Combustible dusts pose significant hazards in many industrial settings, and understanding the types of dust that can cause explosions is crucial for maintaining safety. In the dust collection industry, there are numerous types of combustible dusts that are frequently encountered. This blog post aims to provide an overview of some common combustible dusts, their sources, and the risks associated with them.
What is Combustible Dust?
Combustible dust consists of fine particles that, when suspended in air, can ignite and cause deflagrations. The dangers arise when these airborne dust particles encounter an ignition source, leading to a rapid combustion reaction. The presence of combustible dust in industries is a serious safety concern and has led to many tragic accidents.
Common Combustible Dust Types
1. Wood Dust
Sources: Woodworking industries such as sawmills, furniture manufacturing, and paper mills
Risks: Wood dust is highly flammable and can quickly accumulate in workspaces. Sawdust can create a significant explosion hazard if not effectively managed.
Example: Babine Forest Products, a sawmill in Burns Lake, British Columbia, experienced a dust explosion in 2012. The mill was in the process of installing an upgraded dust collection system. Prioritizing production over safety, they continued operations with an inadequate system during its upgrade. A buildup of wood dust near a conveyor belt motor was ignited by friction rotating belts and caused the explosion.
Sources: Metalworking processes including grinding, cutting, and polishing; Common combustible dust from metals include aluminum, magnesium, and titanium
Risks: Metal dusts are highly explosive. Aluminum and magnesium dusts, for example, can cause violent explosions when ignited, often requiring dust collection with specific combustible dust accessories.
Example: In 2015, a fire caused by metal dust engulfed the Joseph Freedman Recycling Co., a metal recycling facility in Springfield, Massachusetts. The fire was caused by magnesium dust, which is extremely combustible. Due to the nature of the dust, and the high heat of the fire, the responders had no option but to let the fire dissipate on its own, leading to further loss at the facility.
Sources: Agricultural industries, food processing plants, and bakeries. Examples include flour, sugar, grain, and spices.
Risks: Organic dusts from food and grains are very combustible. Historical records show that grain dust explosions are among the most common industrial explosions, often leading to devastating consequences.
Example: In 1878, a grain mill explosion occurred at Washburn A Mill in Minneapolis. This was one of the largest mills in the US at the time and would grow into what is now General Mills. Flour dust suspended in the air ignited, and the mill exploded, leveling five additional mills and spreading flames across several city blocks.
Sources: Mining operations and coal-fired power plants
Risks: Coal dust is highly explosive and has been the cause of many mining accidents. Proper ventilation and dust collection are critical in these environments to prevent coal dust explosions.
Example: Considered the deadliest coal mine accident in history, the Benxihu Colliery Disaster claimed the lives of over 1,500 miners. An explosion of gas and dust caused the 1942 tragedy. Authorities decided to seal the mine, cutting off the fire’s oxygen inside. This devastatingly trapped the miners inside where they were left to die.
Sources: Textile manufacturing, especially during the processing of cotton, wool, and synthetic fibers
Risks: Dust from textile fibers can create a significant explosion risk in mills and production facilities.
Example: In 2001, an Italian wool factory experienced multiple dust incidents because of poor housekeeping. It took one spark to set ablaze dust that had been lying on nearby surfaces. From there, a series of secondary explosions rocked the facility. This incident killed three employees and caused considerable damage to the factory.
Sources: Plastic manufacturing and recycling plants
Risks: Plastic dust can accumulate and ignite under certain conditions. This dust is often produced during the cutting, grinding, and polishing of plastic materials.
Example: Tragedy struck the CTA Acoustics manufacturing plant in Corbin, Kentucky on February 20, 2003. An explosion and fire ripped through the facility, tragically killing seven workers. The plant produced fiberglass insulation for the automotive industry. The cause was determined as a buildup of resin dust in a production area. This dust, likely ignited by flames from a malfunctioning oven, fueled the explosion.
Understanding the risks associated with combustible dusts is the first step in mitigating potential hazards. Here are some key strategies for managing these risks:
1. Dust Collection Systems
Design and Maintenance: Properly designed and maintained dust collection systems are essential. These systems should be designed to capture dust at its source and prevent it from accumulating in the work environment.
Explosion Protection: Implement explosion protection systems such as explosion vents, suppression systems, and isolation devices to protect against dust explosions.
2. Housekeeping Practices
Regular Cleaning: Establish and maintain a rigorous cleaning schedule to prevent dust buildup on surfaces, equipment, and floors.
Proper Disposal: Safely dispose of collected dust to prevent re-suspension and accumulation.
3. Ignition Source Control
Control Sources: Identify and control potential ignition sources, including sparks, static electricity, hot surfaces, and open flames.
Electrical Equipment: Use appropriately rated electrical equipment in areas where combustible dust is present.
4. Training and Awareness
Employee Training: Train employees on the hazards of combustible dust and the proper use of dust collection and explosion protection systems.
Safety Protocols: Develop and enforce safety protocols to ensure consistent and safe handling of combustible dust.
Combustible dusts present significant hazards in various industrial settings, but with proper understanding, planning, and implementation of safety measures, these risks can be effectively managed. Ensuring the safety of workers and facilities requires a comprehensive approach, including effective dust collection systems, control of ignition sources, and ongoing employee training. By recognizing and addressing the dangers of combustible dust, industries can maintain safer and more efficient operations.
While this list highlights the more common combustible dusts, it is by no means comprehensive. Dusts produced or present in a facility should be tested. This will determine the risk for flammability or combustibility with a particular dust.
If your dust has never been tested, or if your process has changed since the last time it was tested, it is imperative to do so. The team at Imperial Systems will facilitate your dust test and help you understand the results. Contact us at 800.918.3013 or aftermarketsales@isystemsweb.com.
Effective dust and fume collectors, also known as air filtration systems, are crucial for ensuring employee safety, safeguarding equipment, and complying with safety, health, and environmental regulations in industrial environments. Planning and purchasing the right industrial dust and fume collector can be a complex process. To help navigate this task, here are some key considerations to keep in mind:
1. Understand Your Needs
Before purchasing a dust and fume collector, 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.
2. Types of Dust Collectors
There are several types of industrial 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.
3. 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.
4. 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.
5. 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.
6. 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.
7. Budget Considerations
Finally, consider your budget when planning and purchasing an industrial dust and fume collector. 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.
Planning and purchasing an industrial dust and fume collector requires careful consideration of a range of factors. By taking these key considerations into account, you can choose the right collector for your application and ensure a safe, healthy, and efficient work environment for your employees. Consulting a dust collection expert who is familiar with system design for various applications as well as regulations and standards can go a long way.
Partnering with Imperial Systems can provide valuable support and guidance throughout the process of selecting a dust collection system. With our extensive experience and expertise in the field, we can help you assess your specific needs, recommend the most suitable collector for your application, and ensure compliance with industry regulations. Our dedication to quality craftsmanship and customer service means you can trust that you are investing in a reliable and high-performance dust collection solution. By partnering with Imperial Systems, you can gain peace of mind knowing that your dust collection system is in capable hands, allowing you to focus on running your facility efficiently and safely.
Foundries are integral to manufacturing and industrial processes, producing metal castings by melting and pouring metal into molds. However, the very processes that make foundries indispensable also generate significant amounts of dust and fumes. Consequently, without proper dust collection systems in place, this dust can pose serious health risks, environmental hazards, and operational inefficiencies.
Health and Safety Concerns Over Foundry Dust
Above all, the primary reason for implementing proper dust collection systems in foundries is to protect the health and safety of workers. Foundries typically produce various dust types, including silica, metal particulates, and chemical residues. As a result of inhaling these particles, severe respiratory issues, including chronic obstructive pulmonary disease (COPD), silicosis, and other occupational illnesses can develop. Effective dust collection systems capture airborne particles before they can be inhaled, ensuring a healthier working environment.
Furthermore, reducing dust levels in the air helps prevent workplace accidents. For instance, dust accumulation can create slippery surfaces and reduce visibility, leading to injuries. By maintaining clean air and surfaces, dust collection systems contribute to overall workplace safety.
Regulatory Compliance
Foundries are subject to stringent environmental and occupational health regulations. Agencies such as the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) in the United States have set limits on permissible exposure levels for various dust and fume contaminants. Consequently, non-compliance with these regulations can result in hefty fines, legal actions, and even operational shutdowns.
Proper dust collection systems ensure that foundries remain compliant with these regulations by effectively capturing and controlling dust emissions. This not only avoids legal repercussions but also demonstrates a commitment to responsible environmental and occupational practices. Working with a dust collection partner familiar with these regulations will ensure a properly designed system.
Protecting Equipment and Product Quality
Dust can be detrimental to the machinery and equipment used in foundries. Accumulated dust can lead to mechanical failures, increased wear and tear, and the need for more frequent maintenance. By implementing an efficient dust collection system, foundries can keep their shop clean and protect their equipment from damage, thereby reducing downtime and maintenance costs.
Moreover, dust can contaminate the products being manufactured, leading to defects and reduced quality. Ensuring a clean environment through proper dust collection helps maintain high product standards and reduces the risk of costly rework or scrap.
Environmental Impact of Foundry Dust and Fumes
The environmental impact of foundry operations is a growing concern, particularly with increased awareness of air pollution and its effects. Dust and fumes released into the atmosphere can contribute to environmental degradation, affecting air quality and harming local ecosystems. Implementing dust collection systems minimizes the release of harmful particulates into the environment, thereby reducing the foundry’s ecological footprint.
Effective dust collection also supports sustainability initiatives by facilitating the recycling and proper disposal of collected dust and particulates. This aligns with broader industry trends toward sustainable and environmentally friendly manufacturing practices.
Operational Efficiency
Efficient dust collection systems can enhance the overall operational efficiency of foundries. By maintaining a clean working environment, these systems reduce the likelihood of equipment malfunctions and extend the lifespan of machinery. This translates to smoother operations, fewer interruptions, and lower maintenance costs.
Additionally, a cleaner workplace improves staff morale and productivity. Employees are more likely to perform better in a safe, clean, and healthy environment. This can lead to improved operational output and efficiency.
The necessity of proper dust collection in foundries cannot be overstated. From protecting worker health and safety to ensuring regulatory compliance, maintaining product quality, minimizing environmental impact, and enhancing operational efficiency, effective dust collection systems are indispensable. Foundries must prioritize the implementation and maintenance of these systems to safeguard their operations, workforce, and the environment. Investing in proper dust collection is not just a regulatory requirement but a critical component of responsible and efficient foundry management.
Leading a company that stands out in the field of thermal plastics compounding, Jim LeGacy, the President of Orion Performance Compounds in Lugoff, South Carolina, emphasizes excellence and innovation in their operations. At Orion, the meticulous process of transforming raw polymers into high-performance materials for a variety of industries is executed with precision and a relentless focus on cleanliness and safety. From military and aerospace applications to electrical and healthcare products, Orion’s reach extends far and wide, serving some of the most demanding sectors.
High Standards in a Demanding Industry
Plastics compounding is a complex field that involves working with different types of polymers. They can include anything from polypropylene to high-temperature resins. Also, different polymers are needed to create materials that meet specific performance criteria. Customers of Orion Performance Compounds rely on these materials to produce their plastic products when using injection molding techniques. Because of the sensitive nature of some industries they serve, the quality and cleanliness of Orion’s manufacturing environment are non-negotiable.
Commitment to Safety and Cleanliness
At Orion, maintaining a pristine facility is more than a matter of aesthetics; it’s a core principle that underscores their commitment to safety and quality. “Safety and cleanliness are at the top of our list of core principles,” says Jim LeGacy. This dedication is certainly evident to anyone who visits their plant. “Yesterday we had a potential customer come through. They got fifty feet outside the door to the plant and they said that it was the cleanest compounding operation they’d seen,” recounts Jim.
The Role of Effective Dust Collection in Plastics Compounding
In order to achieve this level of cleanliness, Orion partnered with Atlantic Dust Collection out of Kernersville, North Carolina, to install a state-of-the-art CMAXX Dust & Fume Collector. This system plays a crucial role in keeping the facility free from airborne contaminants that can stain and discolor materials, ensuring a safe and clean working environment.
Phil Bramblett, the site manager at Orion, underscores the importance of a robust dust collection system, especially when dealing with dry materials in powder, granular, and pellet forms. “Having a good dust collection system is vital to the operation of the plant,” Phil asserts. The effectiveness of the CMAXX unit in maintaining air quality is another testament to Orion’s commitment to operational excellence.
Why the CMAXX Stands Out
Phil shares that while competitors also produce acceptable dust collection systems, they often come with engineering issues. “The unit that we have now, one of the reasons that we chose that, was to try to alleviate some of those problems.” The CMAXX unit, described by Phil as “the Cadillac of dust collection units,” was chosen above all for its superior design and the quality of its construction. The ease of filter removal is another feature that sets it apart to Orion, making maintenance simpler and more efficient.
A Testament to Quality Plastics Compounding
The partnership between Orion Performance Compounds and Atlantic Dust Collection exemplifies the importance of selecting the right equipment and collaborators in maintaining high standards of cleanliness and safety. “Atlantic was great,” Phil notes, appreciating their customer service and attention to detail. This collaboration not only ensures a cleaner facility but also positions Orion ahead of its competition by providing a safer and more appealing environment for both employees and clients.
Orion Performance Compounds’ commitment to cleanliness and safety, reinforced by their partnership with Atlantic Dust Collection and the installation of the CMAXX Dust & Fume Collector, highlights the company’s dedication to excellence. By maintaining a clean and efficient facility, Orion not only meets the rigorous standards of its diverse clientele but also sets a benchmark in the thermal plastics compounding industry. The success story of Orion Performance Compounds serves as an inspiration, showcasing how the right combination of technology, partnership, and core values can drive a company to new heights.
In the world of industrial dust collection, maintaining high efficiency and prolonged baghouse filter bag life is crucial. One effective method to achieve this is by applying a pre-coat to the filter bags with specific materials before use. Pre-coating involves applying a material layer to the filter bag media. This creates a base cake that enhances filtration efficiency and extends the filter’s operational life.
The Importance of Pre-Coating
New filter felt media is inherently porous, allowing fine particulate matter, especially those ½ micron and smaller, to pass through. Pre-coating forms an initial layer on the filter media. This significantly increases its efficiency by capturing fine particles and reduces the chances of premature clogging.
Various pre-coat materials are available, including diatomaceous earth, lime, perlite, cellulose, and activated carbon. But the choice of material depends on the specific filtration requirements and the type of filtered particulate. Consulting the filter manufacturer can provide valuable guidance on selecting the most suitable pre-coat material for your particular application.
Preparing and Mixing Pre-Coat Materials
Some pre-coat materials require mixing multiple ingredients to achieve uniform consistency. Ensuring thorough mixing before application is vital for achieving even distribution and optimal filter performance.
Preparing the Baghouse for Pre-Coat Application
Before applying pre-coat to the filters in a baghouse dust collector, certain preparations are necessary:
Remove all previous dust from the baghouse hopper and deactivate the hopper dust removal equipment, such as airlocks.
Deactivate and lockout the baghouse cleaning system to prevent filter cleaning during the pre-coat period.
Pre-Coat Application Methods for Different Baghouse Systems
Negative Pressure Systems: In negative pressure baghouse systems, where the baghouse is under suction, inject the pre-coat through ports or inspection doors in the duct or directly into the dust collector inlet or hopper.
Positive Pressure Systems: For positive pressure systems, where the fan blows into the dust collector, inject the pre-coat into the system ductwork on the suction side of the fan.
Calculating and Applying Pre-Coat
A good rule of thumb is to use one pound of pre-coat for every 20 square feet of baghouse filter media. Operate the system at 50% of the design airflow to the baghouse. This results in an inlet duct velocity of approximately 2000 FPM. Avoid dropping the velocity below this threshold. Then use a pre-coat feed rate of 1/3 pound per minute per 1000 ACFM of reduced airflow. For instance, for a 25,000 ACFM reduced airflow system, the feed rate would be 7.5 lbs./minute.
Inspecting and Ensuring Adequate Pre-Coat Coverage
Isolate each filter compartment and inspect the filter bags to ensure an adequate pre-coat cake, approximately 1/16 inch thick. Then check the collector hopper to confirm that there is not a significant amount of pre-coat dropout.
Once the pre-coating process is complete, increase the air volume to the normal dust collector design flow level. Then turn on the dust removal equipment (airlock). However, do not reactivate the filter bag cleaning cycle until a differential pressure of 3 to 4 inches SPWG is measured across the bags. This step ensures that a seasoned cake of pre-coat has formed on the filter bags before initiating the initial cleaning cycle.
Pre-coating filter bags is a proven method to enhance the efficiency and longevity of dust collection systems. By selecting the right pre-coat material, properly preparing and applying it, and carefully monitoring the process, facilities can ensure their dust collectors operate at optimal performance levels. This not only improves air quality but also extends the life of the filters, contributing to overall operational efficiency.
6. Plastic Dust
