

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HYDRAULIC FRACTURING SILICA EXPOSURE

Hydraulic fracturing (“fracking”) is a process used to extract oil and gas by high-pressure fracturing of rock or shale. Exposure to respirable crystalline silica is a major hazard in this industry. Massive amounts of sand are used in the process, and silica exposure is a constant issue.

NIOSH has identified silica exposure as the single biggest health issue in hydraulic fracturing. Their research also demonstrated that silica levels on these sites are so high that standard respirators are not sufficient for protection. With a 2018 deadline for hydraulic fracturing sites to comply with new OSHA limits for silica exposure, new tactics for silica dust control are needed.

 

SILICA IN THE HYDRAULIC FRACTURING PROCESS

 

The hydraulic fracking industry uses huge amounts of sand (silica). Most grains are 2 mm or smaller in size. By some estimates, the average site requires somewhere between 1 and 7 million pounds of sand over its lifetime.

After high-pressure water and chemicals are pumped into the rocks to create fractures, the spaces must be filled with sand to keep them open and allow oil and gas to flow. So much sand is used in this industry that mining and production of “frac sand” has become a major industry of its own.

 

FRAC sand production chart in the United States

(Frac sand production: This chart illustrates the spectacular rise in the production of frac sand in the United States. Data from the United States Geological Survey Minerals Yearbook, Silica, 2011)

 

AREAS OF HIGH SILICA EXPOSURE

 

HYDRAULIC FRACTURING SILICA EXPOSURE

image: National Institute for Occupational Safety and Health/Centers for Disease Control and Prevention/OSHA/CDC

Massive amounts of silica move around a hydraulic fracturing site. NIOSH has identified several points in the silica moving process that create the largest amount of silica dust. These areas are:

  • Open hatches on sand movers
  • Through side ports on sand movers during refilling
  • Depositing sand onto transfer belts
  • Sand moving on transfer belts between movers, hoppers, and blenders
  • Blender hoppers that mix sand
  • Accumulated dust stirred up by vehicles driving around the site

 

NIOSH strongly recommends that engineering controls be put in place to control silica exposure at these points. They emphasize that the silica exposure at these points in the process is so heavy that respirators do not provide enough protection.

 

HYDRAULIC FRACTURING SILICA EXPOSURE; CONTROLLING DUST ON SITE

In some situations, newer equipment has been designed to minimize silica dust release. In other situations, older equipment can be modified or rebuilt to these designs.

For many companies, especially with the industry still recovering from the severe drop in oil prices several years ago, these expensive modifications aren’t reasonable.

Another option is to install dust collectors directly on the equipment. A collector specially designed for hydraulic fracturing equipment can be fitted on sand movers, transfer belts, and blenders. With these systems installed, the amount of silica dust released is much lower.

Controlling silica release at these points of capture can decrease silica exposure all over the site. With less silica dust escaping, the overall amount of fugitive silica dust around the site is more manageable. This helps with the amount of dust raised by vehicles or wind all over the site.

 

https://blogs.cdc.gov/niosh-science-blog/2012/05/23/silica-fracking/

http://geology.com/articles/frac-sand/

https://www.osha.gov/dts/hazardalerts/hydraulic_frac_hazard_alert.html

HEALTH RISKS OF SILICA: WHY A NEW SILICA LAW WAS NEEDED

Lung disease from inhaling sand or rock dust is one of the oldest occupational hazards. The health risks of silica were identified as early as 1700. Silicosis, the incurable lung disease caused by inhaling silica dust, causes hundreds of deaths every year. Other health effects include liver and immune system diseases. After studying the research, OSHA concluded that the current silica exposure limits were too high. A new silica exposure limit needed to be set to protect workers.

 

Some silica exposure still comes from well-known occupations like stone cutting, mining, and drilling. Abrasive blasting with sand is especially dangerous. However, newer industries have created new sources of exposure. One example of this is hydraulic fracturing, or fracking, for oil and gas.  Another example is the popularity of natural and manufactured stone countertops.  All of these industries must achieve compliance with OSHA’s new silica law to keep workers safe.

 

HOW DOES SILICA HURT YOU?

 

Silica is one of the most common elements on earth. It makes up a major part of sand, rocks, and all products made from those things, like concrete.

The major health risks of silica happen when it is inhaled into the lungs. Silica that is small enough to be inhaled is called “respirable crystalline silica” in formal OSHA language. Drilling or grinding creates fine silica dust, and sand is already a form of crystalline silica that can become airborne, especially during blasting or fracking operations.

The biggest concern with silica is a disease called silicosis. The American Lung Association warns about the permanent lung damage that happens with this disease.

Silicosis happens when silica dust damages the lining of the tiny air sacs in the lungs. This injury causes scarring and makes it harder for the air sacs to get oxygen into your body.

Acute silicosis can occur within weeks or months of very heavy exposure. In this case, the lungs respond to the injury by swelling up and filling with fluid. This can be very dangerous and make it very hard to breathe.

Chronic silicosis is the most common kind. The swelling and scarring of the lungs happens over years. Symptoms include coughing, chest pain, and sometimes tiredness and weight loss. The scarring can progress to a condition called progressive massive fibrosis, where the lungs become stiff and full of scar tissue. When the disease is severe, people may need oxygen support to be able to breathe. Silicosis can cause death.

The health risks of silica include other deadly conditions. Silica is a known carcinogen, meaning it causes lung cancer. It also makes you more likely to get lung diseases like emphysema, tuberculosis or bronchitis. NIOSH, the research arm of OSHA, reviewed all of the studies on silica exposure and wrote a detailed report on it.

 

HOW CAN THE HEALTH RISKS OF SILICA BE CONTROLLED?

 

OSHA recommends that the first line of defense is replacing silica with safer materials. This isn’t always an option. Replacement products may be expensive or just not available. Silica is common, cheap, and stable, which makes it hard to replace.

The second line of defense, and usually the best option when possible, is using engineering controls. A popular engineering control is a dust collector. A dust collection system removes silica dust from the work area and captures it safely so it can be reused or disposed of. Just venting the dust out of the work area means that it ends up somewhere else, and that can be a problem.

A dust collector filters silica dust from the air. The dust drops into a hopper for safe handling. The air can be returned to the work area. The system can clean a large area and keep an entire facility free of silica dust.

Dust collectors can also be installed on equipment such as sand trucks or conveyors to control silica dust when moving sand around. This is important in fracking applications.

In situations like construction or drilling, the best solution may be a NIOSH-certified respirator. Because respirators are uncomfortable and difficult to fit correctly, they are not the ideal solution. Sometimes, though, they are the only option. If you must wear a respirator to protect you from the health risks of silica, make sure it is NIOSH-certified for the job you’re doing, and make sure it fits correctly.

OSHA SILICA DUST RULE: COUNTDOWN TO COMPLIANCE

In 2016, OSHA issued a new silica dust rule for exposure. Now the clock is ticking for industries to achieve compliance. The construction industry has less than six months to get there. For general industry, you have about a year and a half, which goes by fast when it comes to getting into compliance with an OSHA regulation.

 

The silica dust rule lowered the exposure limit to 50 micrograms per cubic meter of air, averaged over an eight-hour day. This limit has been recommended by NIOSH and other health groups for decades. It is expected to save many lives by preventing silicosis, the lung disease caused by breathing silica dust.

CMAXX Filtration System Silica Dust Rule

This CMAXX Dust Collector was installed on a conveyor line to collect dust and protect employees and the environment.

WHAT’S THE DEADLINE FOR COMPLIANCE?

The construction industry is required to be in compliance by June 23, 2017. For general industry, the deadline is June 23, 2018.

 

This is also the deadline for most fracking processes, although they will have extra time to work out engineering controls. This extended deadline for engineering controls, such as dust collection systems or changes in their processes, exists because OSHA considers these methods to be the best and most effective.

 

Considering that OSHA had been issuing fines and strongly enforcing the previous silica dust rule, it should be expected that they will enforce the new rule as well. If you were near or above the limit before, you’re going to be drastically over the limit now unless you take steps to control silica dust exposure.

 

It’s easy to look at June 2018 as being a long way away, especially when you have more urgent challenges to deal with right now. However, getting into compliance with the silica dust rule may take time. Engineering controls, such as dust collectors, often require researching products and taking bids. Once a product is chosen, there’s the timeline for building and installing your system. There is also the time required to run the system, work out the bugs, and make sure your silica dust levels are now under control.

 

IS YOUR INDUSTRY AFFECTED?

The construction industry will get hit with the new limits first, so it’s expected to be a major target for enforcement. However, there are a lot of activities that fall under general industry and get hit in 2018. These include:

  • Clay, brick, and concrete production
  • Foundries and refractories
  • Landscaping and renovating
  • Stone products (including natural and artificial stone for countertops and other surfaces)
  • Abrasive blasting (in manufacturing and on construction or renovation sites)
  • Hydraulic fracking

 

IS A DUST COLLECTOR THE RIGHT SOLUTION FOR YOU?

A dust collection system like the CMAXX, BRF Baghouse, or SHADOW will be most effective in applications like foundries, stone and clay manufacturing processes, and abrasive blasting. For these applications, a dust collector may be the best way to achieve compliance with the silica dust rule.

 

One area that is expected to be a major target for OSHA is the hydraulic fracking industry. This is a relatively new industry, and massive amounts of silica are moved around these sites every day. Imperial Systems has unique solutions for the fracking industry, especially for sand-moving equipment and vehicles. This industry faces particular challenges in reaching compliance with the new silica dust rule.

References:

https://www.osha.gov/silica/

https://www.osha.gov/dts/hazardalerts/hydraulic_frac_hazard_alert.html

https://www.osha.gov/dsg/topics/silicacrystalline/osha_standards_silica.html

WELD SMOKE RISKS: A SPECIAL CHALLENGE FOR FUME COLLECTORS

CMAXX filtration system managing weld smoke

The CMAXX for managing weld smoke on display at FABTECH 2017. This install is showing an ambient filtration method.

Managing weld smoke risks means dealing with very small particle size, toxic metals, and the combustibility of metal dust. Weld smoke and fumes are different from other types of dust, and a system needs to be designed to deal with it. A CMAXXTM dust and fume collection system will meet any metalworking or weld smoke control needs.

 

WELD SMOKE RISK: HEALTH

 

One of the risks of weld smoke is hexavalent chromium. This compound can cause skin sores and lung damage, and cancer of the lungs, kidneys, and other organs. Many metals are alloyed with chromium to make them corrosion resistant.

 

Most of the particles in welding fumes come from the welding wire, but some of them come from the material being welded. Some of them can cause allergic reactions and an immune response called “metal fume fever”. Lead and manganese can damage the brain. Others, like hexavalent chromium and nickel, are known carcinogens and increase your risk of cancer.

 

The particles that are put into the air as fumes from welding are extremely small. Most are smaller than one micron. This means they are small enough to get inside human cells and cause damage. This also means that welding fumes are lighter than air, especially when heated. A system for collecting these fumes must be designed to handle very small particles.

 

MANAGING WELD SMOKE RISK: FIRE AND EXPLOSION

 

Welding produces metal dust and gases that may be combustible. Some metals, such as aluminum, are very explosive as a dust. Almost all metal dusts have the potential to explode. Handling welding fumes means using appropriate fire suppression and prevention measures.

 

Spark Arrestor - Spark Trap

Spark Arrestor also commonly refereed to as a Spark Trap is being installed in a maintenance weld shop

Suppressing sparks to keep them from getting into the collector can help prevent explosions from welding smoke dust. Spark Arrestors are important in keeping most sparks from getting to the collector. An explosion isolation valve can prevent a fire from traveling back through the ductwork. Chemical control systems can suppress or extinguish a flame, but only certain chemicals are approved for fires involving metal dust.

 

Filters can also be important for fire suppression in a welding smoke system. Filters with a fire-retardant coating they will resist burning and help control a deflagration. Some collectors are designed with filters that help isolate an explosion and keep it from causing damage inside the workplace. DeltaMAXXTM filters with fire-retardant coating will prevent a fire from occurring inside a dust collector.

 

HANDLING WELD SMOKE

Figuring out what type of fume extraction system to use in your facility is an important decision for managing the risks from weld smoke. Our systems engineers will consult with you to help you determine the best way to manage your weld smoke risk.

Portable fume collector for managing weld smoke

Shadow portable weld fume collector at FABTECH 2017. Designed for managing weld smoke

If there are not very many welders and they don’t always work at the same place, portable collectors can be a solution. They can be useful for handling point of source capture. An ambient system is designed to move a volume of air out of a large area and through filters.

 

For managing weld smoke, portable collectors can be easily moved around, but they are not as powerful as a larger collector. Central collectors are the most efficient for large areas, but if they are inside they take up floor space. Locating the collector outside is usually recommended for safe explosion venting.

 

One of the biggest advantages with an ambient system that recirculates the air back into the facility is energy cost savings. When heated or air-conditioned air is vented outside, the energy used is lost. Many businesses find that a fume collection system can pay for itself within two years with money saved in energy costs.

 

CMAXXTM dust and fume collectors have proven themselves in the welding and metalworking fields. Our newest product, the SHADOWTM portable collector, gives you even more options for managing weld smoke . DeltaMAXXTM nanofiber filters are the best available material for capturing metal fumes. At Imperial Systems Inc., we are committed to helping you control your weld smoke risks.

(as seen in The Fabricator Magazine)

 

REPLACEMENT DUST COLLECTOR FILTERS: OUR BEST-SELLERS

You know we manufacture our DeltaMAXXTM filters for our own dust collectors.  If you’re looking for replacement dust collector filters and you own a collector made by another manufacturer, you should know that some of our top selling filters are replacements for the other guys’ OEM filters!

 

WHY PEOPLE BUY DELTAMAXX REPLACMENT DUST COLLECTOR FILTERS INSTEAD OF OEM

Basically, a cartridge filter is a cartridge filter. There’s nothing magical or special that makes one company’s filters superior. As with any product, there are different levels of quality. Choosing a manufacturer who makes a quality product instead of junk is always going to be important.

So let’s assume that most of the big-name OEM companies, like Donaldson Torit, Robovent, and Camfil Farr, make a quality filter. You own one of their collectors, and you’re putting their filters in it. Why would you think about switching?

 

Here are three good reasons:

  • Isn’t that always the best reason? Our replacement dust collector filters are guaranteed to perform as well as, or better than, your OEM filters. And almost everyone who comes to us for replacements finds that our prices are better.
  • NO GIMMICKS. We don’t play games with filter gimmicks. Drug companies that keep releasing “new and improved” versions of the same medication so they can keep their patents. Some OEMs try to do the same thing. Weird new shapes, cool-looking inserts, special new gaskets. Do you really need any of them? Probably not.
  • Getting a good price doesn’t help if the filters aren’t as good. That’s why our guarantee promises you that while we’re beating your OEM’s price, you’re not sacrificing filter quality.

 

If you’re looking for replacement dust collector filters, it’s worth your time to get a quote from us.

 

We make replacement dust collector filters for almost all manufacturers, including:

  • Donaldson Torit
  • Camfil Farr

    various different fume and dust collector filter options

    Filters come in many shapes and sizes. These are a few of those replacement options

  • Robovent
  • Clean Air America
  • TDC
  • Lincoln Electric
  • Mac
  • Chemco
  • Nordson
  • Environmental
  • Micro-Air
  • Many others… just call us and ask!

 

HOW TO GET A QUOTE ON REPLACEMENT FILTERS

It’s easy to get a quote from us on filters made by most other manufacturers. Our specialized cross-matching system will match the part number you usually order with the right filter.

Don’t have a part number? We can still help you. Call us or send an email, and we’ll talk you through the measurements we need to get you a match.

 

Replacement dust collector filters for Donaldson Torit Filters

Replace dust collector filters for Donaldson Torit round and oval cartridge filters

HAVING FILTER PROBLEMS?

Sometimes the wrong kind of filter won’t work for some applications. For example, if you have moisture damaging your filters, you may need a spunbond material that can resist water. If you’ve experienced a fire in your dust collector, it’s definitely worth investing in some fire-retardant filters. If your regular 80/20 filters are getting plugged up with dust after only a few months, you might want to try a nanofiber filter that will collect smaller particles.

Whatever problem you might be having, we can help. Talk to a filter expert right now on Live Chat (during normal business hours) or fill out a contact form!

WELDING AND PLASMA FUMES HEALTH HAZARD

We get a lot of questions about fumes from welding or laser and plasma cutting. People are aware that there are health risks. Many of them have heard about hexavalent chromium. It is a very good reason to be careful when working around plasma fumes, but it’s not the only reason. “Hex chrome” is just one of the hazards involved.

 

WHAT’S HEX CHROME?

You may have heard that hexavalent chromium, often called hex chrome, is mainly a problem for people working with stainless steel. Stainless steel does contain much more chromium than other types of steel. However, many metals are either alloyed or electroplated with chromium to protect them from corrosion.

Metals don’t usually contain hexavalent chromium. Instead, when the metal is heated to a high temperature, the chromium reacts with oxygen to form compounds. Hexavalent chromium is one of them. This compound, when inhaled, is known to increase the risk of lung cancer and other cancers. When in contact with the skin, it can cause irritation and skin sores.

 

WHAT ARE THE OTHER RISKS?

Other common metals that people may encounter in welding smoke or cutting fumes include iron, copper, zinc, nickel, manganese, aluminum, tin, beryllium, cadmium, lead, and titanium. Most of these can irritate your eyes, nose, and throat. Others, like cadmium, are known cancer-causing agents. Some, such as lead and manganese, damage your nerves and brain. Beryllium can cause a fatal lung disease. Components of metal fumes can also cause kidney damage.

No metal fume or smoke from cutting or welding is safe to inhale. Even iron, which is not toxic, can accumulate in the lungs and cause long-term damage. The lungs are very sensitive to damage, and welding or cutting produces metal particles small enough to be easily inhaled. Whether it’s referred to as fumes, smoke, gases, or dust, it’s an airborne cloud of tiny particles that can make their way deep into your lungs. They can be as small as 0.3 microns, which is 250 times smaller than a human hair and about 15 times smaller than a red blood cell.

Other metals, including nickel, zinc, and copper, cause “metal fume fever”, a flu-like response to chemicals released by damaged cells in the lungs. The symptoms resemble the flu, with headaches, fever and chills, muscle aches, and coughing. Welding is the occupation most likely to result in this condition, but plasma fumes and laser cutting fumes can also cause it.

It’s often reported that drinking milk can help prevent this condition, and many people swear by it. Either way, it doesn’t prevent the long-term lung damage that occurs when metal dust is inhaled. Drinking milk won’t hurt, but avoiding the toxic effects of exposure altogether is a safer bet.

 

WHAT CAN I DO?

Fortunately, there’s no reason to put your health in danger just to do your job. OSHA regulations set safe exposure levels for almost all metal fumes. They recommend several methods to prevent over-exposure. A CMAXXTM dust and fume collection system (CMAXX Dust and Fume Collector) is efficient and effective. It can reduce or eliminate the need for uncomfortable and often improperly used respirators. Our team can advise you on the best ways to keep people safe when they’re welding or working around laser or plasma cutting.

The CMAXX Connected to an AKS Plasma Table

 

We hope this information is useful for the people who have asked us questions in the past and who come to us with questions in the future!

 

If you need more information, please click the CHAT NOW box during normal business hours for immediate help. You can also click HERE to request more information.

 

 

 

 

Facts about Plasma Cutting and Plasma Technology. Penrose: BOC, n.d. BOC. Web.

Gibson, Hugh. “Plasma Cutting Using A Hand Held Machine.” Plasma Cutting Danger!N.p., 19 Mar. 2013. Web. 08 Jan. 2014.

Plasma Cutter Safety Guide | Longevity-inc.com.” Plasma Cutter Safety Guide. Longevity-inc.com, n.d. Web. 08 Jan. 2014.

Sheahan, Kyra. “OSHA Safety Standard for Plasma Dust.” EHow. Demand Media, 28 Nov. 2010. Web. 08 Jan. 2014.

Stone, Joe. “OSHA Safety Standard for Plasma Dust.” Work. Demand Media, n.d. Web. 08 Jan. 2014.

Zlotnicki, Steve. “Does Plasma Cutting Produce Hex Chrome.” Plasma Arc Cutting of Stainless Steel Will Produce Hexavalent Chromium. Esab-cutting, 12 May 2013. Web. 08 Jan. 2014.

Portable Power For Weld Fume Extraction: THE SHADOW

If you have welders exposed to smoke from their work, you need some type of portable weld fume extraction to protect them. For some applications, a CMAXXTM is the perfect solution: efficient, reliable, and effective at filtering hazardous dust and fumes from the air.

 

What if your workplace is too small for a full-sized dust and fume collector, though? Some places don’t have enough welders to require a system as big as a CMAXXTM, while others may not have welding happening all the time, or may need a system that can be moved to wherever the welders are working.

 

Portable smoke and fume collector are the solution for many of these welding workplaces, but not all portable collectors are created equal. If you’re searching for something to manage your welding smoke, you want a collector specifically designed to filter metal fumes. You also want one designed for safety, ease of use, and durability.

 

 

If you’re looking for the lowest-cost portable fume extraction system available, you’ll find one cheaper than the SHADOW. But that doesn’t mean you’re getting a bargain. Here’s why:

  1. Many cheap weld fume collectors have a body made entirely of plastic. Considering that they are going to be used very close to hot metal, sparks, and flammable metal fumes, plastic doesn’t seem like a smart (or safe) choice.
  2. Low quality, cheap portable collectors usually come with a low quality filter. When you’re filtering weld fumes, the particles of smoke can be as small as 0.3 microns. That’s why the SHADOWTM is equipped with a filter made of the same DeltaMAXXTM nanofiber material that we use in our larger collectors, over 95% efficient in capturing particles that small. If your filter isn’t catching that smoke, it’s going out into the air in your workplace.
  3. A flimsy design that makes you do extra work might be what you get if you try to go cheap. The SHADOWTM has the easiest filter cleaning and changing of any portable collector, and it’s sturdy enough to handle lots of moving around your shop.
  4. If you’re looking at the general amount of space a collector takes up, the SHADOWTM might look bigger than its cheaper cousins. But look more carefully: in a busy shop, it’s floor space that matters, and the SHADOWTM stands taller so it has a smaller footprint and keeps more of your valuable shop space free.
  5. A weld fume filter system that can’t even suck up weld fumes isn’t worth your money. The SHADOWTM has a small but powerful 1.5HP motor that can efficiently pull air and smoke away from your work area and won’t leave fumes drifting around your welders while they work.
  6. The cheaper portable collector you’re looking at might not be designed specifically for weld smoke and fumes. An “all-purpose” portable filter system that’s designed (and priced) to go into someone’s garage or home workshop may only be good enough to capture general work dust. Weld fumes are much, much smaller, and you need a better filter to handle them.

 

There are things you want from a portable dust collector. The SHADOWTM is designed for welding and metalworking applications. That’s why it offers so many features designed just for this type of use. It offers you choices of fume arms so you can choose the one that’s the perfect fit. It offers you compressed air pulse cleaning to keep your filter working without you having to think about it. And when it is time to change that filter, there’s no portable collector with an easier filter change-out than the SHADOWTM.

 

We’d love to get a chance to talk to you about your application and whether the SHADOWTM is right for you.

Replacement Dust Collector Cartridge Filters

Need replacement dust collector cartridge filters?  Think Deltamaxx™!

A metalworking plant requires the use of quality dust collector systems, and efficient industrial dust collector filters to protect metal fabricators from the dangers they face daily.  What are your essential needs when looking for replacement filters for your dust collector?  As a metalworking business owner your needs are simple. You want replacement dust collector cartridge filters that will give you the security you need while providing you with the savings you want.

In the last 30 years, there have been over 700 injured and 119 deaths due to combustible dust incidents in all forms of manufacturing according to the U.S. Chemical Safety Board.  In order to combat such tragedies, we go above and beyond the safety guidelines established by the Occupational Safety and Health Administration (OSHA) and the National Fire Protection Association (NFPA). Imperial Systems has spent 15 years of our business innovating dust collector industrial filters, and we continue to improve in order to stay one step ahead of your needs.

The Advantage of our DeltaMAXX™ Replacement Dust Collector Filters

  • Up to Twice the Filter Life
  • Advanced NanoFiber Technology
  • A Superior MERV 15 Filtration Efficiency
  • Lower Operational Mass Emissions
  • Less Pulse Cleaning
  • Highest Quality Pleated Media – 99.9% Efficiency .3 to .5 Micron
  • Best Surfacing Loading Performancereplacement dust collector cartridge filters

While these advantages are certainly impressive, how does it translate into the safety and savings you need for your metalworking business?

The nanofiber technology that is used in our filters stops submicron particles from entering and becoming embedded into the media beneath the nanofiber. This gives our filters a higher efficiency rating due to the nanofiber technology being 50% smaller than competitive fibers, thus improving our DeltaMAXX™ filters filtration (.3-.5 Microns).  This allows for a lower resistance to airflow due to our impressive surface loading technology and enhanced dust cake release.

Metalworkers benefit from the added safety of our surface loading technology by reducing their exposure to toxins. The best surface loading technology has less dust build up. Less buildup of dust requires fewer pulses, and fewer pulses means reduced emissions and fewer safety hazards.

With our filters requiring fewer pulses this decreases the stress they are under and increases the life of the filter. In fact, our DeltaMAXX™ industrial dust collector filters pulse up to 94% less often than our competitors. The advantages of our DeltaMAXX™ filters give you longer filter life, increased efficiency and increased savings.

Contact one of our professional, knowledgeable team members to discover all the benefits of Deltamaxx™ replacement dust collector cartridge filters!

Nanofiber Filters Served With Sawdust?

SHOULD YOU SERVE NANOFIBER WITH SAWDUST? A CHART FOR THE DISCRIMINATING FILTER HOST

 

Most everyone knows you can’t just go mixing any kind of filter with any kind of dust. After all, some of them certainly don’t pair well together. Fortunately, we here at Imperial Systems have put together a guide for the thoughtful buyer of dust collection filters. With this handy reference, you’ll never have to worry about showing up with the wrong filter for the occasion!

 

(NOTE: We DO NOT recommend that this be used as a substitute for consulting with an actual filter expert. Please call us At 800-918-3013 for important information that doesn’t fit in an infographic.)

nanofiber

A BIT OF CLARIFICATION:

  • Filter bags, or sometimes cyclones, are usually used for materials that are large, fibrous, or big enough to damage a cartridge filter. Bags are also often used when the temperature or humidity is too high for a cartridge filter to handle.

 

  • Metalworking or welding produce fumes. These are very fine particles and an 80/20 media is not efficient enough to catch them. Since many metal dusts are explosive, we do recommend a DeltaMAXX™ nanofiber FR, which is fire retardant. In some applications such as shot blasting, spunbond is used because it is very durable. If your metal fume or dust has grease or oil in it, you may need a special media.

 

  • Dust from ANY of these categories can be explosive. If your dust is explosive or flammable, we will almost always recommend a DeltaMAXX™ nanofiber FR filter as part of an IDA system.

 

  • Organic dust, like food products, may present some special challenges. Organic dust comes in different sizes, and may clump together, absorb moisture, or present other particular problems. Please consult with us about the characteristics of your particular dust.

 

  • If your dust is oily, abrasive, wet, sticky, or otherwise likely to make a mess of a normal dust collector filter, there are a variety of special materials to help. PTFE resists having anything stick to it, while hydrophobic or oleophobic filters will repel water or oil.

 

AGAIN… THIS IS IN NO WAY MEANT TO SUBSTITUTE FOR TALKING TO A FILTER PROFESSIONAL. PLEASE CONSULT WITH ONE OF OUR KNOWLEDGEABLE TEAM MEMBERS BEFORE MAKING ANY QUESTIONABLE FILTER DECISIONS.

800-918-3013

Combustible Dust Explosion Prevention

You may have heard about a combustible dust explosion before.  You’ve read news about manufacturing facilities that suffered a catastrophe due to ignition of fine combustible dust.  Did you ever wonder how it happens? How a small collection of dust particles can explode with such tremendous power and scale?  We at Imperial Systems, Inc pose an even greater question:  Is your workplace and employees safe from this risk?

Read this industry alert that was written by the North Carolina Department of Labor Safety and Health Division about the Dangers of Combustible Dust.  It is an excellent learning resource that clearly defines the dangerous and sometimes fatal results of an instantaneous combustible dust explosion.

combustible dust explosion

Imperial’s CMAXX dust collector deflagration testing

Over the years Imperial Systems has posted many blogs about explosive dust dangers. We have the knowledge, the experience  and the right equipment to prevent explosive dust ignition in your facility.  Need more information?  Give one of our professional team members a call today at 800-918-3013.  

To learn even more, check out our past articles on combustible dust dangers.  Knowledge is the real power in prevention.

Working With OSHA To Stop Combustible Dust In Your Facility

Imperial Systems Approach to Dust Collection

Eliminating Fumes And Dust From Your Metalworking Facility