2019 Indiana Conference on Energy Management · Applications for Combustible Dust– Wet Collection...
Transcript of 2019 Indiana Conference on Energy Management · Applications for Combustible Dust– Wet Collection...
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2019 Indiana Conference on
Energy Management
40 Plus Years Designing,
Applying, Installing Industrial Air Cleaning Systems
DANIEL BOHRER
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3M‐ UK, Panama
American Airlines‐ Tulsa, OK, Pittsburgh, PA
Electric Boat‐ Quonset Point, RI
Faurecia‐ Queretaro, Mexico
Fort McMurray‐ Alberta, Canada
Greenheck Fan‐ Kings Mountain, NC
John Deere‐Monterrey, Mexico, Binhai Xinqu, Tianjin Shi, China, Preferred Vendor
Kerry Seasoning‐Anaheim, CA
Komatsu – Peru, Chile, Nevada, Wyoming, Arizona
Komatsu/LaTournaeu‐ Longview, TX
PCC‐ Portland, OR, Tacoma, WA
Scan Pac‐ Houston, TX
USA Navy‐Portsmouth, ME
Hastings US & Global Clients
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MINNEAPOLIS, MN
FARMINGTON, MILAKE BLUFF, IL
NEW BERLIN, WI
CINCINNATI, OH
ST. LOUIS, MO
Hastings – USA – Global
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Google Maps – Tour the TEC
Engineered Solutions | Dust Collectors | Automation & Energy Controls | Downdraft Tables | Air Filtration ProductsRemote Monitoring Access | Vehicle Exhaust Systems | Ventilation Equipment | Installation & Service
Technology Experience Center
• 50+ years experience in industrial air cleaning• Proven history of results• Responsible stewardship of your resources• Always available - Proactive and responsive service organization• Flexible solutions from selected manufacturers• Commitment to educating you & your staff on proper air cleaning
techniques• Average employee tenure of 11 years = you receive unequaled
experience
Why Partner with Hastings?
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Providing innovative solutions that create healthier lives for workers and
energy savings for employers.
Core Focus
Core Values
• Strong Work Ethic• Innovative and Growth Driven• Positive Mental Attitude, Have Fun• Committed to Excellence, Perfection• Sense of Urgency, Responsive• Honesty, Integrity, Ethical• Service the Customer Above All Else
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• To reduce worker exposures to air contaminants to below allowable limits
• To minimize buildup of air contamination in the in‐plant environment, improve housekeeping and erase the perception of poor environmental control
• To improve worker comfort while performing “hot work” such as welding, gouging, etc.
Primary Objectives
• Particulates• Lung diseases such as cancer• Lung irritants• Toxic
• Gases• Pulmonary effects
• Non‐pulmonary effects
Health Hazards
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Everything is Connected
Health
Equipment
Labor
Facility
Air Quality
Air Quality
SAFETY
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• Energy Management Systems• Industrial Air Cleaners• Bag Houses• Dust Collectors• Mist collectors• Wet Collectors/Scrubbers• Source Capture Extraction Arms• Booths and Downdraft Tables
(Fire Dept VEX systems)
• Curtain Walls and Barriers• Hard Duct and Flexible Duct• Filters/Service/Parts• Blowers, Fans, Ventilators• Commercial Air cleaners• Odor Control Systems
What We Do
• Environmental control within the plant
• Energy conservation
• Design of filtration systems
• Being Green
• ‐ General Combustible Dust (NFPA)
Application Focus: (Industrial processes)
A: Wood working
B: Grinding/Polishing/Sanding
C: Welding
D: Sand/Shot Blast
E: Mist collection
Our Discussion Today
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Engineering Principles
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Air can be blown 30 times farther with pushing vs. pullingThe Hastings solution directs the fugitive air toward a specific location (collector)
Push / Pull
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Before
Before
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After
Source Capture
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Flanged Velocity Contours
100% Velocity – 9% of Diameter
60% Velocity – 20% of Diameter
30% Velocity – 46% of Diameter
15% Velocity – 76% of Diameter
7.5% Velocity – 113% of Diameter
Source Capture at 1,400 CFM for Weld Lab
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Controlling Your Power Usage
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IVEC Energy Control Systems
• Fully Automatic
• Fume/Dust Extraction “On Demand”
• Pay Only For Effective Work Time
•Reduce Size Of The System, Fan & Filter
• Improve the Environment
•Reduced Noise Levels•More Effective Extraction
1. A sensor reacts when A start up occurs (arc, machine, engine)
2. A damper opens / a fan starts
3. A sensor indicates the need for more or less “pressure” (based on a predetermined benchmark from a consultant experienced in multiple particulates )
4. The fan rpm goes up or down accordingly – along with HP needs
IVEC – How Does it Work?
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Static System
Dynamic System
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Legacy Steward Design
Steward
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Sensors – IVEC Assist
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IRONWORKERS 011
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IVEC™ Systems Node
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• Reduce CFM BY 10% = 27% SAVINGS
• Reduce CFM BY 25%= 68% SAVINGS
• Reduce CFM BY 50%= 87.5% SAVINGS
Affinity Fan Law
Project: Client had run out of capacity on their 50 HP collector –RetrofitStandard Alternative: Replace the dust collector at a cost of $80K & 2 weeks downtimeRecommended Solution: iVEC™ Systems 16 gate IPS/Advanced SystemResults: ● $1000 monthly savings on electricity● More capacity than Boehm can use (Allows for added
machinery ventilation in the future.)● Noise reduction is significant
From the customer: The utility company contacted me and asked “Did you go out of business?” because my electric consumption dropped so significantly. iVEC™ saved me $80,000 because I didn’t
have to purchase a new, larger dust collector that the other guys recommended.”
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Steward – Fender Guitar
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Tom’s Towers
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Duct Design
• Ductwork should be as short and straight as possible• Ductwork must be made of conductive material and have a smooth interior• Duct velocities 3500 – 4500 FPM• There cannot be any unused capped outlets, pockets, or dead‐end spaces• Additional branch ducts cannot be added unless a redesign of the system is performed
• Duct system along with machinery, hoods, and collectors must be bonded and grounded
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Ductwork
• Ducts short and straight to maximize free airflow
• No dead‐ends or unused caps in ducts that could trap accumulations of dust
• Ducts grounded and bonded to dissipate static electricity
Particles are suspended
Air velocity at least 4500 ft./min
Build‐up of dust particles
Air velocity less than 3500 ft./min
Entrainment! is what you need!
Bad!
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Hooding & Ductwork
• All operations producing dust should have some type of hooding to collect dust – Refer to Industrial Ventilation Manual
• Backdraft Hood
• Extractor Arm
• Duct directly to operation – mixers/blenders
• Bonded to equipment to hooding. Limit static.
• Ductwork to be conductive/bonded – NO PVC. Flex ductwork should be bonded/conductive
• Velocity is ductwork should be 4000 FPM to minimize particulate fallout
• Systems should be reviewed when new drops are added to system
Air Material Separator
• Bag House, Cartridge Collector, Cyclone, Open Collector
• Must have correctly sized explosion vent (NFPA 68) or suppression NFPA 69
• Filters to be grounded to dissipate static electricity
• Hopper discharge to drum or rotary airlock
• Is collector located inside? If so, if venting correct to outside or using flameless vent?
• Is collector designed to withstand deflagration?
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Industrial Applications
Before
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After
Mercury Marine
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Mercury Marine
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Booth‐Regain–Push/Pull
Air outside the booth is drawn into the air stream system and cycled through the filtering system as shown on Fig 1.
Fig. 1.
Ambient Air
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Dust Collectors
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Industrial Explosion Protection Overview
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Industries at Risk• Chemical
• Petrochemical
• Grain
• Food
• Pharmaceutical
• Aerosol
• Steel
• Cement
• Wood
Food 24%
Wood 15%
Chemical 12%Metal 8%
source OSHA NEP, 2008
Who’s at Risk?Industries having high incidence of combustible dust issues
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OSHA Poster
Dusts specifically highlighted:
• Aluminum
• Magnesium
• Sugar
• Phenolic Dust
NFPA Definitions
• Combustion – the chemical process of oxidation that occurs at a rate that is fast enough to produce heat and usually light, in the form of either a glow or flames
• Deflagration – propagation of a combustion zone at a velocity that is less than the speed of sound in the unreacted medium
• Explosion – the bursting or rupture of an enclosure or container due to the development of internal pressures from a deflagration
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NFPA “Industry” Codes Requiring Explosion Protection
• NFPA 652 (2016) Fundamentals of Combustible Dusts
• NFPA 654 (2013) Manufacturing, Processing and Handling of Combustible Particulate Solids
• NFPA 61 (2013) Agricultural and Food Products Facilities
• NFPA 664 (2012) Wood Processing and Woodworking Facilities
• NFPA 484 (2015) Combustible Metals
• NFPA 30B (2011) Manufacture and Storage of Aerosol Products
• NFPA 33 (2011) Spray Application Using Flammable or Combustible Materials
• NFPA 91 (2010) Exhaust Systems for Air Conveying of Vapors, Gases, Mists
Dust Explosion Pentagon
1. A fuel is needed to burn (combustible dust)
2. Oxygen is needed to sustain the fire (air)
3. Heat from an ignition source is needed (spark)
4. A high concentration of dust is dispersed into the air (deflagration)
5. The dust must be confined within an enclosure or structure (explosion) FUEL
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Aluminum Dust Explosion
Filtration Methods
Media• Cartridge• Bag ‐ Glass Or Synthetic• Pre‐Filter
ESP
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Cartridge Filters
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Housekeeping Program
• Required – Fugitive Dust Control and Housekeeping
• Comprehensive cleaning
• Visual baseline – establish threshold value
• Cleaning frequency
• Cleaning techniques and equipment
• Vacuum procedures and prohibitions
• Compressed air blow‐downs
• Fugitive dust control
• Inspections
Industrial Strength VacuumsFiltration
• Multiple stages/types of filtration
• HEPA/ULPA efficiency
• Automatic filter cleaning options
• Large surface area (Low ATC)
Accessories
• Overhead Cleaning
• Confined, hard‐to‐reach spaces
• High‐temperature hose and tool options
• Conductive tools
Features/Benefits
• Cleanable/shakable filters
• Rugged, durable construction
• Collection/containment options
• Stainless steel, wet/dry models
• Ergonomic design for easy transport and disposal
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Maintenance & Housekeeping
• Develop and maintain a housekeeping program (this is something OSHA inspectors are checking for).
• Replace mops, brooms and blow guns with more effective cleaning tools/practices. These products push dust around without removing it and can create dangerous dust clouds.
• Limit/reduce the amount of overhead horizontal surfaces (racks, piping, ductwork, drop ceilings). These areas are hard to clean and trap dust.
• Make sure equipment is grounded to avoid electrical and static sparking.
Common HazLoc Applications
• Industry: Paper
• Location: Ceiling rafters and HVAC piping system.
• Application: Vacuuming dust from overhead piping. Class II, Group G area.
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Combustible Dust – Wet Collectors
• Can recirculate if tests conducted determine that the efficiency is great enough
• Dry filters in the collector or down stream are prohibited
• Level (high and low) must interlock with blower
• Sump must be vented at all times (for magnesium, must have a independent blower vent when primary blower is shut down)
• Sludge should be removed daily
• 99% efficient on 10 micron and 95% efficient at 5 micron
• Adds humidity back into room if recirculated
• Cannot mix grinding & buffing/polishing operations
Applications for Combustible Dust–Wet Collection
• Rubber • Smoldering rubber dust from grinding caused many fires in dry collectors before going to a Filter‐1 wet collector
• Leather• Estwing Manufacturing, where leather handle is sanded and sparks can be generated from steel
• Food Industry • Wet collector to collect dust from batching, blending, weighing, dumping
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Wet Downdraft
• Single or Double work area
• Regain for “push/pull” to get up to 400 FPM
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Wet Ducted Collector
Wet Ducted Collector
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Hastings Air Energy Control, Inc.hastingsairenergy.com
1.800.236.845Wisconsin‐Illinois‐Michigan‐Minnesota‐Ohio‐Iowa‐North & South Dakota
TECHNOLOGY CENTER..
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